HYDRO CONVERSION SYSTEMS

By:
Satish Kumar
NIT JAMSHEDPUR
 CONTENTS

• Pump
• Centrifugal pump
• Problem in pump
• Data required in selection on of pump
• Cavitation and NPSH
• Design Of Centrifugal Pump
 BERNOULLI’S THEOREM
• The Bernoulli equation is a special statement of
the general energy equation.
• Work added to the system is referred to as pump
head (hP).
• Losses from the system are referred to as head
loss (hL).
• Pressure is a form of work.
• Strictly Mechanical Energy so we get the
equation:
P1 + PE1 + KE1 + WK = PE2 + KE2 + WKFRIC + P2
 BERNOULLI’S EQUATION

Z1 + (P1/g) + (V12/2g) = Z2 + (P2/g) + (V22/2g) + - hL

Z : Elevation Hp: pump head

P : Pressure HL: Head Loss = f(L/D)(V2/2Zg)
where ,
: Density f : friction factor
V : Velocity L: Length
g : acceleration D: Diameter
 THE CONCEPT OF “HEAD”
• Pressure Head: difference in water pressures between the source and
the delivery point
• Friction Head: total friction loss between the source and the delivery
point
• Friction Head
Hl= f(L/D)(V2/2g)
where,
• f : friction factor
• L: Length
• D: Diameter

• Velocity Head: V2/(2g)

•
 PRESSURE HEAD

NET STATIC STATIC

HEAD DISCHARGE
HEAD

STATIC SUCTION
PRESSURE

PUMP
OBJECTIVE OF PUMPING SYSTEM

• Transfer liquid
from source to
destination
• Circulate liquid
around a system

© UNEP 2006
• Main pump components
• Pumps
• Prime movers: electric motors, diesel engines,
air system
• Piping to carry fluid
• Valves to control flow in system
• Other fittings, control, instrumentation
• End-use equipment
• Heat exchangers, tanks, hydraulic machines
 PUMP COMPONENTS
DRIVE TYPE
(electric motor,
steam drive, gear
driven, etc…) IMPELLER

PUMP SHAFT
DISCHARGE

CASING SUCTION
 PUMPS - Types
• Positive Displacement Type: high ΔP (head), low volumetric flow
• Gear Pumps:, 150 gpm, low cost, long life, high η
• Vane Pumps: low cost, reliable,
• Lobe Pumps: quieter and higher flows than Gear Pumps
• Reciprocating:
• single or double acting, for clean fluids, low speed (200rpm), small flow,
high pressures
• Centrifugal Pumps:
• large volume, low ΔP
• Diffuser/volute types: velocity converted to static pressure, low cost,
• high reliability, many fluids
• Propeller (Axial) Pumps:
• Large size range, large flow rate, low head
• Can handle dirty fluids and sludge
 PUMPS
• Two types

Flow
Flow rates Pressure
characteristics
Displacement
- plunger
- piston Low High Pulsating
- rotary

Dynamic
- centrifugal
High Low Steady Flow
- jet
- airlift
Dr. C. L. Jones
Biosystems and Ag. Engineering
12
 TYPES OF PUMPS

Positive Displacement Pumps

• Reciprocating pump
• Displacement by reciprocation of piston
plunger
• Used only for viscous fluids and oil wells

• Rotary pump
• Displacement by rotary action of gear, cam
or vanes
• Several sub-types
• Used for special services in industry
© UNEP 2006
 POSITIVE DISPLACEMENT PUMP

• Fixed Volume
• Volumetric Flow rate is proportional to
speed
RECIPROCATING AND PISTON PUMPS

– Crank
– Connecting rods
– Pistons or plungers
– Vol. efficiencies > 97%, Mech. eff. approx. 90%
– For more stable flow, increase number of cylinders

Dr. C. L. Jones
Biosystems and Ag. Engineering
15
Main Characteristics of centrifugal & Positive Displacement Pumps

Positive Displacement pumps

Centrifugal pumps (very few using in plumbing
system)

