presentation on pumps
DESCRIPTION
Presentation on PumpsTRANSCRIPT
QUALITY CIRCLE PRESENTATIONA PRESENTATION
ON“PUMPS IN POWER PLANTS”
BYM.K. ASTHANA, SR. MANAGER (QA)
COMING UP……..
BRIEF INTRODUCTION OF THERMAL POWER PLANT
EXAMPLES OF MAJOR PUMPS
DEFINITIONS
CLASIFICATION OF PUMPS
FUNDAMENTAL EQUATIONS OF PUMP
TYPES & CHARACTERISTICS OF PUMPS
MATERIAL SELECTION
QUALITY CONTROL & TESTING
P.G. TEST OF CW PUMP – SIPAT – II, KhSTPP - II
SUB - CRITICAL STEAM POWER PLANT
T
1
2
3
56
79
10
11
s
SCHEMATIC DIAGRAM T-s DIAGRAM
1
HPT IPT LPT GEN.
LPH
DEAERATOR
BFPHPH CEP
BOILER
2
34
5
78
91011
CONDENSER
6CWP
Saturated vapor line
CRITICAL POINT
p = 15 Kgf/cm2
p = 1.0332 Kgf/cm2
p =225.65 Kgf/cm2
LIQUID - VAPOR REGION
LIQUID REGION
VAPOR REGION
T
vTemperature - Specific Volume Diagram for Water
Saturated liquid line
PUMPS
CONDENSATE EXTRACTION PUMP
C.W. PUMP
HORIZONTALCENTRIFUGAL PUMP
PUMPS PUMPS DESIGN PARAMETERS
PARAMETERS CW PUMP C.E. PUMP B.F. PUMP
TYPE VERTICAL VERTICAL HORIZONTAL, CENTRIFUGAL
FIVE
1080.3 M3/Hr
2088 MWC
5690 RPM
6765 KW
FORGED CARBON STEEL WITH AUSTENITIC SS INLAY IN HIGH VELOCITY ZONE
13 Cr, SS
13 Cr, SS FORGING
NO. OF STAGES SINGLE FIVE
FLOW 30,000 M3/Hr 810 M3/Hr
DISCHARGE HEAD 20.50 MWC 307 MWC
OPERATING SPEED 331 RPM 1480 RPM
MAX. WATER TEMP. 43.1O C
PUMP INPUT 1903.22 KW
MATERIAL
SUCTION BELL 2% Ni CI CAST IRON
PUMP CASING 2% Ni CI CAST IRON
IMPELLER CF – 8M 12% Cr, SS
SHAFT, SHAFT SLEEVE ASTM A 276 Gr. 410, H&T
12% Cr, SS FORGING
PUMPS PUMPS DESIGN PARAMETERS
PARAMETERS RAW WATER PUMP
MAKE UP WATER PUMP (PT)
MAKE UP WATER PUMP (ASH)
TYPE VERTICAL, MIXED FLOW
VERTICAL, MIXED FLOW
VERTICAL, MIXED FLOW
NO. OF STAGES SINGLE SINGLE TWO
FLOW 5500 M3/Hr 4000 M3/Hr 2200 M3 /Hr
DISCHARGE HEAD 11.5 MWC 25 MWC 40 MWC
OPERATING SPEED 750 RPM 1000 RPM 1000 RPM
SERVICE DUTY CONTINUOUS CONTINUOUS CONTINUOUS
MAX. WATER TEMP. 36O C 36O C 36O C
Categories
• Pumpadds energy to a fluid, resulting in an increase in pressure across the pump.
• Turbineextracts energy from the fluid, resulting in a decrease in pressure across the turbine.
CATEGORIES• For gases, pumps are further broken down into
– FansLow pressure gradient, High volume flow rate. Examples include ceiling fans and propellers.
– BlowerMedium pressure gradient, Medium volume flow rate. Examples include centrifugal and squirrel-cage blowers found in furnaces, leaf blowers, and hair dryers.
– CompressorHigh pressure gradient, Low volume flow rate. Examples include air compressors for air tools, refrigerant compressors for refrigerators and air conditioners.
