Centrifugal Pumps -  Val S. Lobanoff,  Robert R. Ross

Centrifugal Pumps (eBook)

Design and Application
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2013 | 2. Auflage
640 Seiten
Elsevier Science (Verlag)
978-0-08-050085-0 (ISBN)
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Centrifugal Pumps: Design and Application
Centrifugal Pumps: Design and Application, Second Edition focuses on the design of chemical pumps, composite materials, manufacturing techniques employed in nonmetallic pump applications, mechanical seals, and hydraulic design. The publication first offers information on the elements of pump design, specific speed and modeling laws, and impeller design. Discussions focus on shape of head capacity curve, pump speed, viscosity, specific gravity, correction for impeller trim, model law, and design suggestions. The book then takes a look at general pump design, volute design, and design of multi-stage casing. The manuscript examines double-suction pumps and side-suction design, net positive suction head, and vertical pumps. Topics include configurations, design features, pump vibration, effect of viscosity, suction piping, high speed pumps, and side suction and suction nozzle layout. The publication also ponders on high speed pumps, double-case pumps, hydraulic power recovery turbines, and shaft design and axial thrust. The book is a valuable source of data for pump designers, students, and rotating equipment engineers.

Front Cover 1
Centrifugal Pumps: Design & Application
Copyright Page 
5 
Table of Contents 6
Preface 12
Part 1: Elements of Pump Design 16
Chapter 1. Introduction 18
System Analysis for Pump Selection 18
Differential Head Required 18
NPSHA 19
Shape of Head Capacity Curve 19
Pump Speed 21
Liquid Characteristics 22
Viscosity 22
Specific Gravity 22
Construction 23
Pump Selection 25
Chapter 2. Specific Speed and Modeling Laws 26
Definition of Pump Specific Speed and Suction Specific Speed 26
The Affinity Law 27
Specific Speed Charts 29
Correction for Impeller Trim 33
Model Law 34
Factoring Law 36
Conclusion 40
Chapter 3. Impeller Design 43
Impeller Layout 52
Design Suggestions 54
Notation 59
Chapter 4. General Pump Design 60
Performance Chart 61
Chapter 5. Volute Design 65
Types of Volute Designs 67
General Design Considerations 71
The Use of Universal Volute Sections for Standard Volute Designs 73
General Considerations in Casing Design 76
Notation 79
Reference 79
Chapter 6. Design of Multi-Stage Casing 80
General Considerations in Crossover Design 82
Specific Crossover Designs 85
Crossovers with Radial Diffusion Sections 86
Crossovers with Diagonal Diffusion Sections 87
Mechanical Suggestions 87
Notation 91
Chapter 7. Double-Suction Pumps and Side-Suction Design 92
Double-Suction Pump Design 92
Side Suction and Suction Nozzle Layout 94
Chapter 8. NPSH 100
Establishing NPSHA 100
Moderate Speed Pumps 103
Influence of Suction Specific Speed (Nss) 
105 
High Speed Pumps 105
Suction Piping 118
Effect of Viscosity 118
Notation 124
References 124
Part 2: Application 126
Chapter 9. Vertical Pumps 128
Configurations 129
Applications 137
Design Features 146
Pump Vibration 151
References 153
Chapter 10. Popeline, Waterflood, and CO2 Pumps 154
Pipeline Pumps 154
Waterflood Pumps 179
CO2 Pumps 
181 
Notations 187
References 187
Chapter 11. High Speed Pumps 188
References 219
Chapter 12. Double-Case Pumps 221
Configurations 221
Applications 223
Design Features 225
Double-Case Pump Rotordynamic Analysis 234
Comparison of Diffuser Casings with Volute Casings 237
References 239
Chapter 13. Slurry Pumps 241
Slurry Abrasivity 241
Pump Materials to Resist Abrasive Wear 243
Slurry Pump Types 247
Specific Speed and Wear 247
Areas of Wear 249
Chapter 14. Hydraulic Power Recovery Turbines 261
Selection Process 263
Turbine Performance Prediction 266
Optimizing and Adjusting Performance Characteristics 269
Design Features (Hydraulic and Mechanical) 271
Operating Considerations 286
Performance Testing 286
Applications 287
Operation and Control Equipment 294
Conclusion 296
References 297
Chapter 15. Chemical Pumps Metallic and Nonmetallic 298
ANSI Pumps 298
General Construction 305
Casing Covers 312
Frame 312
Bearing Housing 313
Bedplates 319
Other Types of Chemical Pumps 320
Nonmetallic Pumps 324
General Construction of Nonmetallic Pumps 332
Nonmetallic Immersion Sump Pumps 336
Processes 338
References 344
Part 3: Mechanical Design 346
Chapter 16. Shaft Design and Axial Thrust 348
Shaft Design 348
Axial Thrust 358
Notation 366
References 368
Chapter 17. Mechanical Seals 369
References 436
Chapter 18. Vibration and Noise in Pumps 437
Introduction 437
Sources of Pump Noise 438
Causes of Vibrations 439
Rotordynamic Analysis 456
Diagnosis of Pump Vibration Problems 484
Appendix Acoustic Velocity of Liquids 501
References 506
Part 4: Extending Pump Life 510
Chapter 19. Alignment 512
Definitions 512
Why Bother With Precise Alignment? 512
Causes of Misalignment 513
Pre-Alignment Steps 522
Methods of Primary Alignment Measurement 526
Methods of Calculating Alignment Movements 531
Jig Posts 531
Numerical Examples 534
Thermal Growth 534
References 537
Chapter 20. Rolling Element Bearings and Lubrication 539
Friction Torque 540
Function of the Lubricant 540
Oil Versus Grease 540
Oil Characteristics 541
General Lubricant Considerations 544
Application Limits for Greases 548
Life-Time Lubricated, "Sealed" Bearings 549
Oil Viscosity Selection 551
Applications of Liquid Lubricants in Pumps 551
Oil Bath Lubrication 552
Drip Feed Lubrication 554
Forced Feed Circulation 554
Oil Mist Lubrication 554
Selecting Rolling Element Bearings for Reduced Failure Risk 560
Magnetic Shaft Seals in the Lubrication Environment 564
References 570
Chapter 21. Mechanical Seal Relibility 571
Failure Analysis 572
Seal Hardware Failures 574
Seal Failures from Installation Problems 576
Seal Failures Related to Pump Hardware 578
Seal Failures Caused by Pump Repair and Installation 579
Seal Failures Caused by Pump Operation 580
Reliability 582
Index 584

