First Portion 1

DESIGN AND ANALYSIS OF MULTISTAGE CENTRIFUGAL WATER PUMP
CHAPTER ONE
1. Introduction
1.1 Background of the Study
One of the primary pieces of fuelled apparatus to be designed at the daybreak of the mechanical age was
a rough (basic) frame of the pump. The pump has since advanced into an unending assortment of sorts,
sizes, and applications. This article will provide a diagram of the common sorts of pumps that are
commonly utilized in handle plants. A utilitarian understanding of pumps, their utilization, and
application, is basic to get how most forms are dealt with in prepare plants nowadays.
Pump is a machine or mechanical equipment which is required to lift liquid from low level to high level
or to flow liquid from low pressure area to high pressure area or as a booster in a piping network system.
Principally, pump converts mechanical energy of motor into fluid flow energy. Pump also can be used in
process operations that require a high hydraulic pressure. This can be seen in heavy duty equipment’s.
Often heavy-duty equipment’s requires a high discharge pressure and a low suction pressure. Due to low
pressure at suction side of pump, fluid will lift from certain depth, whereas due to high pressure at
discharge side of pump, it will push fluid to lift until reach desired height. Times have changed, but
pumps still operate on the same fundamental principle – expend energy to raise, transport, or compress
liquids.
Over time, the application of pumps in the agricultural domain has expanded to cover other domains as
well. The following are a few main domains that use pumps extensively:
Water supply: To supply water to inhabited areas.

Drainage: To control the level of water in a protected area.
Sewage: To collect and treat sewage.
Irrigation: To make dry lands agriculturally productive.
Chemical industry: To transport fluids to and from various sites in the chemical plant.
Steel mills: To transport cooling water.
Construction: Bypass pumping, well-point dewatering, remediation, and general site pumping
applications.
1.1.1. Centrifugal Pumps
Centrifugal pumps are commonly utilized since of their simplicity and capacity to produce moderately
high-pressure proportion in a brief pivotal remove. In common, centrifugal pumps are utilized wherever
any amount of fluid is required to move from one put to another. This applies to a huge number of
applications and administrations counting electric control plants, water supply plants (i.e. sewage, waste
or water system, etc.), oil refineries, chemical plants, steel plants, nourishment preparing, mines,
digging, and flying operations, pressure-driven control administrations, and nearly all ships whether
impelled by steam or diesel motor. Moreover, centrifugal pumps are found in administrations such as
air-conditioning, refrigeration, mash, and paper plants and materials. Although these pumps have much
in common, they vary in design and construction to meet specific requirements of each service of
various different categories of pumps used in different applications, the centrifugal pumps are the most
commonly used. [ ] According to the business plan of ISO issued in January 2004, centrifugal pumps
represent around 64% of the pump market.
Figure 1 the pump market [ ]
1.1.1.1. Types of centrifugal pumps
Centrifugal pumps can be categorized in various ways. Some of the main types are on the following
basis:
Orientation of the pump shaft axis
This refers to the plane on which the shaft axis of the pump is placed. It is either horizontal or vertical as
shown in figure below
Figure 2 Vertical and horizontal pump

Number of stages
This refers to the number of sets of impellers and diffusers in a pump. Set forms a stage and it is usually
single, dual, or multiple (more than two) stages.
Figure 3. Multistage pump

Suction flange orientation
This is based on the orientation of the pump suction flange. This orientation could be horizontal (also
known as End) or vertical (also known as Top.)
Figure 4 Multistage pump with end suction

Casing split
This classification is based on the casing split. It is either Radial (perpendicular to shaft axis) or Axial
(plane of the shaft axis.)
Bearing support
This is judged based on the location of the bearings supporting the rotor. If the rotor is supported in the
form of a cantilever, it is called as an overhung type of pump. When the impellers on the rotor are
supported with bearings on either side, the pump is called as an in-between bearings pump.
Pump support
This refers to how the pump is supported on the base frame. It could be a center-line support or foot-
mounted support
Figure 5 Models of pump supports and Axial split casing

1.1.2. Multi stage Centrifugal Pump
A centrifugal pump containing two or more impellers is called a multistage centrifugal pump. The
impellers may be mounted on the same shaft or on diverse shafts. At each organize, the liquid is
coordinated to the center sometime recently making its way to the release on the external distance
across.
The essential contrast between single-stage and multistage centrifugal pumps lies within the number of
stages (too alluded to as impellers) they have. As the title suggests, single-stage pumps have as it were
one impeller, though multistage pumps have at slightest two.
A centrifugal pump’s impeller is what pressurizes and transfers the liquid. Because multistage pumps
have multiple impellers, their pressure ranges and flow rates are far superior. Within a multistage
centrifugal pump, each impeller acts like a single-stage pump within a chain of pumps. The advantages
of multistage centrifugal pumps stem from this chain-like design. As the liquid is propelled from one
impeller to the next, its pressure increases while the flow rate remains constant.
By relying on multiple impellers to distribute the pressure-building load of the pump, multistage
centrifugal pumps can generate greater power and higher pressure with smaller motors, therefore using
less energy.
Function of a multistage centrifugal pump

There are following important functions of a multistage centrifugal pump as mentioned here.
To produce a high head
In order to secure high head, a number of impellers will be assembled in series or impellers will be fixed
on same shaft as displayed here in following figure.
Figure 6 Two stage pump with impeller in series

The water from suction pipe will enter in to the first impeller at its inlet and will be discharged at the
outlet of this impeller with increased pressure. Water with increased pressure, discharged from first
impeller outlet, will be taken to the inlet of second impeller i.e. water with increased pressure coming
out from outlet of first impeller will enter in to the second impeller inlet with the help of a connecting
pipe as displayed in figure above. Pressure of water coming out from outlet of second impeller will be
more as compared to the pressure of water coming out from the outlet of first impeller.
Therefore, we can conclude that pressure at the outlet could be increased further if more impellers
mounted on same shaft.
To discharge a large quantity of liquid

In order to secure the high discharge, pumps will be connected with each other in parallel as displayed
here in following figure.
Figure 7 Pumps in parallel

Each pump of such multistage centrifugal pump will take water from a common sump and will deliver
the water to a common pipe. Delivery pipe of each pump will be connected with this common pipe as
displayed in the figure. Each pump will work here against same head{}.
1.2. Problem Statement
Now a days there is a very high water shortage and demand in different part of our country caused by
not only water scarcity but also less efficient and inconsistent distribution system. To avoid this problem
multi stage centrifugal water pump must come into action which are a core equipment in achieving
increased liquid pressure, higher head, larger flow rate and higher efficiency and can meet the need of
high lift and high flow conditions than most of the other types of pumps. This study helps to resolve
water supply and distribution inadequacy for beneficiaries like hospitals, universities, water supply
institutions, agricultural and irrigation sectors. This thesis is especially for institutions demanding higher
head like hospitals
Cities are also expanding from time to time increasing the water demand across the cities therefore to
transport water, multistage of having highest possible efficiency is demanding, so the design of
multistage centrifugal pump is crucial.
1.3. OBJECTIVE
1.3.1. General Objection
The main objective of this project is to Design and Analyze Multistage Centrifugal water pump for
beneficiaries like hospitals, universities, water supply institutions, agricultural and irrigation sectors.
1.3.2. Specific Objective
1. To determine the optimized stage of centrifugal pump.