PUMPS
PUMP COMPRESSOR BLOWER FAN
FUNCTION A MACHINE FOR RAISING A LIQUID
A RELATIVELY INCOMPRESSIBLE FLUID
TO A HIGHER LEVEL OF PRESSURE OR HEAD
A MACHINE FOR RAISING A GAS
A MACHINE FOR MOVING VOLUMES OF A GAS
A MACHINE FOR MOVING LARGE AMOUNT OF A GAS
TYPE OF FLUID A COMPRESSIBLE FLUID
COMPRESSIBLE COMPRESSIBLE
END RESULT TO A HIGHER LEVEL OF PRESSURE
WITH MODERATE INCREASE OF PRESSURE
WITH LOW INCREASE IN PRESSURE
PUMPS
PUMPS
POSITIVEDISPLACEMENT
KINETIC
RECIPROCATING
ROTARY
BLOW CASE
CENTRIFUGAL
SPECIAL
PERIPHERAL
PISTON
DIAPHRAGM
PLUNGER
SINGLE ROTOR
MULTIPLE ROTOR
RADIAL FLOW
AXIAL FLOW
MIXED FLOW
PUMPS
RECIPROCATING PUMPGEAR PUMP
JET PUMP PITOT TUBE PUMP
• CENTRIFUGAL PUMPSFluid enters axially, and is discharged radially.
PUMPS
• MIXED FLOW PUMPSFluid enters axially, and leaves at an angle between radially & axially.
• AXIAL FLOW PUMPSFluid enters & leaves axially.
PUMPS CURVES
VOLUME FLOW
PRES
SUR
E IN
CR
EAS E
CENTRIFUGAL PUMP
POSITIVE DISPLACEMENT PUMP
PERIPHERAL PUMP
PUMP CURVES FOR DIFFERENT PUMP TYPES
PUMPS CURVES
VOLUME FLOW
PRES
SUR
E IN
CR
EAS E
POSITIVE DISPLACEMENT PUMP AND SYSTEM CHARACTERISTICS
Normal
System
Res
istan
ce
Increa
sed S
ystem
Res
istan
ce
25%Speed
50%Speed
75%Speed
100%Speed
Pum
p C
hara
cter
istic
s
A1A2
v1
v2
m = ρ1* A1* v1 = ρ2* A2* v2
For an incompressible liquid flow,
Q = A1* v1 = A2* v2
THE CONTINUITY EQUATION
THE CONTINUITY EQUATION
For an incompressible liquid flow,
Q1 = Q2 + Q3
A1* v1 = A2* v2 + A3* v3
A1 A2
v1v2
A3
BERNOULLI’S EQUATION
A1
A2
v1
v2
z1
z2
Horizontal Datum
p1 + v21 + gz1 = p2 + v2
2 + gz2 + Δpf
ρ 2 ρ 2 ρ
p1 + v21 + z1 = p2 + v2
2 + z2 + Δpf
w 2g w 2g w ⇒
STATIC, TOTAL & DYNAMIC PRESSURE HEADSTATIC PRESSURE TAP PITOT TUBE PRANDTL TUBE
pp0
pp0
pv
p1
w STATIC HEAD =
v2
2g VELOCITY HEAD =
z POTENTIAL HEAD =
= p + ρv2
w 2
TOTAL PRESSURE OR STAGNATION PRESSURE
PUMPS
Blade Losses
Impeller frictionInternal Leakages(Slip)
External Losses
Bearing Losses
Sealing friction
Impeller Friction Losses
Blade Losses
P Pi Pblade Puseful
Bearing & Sealing Friction Losses
Internal Leakage (Slip)
External Leakage
Centrifugal Pumps
• Snail--shaped scroll • Most common type of
pump: homes, autos, industry.
Centrifugal Pumps
Side view of impeller blade.Vector analysis of leading and trailing edges.