2

Specific Speed and Modeling Laws


Specific speed and suction specific speed are very useful parameters for engineers involved in centrifugal pump design and/or application. For the pump designer an intimate knowledge of the function of specific speed is the only road to successful pump design. For the application or product engineer specific speed provides a useful means of evaluating various pump lines. For the user specific speed is a tool for use in comparing various pumps and selecting the most efficient and economical pumping equipment for his plant applications.

A theoretical knowledge of pump design and extensive experience in the application of pumps both indicate that the numerical values of specific speed are very critical. In fact, a detailed study of specific speed will lead to the necessary design parameters for all types of pumps.

Definition of Pump Specific Speed and Suction Specific Speed


Pump specific speed (Ns) as it is applied to centrifugal pumps is defined in U.S. units as:

Specificspeed is always calculated at the best efficiency point (BEP) with maximum impeller diameter and single stage only. As specific speed can be calculated in any consistent units, it is useful to convert the calculated number to some other system of units. See Table 2-1. The suction specific speed (Nss) is calculated by the same formula as pump specific speed (Ns) but uses NPSHR values in feet in place of head (H) in feet. To calculate pump specific speed (Ns) use full capacity (GPM) for either single- or double-suction pumps. To calculate suction specific speed (Nss) use one half of capacity (GPM) for double-suction pumps.

Table 2-1

Specific Speed Conversion.

It is well known that specific speed is a reference number that describes the hydraulic features of a pump, whether radial, semi-axial (Francis type), or propeller type. The term, although widely used, is usually considered (except by designers) only as a characteristic number without any associated concrete reference or picture. This is partly due to its definition as the speed (RPM) of a geometrically similar pump which will deliver one gallon per minute against one foot of head.

To connect the term specific speed with a definite picture, and give it more concrete meaning such as GPM for rate of flow or RPM for rate of speed, two well known and important laws of centrifugal pump design must be borne in mind—the affinity law and the model law (the model law will be discussed later).

The Affinity Law


This is used to refigure the performance of a pump from one speed to another. This law states that for similar conditions of flow (i.e. substantially same efficiency) the capacity will vary directly with the ratio of speed and/or impeller diameter and the head with the square of this ratio at the point of best efficiency. Other points to the left or right of the best efficiency point will correspond similarly. The flow cut-off point is usually determined by the pump suction conditions. From this definition, the rules in Table 2-2 can be used to refigure pump performance with impeller diameter or speed change.

Table 2-2

Formulas for Refiguring Pump Performance with Impeller Diameter or Speed Change.

Q1, H1, bhp1, D1, and N1 =Initial capacity, head, brake horsepower, diameter, and speed.

Q2, H2, bhp2, D2, and N2 =New capacity, head, brake horsepower, diameter, and speed.