2. To select material for the shaft
3. To select material for impeller shaft
4. To select material for the casing
5. To design the impeller
6. To design the casing
7. To design the shaft
8. To design the bearing
9. To Analysis mechanical losses and hydraulic losses
10. Part Drawing and Assembly Drawing.
1.4. Significance
Not only efficiency enhancement multistage centrifugal water pumps also achieve higher head, larger
flow rate and customizable build. Multistage centrifugal water pumps are important in:
Water circulation in which pressure is added to the system to continuously circulate water.
Water supply boosting by increases pressure for water usage.
Irrigation which is used to pump water throughout an irrigation system.
Firefighting which is used to pressurize water to help extinguish fires and many more
Therefore, this project will have a great purpose on how to increase pump efficiency and decrease
energy and time loss.
1.5. Scope and Limitation
In this research paper, using the theoretical analysis, governing equations, the scope of the project were
on the designing and analysis of multistage centrifugal pump. The domain is comprised of solution
principle of impeller, casing, shaft, bearing and mechanical which is succeeded by detail design of each
components. After the completion of the detail design is followed by material selection which suits the
best for our design. Additionally different losses are explained and solved. Finally the thesis is
concluded by three dimensional drawing.
The major factors limiting this study are unfortunate unstable national situations and very limited to
further accomplish this research.
1.6. Organization of the Study
The thesis is organized by seven chapters. Which are described below.
Figure 8 Thesis Organization

CHAPTER TWO
2. Literature Review
Many scholars have design of multistage centrifugal pump and abled to design different kind of pump.
And some of the researches are reviewed in this section.
According to (Shamsuddeen et al., 2021) a multistage centrifugal pump is designed for pumping low-
viscosity, highly volatile and flammable chemicals, including hydrocarbons, for high head requirements.
The five-stage centrifugal pump consists of a double-suction impeller at the first stage followed by a
twin volute. The impellers for stages two through five are single-suction impellers followed by diffuser
vanes and return channel vanes. The analytical performance is calculated initially in the design stage by
applying similarity laws to an existing scaled-down pump model designed for low flow rate
applications. The proposed pump design is investigated using computational fluid dynamics tools to
study its performance in design and off-design conditions for water as the base fluid. The design
feasibility of the centrifugal pump is tested for other fluids, such as water at a high temperature and
pressure, diesel and debutanizer diesel. The pump design is found to be suitable for a variety of fluids
and operating ranges. The losses in the pump are analyzed in each stage at the best efficiency point. The
losses in efficiency and head are observed to be higher in the second stage than in other stages. The
detailed flow behavior at the second stage is studied to identify the root cause of the losses. Design
modifications are recommended to diminish the losses and improve the overall performance of the
pump.
On the basis of (Pandey, Singh and Mahar, 2020) the operation of multistage pumps transporting water
from the source to the delivery point requires balancing of the pressure at the junction of the pump and
pipeline according to their characteristics. In this paper, nonlinear optimization models are developed to
minimize the total annual cost for selecting the sizes of the pipelines in series and parallel connections of
pumps taking water from one or more sources. The models are based on life cycle cost analysis,
including replacement cost and escalating energy cost factors. The combined characteristic equations of
the pumps in series and parallel connections are obtained using the characteristic equation of a single-
stage pump. The constraints are imposed for the pressures at the junctions of the pipeline, with the
pumps having different characteristics especially drawing water from different sources. The discharges
of the pumps are regulated automatically according to the pressures adjusted at the junctions due to the
resistance developed by the optimally designed pipe sizes. The requirements of the desired efficiency
also are considered constraints in the models. The applicability of the developed models is illustrated
through design examples to obtain optimal discharge and pipe sizes from a single water source for series
and parallel connections. Also, the examples are solved to obtain the optimal pipe sizes and discharges
from different pumps with the same and different characteristics and drawing water from multiple
sources.
As claimed by (Bai et al., 2019) multistage pumps are intended to improve designs with low-vibration
and-noise features as the industry applications increase the technical requirements. In this frame, it
becomes really important to fully understand the vibration patterns of these kinds of complex machines.
In this study, a vibration test bench was established to examine the vibration and stability of a cantilever
multistage centrifugal pump under different flow rates. The vibration spectrum diagrams for the inlet
and outlet sections and the pump body were evaluated under varied flow conditions. Results showed the
effects of operational conditions on the vibration of the cantilever multistage centrifugal pump.
Vibration velocity was primarily caused by mass unbalance at the shut-off flow rate point. Under
different flow conditions, the blade passing frequency (BPF) and two times the blade passing frequency
(2BPF) were the main excitation frequencies. The vibration frequency of the final pump body remained
at the BPF under different flow conditions due to the contact with the outlet section. The major type of
vibration frequency for the inlet and outlet was high frequency.
According to (Wang et al., 2017) propose a method to optimize the design of a typical multistage
centrifugal pump based on energy loss model and Computational Fluid Dynamics (ELM/CFD). In this
work it is found that polishing the impeller shroud and pump cavity is beneficial in improving pump
efficiency and reducing pump shaft power under the premise that the surface roughness has a significant
influence on the pump performance.
As started by (La Roche-Carrier, Dituba Ngoma and Ghie, 2013) study the Numerical Investigation of a
First Stage of a Multistage Centrifugal Pump: Impeller, Diffuser with Return Vanes, and Casing. In this
study, a steady-state liquid flow in the three- dimensional first stage of a multistage centrifugal pump
was numerically investigated. A model of a centrifugal pump stage composed of an impeller, diffuser,
and casting was developed to analyze the impacts of the height of the impeller blades and diffuser vanes,
the number of impeller blades, diffuser vanes and diffuser return vanes, and the wall roughness height
on the pump stage head, brake horse power, and efficiency. The results obtained demonstrate, among
other things, that the pump stage head and brake horsepower increase as the height of the impeller
blades and diffuser vanes and the number of impeller blades increase. Moreover, the head and efficiency
increase for large volume flow rates with increasing numbers of diffuser vanes and diffuser return vanes.
The brake horsepower hardly varies at all regardless of the number of diffuser vanes and diffuser return
vanes. Furthermore, higher wall roughness heights of the impeller and diffuser negatively affect the
head, brake horsepower, and efficiency. In all, the numerical curves obtained for the head, brake
horsepower, and efficiency follow the trend of the experimental results.
On the authority of (Della Gatta et al., 2006) investigated CFD study for assessment of axial thrust
balance in centrifugal multistage pumps.in this investigation, a numerical investigation of a multistage
centrifugal pump has been carried out. Driving the correct design and dimensioning of the axial bearings
to balance the hydraulic thrust is the present study main target. To reach the task, both the main, the
impeller chambers and the balancing drums flow have to be considered because of their relevance to the
problem of axial load unbalance. Separated CFD analysis have been carried out for stage (with a mixing
plane approach) and side chambers. 2D analysis to characterize the central drum and the lateral
balancing drum have been developed. A methodology to predict the residual axial thrust for a complex
machine has been presented and pump sensitivity to the different variables which influence axial thrust
have been pointed out. Actual results show the calculated characteristics maps of the pump and how the
axial thrust depends on the operating conditions of the pump as well as its mechanical wear conditions,
because of effects on the main flow head and on the pressure distribution inside the side chambers.
According to (Li et al., 2016) analyzes Numerical simulation and performance analysis of a four-stage
centrifugal pump. The numerical simulations under multi-conditions were performed based on standard
k-e turbulence and standard wall function. Pump performance curves acquired by numerical simulation
and the test are basically coincident; the total head, total power, and efficiency values are similar and
changing trend is consistent under the different flow conditions. Flow in first stage is dramatically
different compared with other stages. The results present that the four-stage simulation could reflect the
real flow more precisely than the two-stage simulation, but also have higher requirements about the
computer configuration. To balance the time consuming and numerical accuracy, two-stage simulation is
a better choice to predict the pump performance. The results of this study provide the basis and reference
for the further improvement of multistage centrifugal pump performance.
2.1. Fundamental theory
2.1.1. Pump Types
Pumps can be classified by their method of displacement into Positive displacement pumps
(reciprocating, rotary pumps) and Roto-dynamic pumps (centrifugal pumps), others include velocity
pumps, gravity pumps, steam pumps, valve less pumps etc.
A. Positive displacement pumps
Positive displacement pumps, which lift a given volume for each cycle of operation, can be divided into
two main classes, reciprocating and rotary. Reciprocating pumps include piston, plunger, and diaphragm
types. The rotary pumps include gear, lobe, screw, vane, regenerative (peripheral), and progressive
cavity pumps.
B. Roto-dynamic pumps (centrifugal pumps)