Centrifugal Pumps: Blade Design
PUMPS
Change in Angular Momentum of fluid from inlet to exit
= Mt = m* (r2C2u – r1C1u)
Mt *δφ= δφ* δm * (r2C2u – r1C1u)δt
Work Done per unit mass = Blade Work = Mt *δφ = Ib = ω * (r2C2u – r1C1u) = gΔHδm ηh
⇒ gΔH = (u2C2u – u1C1u)ηh
ΔH = Differential Headηh = Hydraulic Efficiencyu = peripheral velocityCu = tangential component of
absolute velocity
PUMPS
C1u ≈ 0, ⇒ gΔH = u2C2u
ηh
If ηh = 1, ΔHi = Ideal Differential Head = “Euler Head”
ΔHi = u2C2u/g = u2 [u2 – C2m/tanβ2 ]/g
C2m = Q / (2π * r2 * b2)
ΔHi = u2 u2 – Q g 2π * r2 * b2 tanβ2
Pump Head
• Net Head
• Water horsepower
• Brake horsepower
• Pump efficiency
PUMPS
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
0 20 40 60 80 100FLOW “Q”
CENTRIFUGAL PUMP H – Q CURVE
Hydraulic Losses
Actual Differential Head
Ideal Differential Head
DIF
FER
ENTI
AL
HEA
D “
H”
PUMPS
10
20
30
40
50
60
70
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
0 20 40 60 80 100FLOW “Q” in m3/h
DIF
FER
ENTI
AL
HEA
D “
H”
in m
CENTRIFUGAL PUMP H – Q CURVE
EFFI
CIE
NC
Y “η
”IN
%
170
160
150
170
150
N = 1450 rpmMedium = Water
Pump – Performance CurveCentrifugal Pump
• BEP: best efficiency point
• H*, bhp*, V* correspond to BEP
• Shutoff head: achieved by closing outlet (V=0)$
• Free delivery: no load on system (Hrequired = 0)
Matching a Pump to a Piping System
• Steady operating point:
• Energy equation:
Centrifugal Pumps: Blade Design
PUMPS
4
8
12
16
20
24
28
32
0 120 240 360 480 600
DIF
FER
ENTI
AL
HEA
D “
H”
in m
FLOW “Q” in m3/h
CENTRIFUGAL PUMP H – Q CURVE WITH ISO – EFFICIENCY LINES
5055
6062
6362
6055
50
425
426
427429
430
PUMPS
H
SHUT OFF HEAD(ZERO DISCHARGE)
Q
UNSTABLE PART OF THE CURVE
Q
H
STABLE UNSTABLE
STABLE AND UNSTABLE PUMP CURVES
PUMPS
FLAT AND STEEP PUMP CURVES FOR CENTRIFUGAL PUMPS
H
QO
H H
Q Q QQO QO
HO
Hmax
PUMPS
THE EFFECT ON PUMP PERFORMANCE DUE TO WEAR IN SEALS & CLEARANCES
H
Q
DIFFERENTIAL HEAD
WORN PUMP
NEW PUMP P
Q
POWER REQUIREMENTS
WORN PUMP
NEW PUMP
Q
H
DIFFERENTIAL HEAD
WORN PUMP
NEW PUMP P
Q
POWER REQUIREMENTS
WORN PUMP
NEW PUMP
THE EFFECT ON PUMP PERFORMANCE DUE TO WEAR ON PUMP BLADES
PUMPS
ROTODYNAMIC PUMP CURVES RELATIVE TO BEP
REL
ATI
VE D
IFFE
REN
TIA
L H
EAD
RELATIVE VOLUME FLOW
1
1
0RELATIVE VOLUME FLOW
1
1
0
REL
ATI
VE P
OW
ER
PUMPS
THE EFFECT OF VISCOSITY ON SMALL CENTRIFUGAL PUMP
DIF
FER
ENTI
AL
HEA
D IN
M
VOLUME FLOW IN M3/Hr
200 40 60 80 100 120 140
10
20
30
40
50
150 mm2/s
100 mm2/s
50 mm2/s
1 mm2/s
SHA
FT P
OW
ER IN
KW
VOLUME FLOW IN M3/Hr
200 40 60 80 100 120 140
10
20
30
40
50
1 mm2/s
30 mm2/s
50 mm2/s
100 mm2/s
150 mm2/s
PUMPS
PERFORMANCE CURVE OF A PERIPHERAL PUMP
50
SHA
FT P
OW
ER IN
KW
VOLUME FLOW IN M3/Hr
0 10 20 30
1
2
3
4
5
