Power Station Pumps

By M.K.Jha, Deputy Director NPTI(NR), Badarpur, New Delhi

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Power Station Pumps

Major pumps include Boiler feed pump (BFP),

Condensate extraction Pump (CEP), circulating Water Pump (CW Pump), Ash Water Pump, Ash Slurry Pump, ACW Pump, BCW Pump, Chemical Dosing Pumps, Oil transfer Pumps, Stator water Pump, RCU Pump, DM Transfer Pump, Clear Water Pump, Raw Water Pump, Acid Transfer Pump, Main Oil Pump, SOP, AOP, Seal Oil Pump, Various other small Pumps

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PRESENTATION OUTLINE

Pump Terminology Pump Classification: - Centrifugal Pumps - Reciprocating Pumps - Rotary Pumps Pumping Problems Power and Efficiency Calculations Pump Selection

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What is a pump?
Pumps are a device which moves a liquid by means of suction or pressure from one location to another.
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PUMPS
POSITIVE DISPLACEMENT PUMPS RECIPROCATING PUMPS
PISTON PUMPS PLUNGER PUMPS DIAPHRAGM PUMPS

CENTRIFUGAL PUMPS

ROTARY PUMPS
GEAR PUMPS LOBE PUMPS SCREW PUMPS CAM PUMPS VANE PUMPS

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Centrifugal Pumps (Roto-dynamic pumps)

produce a head and a flow by increasing the velocity of

the liquid through the machine with the help of a rotating vane impeller Centrifugal pumps include radial, axial and mixed flow units.

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Centrifugal Pumps

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Centrifugal Pumps

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Centrifugal Pumps

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Centrifugal Pumps

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Centrifugal Pumps
Centrifugal means "directed or moving away from a center or axis
therefore a centrifugal pump uses a rotating impeller to move the fluid outward

A centrifugal pump is a kinetic device

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Centrifugal Pumps
Action of the centrifugal pumps consists of liquid moving at some velocity through a system by overcoming resistance Resistance comes from pipes, physical restrictions from valves, heat exchangers and other in-line devices and also from elevation changes between the liquid's starting location and final destination

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Centrifugal Pump how they work?

Liquid forced into impeller Vanes pass kinetic energy to liquid: liquid rotates and leaves impeller Volute casing converts kinetic energy into pressure energy

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Centrifugal Pumps -mechanism

When velocity is reduced due to resistance encountered in the system, pressure (P) increases. As resistance is encountered, the liquid expends some its energy in the form of heat, noise, and vibration in overcoming that resistance. The result is that the available energy in the liquid decreases as the distance from the pump increases. The actual energy available for work at any point in a system is a combination of the available velocity and pressure energy at that point.
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Centrifugal Pump Rotating and stationary Components

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Centrifugal Pump Rotating and stationary Components

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Centrifugal Pump- Components

Impeller

Main rotating part that provides centrifugal acceleration to the fluid Number of impellers = number of pump stages Impeller classification: direction of flow, suction type and shape/mechanical construction

Shaft
Transfers torque from motor to impeller during pump 5/1/2012 start up and operation

Casings Functions
Enclose impeller as pressure vessel Support and bearing for shaft and impeller

Volute case
Impellers inside casings Balances hydraulic pressure on pump shaft

Circular casing
Vanes surrounds impeller Used for multi-stage pumps
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Volute Casing

Vortex Casing

Volute

Diffuser (guide Vane)

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Volute Casing: In this type of casing the area of flow gradually increases from the impeller outlet to the delivery pipe. Vortex Casing: If a circular chamber is provided between the impeller and volute chamber the casing is known as Vortex Chamber. Diffuser Casing : The impeller is surrounded by a diffuser. The guide vanes are designed in such a way that the water from the impeller enters the guide vanes without shock. It reduces the vibration of the pump. Diffuser casing, the diffuser and the outer casing are stationery parts.
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Centrifugal pump fundamentals

HEAD energy supplied to the liquid by the pump is independent of the type of liquid being pumped Is the height of a static column of liquid that could be supported by the pressure (P) expressed in Feet or Meters
H (
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P ,g P ,g d s

V Vs )( d ) (Z d Z s ) 2g 2g

Head
SUCTION HEAD exists when the source of supply is

above the centerline of the pump STATIC SUCTION HEAD is the vertical distance in feet from the centerline of the pump to the free level of the liquid to be pumped