- Capacity varies with head - Capacity substantially

- Capacity proportional to pump independent of head
speed - Capacity proportional to speed
- Head proportional to the square - Self-priming
of pump speed - Suitable for various liquids
- Non self-priming (reduced speeds usually necessary
- Suitable for low-viscosity liquid for high viscosity
ROTARY PUMPS
Most positive displacement pumps in use
are of the rotary type.
Rotary pumps operate in a circular motion
and displace a constant amount of liquid
with each revolution of the pump shaft.
This is accomplished by the pumping
elements moving in such a way as to expand
volumes to allow liquid to enter the pump.
These volumes are contained by the pump
until the geometry causes the elements to
move to reduce the volume and force the
liquid out
The clearances of the elements within the
pump separate the suction from the
discharge and are critical for efficient
operation.
 SCREW TYPE PUMPS

Twin-screw pumps Three-screw pumps

Screw type pumps usually have either two or three screws. They
can operate at high speeds and give a smooth discharge with
almost no pulsations.
They come in two configurations, either Twin-screw pump or
Three-screw pump.
E
X
A
M
P
L
E
S
Radial Piston Pump
Operation of the radial piston
pump
• You can see that the pistons rotate
eccentrically to the rotor axis. This causes the
cylinder volume to increase as the pistons pass
the suction port,and decrease as the pistons
pass the delivery port.
• In some applications such as steering gear
applications,the pump can have a variable
discharge .This is achieved by increasing and
decreasing the eccentricity of the pistins
thereby changing the amount of cylinder
volume increase.
• The nature of the ports can also change by
moving the piston eccentricity past the pump
centre line.
 Operation of the axial piston pump
2. and are forced back
OUTLET PORT in at outlet PISTON

DRME

SWASH

1. Pistons withdraw
from bore at inlet.
An axial piston pump is sometimes known as a swash plate pump.
The principle is the same as for the Radial type.
An axial piston pump can also be used as a variable delivery pump.
 Flexible vane pumps

Casing Rotor

The rotor is made of an

elastomer, and as the vanes
pass the cam they deflect,
decreasing the cavity and so
discharging the liquid.
Sliding vane pumps

The vanes are a sliding fit

in slots cut in the rotor. The
rotor turns eccentric to the
casing, causing the cavities to
decrease in volume.
Vanes can be forced out by
centrifugal force, use springs
or utilise the pressure of the
discharge liquid.
 ROTODYNAMIC PUMP
• Rotodynamic pumps generate the head or
pressure by the dynamic action of moving
blades (runner).
WORKING PRINCIPLE OF CENTRIFUGAL PUMP

• Centrifugal pump works on the

basis of 2nd law of Newton.
• Power supplied by Motor
P=T×ώ
• Torque = Rate of change of
angular Momentum
= The head of fluid developed
 COMPONENTS

1- Impeller
• Rotating part of
centrifugal pump is
called impeller.
• It consist of a series
of backward curved
vanes. By centrifugal
action the head is
developed .
2- Volute Casing:

 Volute is to convert kinetic

energy imparted by impeller
into pressure
 Water in the volute has free
vortex flow
 R.Vu = constant. By
increasing cross section area
decreasing the velocity.
3-Suction Pipe-
A pipe whose one end is
connected to the inlet of the
pump and other end dips into
water in a sump is known as
suction pipe.
4-Foot valve and Strainer-
A non-return valve is fitted at
the lower end of the suction
pipe. It opens only in the
upward direction.
A strainer is also fitted at the
lower end of the suction pipe.
5-Delivery Pipe-
A Pipe whose one end is
connected outlet of pump and
other end delivers the water at
a required height is known as
delivery pipe.
Typical Horizontal Centrifugal Pump Installation
 CLASSIFICATION
1. Working head
2. Type of casing
3. Number of entrance of impeller
4. Liquid handled
5. Specific speed
6. Outlet blade angle
7. Relative direction of flow.
8. Number of stages.
9. Position of impeller
 Centrifugal Pump Impellers