Roto-dynamic pumps raise the pressure of the liquid by first imparting velocity energy to it and then
converting this to pressure energy. These are also called centrifugal pumps. Centrifugal pumps include
radial, axial, and mixed flow units. A radial flow pump is commonly referred to as a straight centrifugal
pump; the most common type is the volute pump. Fluid enters the pump through the eye of impeller,
which rotates at high speed. The fluid is accelerated radially outward from the pump casing. A partial
vacuum is created that continuously draws more fluid into the pump if properly primed. In the axial flow
centrifugal pumps, the rotor is a propeller. Reciprocating pumps are positive displacement pumps and
are based on the principle of the 2000-year-old pump made by the Greek inventor, Ctesibius.
The centrifugal pumps are by far the most commonly used of the pump types. Among all the installed
pumps in a typical petroleum plant, almost 80–90% is centrifugal pumps. Centrifugal pumps are widely
used because of their design simplicity, high efficiency, wide range of capacity, head, smooth flow rate,
and ease of operation and maintenance. The ‘modern’ era pumps began during the late 17th and early
18th centuries AD. British engineer Thomas Savery, French physicist Denis Papin, and British
blacksmith and inventor Thomas Newcomen contributed to the development of a water pump that used
steam to power the pump’s piston. The steam-powered water pump’s first wide use was in pumping
water out of mines. However, the origin of the centrifugal impeller is attributed to the French physicist
and inventor Denis Papin in 1689. Papin's contribution lies in his understanding of the concept of
creating a forced vortex within a circular or spiral casing by means of vanes. The pump made by him
had straight vanes. Following Papin’s theory, Combs presented a paper in 1838 on curved vanes and the
effect of curvature, which subsequently proved to be an important factor in the development of the
centrifugal impeller. In 1839, W.H. Andrews introduced the proper volute casing and in 1846, he used a
fully shrouded impeller. In addition, in 1846, W.H. Johnson constructed the first three-stage centrifugal
pump, and in 1849, James S. Gwynne constructed a multistage centrifugal pump and began the first
systematic examination of these pumps. Around the same time, British inventor, John Appold conducted
an exhaustive series of empirically directed experiments to determine the best shape of the impeller,
which culminated in his discovery that efficiency depends on blade curvature. Appold’s pump of 1851
with curved blades showed an efficiency of 68%, thus improving pump efficiency three-fold.
The subsequent development of centrifugal pumps was very rapid due to its relatively inexpensive
manufacturing and its ability to handle voluminous amounts of fluid. However, it has to be noted that
the popularity of the centrifugal pumps has been made possible by major developments in the fields of
electric motors, steam turbines, and internal combustion (IC) engines. Prior to this, the positive
displacement type pumps were more widely used. The centrifugal pump has a simple construction,
essentially comprising a volute (1) and an impeller (2) (refer to figure below.) The impeller is mounted
on a shaft (5), which is supported by bearings (7) assembled in a bearing housing (6). A drive coupling
is mounted on the free end of the shaft.
Figure 9 Centrifugal pump – basic construction