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Head

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Head
STATIC DISCHARGE HEAD is the vertical distance in

feet between the pump centerline and the point of free discharge or the surface of the liquid in the discharge tank TOTAL STATIC HEAD is the vertical distance in feet between the free level of the source of supply and the point of free discharge or the free surface of the discharge liquid

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Head
FRICTION HEAD (hf) is the head required to

overcome the resistance to flow in the pipe and fittings VELOCITY HEAD (hv) is the energy of a liquid as a result of its motion at some velocity V SUCTION LIFT exists when the source of supply is below the center line of the pump

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Head
STATIC SUCTION LIFT is the vertical distance in feet

from the centerline of the pump to the free level of the liquid to be pumped

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Head

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Head
TOTAL DYNAMIC SUCTION LIFT (hs) is the static

suction lift minus the velocity head TOTAL DYNAMIC SUCTION HEAD (hs) is the static suction head plus the velocity TOTAL DYNAMIC DISCHARGE HEAD (hd) is the static discharge head plus the velocity TOTAL HEAD (H) or TOTAL Dynamic HEAD (TDH) is the total dynamic discharge head minus the total dynamic suction head TDH = hd + hs (with a suction lift) TDH = hd - hs (with a suction head)
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Head Developed
the head developed is approximately equal to the

velocity energy at the periphery of the impeller h = (p2 - p1)/( g) + v22/(2 g) where h = total head developed (m) p2 = pressure at outlet (N/m2) p1 = pressure at inlet (N/m2) = density (kg/m3) g = acceleration of gravity (9.81) m/s2 v2 = velocity at the outlet (m/s)

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Head (Summary)
So Head can be described in simple terms:-

The vertical lift in height - usually measured in feet or m of water - at which a pump can no longer exert enough pressure to move water. i.e. "shut-off" head pressure. "shut-off head" is the point on the graph where the flow rate is zero
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Centrifugal Pump Fundamentals Capacity or Flow rate

Q=A*V m3/Hour

Pump output/Hydraulic/Water horsepower (Hp)

is the liquid horsepower delivered by the pump

Hydraulic power (Hp): Hp = Q (m3/s) x Total head, hd - hs (m) x (kg/m3) x g (m/s2) / 1000
hd - discharge head hs suction head, - density of the fluid g acceleration due to gravity
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Pump Efficiency
Pump efficiency, (%) is a measure of the efficiency with wich the pump transfers useful work to the fluid.

= Pout/Pin where

= efficiency (%)
Pin = power input Pout = power output
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NPSH (Net Positive Suction Head)

Total suction head in meter absolute, determined at the suction nozzle and corrected to datum, less the vapor pressure of the liquid in meter absolute

Is a test of whether the liquid will vaporize at the lowest pressure point in the pump.

A liquid increases greatly in volume when it vaporizes. One cubic foot of water at room temperature becomes 1700 cu. ft. of vapor at the same temperature

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NPSH
As the liquid passes from the pump suction to the eye of the impeller, the velocity increases and the pressure decreases

NPSH is simply a measure of the amount of suction head present to prevent vaporization at the lowest pressure point in the pump

Also other pressure losses due to shock and turbulence

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NPSH- Available
function of the system in which the pump operates

Function of the specific gravity of the liquid Depends upon specific speed
Temperature is another important factor

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NPSH- Required
The NPSHr, called as the Net Suction Head as required by the pump in order to prevent cavitation for safe and reliable operation of the pump The available NPSHa of the system should always exceeded the required NPSHr of the pump to avoid vaporization and cavitation

required NPSHr increases proportionately with the square of capacity

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NPSH-Required

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Cavitation
small vapor bubbles begin to form , move along the impeller vanes to a higher pressure area above the vapor pressure and rapidly collapse

Formation and collapse of bubbles

insufficient NPSH Available

the pressure of the liquid is reduced to a value equal to or below its vapor pressure

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Cavitation

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Cavitation

Rumbling noise

Minute pockets of fatigue failure on the impeller vane surfaces

Pitting damage to the impeller

Reduced capacity of the pump due to vapour

Head may be reduced and/or be unstable

Power consumption may be erratic

Vibration and mechanical damage such as bearing failure

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Types of Cavitation
Classic cavitation

Internal recirculation cavitation Air ingestion induced cavitation

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Cavitation Number

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Application Ratio
Another common way to characterize potential cavitation conditions is the "applications ratio AR = pi - po / (pi - pv) where AR = Application Ratio pi = inlet pressure, absolute po = outlet pressure, absolute pv = vapor pressure of the fluid, absolute

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Application Ratio
For application ratios above 1 - the fluid flashes closer the ratio is to 1, the higher the potential for

cavitation.