DIF
FER
ENTI
AL
HEA
D IN
M
VOLUME FLOW IN M3/Hr
0 10 20 30
10
20
30
40
OPTIMUM POINT
PUMPS
PERFORMANCE CURVE OF A POSITIVE DISPLACEMENT PUMP
75
DIS
CH
AR
GE
PRES
SUR
E B
AR
g
VOLUME FLOW IN M3/Hr
0 20 40 60
30
15
45
60
90
105
80 100 120 140
50
POW
ER IN
KW
VOLUME FLOW IN M3/Hr
0 20 40 60
20
10
30
40
60
70
80 100 120 140
PUMPS
120
VOLU
ME
FLO
W IN
M3 /H
r
DISCHARGE PRESSURE BAR g
PERFORMANCE CURVE OF A POSITIVE DISPLACEMENT PUMP
0 15 30 45
105
100
110
115
125
130
60 75 90 10590
70
MEC
HA
NIC
AL
EFFI
CIE
NC
Y %
DISCHARGE PRESSURE BAR g
0 15 30 45
40
30
50
60
80
90
60 75 90 10520
POW
ER IN
KW
40
10
0
20
30
50
60
70ηmech
POWER
PUMPS
p2
p1p3
Pumped Medium mp
Motive Medium md
mp + md
DIFFUSER (VENTURI)
c4
c5
q = mp / md
Pressure relationship = z = (p03 – p02) / (p01 – p03) = Hp/Hd
Pump Efficiency = η = q*z
DIAGRAMATIC PRINCIPLE OF A JET PUMP
PUMPS
FLOW RELATIONSHIP “q”
PRES
SUR
E R
ELA
TIO
NSH
IP “
z”
PERFORMANCE CURVE FOR A JET PUMP
z
η
EFFI
CIE
NC
Y η
Blade number affects efficiency and introduces circulatory losses (too few blades) and passage losses (too many blades)
Centrifugal Pumps: Blade Design
Axial Pumps
Open vs. Ducted Axial Pumps
Pump Specific Speed
Pump Specific Speed is used to characterize the operation of a pump at BEP and is useful for preliminary pump selection.
Propeller has radial twist to take into account for angular velocity (=ωr)
Blades generate thrust like wing generates lift.
Open Axial Pumps
• Tube Axial Fan: Swirl downstream
• Counter-Rotating Axial-Flow Fan: swirl removed. Early torpedo designs
• Vane Axial-Flow Fan: swirl removed. Stators can be either pre-swirl or post-swirl.
Ducted Axial Pumps
Absolute frame of reference Relative frame of reference
Ducted Axial Pumps - Blades
Dimensional Analysis
Π analysis gives 3 new non-dimensional parameters– Head coefficient
– Capacity coefficient
– Power coefficient• Reynolds number also appears,but in terms of angular
rotation– Reynolds number
• Functional relation is– Head coefficient
– Power coefficient
Dimensional Analysis
• If two pumps are geometrically similar, and
• The independent Π’s are similar, i.e., CQ,A = CQ,BReA = ReBεA/DA = εB/DB
• Then the dependent Π’s will be the sameCH,A = CH,BCP,A = CP,B
• When plotted in non-dimensional form, all curves of a family of geometrically similar pumps collapse onto one set of non-dimensional pump performance curves
• Note: Reynolds number and roughness can often be neglected,
Dimensional Analysis
AFFINITY LAWS
SUMP
WIER
FLOWMETER
FLOW NORMALIZER TRASH RACK
C.W. PUMP
CREST
TEST BED
PUMPS
LAY OUT OF CW PUMP TEST BED
PUMPS
H
Q = 0.4046 + 0.003607 √2gLH1.5
L = LENGTH OF WEIR “M”
H = HEIGHT OF LIQUID “M”
Q = VOLUME FLOW IN M3/SEC.