The prime mover, which is usually an electrical motor, steam turbine, or an IC engine, transmits the
torque through the coupling. As the impeller rotates, accelerates, and displaces the fluid within itself,
more fluid is drawn into the impeller to take its place; if the pump is properly primed. The impeller thus,
impacts kinetic or velocity energy to the fluid through mechanical action. This velocity energy is then
converted to pressure energy by the volute. The pressure of the fluid formed in the casing has to be
contained and this is achieved by an appropriate sealing arrangement (4). The seals are installed in the
seal housing (3). The normal operating speed of pumps is 1500 rpm (1800 rpm) and 3000 rpm (3600
rpm). However, there are certain designs of pumps that can operate at speeds in the range of 5000–
25000 rpm
2.1.2. Working Principle of Multistage centrifugal Pump
A multistage pump has multiple stages. It works in more than one stages. A multistage pump works in
the following way:
First of all, the fluid introduces from the outside into the impeller eye of the 1st stage.
As the fluid strikes the impeller vanes, the vanes provide kinetic energy and increase fluid speed.
A centrifugal force inside the impeller moves the fluid axially and radially
Due to the centrifugal force, this fluid discharge from the impeller blades and enters into the
diffuser.
The diffuser increases the fluid pressure by reducing its speed and sending it into the 2nd stage.
This process continues until fluid passes from all the stages of the pump, and then it discharges
and pumps to the desired area.
CHAPTER THREE
3. Methodology and Material
3.1. Methodology
The methods used in this design; the first involves literature review about multistage centrifugal pump,
design by numerical and analytical method and drawing of part and assembly drawing.
NO
YES
Figure 10 flow chart of the project
3.2. Product Definition
This section discusses definition and function of the components (parts) of the multistage centrifugal
pump lie impeller blades, casing (volute), shaft, bearings, seal etc.
3.2.1. The Impeller
The impeller is the main rotating part that provides the centrifugal acceleration to the fluid. The
impeller is the fundamental component of a centrifugal pump. It is responsible for converting the
torque applied to the pump shaft into pressure and kinetic energy in the pumped liquid. It does this
by the action of its blades on the liquid. Accordingly, impellers can be classified as:
3.2.1.1. Open Impeller
An open impeller consists of vanes attached to a central hub for mounting on the shaft without any
form of shroud. The main advantage of open impellers is that they are suitable for pumping liquids
containing stringy materials. It is also claimed sometimes that they are better suited for handling
liquids containing suspended matter because the solids in such matter are more likely to be clogged
in the space between the rotating shrouds of a closed impeller. The disadvantage of these impellers is
structural weakness.
3.2.1.2. Semi-Open Impeller
The semi-open impeller incorporates a single shroud, usually at the back of the impeller. This shroud
may or may not have pump out vanes, which are vanes located at the back of the impeller shroud.
This function reduces the pressure at the backrub of the impeller and prevents foreign matter from
lodging-in from back of the impeller that would interfere with the proper operation of the pump and
the seal chamber.
3.2.1.3. Closed Impeller
The closed impeller, which is almost commonly used in centrifugal pumps handling clear liquids,
includes shrouds that totally enclose the impeller waterways from the suction eye to the periphery.
Although, the design of closed impellers prevents liquid slippage, which occurs in an open or semi-
open impeller, there should be a running joint between the casing and the impeller in order to
separate the suction and discharge chambers of a pump. The running joint comprises of a short
cylindrical surface mounted on an impeller shroud which rotates on a slightly larger static cylindrical
surface.
Figure 11 types of impellers
3.2.2. The Casing
The component that contains the pump impeller is generally referred as the pump casing. A pump
comprises of a suction as well as a discharge penetration for the pump’s main flow path. The pump
normally has vent fittings and small drain to eliminate gases confined in the casing of the pump or to
drain the pump’s casing to perform maintenance. In addition to all of these functions of the pump
casing, it also performs five other important functions
Provides pressure containment.
Incorporates the collector.
Allows rotor installation and removal.
Supports the pump.
Maintains the alignment of the pump and its rotor under the action of pressure and reasonable
piping loads. The required type of the collector classifies the centrifugal pump. The purpose of
the collector is to collect and diffuse the high velocity liquid discharged by the impeller. This
process is necessary to slow the liquid to a usable velocity and convert the kinetic energy into
pressure energy, thereby recovering most of the pump’s energy input. The selection of the pump
casing type depends on the application of the pump.
Figure 12 casing
3.2.3. The Shaft
The device that transmits the required torques for the rotation of an impeller of a centrifugal pump is
referred to as shaft. The shaft also supports the impeller and rotating parts. The shape of the shaft and
materials are designed in a way that the deflection is maintained to less than the allowance between the
stationary and rotating parts. The pump shafts are normally protected from corrosion, wear and erosion
at the leakage joints, seal chambers as well as internal bearings.
Figure 13 shaft
3.2.4. The Bearings and Bearing Housing
The shaft bearings are enclosed within the bearing housing. These bearings maintain the rotor and shaft
in the appropriate alignment with the other stationary components, despite the action of transverse and
radial loads. Moreover, the bearing housing comprises of oil reservoir that facilitates lubrication, as well
as cooling jacket with circulating water. Also, the bearings help to support both axial and radial loads
that are imposed on a centrifugal pump, especially because of the weight and hydraulic loads which are
enforced on the impeller. The shrouds of an impeller experiences high pressure which is exerted by the
high pressure liquid that flows continuously over the impeller’s circumference. This pressure produces
forces in both longitudinal and lateral directions.
Figure 14 bearing housing and bearings
3.2.5. The Mechanical Seal
A chamber is also known as a stuffing box or a seal chamber. The chamber is either part of or separate
from the pump’s casing house which is the region between the casing and the shaft where the sealing
media is located. The chamber is usually called a seal chamber when a mechanical seal is used to
achieve the seal. On the other hand, a chamber will be known as a stuffing box when the sealing is
realized through packing. Both the stuffing box and seal chamber protect against leakage, especially
when the shaft penetrates through the casing of the pump. The sub-ambient pressure experienced at the
chamber’s bottom level prevent all air leakages into a pump. The chambers eliminate liquid leakages out
of a pump, when the pressure is above the atmospheric pressure. The heating or cooling arrangement of
the stuffing boxes and seal chambers ensure that there is proper control of temperature.
Figure 15 mechanical seal
3.2.6. Key and Key Way
A key is a piece of mild steel inserted between the shaft and hub or loss in order to prevent relative
motion between them. It is always inserted parallel to the axis of the shaft. Keys are used as temporary
fastening and are subjected to considerable crushing and shearing stress. Common types of keys are
sunk key, saddle key, tangent keys and round keys.
3.3. Functional Structural Diagram
Functional structural diagram (FSD) is a graphical representation of operations that product performs on
its input or sets of flows to transform it from its input state to its output state. FSD’s are used for many
tasks in the design process. Most importantly they can help break down a complicated design problem
into manageable chunks.
Figure 16 functional structural diagram (FSD)
3.4. Solution Principles and Concept generation
3.4.1. Solution Principle
3.4.1.1. Solution principle for Shaft
1. The characteristics of Solid stepped shaft
It has good machinability.
It has low notch sensitivity factor.
It should have high wear resistant properties.
Easy to manufacture
2. The characteristics of Hollow shaft
It has less weight.
It is difficult to machine.
It has higher cost.
Table 1 Solution principle for shaft
Design Criteria Solid Stepped Shaft Hollow Shaft

Score Score
Ease to manufacture 4 3
Design 3 2
Reliability 4 2
Strength 4 3
Cost 4 3
Time to manufacture 3 2
Total 22 15
Rank 1 2
Therefore, according to the solution principle computed on the above table solid with stepped type is
selected. Key: 4 –excellent 3 –good 2 - Moderate 1 – Poor
3.4.1.2. Solution Principle for Bearing
Advantages and disadvantages of rolling contact bearings over sliding contact bearings
Advantage:
Low coefficient of friction.
Ability to withstand shock load.
Small overall dimensions.
Reliability of service.
Easy to estimate life
Disadvantages:
More noisy at very high speeds.
More initial cost.
Design of bearing housing complicated.
Table 2 Solution principle for bearing
Design criteria Rolling contact bearing Sliding contact bearing

Score score
Efficiency 4 3
Shock load resistance 3 2
Friction 4 2
Speed 4 2
Life estimation 3 2
Design 2 3
Lubrication 2 3
Noise 3 4
Cost 2 3
Time to manufacturing 2 3
Total 29 27
Rank 1 2
Key: 4 –excellent 3 –good 2 - Moderate 1 – Poor
Therefore, according to the solution principle computed on the above table rolling contact bearing type
is selected. Among the rolling contact bearing we need to select the right type so, the following solution
principle is computed.
Table 3 Solution principle for type of rolling contact bearing
Design Tapered roller bearing Needle Bearing Angular contact Thrust ball bearing
criteria bearing
Score Score score
Score
Efficiency 4 4 2 3
Shock load 4 3 3 2
resistance
Design 3 3 2 3
Reliability 4 3 3 2
Noise 4 4 3 4
Cost 4 3 2 3
Total 23 20 15 17
Rank 1 2 4 3

Therefore, according to the solution principle computed on the above table Tapered roller bearings type
is selected.
3.4.1.3. Solution Principle for Impeller
The characteristics of open impeller
The efficiency of an open impeller can be maintained through clearance adjustment.
The disadvantage of this impeller is structural weakness.