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To prevent Cavitation..
Multi Stage Control Valves

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To prevent Cavitation..
avoid low pressure - pressurize supply tanks if

necessary reduce fluid temperature use larger suction pipe diameters - reduce minor losses use cavitation resistant materials or coatings small amounts of air supplied to the suction system may reduce the amount of cavitation damage In NUTSHELL keep available NPSH well above required NPSH
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The operation of filling the suction pipe, casing and a

portion of delivery pipe with the liquid to be raised, before starting the pump is known as Priming It is done to remove any air, gas or vapour from these parts of pump. If a Centrifugal pump is not primed before starting air pockets inside impeller may give rise to vortices and causes discontinuity of flow

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System Performance Curves

The capacity and pressure needs of any system can be defined with the help of a graph called a system curve the capacity vs. pressure variation graph for a particular pump defines its characteristic pump performance curve
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System Curve
A pumping system operates where the pump curve and the system resistance curve intersect. The intersection of the two curves defines the operating point of both pump and process However, it is impossible for one operating point to meet all desired operating conditions

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Stable head-flow characteristics

h - progressively falls with increasing flow rate - q.

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Unstable head-flow characteristics

- h - rises to a maximum and then progressively falls

with increasing flow rate - q.

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Unstable Flow

An unstable pump may start to oscillate between the two possible combinations of headflow

The flow rate will modulate

pipeline vibrate

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Radial Flow Pump

Mixed Flow Pump

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Axial Flow Pump

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Composite Performance Curve

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Capacity Regulating by Varying Speed

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Capacity Regulating by Constant Speed

throttling
bypassing flow changing impeller diameter modifying the impeller

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Throttling

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Throttling
Throttling is energy inefficient since the energy to the pump is not reduced

Energy is wasted by increasing the dynamic loss.

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Other Methods of Regulation

Bypassing Flow

Changing the Impeller Diameter

Modifying the Impeller

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Pump Regulation and Power Consumption

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Pump operating point

Intersection of pump curve and system curve

Pump performance curve

Pump operating point System curve

Head

Static head

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Flow

System Curve

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NO STATIC HEAD
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Positive Suction Head

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Negative Suction Head

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LIFTS
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Pump Performance Curve

Increasing the impeller diameter or speed increases the head and flow rate capacity - and the pump curve moves upwards

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Selection of Pump
A pump can be selected by combining the System Curve and the Pump Curve

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Pump Affinity Laws

express the mathematical relationship between the several variables involved in pump performance

They apply to all types of centrifugal and axial flow pumps

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With impeller diameter D held constant

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With impeller diameter D held constant

If the speed of a pump is increased with 10% the volume flow increases with 10% the head increases with 21% the power increases with 33 %

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With speed N held constant

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Energy Efficiency Opportunities Centrifugal Pumps

1. Selecting the right pump
2. Controlling the flow rate by speed variation 3. Pumps in parallel to meet varying demand

4. Eliminating flow control valve

5. Eliminating by-pass control 6. Start/stop control of pump 7. Impeller trimming
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1. Selecting the Right Pump

Pump performance curve for centrifugal pump

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1. Selecting the Right Pump

Oversized pump
Requires flow control (throttle valve or by-pass line) Provides additional head System curve shifts to left

Pump efficiency is reduced

Solutions if pump already purchased

VSDs or two-speed drives

Lower RPM
Smaller or trimmed impeller

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2. Controlling

Flow: speed

variation
Explaining the effect of speed
Affinity laws: relation speed N and
Flow rate Q N
Head H N2 Power P N3

Small speed reduction (e.g. ) = large power reduction

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2. Controlling Flow: speed variation

Variable Speed Drives (VSD)
Speed adjustment over continuous range Power consumption also reduced!

Two types
Mechanical: hydraulic clutches, fluid couplings,

adjustable belts and pulleys Electrical: eddy current clutches, wound-rotor motor controllers, Variable Frequency Drives (VFDs)

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2. Controlling Flow: speed variation

Benefits of VSDs
Energy savings (not just reduced flow!)