Enclosed Impeller Semi-Open Impeller

5. SPECIFIC SPEED

• Slow speed radial flow runner- 10 to 30

• Normal speed radial flow impeller- 30 to 50
• High speed radial flow impeller- 50 to 80
• Mixed flow runner- 80 to 160
• Axial flow runner- 110 to 150
6. OUTLET BLADE ANGLE
7. RELATIVE DIRECTION FLOW THROUGH
IMPELLER:
• Radial flow pump:
Ordinarily all the Centrifugal pumps manufacture with radial flow
impeller.
• Mixed flow pump:
Outlet mixed radial as well as axial combination. This is used for
large quantity of water to low height.
• Axial flow pumps:
Used in irrigation, high flow, low head.
8. NUMBER OF STAGES:
• Single stage pump
• Multistage pump
9. DEPENDING ON THE POSITION OF
IMPELLER:
• Horizontal impeller shaft pump
• Vertical impeller shaft pump
 CENTRIFUGAL PUMPS
• Horizontal
– Drive shaft is horizontal
– Often used when pumping from a surface
source (pond, lake, stream, etc.), Or for
boosting the pressure in an irrigation pipeline
(booster pump)
– Usually sold as completely assembled units
 Horizontal
Centrifugal Pumps
VERTICAL PUMP
 Single-Stage Vertical Pump

Water Flow Path

Through a One-Stage
Vertical Pump
 Two-Stage Vertical Pump

Water Flow Path

Through a Two-Stage
Vertical Pump
Submersible Water Pumps
- Same as vertical pump
design
- Driven from below by
electric motor
- Good for deep wells
- High efficiency
- Wells as small as 4” diameter
Pumps in Parallel
 PUMPS

– Centrifugal:
• Parallel pumps:

V2 = 2V1
HP 2 pumps
HP2 = HP1
1 pump

GPM
V
 PUMPS
• Series (called staging):

2 pumps
HP2 = 2HP1
HP
V2 = V1
1 pump

GPM
V
 PUMP LAWS
Apply to centrifugal (non-positive displacement)
pumps only

. N
V
Hp  N2
W.  N3

V = volumetric flow rate

N = speed of rotation
Hp = pump head
W =. power required (prime mover)
Pump
characteristics
curves
(centrifugal)
System Head Curve
 Pump Operating Point
• As indicated by its H-Q curve, a
pump can operate at many possible
points
• A pump will operate at a Q and H
determined by the point where the
pump curve and the system head
curve cross
• The same pump is likely to operate at
two different H-Q combinations when
placed in two different irrigation
systems
Pump Operating Point in a System
Different Pumps in the Same System
 Pump Selection
• System Head
• Definition:
– Total head imposed on a pump by the irrigation
system also called TDH (Total Dynamic Head),
total pumping head, etc.
• Components
• Static Head (Elevation Head): elevation
difference between water level on the inlet side
and the water delivery point
 Components of Total System
Head
(or Total Dynamic Head, Total Pumping Head)
 PUMPS PROBLEMS
1. Pumps fail to start pumping
• Suction lift and delivery head to high.
• Too low speed.
• Wrong direction of pump rotation
• Pump may be properly primed.
2.Pumps take too much power
• Speed may be too high.
• Head may be too low and pump delivers too much
liquid.
• Liquid may have too high a specific gravity.
• Pump may be operating in wrong direction.
3.Pumps starts and then stop pumping
• Improperly primed or leaky suction line.
• Air pockets in suction line.
• Suction lift may be too high.
4.Pump working but not up to capacity and
pressure
• Air may be leaking into pump through suction
line or through .
• Speed may be too low
• Discharge head may be higher then anticipated.
• Suction lift may be too high.
• Impeller may be partly dogged or too small in
diameter
• Rotation may be wrong direction.
ESSENTIAL DATA REQUIRED IN SELECTION
OF CENTRIFUGAL PUMPS

(1) Number of unit required.