Are usually used in small, inexpensive pumps or pumps handling abrasive liquids or suspended
solids.
As they don’t have any support either side they tend to be weaker, and therefore are typically
used in smaller, inexpensive pumps that aren’t operated under significant strain.
They are able to handle a degree of solid content
The characteristics of closed impeller
They can deal with volatile and explosive fluids.
Has enclosed at the back and front, providing maximum strength.
They are the most popular impeller for large pumps transferring clean liquid as they are prone to
clogging when in contact with solids.
They have a low NPSH required and provide a more efficient flow.
Therefore, according to the solution principle computing by their characteristics closed type of impeller
is selected.
3.4.1.4. Solution Principle for Casing
The characteristics of single volute casing
It is simple so it is less difficult to cast.
Less expensive to produce given the open areas surrounding the impeller periphery. At flow rates
near the pump BEP, single volute casings are more efficient than double volute casings.
The inherent greater throat areas can also handle larger solids, as found in wastewater.
The characteristics of Double Volute Casing
The hydraulic performance of double volute pumps is nearly as good as that of single volute
pumps.
are most common with larger-axial, split-case, double-suction impeller pumps
Should not be used for a flow of below about 400gpm.

Therefore, according to the solution principle computing by their characteristics single volute casing
type of casing is selected.
3.5. Material Selection
Selecting construction materials is an important component to the success of any pump application, and
their initial cost is normally the first consideration. Other factors to be considered in selecting these
materials for wetted pump parts are users’ experience, expected pump life, intermittent or continuous
duty, the pumping of hazardous or toxic liquids, condition of the liquid, pump suction energy level, and
conditions of service.
3.5.1. Material Selection for Shafts
The material used for shafts should have the following properties:
It should have high strength
It should have good machinability.
It should have low notch sensitivity factor.
It should have good heat treatment properties.
It should have high wear resistant properties.
It should have high rust resistant properties
Table 4 Material selection for shaft
Design Criteria Mild Steel Stainless Steel Aluminum

Score Score Score
Availability 4 2 3
Strength 4 4 1
Cost 3 1 3
Rust Resistance 2 4 4
Wear 3 4 3
Total 16 15 14
Rank 1 2 3
Therefore, according to the above table mild steel is selected.
3.5.2. Material Selection for Impeller
The material used for impeller should have the following properties
It should have Corrosion resistance
It should have Abrasive-wear resistance
It should have Cavitation resistance
It should have Strength
It should have Casting and machining properties.
Table 5 Material selection for impeller
Design Criteria Mild steel Stainless steel Aluminum

Score Score score
Cavitation Resistance 2 4 2
Strength 4 4 1
Rust Resistance 2 4 4
Wear Resistance 3 4 3
Total 11 16 10
Rank 2 1 3
3.5.3. Material Selection for Casing
The material used for casing should have the following properties, but since it is cover for the impeller
and body the strength is the main concern.
It should have Corrosion resistance

It should have Abrasive-wear resistance
It should have Cavitation resistance
It should have Strength (primarily for the casings)
Table 6 Material selection for casing
Design Criteria Mild steel Stainless Steel Cast iron

Score Score Score
Strength 4 4 4
Rust resistance 2 4 3
Wear resistance 3 4 3
Total 9 12 10
Rank 3 1 2
Therefore, based on the above properties stainless steel is selected.
3.6. Design Concept Generation
Concept-one: Single stage centrifugal pump

A single-stage centrifugal pump consists of one impeller rotating on a shaft within a pump casing which
is designed to produce fluid flow when driven by a motor. It is one of the simplest designs of pumps
available and many variations in design exist to satisfy the duty requirements of applications. Impeller
design is changed to accommodate clean, dirty, and solid-laden liquids, with several mechanical seal
types to accommodate variations in applications.
However have a It has low efficiency and it has only one stage for the fluid. Therefore, it can only pump
fluids for a short distance.
Concept-Two: Multistage centrifugal pump

A multistage pump is a type of centrifugal pump that pressurizes the fluid in multiple stages (two or
more stages). Because this pump uses more than one stage, therefore, it is known as a multistage pump.
Each stage has guide vanes, a diffuser, and an impeller, and these components are enclosed in the pump
casing. A multistage pump uses an impeller to increase the pressure of the water instead of a piston. The
types of impellers for each stage may be different or identical.
Concept-Three: Vertical multistage centrifugal pump

This type of pump uses a centrifugal force to transfer the fluid from the impeller to the diffuser. A
diffuser uses to increase the pressure of the fluid by reducing its speed. Vertical multistage pumps can
easily install in the low space location. However, they need small space for their installation due to their
vertical design.
Concept-Four: Horizontal multistage centrifugal pump

This multistage centrifugal pump has a segmented pump housing with modular intermediate parts. The
spinning parts are fixed between the bearing housings, which improves the balance of the parts under
high pressure.
In general, this pump can handle higher flow rates compared to a vertical multistage pump (except for a
vertical turbo pump). It shows excellent productivity and high-quality material.
3.7. Detail Design and Development of Thesis Work
In the design of multi-stage centrifugal pump, the first thing is to know the number of stages that the
pump will have in order to have possible highest efficiency.in order to do that we have to know the
specific speed by using the given parameters.
Q = A*v
Where: A – Area of the pipe = Π*(d/2)^2 (m^2)
: v – Speed of the liquid (water) in the pipe (m/s)
v ≤ 1 m/s Domestic application
v ≤ 2 m/s other application
v ≤ 5 m/s Waste water application [ ]
: Q – Quantity of liquid (water) flowing through the pipe
Let’s use 11cm diameter pipe for transporting the water.
And from the above data let’s use v = 2m/s
Now we can solve for quantity of water Q;
Q = A*v
= Π*(d/2)^2 * v
= 3.14*(0.0121/4) * 2m/s
= 0.0183m^3/s
Q = 0.0183m^3/s = 66m^3/hr
1m^3 = 4.39 GPM
Q=66m3 /hr.=0.01833m3 /sec=290.53GPM

Assuming to supply water from a nearby well to a detached building and the water level in the well with
respect to the pump suction port is located at hs = 3m
Supposing a 17 story building (57m building), Thus the total head (H) is:
H = hs + 57m
= 3m + 57m
H = 60m
H=60m=196.8504ft
n=2900rpm (most pumps operate at rotational speed between 1000 - 3000 rpm)
Specific speed
Specific speed is a number characterizing the type of impeller in a unique and coherent manner.
Specific speed is defined by the equation
n Q
Ns  0.75
H
f
Where f = number of stage
To find the number of stages, by using a graph of efficiency vs. specific speed by which for which stage
number it can attain higher efficiency.
For f =1 (1 stage only)
n Q
Ns  0.75
2900rpm * 290.53 gpm
H =
196.85 ft
0.75 = 940.63
f
𝑓𝑜𝑟 𝑁𝑠 = 940.63 𝑎𝑛𝑑 𝑄 = 290.53, 𝑡ℎ𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦()𝑤𝑖𝑙𝑙 𝑏𝑒 73.4% as can be seen from the graph
below. Based on this calculation changing the number of stages, the best number of stages can be
selected.
Figure 17 specific speed vs. efficiency
Table 7 Selection of stage
No. stages Head/f Specific speed Flow rate (Q in efficiency

gpm)
1 196.85 940.64 290.53 69.94
2 98.425 1581.85 290.53 74.6
3 65.616 2144.04038 290.53 78.68
4 49.213 2660.13 290.53 75.4
5 39.37 3144.98 290.53 73.8
Based on this the number of stage should be 3.
3.7.1. Design of impeller
Impeller is a rotating component of a centrifugal pump that accelerates fluid outward from the center of
rotation, thus transferring energy from the motor that drives the pump to the fluid being pumped.
The first thing for the design of impeller is the type of impeller.
There are 3 types of impeller
Radial
Axial
Mixed types
For centrifugal pump, radial type is commonly used
Figure 18 type of vane [ ]