FLOW MEASUREMENT BY RECTANGULAR WEIR
D
PUMPS FLOW MEASUREMENT BY ORIFICE PLATE
d
p1 p2
PUMPS
MATERIAL & MATERIAL
COMBINATION
COST
MANUFACTURING TECHNIQUES
STRENGTH
CORROSION
EROSION
CAVITATION
PROCESS UPSET
CONDITIONS
PROCESS VARIATIONS
FACTORS AFFECTING MATERIAL SUITABILITY FOR PUMPS
PUMPS
TYPICAL MATERIALS
MATERIAL WITH IRON AS ITS MAIN CONSTITUTENT
MATERIAL WITH SIGNIFICANT PROPORTIONS OF Cr & Ni
MATERIAL WITH Cu OR Al AS ITS MAIN CONSTITUENTS
OTHER METALLIC MATERIALS
NON – METALLIC MATERIALS
PUMPS COMMONLY USED MATERIAL COMBINATIONS FOR CENTRIFUGAL PUMP
CASING IMPELLER SHAFT APPROX. RELATIVE COST
GREY CAST IRON GREY CAST IRON STAINLESS STEEL 0.97
GREY CAST IRON GUN METAL STAINLESS STEEL 1.0
GREY CAST IRON PLASTIC STAINLESS STEEL 0.95
GREY CAST IRON STAINLESS STEEL STAINLESS STEEL 1.08
S. G. IRON STAINLESS STEEL STAINLESS STEEL 1.25
CAST STEEL GREY CAST IRON STEEL 1.1
CAST STEEL CAST STEEL STEEL 1.2
CAST STEEL BRONZE STEEL 1.25
CAST STEEL 13 Cr STEEL STEEL 1.3
CAST STEEL STAINLESS STEEL STAINLESS STEEL 1.5
13 Cr STEEL 13 Cr STEEL 13 Cr STEEL 1.4
TITANIUM TITANIUM TITANIUM 10
STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL 1.8
PUMPS MATERIAL STANDARDS
EQUIVALENT INTERNATIONAL STANDARDMATERIAL IS
BS ASTMCAST IRON IS 210, Gr. FG 260 BS 1452 Gr. 250 ASTM A – 48 CL 35
Ni RESIST IS2749, Gr. AFG Ni 15Cu 6 Cr3
BS 3468 AUS 102 Gr. B
ASTM A – 436 TYPE – 2
CARBON STEEL IS 1570 Gr. 40C8 BS 970 080M40 ASTM A 107 Gr. 1040
SS 304 BS 970 304S15 ASTM A – 276 TYPE 304
SS 316 IS 1570 Gr. 05Cr18Ni11Mo3 BS 970 304S16 ASTM A – 276 TYPE 316
SS 410 GREY CAST IRON BS 970 410S21 ASTM A – 276 TYPE 410
K MONEL IS 3444 Gr. 22 STEEL ASTM A 743 Gr. M-35
BRONZE IS 318 Gr. LTB 2 BS 1400 LG 2C ASTM B – 62, B145 ALLOY 4A
CF8M IS 3444 Gr. 9 BS 1632 Gr. B ASTM A 351 Gr. CF8M
CF8C ASTM A 351 Gr. CF8C
CA 15 BS 3100 – 410 C 21 ASTM A 217 Gr. CA 15
Al. BRONZE IS 305 Gr.2 ASTM B 148, B271 ALLOY 9A
CAST STEEL BS 1504 101A ASTM A216 Gr. WCB
PUMPS MATERIAL OF CENTRIFUGAL PUMP & MAIN AREAS OF APPLICATION
MATERIALS APPLICATIONSCAST STEELCAST STEEL DEDE--AERATED HOT WATER, BOILER FEED PUMPSAERATED HOT WATER, BOILER FEED PUMPS
SG IRON, NODULAR SG IRON, NODULAR IRONIRON
AS ABOVE. BETTER RESISTANCE TO CORROSION AT HIGH LIQUID AS ABOVE. BETTER RESISTANCE TO CORROSION AT HIGH LIQUID VELOCITIES THAN CAST STEEL BUT NOT AS GOOD AS CIVELOCITIES THAN CAST STEEL BUT NOT AS GOOD AS CI