(2) Nature of the liquid to be pumped—Is the
liquid.
• Fresh or salt water, acid or oil, slurry or paper
stock.
• Cold or hot and if not, at what temp. What is the
vapour pressure of the liquid at the pumping
temp?
• what is the specific gravity of the liquid
• Clear and free from suspended foreign matter or
directly and gritty.
 3.Capacity

What is the required capacity as well as the minimum and maximum

amount of liquid the pump will ever called upon to deliver
4.Suction condition
• What is the length and diameter of the suction pipe.
• No. of bends and elbows in suction pipe.
5.Discharge condition
• What is the delivery head? Is it constant or variable?
• What is the friction head?
• What is the max. Pressure against which the pump must
deliver liquid?
• What is the length and dia of delivery pipe?
6.Total head -what will be total head?

7.Service:-
• Is the service continuous or intermittent, and for
what duration .
• Pump installed in horizontal direction or a vertical
direction.
8. Location
• Geographic allocation.
• Elevation above sea level
• Indoor or outdoor installation
9.Power

what type of power is available to drive the pump

and what is the characteristic of power?
 NET POSITIVE SUCTION HEAD AND CAVITATION

• Net Positive Suction Head: that pressure required at the

suction of a pump to prevent cavitation.
– cavitation: the formation of bubbles due to area where
P < PSAT, and the subsequent collapse upon migration
to a high-press. area.
• causes noise and damage due to erosion and
fatigue failure.
NPSH AVAILABLE:
Net positive suction available head is defined as the net head
required to force the liquid into the pump through the suction pipe.
NPSHA = Pb - (Hs + Pvap / ρg + frictional head + kinetic head)

Hs (Suction head)

Barometric
pressure
NPSH

Pav/Pg

NPSHA depends upon barometric pressure, location, up to sea level,

suction height of machine , loss in suction head , all the factors depends
on the layout independent of the pump performance.
THOMA CAVITATION COFFICIENT: σ th = NPSHA/ H;
NET POSITIVE SUCTION HEAD REQUIRED (NPSHr):
Pressure of the liquid increase inlet to outlet. At any point of lowest
pressure, is (H) below the suction side pressure of machine. This fall in
pressure below the suction pressure is called net positive suction head
required (NPSHr). NPSHr depends on geometry of machine and
performance parameter. In order to prevent the cavitation
NPSHA> NPSHr.
And σr = NPSHr/ H.
To prevent cavitation σ > σr
NPSHr is a pump characteristic
(increases as Q increases)

If NPSHa > NPSHr:

Design is OK
If NPSHa < NPSHr:
Cavitation will be a
problem (good idea to have
a factor of safety)
 Neutral point

= h x density x 9.81
= atmospheric
= 101,325 Pa
Thus, h = 10.33 m

Pump pressure effects in an open system

CONVENTIONAL DESIGN OF PUMP:
Conventional design method of centrifugal pump are largely based on the
application of empirical and semi-empirical rules along with the use of available
information in the form of different types of charts and graphs in the existing
literature. The program developed is best suitable for low specific speed centrifugal
pump. Same program is also suitable for the design of high specific speed and
multistage centrifugal pump with few modifications.
DESIGN PROBLEM

INPUT DATA

Head = 40m Flow Rate =0 .080m3/sec Speed = 1450 rpm

DESIGN OF IMPELLER:

SPECIFIC SPEED:

N Q 1450 x .080
Ns   25.79rpm
Ns =  H3/4  For given data 40
3
4
POWER INPUT AND SHAFT INPUT POWER:
P0 = output = ρgQH = 1000* 9.81*Q*H / 1000
Input power ( Pin)= (9.81*Q*H / η0 )
Input required power = 1.15 Pin
1000  9.81 0.080  40
For given data input power = 1000  0.78 = 40.28 kw
Psh = 1.15 x 40.28 = 46.23 kw
SHAFT DIAMETER:
P  60 
Torque, T = Nm = f s  d3sh , where Fs = stress depend the material constant
2 N 16

dsh = (16T/Л Fs)1/3 = 0.042486 m

HUB DIAMETER:
(a) Dhb = Dsh + 10 mm for shaft 20mm diameter.
Dhb = Dsh + 20 mm for shaft upto 100mm diameter.
(b) Dh = (1.2 to 1.3) Dsh
for given data Dhb = 1.2 x .042 = 0.0509m
 IMPELLER EYE DIAMETER (DE):