Steps
Step 1 - calculating the specific speed
Specific speed (𝑁𝑠) = 𝑟𝑝𝑚∗ (𝐺𝑃𝑀) ^ 0.5 / 𝐻^0.75
Ns=2144.11
Step 2 - Select vane number and discharge angle.
From the previous works the best efficiency is found mainly by using 6 or 7 number of vanes (blades) is
used. In order to find vane number and discharge angle a diagram is used, in which the percent by which
discharge head rise from BEP to zero GPM is used to find it.as can be seen from the figure below the
desired head rise from BEP to zero GPM is 25% continuously rising. To produce this type of head rise,
the impeller should be designed with six (6) equally spaced vanes having a 25⁰ discharge angle as can
be seen from figure.
Figure 19 Head vs capacity graph

Based on this, using of the figure below we chose the number of vanes, which for our case is 6.
Figure 20 vane number [ ]

Step 3 - Calculate impeller diameter
The outer diameter of the impeller can be found by using;
1.840 * Ku * H 0.5
D2 
n
Where - ku is a head constant which can be found from the figure below.
Figure 21 specific speed vs head constant [ ]

As can be seen from the figure with a specific speed of 2144 and 6 vanes the head constant ku=1.11
1.840 * Ku * H 0.5
D2  = 1.840 * 1.11 * 196.8504^0.5 / 2900 = 9.88in
n
Step 4 - calculate impeller width b2

GPM * 0.321
b2 
Cm2 * ( D2 *   Zsu )
Where z - number of vanes
Su - is estimated value for which is given 0.5inch.
Cm2  Km2 * (2 * g * H ) 0.5
Here the value of Km2 can be found from the figure below
Figure 22 capacity constant [ ]

From the figure Km2= 0.145
Cm2  Km2 * (2 * g * H ) 0.5 = 0.145 ∗ (2 * 9.81 *196.8504)^ 0.5 = 9.0112 ft/sec
GPM * 0.321 290.53 * 0.321

b2  =  0.36991in
Cm2 * ( D2 *   Zsu ) 9.0112 * (9.88 *   6.05)
Step 5 - Determining eye diameter

The dimension in which the eye of the impeller is found with the ratio to the outer diameter of the
impeller. The ratio for which the impeller outer and eye diameter is found from the figure below with an
accepted value and unaccepted value.
Figure 23 ratio of eye to outer diameter [ ]
D1
From the figure above the ratio = eye diameter / impeller diameter = = 0.515
D2
Since the outer diameter is found, the inner (eye)diameter is found
D1w  0.515 * 9.88  5.0882in
The inlet area of impeller is
 2 
A1  D1  5.08822  20.334in
4 4
The outlet area of impeller
A2   * D2 * b2   * 9.88 * 0.3699  11 .481in 2
From the equation Q=A*V2

Q 0.01833
V2    24.7 m / s
A2 0.007407
The impeller inlet blade width

b1  0.221* d1  0.221* 5.0082  1.2449in
Figure 24 impeller dimension
Velocity profile
A study of the several component velocities of flow through an impeller is best carried out graphically
by mean of velocity vectors. The shape of such vector diagram is triangular and they are called velocity
triangles. It can be drawn for any point of the flow path through the impeller, but usually attention is
focused on the inlet and outlet triangles.
Figure 25 Inlet flow velocities and outlet flow velocity Diagram

The Effect of impeller blade shape on performance
The blade shapes can be classified as:
Backward-curved blades (β2 < 90° )
Radial blades (β2 = 90° )
Forward-curved blades (β2 > 90° )
As shown in Fig., for backward-curved vanes, the value of Cw2 (whirl component at outlet) is much
reduced, and thus, such rotors have a low energy transfer for a given impeller tip speed, while forward-
curved vanes have a high value of energy transfer. Therefore, it is desirable to design for high values of
β2 (over 90°), but the velocity diagrams show that this also leads to a very high value of C2. High
kinetic energy is seldom required, and its reduction to static pressure by diffusion in a fixed casing is
difficult to perform in a reasonable sized casing.
Figure 26 Centrifugal pump outlet velocity triangles for varying blade outlet angle.
Figure 27 Characteristics for varying outlet blade angle.
So, based on this for a higher head forward curved blade is selected.
Radial velocity at inlet Vr1 is
Vr1  K1m (2 gH ) 0.5

Figure 28 Km1 and other constants
n * Q 0.5
Ns 
H 0.75
f
0.5
66
2900 *
 60  321.6
600.75
3
Thus: Km1=0.176
Vr1  K1m (2 gH ) 0.5 = 0.176( 2 * 9.81* 60) 0.5  6.03
Then solving for Radial velocity at outlet, Vr2
Vr 2  Km2 (2 gH )  9.0112
Now using trigonometric equation tangential velocity will be
2 2
V 2  (V2  Vr 2 ) 0.5  (24.7 2  9.01122 ) 0.5  22.99m / s 2
Vane outlet velocity, U2 is
D2 n  * 9.88 * 2900

U2    772.6108in / min
60 60
The blade velocity at the inlet (U1) is
 * D1n  * 5.0882 * 2900

U1    1500.215in / min
60 60
The water is assumed to enter the vanes radially, so that the absolute velocity α1 is 90˚. After Vm1 and
U1 have been calculated, the vane inlet angle β1 is obtained by the Equation:
V1 6.03
1  tan 1  tan 1  23.66
U1 772.61
60
The blade angle at outlet is;
V2 9.011
 2  tan 1  tan 1  33.68
U2 1500.215
60
The normalized inlet diameter of impeller D1 is given by;
(Q) 0.5
D1, adj  4.25  56.7 mm
n
Impeller Blade Shape

A method of drawing the impeller blade by three circular arcs is used for this present design. Each
radius is given by;
Figure 29 Curvature of Impeller Blade Curvature of Impeller Blade

2 2
( RA  RD ) (4.942  2.5442 )
A    10.0735
2( RA cos  2  RD cos 1 ) 2(4.94 cos 33.68  2.544 cos 23.66)
2 2
( RA  RC ) (4.14132  303426 2 )
B    1.5595
2( RB cos  2  RC cos 1 ) 2(4.1413 cos 33.68  3.3426 cos 23.66)
2 2
( RC  RD ) (3.3426 2  2.544 2 )
C    1.4541
2( RC cos  2  RD cos 1 ) 2(3.34226 cos 33.68  2.544 cos 23.66)
Where, RA, RB, RC and RD are base circle radii, RA=D2/2 and RD = D1/2. The angles between β1 and
β2 are divided into three angles.
D2 9.88
RA    4.94in
2 2
D1 5.088
RD    2.544in
2 2
RA  RD 4.94  2.544
RB  RA   4.94   4.1413in
3 3
RA  RD 4.94  2.544
RC  RB   4.1413   3.3426in
3 3
To find the length of the blade Kovats (1971, pp. 142-146) introduced a method. According to this
method, approximate blade length is calculated first:
d 2  d1 9.88  5.088 4.792