Improved process control

Improved system reliability Reduced capital and maintenance costs Soft starter capability
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3. Parallel Pumps for Varying Demand

Multiple pumps: some turned off during low demand

Used when static head is >50% of total head System curve does not change Flow rate lower than sum of individual flow rates

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4. Eliminating Flow Control Valve

Closing/opening discharge valve (throttling) to reduce flow Head increases: does not reduce power use

Vibration and corrosion: high maintenance costs and reduced pump lifetime

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5. Eliminating By-pass Control

Pump discharge divided into two flows
One pipeline delivers fluid to destination Second pipeline returns fluid to the source

Energy wastage because part of fluid pumped around for no reason

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6. Start / Stop Control of Pump

Stop the pump when not needed
Example:
Filling of storage tank

Controllers in tank to start/stop

Suitable if not done too frequently Method to lower the maximum demand (pumping at non-peak hours)
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7. Impeller Trimming
Changing diameter: change in velocity
Considerations
Cannot be used with varying flows

No trimming >25% of impeller size

Impeller trimming same on all sides Changing impeller is better option but more expensive

and not always possible

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7. Impeller Trimming
Impeller trimming and centrifugal pump performance

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Comparing Energy Efficiency Options

Parameter Impeller diameter Pump head Pump efficiency Rate of flow Power 5/1/2012 consumed Change control valve 430 mm 71.7 m 75.1% 80 m3/hr 23.1 kW Trim impeller 375 mm 42 m 72.1% 80 m3/hr 14 kW VFD 430 mm 34.5 m 77% 80 m3/hr 11.6 kW

ADVANTAGES OF CENTRIFUGAL PUMPS

Advantages

Simple in construction and cheap Handle liquid with large amounts of solids No metal to metal fits No valves involved in pump operation Maintenance costs are lower

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DISADVANTAGES OF CENTRIFUGAL PUMPS

Disadvantages
Cannot handle highly viscous fluids efficiently Cannot be operated at high heads Maximum efficiency holds over a narrow range of

conditions
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The positive displacement pump can be classified as

Reciprocating pumps - piston, plunger and

diaphragm Rotary pumps - gear, lobe, screw, vane, regenerative (peripheral) and progressive cavity

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RECIPROCATING PUMPS
Based on two stroke principles:

High pressure, high efficiency Self-priming X Small quantity, vibration, physical dimension, uneven flow
Used mainly for handling slurries in plant processes and

pipeline applications

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It is a positive displacement pump

It sucks and raises the liquid by actually displacing it

with a piston/plunger that executes a reciprocating motion in a closely fitting cylinder.

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Single Acting Reciprocating Pump

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 During suction stroke the piston moves to the left,

causing the inlet valve to open. Water is admitted into the cylinder through the inlet valve. During the discharge stroke the piston moves to the right closes the suction valve and opens the out let valve. Through the outlet valve the volume of liquid moved out of the cylinder.

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Discharge Pipe Outlet Valves

Piston Rod

Inlet Valves

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 Each cycle consists of two strokes. Both the strokes are effective, hence it is known

as double acting pump Liquid is filled at one end and discharged at other end during forward stroke. During the return stroke, end of cylinder just emptied is filled and the end just filled is emptied.

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Air vessel is a closed chamber containing compressed air in the upper part and liquid being pumped in the lower part.

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To get continuous supply of liquid at a uniform rate.

To save the power required to drive the pump (By

using an air vessel the acceleration and friction heads are considerably reduced) To run the pump at much higher speed without any danger of separation.

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POSITIVE DISPLACEMENT PUMPS

RECIPROCATING PUMPS

Two valves and one stuffing box A rotating mechanism for the

PISTON PUMPS PLUNGER PUMPS DIAPHRAGM PUMPS

reciprocating piston Uses suction to raise liquid into the chamber.

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POSITIVE DISPLACEMENT PUMPS

RECIPROCATING PUMPS

PISTON PUMPS PLUNGER PUMPS DIAPHRAGM PUMPS

Two ball check valves on each side Low pressure on the upward part, high pressure on the downward part

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POSITIVE DISPLACEMENT PUMPS

RECIPROCATING PUMPS

PISTON PUMPS PLUNGER PUMPS DIAPHRAGM PUMPS

Rod is moved to push and pull the diaphragm. Can be used to make artificial hearts.

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 Relatively compact design

High viscosity performance Ability to handle high differential pressure.