Q(Flow rate) = Л / 4( DE2 – DH2 ) Vm1 VM 1

De = [ 4Q / ЛVm1 + Dh2 ]1/2 = 0.149 m
β1
INLET DIAMETER (D1):
D1 = (De + 0.020) m = 0.1696 m U1

Inlet velocity triangle

INLET BLADE VELOCITY (U1):
U1 = (Л D1 N / 60) = 12.87 m/sec

INLET BLADE ANGLE (B1):

V 
1  tan 1  m1 
fluid at inlet assumed no pressure whirl ; = 21.82
 U1 
Thickness of the blade is mostly taken leading and trailing tips are 4 mm and 5
mm, respectively.

WIDTH OF IMPELLER (B):

Flowrate (Q) = D 2 B 2     u 2
Q
B2 
  D 2  u 2   = 0.011 m
BLADE ANGLE AT OUTLET (B2):
u 22 u V
H  2 m2 '
g g  tan B 2 ;
29.432 29.43x 5.92
for given data 40   ; so B2 = 24.58 degree;
g g  tan B'2

NUMBER OF BLADES (Z):

Number of blades generally taken between 5 to 12. According to Pleider Z = (B2 / 3).
For given data Z = (24.58/3) = 8.2
OUTLET BLADE TRIANGLE:
From inlet velocity triangle
(a) V1 = Vm1 = 5.15 VM 2
Vr1
2 2
V2
(b) Vr12 = U 1  Vm1
= 5.152  12.87 2 α2
β2

= 13.86 m/sec
(c) Vrui = U1 = 12.87 m/sec u2
(d) From outlet velocity triangle
Vr2 = Vm2/sin β2
= 5.92/sin 24.58
=11.28 m/sec
OUTLET BLADE VELOCITY (U2):
Head coefficient φ = pressure head generated / maximum Euler head
= gh / η U 22
For given data U 2 = 29.43 m/sec
OUTLET DIAMETER (D2):

U 2 = Л D N / 60; D2 = (60U2 / ЛN) = 0.388 m

FLOW VELOCITY INLET & OUTLET:

Ф = Vm2 / U2 = Flow velocity / Blade velocity

Vm2 = Ф U2

K m1 
Vm1 K m2  Vm2
2gh 2gh

For given data Vm1 = .175 x 29.44 = 5.15m/sec

Vm2 = 1.15 x 5.92 = 5.924 m/sec

VOLUTE DESIGN CALCULATION
a) Inlet Width of Volute B3 = 1.8 B2 = 0.0199 m
b) Dia. Of Inlet at Volute
D3 = 1.15D2 = 0.446 m
 D 2  D3 
c) Rv =   = 0.2085
 4 

 2R v  D 2 
Width at x distance Bx = B3 + 
 1.73 
 = 0.0367 m

d) Whirl component of velocity at volute

Vu3 = V2 cos α 3 = 1.623 m/sec
e) Throat angle Qt = [ ln (0.223 / 0.196 ) / tan 8.29
= 38.56o
f) Velocity at throat Vth = (0.387 x 39.03)/0.448
= 33.94 m/sec
CALCULATION OF NPSH:-
P = Ks x R
Where P = Pfle i derer’s coefficient 0.2447( for low specific speed)
R = Blade loading ratio
Ks = constant for free vortex volute casing range 1.6 to 1.8
R = P/K = 0.2447/1.6 = 0.1529
Impeller mean Blade loading can be found as dp/r = R x Ht Ht = theoretical head =
40 m
So dp/? = 0.1529 x 40 = 6.116 m

. Depression head Hd = K x (dp/r )

K = 0.620
Hd = 0.62 x 6.116 = 3.796 m
Net Positive available suction head = Hd + (Vm12/2g) = 5.1294 m
Thoma Cavitation Coefficient σth = NPSH/ H; = 0.12829 m
NPSHr = 1   b Vm12  U
 b 1
2

= 4.29 m
2g 2g

Thoma caviataion coefficient for required head σr = NPSHr/ H. = 0.107

And 5.129 > 4.2954
Hence pump non cavitation condition
NPSHA> NPSHr
Centrifugal Impeller
Thank you