    4.55in
1B   2 B 33.68  23.66 1 .05
2 sin( ) 2 sin( )
2 2
Figure 30 how the impeller blade is drawn

3.7.2. Design of Volute Casing
Spiral or volute casing is an approach or suction channel kept before the impeller inlet as well as a
delivery channel kept after impeller outlet. The channel passage may be in the form of vanless spiral
casing or in the form of vanned or vanless divergent passage called diffuser or return guide passage.
Design of casing or diffuser must ensure the following:
Axisymmetric and equal velocity distribution of flow must always be ensured, since at optimum
conditions, the flow in impeller is axisymmetric. Hydraulic efficiency is also higher.
Must uniformly and efficiently convert kinetic energy coming out from the impeller outlet into
useful pressure energy.
Momentum at the outlet of impeller must be completely converted in volute casing and
momentum at the casing outlet should be zero.
Volute casing at the outlet of the impeller
Volute casings at outlet are of two types:
1. Spiral shaped, vanless form of casing and
2. Diffuser type vanned system of casing.
For this paper vanless type is selected.
First stage volute design
N * (Q) 0.5
Ns 
H 0.75
Where n = Speed H = Head developed by impeller Since we assume that each amount of head then H =
60m and for three stage each impeller collects 20m. So H becomes 20m, H = 20.
66 0.5
2900 * ( )
60 3041.54
Ns  0.75
  321.6
( 20) 9.4574
Correlate specific speed Vs ratio of throat velocity to impeller peripheral speed. We find average value
for ratio:
Cthr
( )  0.374
U2
Where Cthr = throat velocity (m/s)
U2 = Impeller peripheral speed
U2 =772.6108in/min
Cthr  U 2 * 0.374  772.6108in / min* 0.374  288.956in / min
Change the parameter inch into meter 1in = 0.0254m
Where, x is the distance between any radius R and impeller outside radius R2
0.0254 * 288.956
X   7.3394m
1
Tentative throat area
Q *106 mm 3 / 60 min
Athr   149,876mm 2
7.3394 *103
Assuming A circular throat section its radius is:
rthr * 4
(
rthr    190828.0649  218.41mm
2 2
Distance of the throat center of the throat section from axis is
r4  r2  t  rthr
Where r4 =Distance of the throat center from axis (mm)
r2 = Outer radius of impeller (mm)
t= Tongue distance (mm)
The intermediate volute areas are calculated on the basis of constant angular momentum.
Intermediate areas can be calculated

Athr *
A 
360
Radius of intermediate Area can be calculated as
A * 4
r  
2
Where rθ =radius of intermediate section of volute at angle
Aθ = area of intermediate section of volute at angle
θ = Central angle (degree).
The distance of section center at angle
r4  r2  t  rthr
The central angle which is from center of the impeller to the outer circle which is divided by the number
of blades (vanes) is assumed to be 45°
Athr * 149876 * 45
A    18734.5mm 2
360 360
The intermediate volute areas are calculated on the basis of constant angular momentum. Stepanoff [ ]
recommends a constant mean velocity for all volute sections, which results in volute areas being
proportional to the central angle θ Radius of intermediate section of volute at angle θ.
A * 4 18,734.5 * 4
r      77.222mm
2 2
The trapezoidal shape for intermediate area of volute is selected for better efficiency. The trapezoidal
shape makes the entrance width of the volute to be appreciably greater than the impeller discharge width
(b2) which leads to smooth flow. For pumps of medium specific speeds, b3 = 1.75 b2. For small pumps
of lower specific speed (b2 is small), including multistage pumps, b3 = 2.0 b2. For high specific speed
pumps (ns > 3000 double-suction) b3 can be reduced to b3 = 1.6 b2. Where b2 is impeller width at
discharge and b3 is base width at D2. Thus, the base width in this study is taken as
b3  2.0 * b2  2 * 9.395  18.79mm 2
 60
bmax  b3  (2 * X * tan( ))  18.79  ( 2 * 7.34 * tan( )  27.2655
2 2
Where b3 = Minimum entrance width of volute casing (mm)
b2 = Width of impeller (mm)
bmax = Maximum entrance width of volute casing (mm)
q = Shroud thickness (mm)
x= Distance between any radius r0 and impeller radius r2 (mm) 
φ= Angle with radial line of section (degree), generally considered as 60 degrees
Figure 31 shape for intermediate area of volute

Design stress value is taken as minimum value obtained from 0.25 times the tensile strength and 0.67
times the yield strength which is 1240 bar for casing material. Thus T=51.78mm.
The provided thickness for volute casing is 52mm.which gives a Total Volute area of 1,093,074 mm2
Considering, Casing as a cylindrical body
  * D2 
   1093074
 4 
D  1179 .722mm  46.445inches
From ASTM B16.47-2006, thickness of casing at 103.4 bar pressure and at ambient temperature 46”
class 600 flange is 179.4 mm. The thickness of casing at maximum discharge pressure is calculated as
110 mm. And by considering corrosion allowance and for more safety thickness of casing is finalized as
140 mm. The total separating force acting on casing halves is calculated using total volute area and the
pressure exerted on volute. Size and minimum number of bolts required to withstand this force is
calculated as M48 x 52 numbers.
3.7.3. Design of Shaft
Shaft is a rotating machine element which is used to transmit power from one place to another. The
power is delivered to the shaft by some tangential force and the resultant torque (or twisting moment) set
up within the shaft permits the power to be transferred to various machines linked up to the shaft.
Types of Shafts
The following two types of shafts are important from the subject point of view:
1. Transmission shafts.
These shafts transmit power between the source and the machines absorbing power. The counter shafts,
line shafts, overhead shafts and all factory shafts are transmission shafts. Since these shafts carry
machine parts such as pulleys, gears etc., therefore they are subjected to bending in addition to twisting.
2. Machine shafts.
These shafts form an integral part of the machine itself. The crank shaft is an example of machine shaft.
For this case, since it is transmitting power to the impeller by rotating transmission shaft is used.
Hydraulic efficiency
The hydraulic efficiency (h) can be determined from the relation
g*H 9.81* 60
h    0.84
U 2 *V 2 30.59 * 22.9
Pump Shaft Power ‘N’
QgH
N
1000
Since water is used ρ = 1000kg/m2 , Q = 0.01833m3/s, H=60m
1000 * 0.01833* 9.81* 60

N  13.48kw
1000 * 0.84
The Torque Mt on the Shaft.
9600 * N
Mt 
n
Where
n = rpm
N = power
9600 *13.48
Mt   44.62
2900
Now we should find the shear stress induced in the shaft.
16 * M t 16 * 44623376.35 191523326.60
  
d 3 d 3 d3
But
0.5 Yt
 all 
FS
FS = 4 from table in appendix for steel with steady load and take σYt == 1640Mpa a for 4140 quenched
and tempered (Q&T) steel
0.5 *1640
 all   205 N
4
191523326.6077
205 
d3
d  40.75mm  41mm
The pump shaft coupling
The diameter of the coupling can be determined by
D  2d  13mm
Where d=diameter of the shaft
D  2 * 41*13  95mm
Length of the coupling
L = 3.5 × 41 = 3.5 × 41= 143.5mm
The pump shaft coupling key
Length of the coupling key (l)
3.5 * d 3.5 * 41
   71.5mm
2 2
from proportions of standard parallel tapered and gib head keys that is for a shaft of 21mm diameter the
width and thickness of the key is w = 6mm and t = 6mm.
Figure 32 key size [ ]
Impeller Hub Diameter 𝑑ℎ𝑢𝑏