Example

A pump operating at 3,550 RPM has a performance as shown in solid lines in Figure 2-1. Calculate the new performance of the pump if the operating speed is increased to 4,000 RPM.

Figure 2-1 New pump factored from model pump—different speed.

Step 1

From the performance curve, tabulate performance at 3,550 RPM (Table 2-3).

Table 2-3

Tabulated Performance at 3,550 RPM

Step 2

Establish the correction factors for operation at 4,000 RPM.

Step 3

Calculate new conditions at 4,000 RPM from:

Results are tabulated in Table 2-4 and shown as a dotted line, in Figure 2-1. Note that the pump efficiency remains the same with the increase in speed.

Table 2-4

Tabulated Performance at 4,000 RPM

Specific Speed Charts


We have prepared a nomograph (Figure 2-2) relating pump specific speed and suction specific speed to capacity, speed, and head. The nomograph is very simple to use: Locate capacity at the bottom of the graph, go vertically to the rotating speed, horizontally to TDH, and vertically to the pump specific speed. To obtain suction specific speed continue from the rotating speed to NPSHR and vertically to the suction specific speed. Pump specific speed is the same for either single-suction or double-suction designs.

Figure 2-2 Specific speed and suction specific speed nomograph.

For estimating the expected pump efficiencies at the best efficiency points, many textbooks have plotted charts showing efficiency as a function of specific speed (Ns) and capacity (GPM). We have prepared similar charts, but ours are based on test results of many different types of pumps and many years of experience.

Figure 2-3 shows efficiencies vs. specific speed as applied to end-suction process pumps (API-types). Figure 2-4 shows them as applied to single-stage double-suction pumps, and Figure 2-5 shows them as applied to double-volute-type horizontally split multi-stage pumps.

Figure 2-3 Efficiency for overhung process pumps.

Figure 2-4 Efficiency for single-stage double-suction pumps.

Figure 2-5 Efficiency for double-volute-type horizontally split multi-stage pumps.

Figure 2-5 is based on competitive data. It is interesting to note that although the specific speed of multi-stage pumps stays within a rather narrow range, the pump efficiencies are very high, equal almost to those of the double-suction pumps. The data shown are based on pumps having six stages or less and operating at 3,560 RPM. For additional stages or higher speed, horsepower requirements may dictate an increase in shaft size. This has a negative effect on pump performance and the efficiency shown will be reduced.

As can be seen, efficiency increases very rapidly up to Ns 2,000, stays reasonably constant up to Ns 3,500, and after that begins to fall off slowly. The drop at high specific speeds is explained by the fact that hydraulic friction and shock losses for high specific speed (low head) pumps contribute a greater percentage of total head than for low specific speed (high head) pumps. The drop at low specific speeds is explained by the fact that pump mechanical losses do not vary much over the range of specific speeds and are therefore a greater percentage of total power consumption at the lower specific speeds.

Correction for Impeller Trim


The affinity laws described earlier require correction when performance is being figured on an impeller diameter change. Test results have shown that there is a discrepancy between the calculated impeller diameter and the achieved performance. The larger the impeller cut, the larger the discrepancy as shown in Figure 2-6.

Figure 2-6 Impeller trim correction.

Example

What impeller trim is required on a 7-in. impeller to reduce head from 135 ft to 90 ft?

Step 1.

From affinity laws:

Calculated percent of original diameter = 5.72/7 = .82

Step 2.

Establish correction factor:

From Figure 2-6 calculated diameter .82 = Actual required diameter .84.

Impeller trims less than 80% of original diameter should be avoided since they result in a considerable drop in efficiency and might create unstable pump performance. Also, for pumps of high specific speed (2,500–4,000), impeller trim should be limited to 90% of original diameter. This is due to possible hydraulic problems associated with inadequate vane overlap.

Model Law


Another index related to specific speed is the pump modeling law. The “model law” is not very well known and usually applies to very large pumps used in hydroelectric applications. It states that two geometrically similar pumps working against the same head will have similar flow conditions (same velocities in every pump section) if they run at speeds inversely proportional to their size, and in that case their capacity will vary with the square of their size. This is easily understood if we realize that the peripheral velocities, which are the product of impeller diameter and RPM, will be the same for the two pumps if the diameter increase is inversely proportional to the RPM increase. The head, being...

Erscheint lt. Verlag 22.10.2013
Sprache englisch
Themenwelt Naturwissenschaften Physik / Astronomie Strömungsmechanik
Technik Bauwesen
Technik Maschinenbau
ISBN-10 0-08-050085-4 / 0080500854
ISBN-13 978-0-08-050085-0 / 9780080500850
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