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ROTARY PUMPS
Positive displacement type

CHigh pressure, high efficiency DLiquids must be free of solids CHandle viscous fluids
Used mainly in, oil burners, soaps and cosmetics, sugars, syrup, and molasses, dyes, ink, bleaches, vegetable and mineral oils

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ROTARY PUMPS

GEAR PUMPS LOBE PUMPS

SCREW PUMPS CAM PUMPS VANE PUMPS

Gears create voids as they come out of

mesh and liquid flows into the cavities As the gears come back into mesh, the volume is reduced and the liquid is forced out of the discharge port

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ROTARY PUMPS

GEAR PUMPS LOBE PUMPS

SCREW PUMPS CAM PUMPS VANE PUMPS

As the teeth come out of mesh, liquid flows into the pump and is carried between the teeth and the casing to

the discharge side of the pump The teeth come back into mesh and the liquid is forced out the discharge port

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ROTARY PUMPS

GEAR PUMPS LOBE PUMPS

SCREW PUMPS CAM PUMPS VANE PUMPS

Fluid is carried between the rotor teeth and the pumping chamber The rotor surfaces create continuous

sealing Rotors include bi-wing, tri-lobe, and multi-lobe configurations

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ROTARY PUMPS

GEAR PUMPS LOBE PUMPS

SCREW PUMPS CAM PUMPS VANE PUMPS

Screw pumps carry fluid in the spaces

between the screw threads. The fluid is displaced axially as the screws mesh.

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ROTARY PUMPS

GEAR PUMPS LOBE PUMPS

SCREW PUMPS CAM PUMPS

VANE PUMPS

Piston slide arm moves around inside a slot in the casing. An eccentric cam rotates the circular plunger (shown in gray) around the edge of the casing, fluid is swirled around the edge to the outlet port. It is not in use now and is mainly of

historical curiosity.

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ROTARY PUMPS

GEAR PUMPS LOBE PUMPS

SCREW PUMPS CAM PUMPS

The vanes are in slots in the rotor. Rotor spins, centrifugal force pushes the

VANE PUMPS

vanes out to touch the casing, where they tra and propel fluid.

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Progressive cavity pumps

Progressive cavity pumps consist of a metal rotor

rotating within an elastomer-lined or elastic stator. When the rotor turns progressive chambers from suction end to discharge end are formed between the rotor and stator, moving the fluid.

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Scroll Pump
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Comparison between Centrifugal Pumps and PD Pumps

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Pump Selection Scenarios

High Viscosity Even modest viscosity dramatically affect the flow rate and efficiency of a centrifugal pump. While many centrifugals are cataloged to 1,000 cSt and higher, PD pumps are clearly the better choice when considering the high energy costs resulting from this lost efficiency

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Away from the Middle of the Curve

. Centrifugals do not operate well when operated too far away from the middle of the curve. At best, this results in reduced efficiency which would require larger motors and higher energy costs. At worst, this can result in cavitation damage, shaft deflection, and premature pump failure. PD pumps on the other hand can be run at any point on their curve without damaging the pump or greatly affecting the efficiency.

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Variation in Pressure
The first graph above clearly illustrates the effect that even modest changes in pressure can have on the flow rate of a centrifugal pump. Additional restrictions such as debris in a filter, corroded / rough pipingor a valve left too far closed (or too far open) can have a dramatic effect on a centrifugal pumps flow rate and efficiency. PD pumps maintain their flow rate and efficiency even with significant changes in pressure

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Variation in Viscosity
Many liquids vary in viscosity depending on

temperature or due to chemical reaction. A rise in viscosity will independently alter the flow rate and efficiency. Add to that the rise in pressure due to the increase in frictional line losses and PD pumps become the clear choice for variable viscosity applications.

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High Pressures
While some centrifugals can be run in series to boost

their pressure none can compete with PD pumps for high pressure applications. Pressure limits will depend on the design of each pump, but pressuof 250 PSI (580 feet) are not unusual for a PD pump, with some models going over 3,000 PSI (7,000 feet). The capability for a PD pump to produce pressure is so great that some type of system overpressure protection is required.

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Suction Lift Applications

By their nature, PD pumps create a vacuum on the

inlet side making them capable of creating a suction lift. Standard ANSI centrifugals do not create a vacuum and cannot create a suction lift. There are selfpriming centrifugal designs that can lift liquid an average of 15 feet when partially filled (13 hg vacuum). Many dry PD pumps can pull or better and wetted PD pumps (a pump that is not full of liquid but with some liquid in it) can often reach vacuums of 25 to 28 hg. PD pumps are the logical choice when a suction lift is required.
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Thank You!
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