From the design consideration 𝑑ℎ𝑢𝑏 is assumed to be (1.2 to 1.4) ds.
𝑑ℎ𝑢𝑏 = 1.4 ∗ 𝑑𝑠 = 1.4 ∗ 41 = 57.4𝑚𝑚
Impeller Hub Length (Lub)
Lhub = 1x dhub =41mm
3.7.4. Design of Bearing
A bearing is a machine element which support another moving machine element like shaft and axle. The
shaft bearings are enclosed within the bearing housing. These bearings maintain the rotor and shaft in
the appropriate alignment with the other stationary components, despite the action of transverse and
radial loads. Moreover, the bearing housing comprises of oil reservoir that facilitates lubrication, as well
as cooling jacket with circulating water. Also, the bearings help to support both axial and radial loads
that are imposed on a centrifugal pump, especially because of the weight and hydraulic loads which are
enforced on the impeller.
Figure 33 Ball bearing

Assumptions and working conditions
Reliability 95%
2900 rpm
24 hr./day, 7 days/week
Replace quarterly
Design factor 1.3 and assume catalog data 106 rev
1
 a
XD
C10  a f FD  
 1 
 X 0  (  X 0 )(1  RD ) b 
Where;
𝐶10 – dynamic load rating,
𝑎𝑓 = 1.3 -design factor,
𝐹𝐷 = 112746 𝑁 - design load
𝑋𝑜, 𝑏 𝑎𝑛𝑑 𝜃- Weibull parameters
𝑅𝐷 = 0.95- design reliability
𝑎 = 3 (𝑏𝑎𝑙𝑙 𝑏𝑒𝑎𝑟𝑖𝑛𝑔) function of ball vs roller
 365.25days  24hr  60 min 

cycles      2900rev / min 
 4  days  hr 
Cycles=381.321*10^6
Torque 37.57 Nm
F D   2504.66 N  563.074lb
radius 15 *10 3 m
Figure 34 Rating life

1
 3
4.21
C10  (1.3)(563.073)  
 1 
 0.02  ( 4.459  0.02)(1  0.95) 1.483
 

4.21 0.33
C10  731.9949( )
0.61
C10  999.26lb  4444.9090 N
With having a shaft diameter of 40.95mm, from the figure below we can choose
Outer diameter = 80mm

Width =18mm
Fillet radius = 1
Shoulder diameters of bearing ds = 46mm and dh=72mm
3.7.5. Design of Seal
Mechanical seals consist of two basic parts, a rotating element attached to the pump shaft and a
stationary element attached to the pump casing. Each of these elements has a highly polished sealing
surface. The polished faces of the rotating and stationary elements come into contact with each other to
form a seal that prevents leakage along the shaft.
Figure 35 Types of seals

Multi-stage pumps are seldom as sensitive to operating off the best efficiency point (BEP) as single
stage centrifugal pumps. The opposing cutwaters in these pumps tend to cancel out the radial forces
created when the pump is operating off of its best efficiency point (BEP).
Figure 36 mechanical seal in a centrifugal pump

BASIC DESIGN OF A MECHANICAL SEAL
The stationary part of the seal is fitted to the pump housing with a static seal, this may be sealed with an
O ring or gasket clamped between the stationary part and the pump housing. So sealing points in the seal
design are straightforward and static seals.
The rotary portion of the seal is conserved onto the shaft typically using an O ring. This sealing
point can also be looked upon as static as this component of the seal rotates with the shaft. The
mechanical seal itself is the interface between the static and rotary portions of the seal.
One part of the seal, either to static or rotary portion, is always resiliently mounted and spring
loaded to accommodate any small shaft deflections, shaft movement due to bearing tolerances
and out-of-perpendicular alignment due to manufacturing tolerances
3.7.5.1. Stuffing Box
The “pump” portion consists of a volute casing with inlet and outlet ports for the fluid. The impeller
rotates inside the volute casing that throws the fluid. This impeller is driven by a shaft, which is
connected to the electric motor which drives it.
Now, this shaft has to rotate. The fluid should not come out of the volute casing from the location of the
shaft. This leakage is prevented by the stuffing box or a mechanical seal. The stuffing box essentially
prevents water leakage.
A stuffing box is an assembly which is used to house a gland seal. It is used to prevent leakage of fluid,
such as water or steam, between sliding and turning parts of machine elements.
Figure 37 stuffing box

When a lantern gland is used. A depth of 5W is used when a lantern ring is not being used.

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DESIGN AND ANALYSIS OF MULTISTAGE CENTRIFUGAL WATER PUMP

1.1 Background of the Study

Water supply: To supply water to inhabited areas.

1.1.1. Centrifugal Pumps

Figure 1 the pump market [ ]

1.1.1.1. Types of centrifugal pumps

Figure 2 Vertical and horizontal pump

Figure 3. Multistage pump

Figure 4 Multistage pump with end suction

Figure 5 Models of pump supports and Axial split casing

1.1.2. Multi stage Centrifugal Pump

Function of a multistage centrifugal pump

Figure 6 Two stage pump with impeller in series

To discharge a large quantity of liquid

Figure 7 Pumps in parallel

1.2. Problem Statement

1.3.1. General Objection

1.3.2. Specific Objective

1. To determine the optimized stage of centrifugal pump.

10. Part Drawing and Assembly Drawing.

Water supply boosting by increases pressure for water usage.

Irrigation which is used to pump water throughout an irrigation system.

1.5. Scope and Limitation

1.6. Organization of the Study

The thesis is organized by seven chapters. Which are described below.

Figure 8 Thesis Organization

2.1. Fundamental theory

2.1.1. Pump Types

A. Positive displacement pumps

B. Roto-dynamic pumps (centrifugal pumps)

Figure 9 Centrifugal pump – basic construction

2.1.2. Working Principle of Multistage centrifugal Pump

Figure 10 flow chart of the project

3.2. Product Definition

3.2.1. The Impeller

3.2.1.1. Open Impeller

3.2.1.2. Semi-Open Impeller

3.2.1.3. Closed Impeller

Figure 11 types of impellers

3.2.2. The Casing

Provides pressure containment.

Incorporates the collector.

Allows rotor installation and removal.

Supports the pump.

3.2.3. The Shaft

3.2.4. The Bearings and Bearing Housing

Figure 14 bearing housing and bearings

3.2.5. The Mechanical Seal

Figure 15 mechanical seal

3.2.6. Key and Key Way

3.3. Functional Structural Diagram

Figure 16 functional structural diagram (FSD)

3.4. Solution Principles and Concept generation

3.4.1. Solution Principle

3.4.1.1. Solution principle for Shaft

1. The characteristics of Solid stepped shaft

It has good machinability.

It has low notch sensitivity factor.

It should have high wear resistant properties.