GREY CAST IRONGREY CAST IRON HAS GOOD RESISTANCE TO MANY FLUIDSHAS GOOD RESISTANCE TO MANY FLUIDS120120OO C MAXIMUM, pH > 5.5C MAXIMUM, pH > 5.5
13 Cr STEEL13 Cr STEEL DE DE –– AERATED HOT WATER, BOILER FEED PUMPSAERATED HOT WATER, BOILER FEED PUMPS360360OO C, A GOOD REPLACEMENT OF CAST STEEL ABOVE 200C, A GOOD REPLACEMENT OF CAST STEEL ABOVE 200OO C C BETTER THERMAL STABILITYBETTER THERMAL STABILITYHIGHER PRESSURE CAPABILITIESHIGHER PRESSURE CAPABILITIES
SiSi IRON 14SiIRON 14Si RESISTANT TO ACID CORROSION, HCL, H2SO4 AND STRONG SALT RESISTANT TO ACID CORROSION, HCL, H2SO4 AND STRONG SALT SOLUTIONSSOLUTIONSNOT SUITABLE FOR THERMAL SHOCKNOT SUITABLE FOR THERMAL SHOCK
Ni Ni –– RESIST, 20Ni3CrRESIST, 20Ni3Cr HOT, SEA WATERHOT, SEA WATER
GUN METAL, GUN METAL, BRONZEBRONZE
SALT WATER, SEA WATER, BRINE & OTHER MODERATELY CORROSIVE SALT WATER, SEA WATER, BRINE & OTHER MODERATELY CORROSIVE WATER SOLUTIONSWATER SOLUTIONS
MONELMONEL SEA WATER, BRINESEA WATER, BRINE
AUSTENITIC SSAUSTENITIC SS BFP, GENERAL CORROSIVE APPLICATIONS, POOR IN CHLORIDE BFP, GENERAL CORROSIVE APPLICATIONS, POOR IN CHLORIDE SOLUTIONSOLUTION
HAST ALLOY CHAST ALLOY C VERY RESISTANT TO CORROSIONVERY RESISTANT TO CORROSION
TITANIUMTITANIUM CHLORIDE SOLUTIONSCHLORIDE SOLUTIONS
PUMPS
1 101 102 103 104 105 106 107 106 105 104 103 102 101 1
pH 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
STRONG ACID WEAK ACID WEAK ALKALINE STRONG ALKALINE
H+ CONCENTRATION mol/l OH- CONCENTRATION mol/l
ION CONCENTRATION, pH VALUE, DEGREE OF ACIDITY AND ALKALINITY
NEUTRAL
PUMPS1
2
3
4
5
6
7
8
9
10
11
12
13
14
STA
INLE
SS
STE
EL,
P
LAS
TIC
BR
ON
ZEB
RO
NZE
,CA
ST
IRO
N,S
TEE
L A
LLO
YS
STA
INLE
SS
STE
EL,
P
LAS
TIC
,Ni-S
iALL
OY
S,C
AS
T IR
ON
ACID HCL , H2SO4, HNO3 CONCENTRATED
SULPHURIC ACID 10%FORMIC ACID
WINE – CITRIC ACID 10%ACETIC ACID CONCENTRATED
CARBONIC ACID
AMMONIUM CHLORIDE
BORIC ACID
HUMUS ACID
SODIUM BICARBONATE 10%NATRON SOAP MAGNESIA
BORAX 1%
MAGNESIUM HYDROXIDE
AMMONIA 1%
AMMONIA CONCENTRATED, NaOH 1%NaOH 10%KOH 10%
NaOH CONCENTRATEDKOH CONCENTRATED
CIDER
BEER
DRINKINGWATER
HOUSE HOLD WASHING UP & CLEANING PREPARATIONS
WINE
TOMATO
COW’S MILK
CABBAGE
MOTHER’S MILK
EGG WHITE
LEMON
VINEGAR
SALIVA
GRAPEFRUIT
STOMACH ACID
ORANGE
SEWAGE
NEUTRAL
OH
-C
ON
CE
NTR
ATI
ON
H+
CO
NC
EN
TRA
TIO
N