Schedule

16 September, Monday: 17 September, Tuesday: 23 September, Monday: 24 September, Tuesday: 30 September, Monday: 1 October, Tuesday: 7 October, Monday: 8 October, Tuesday: 14 October, Monday: 15 October, Tuesday: 21 October, Monday: 22 October, Tuesday: Intro, dimensional analysis Dimensional analysis, problems Head loss, friction factor, hydraulic diameter Problem solving Laminar & turbulent flow in pipes, channels Problems Pitot tubes, Venturi meters, rotameters Problems Pumps and valves, efficiency Net positive suction head, cavitation Test (50 mins, closed book) Solution of the test
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C hemical & M aterials

ENGINEERING

ChemMat 213 Transfer Processes

Pumps, Valves Pump efficiency

Murat Balaban 2013

Objectives
! To know the concepts, definitions, and terms ! To know different types of pumps and where they are used ! To know different valves and their use ! To be able to solve problems involving pumps
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Pumps
Except when gravity is used to move liquids, mechanical energy must be used to overcome the forces opposing the transport of a fluid. The mechanical energy is provided by: Pumps (for liquids) Fans (very low P), for gases Blowers (about 1 atm) for gases Compressors (above 1 atm) for gases A pump increases the energy of the fluid. A turbine extracts energy from the fluid.
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Definition
A pump moves fluids (liquids or gases, and sometimes slurries) by mechanical action. Pumps consume energy to perform mechanical work to move the fluid. The energy can come in many types: Human powered, electricity, wind, combustion engine, etc.

Human powered
Treadle pump Designed to lift water using a foot-driven lever from wells, boreholes, lakes and rivers.

The pump mechanism has two cylinders with piston and check valve assemblies. The pedalling action on the foot-treadles creates alternate strokes in the two pistons to lift the water in pulses. Using twin cylinders means that the water output is continuous, making the treadle pump more efficient than a single cylinder pump such as a hand pump.
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History
The pump is the oldest fluid-energy-transfer device known. Two very old designs: (1)! the undershot-bucket waterwheels, or norias, used in Asia and Africa (1000 B.C.) and (2) Archimedes screw pump (250 B.C.), still being manufactured today to handle solid-liquid mixtures. Paddlewheel turbines were used by the Romans in 70 B.C. Babylonian windmills date back to 700 B.C.
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Momentum change

Positive displacement pumps (PDP)

Direct force is applied to a confined liquid (example: our heart) Liquid movement directly related to the speed of moving parts in the pump. Accurate control of flow rate High viscosity liquid can be pumped Pulsating discharge of flow (design can mitigate this) Tight seal between the moving part and stationary part needed.

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Safety valve PDP

Valve

Very high pressures can be generated. Moderate flow rates can be obtained. A positive displacement pump must not operate against a closed valve on the discharge side of the pump. A relief valve (safety valve) can be placed on the discharge side. PDPs are generally self-priming.
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Types of PDPs
A. Reciprocating 1. Piston or plunger 2. Diaphragm B. Rotary 1. Single rotor a. Sliding vane b. Flexible tube or lining c. Screw d. Peristaltic (wave contraction) 2. Multiple rotors a. Gear b. Lobe c. Screw d. Circumferential piston

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Gear Pump
file://localhost/Volumes/KINGSTON/Fluid flow control files/Fluid Flow Control - Dampener WaG Ram Jet Matches Gear Pump.htm

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Lobe pump
/Fluid flow control files/Fluid Flow Control - Lobe Pump Animation.htm

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Peristaltic Pump

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The stress point (where the rotor pinches the tube against the side) moves clockwise and pushes the fluid in front of it.
/Fluid flow control files/Fluid Flow Control - Dampener Matches Hose Pump.htm

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Reciprocating piston

/Fluid flow control files/Fluid Flow Control - Dampener Matches Intensifier Pump.htm

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Diaphragm pumps

/Fluid flow control files/Fluid Flow Control - Cam Dosing Metering Pump.htm

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Sliding vane pump

/Fluid flow control files/Fluid Flow Control - Damper Matched Vane Pump - WaG Ram Jet.htm

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Double screw pump

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Dynamic (kinetic) pumps

They add momentum to the fluid by means of fast-moving blades or vanes or certain special designs. There is no closed volume: The fluid increases momentum while moving through open passages and then converts its high velocity to a pressure increase (head).

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Dynamic pumps generally provide: -! a higher flow rate than PDPs (million L/min) -! a much steadier discharge -! are ineffective in handling high-viscosity liquids. Dynamic pumps also generally need priming; i.e., if they are filled with gas, they cannot suck up a liquid from below into their inlet.

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Types of dynamic pumps

A. Rotary 1. Centrifugal or radial exit flow 2. Axial flow 3. Mixed flow (between radial and axial) B. Special designs 1. Jet pump or ejector 2. Electromagnetic pumps for liquid metals 3. Fluid-actuated: gas-lift or hydraulic-ram

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Centrifugal Pump
Motor-driven impeller, enclosed in a case Liquid enters at the center Rotation = centrifugal force Liquid moves to the periphery

Two-vane impeller (or more vanes)

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Uses
Used for low viscosity liquids, high flow rates, and moderate pressure requirements. Discharge flow is steady. Liquids with solid particles can be pumped. Even when there is no flow, running pump is not damaged (short periods of time). Not good for high viscosity liquids.
/Fluid flow control files/Fluid Flow Control - Damper Matches Centrifugal Pump.htm

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Recap: Bernoulli head

Between the entrance (point 1) and exit (point 2) of the pump:

" P2 V22 % " P1 V12 % H = hs ! h f = $ + + z2 ' ! $ + + z1 ' # !g 2g & # !g 2g &

hs: pump head supplied by the pump hf: frictional losses Generally: V1 ! V2 z1 ! z2

# P2 " P1 & # )P & H !% (=% ( $ !g ' $ !g '

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Total power delivered to the fluid is:

Pw = ! gQ H

kg m m 3 m2 1 J m = kg 2 = = watts 3 2 m s s s s s

For centrifugal pumps, ideal conditions:

Pw = ! T
Where: ! = shaft angular velocity T = shaft torque Efficiency:

Pw != "T
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Problem
The following data were collected while testing a centrifugal pump for water at 30 C. Suction pressure 5 bar, discharge pressure 8 bar, volumetric flow rate 15,000 L/h. Calculate the pump head at the given flow rate, and power requirements.

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Solution
Suction pressure = 5 bar = 5 105 Pa = 5 105 N/m2 = 5 105 kg/(m s2 ) Discharge pressure = 8 bar = 8 105 Pa = 8 105 N/m2 = 8 105 kg/(m s2 ) Volumetric flow rate = 15,000 L/h = 0.0042 m3/s

Pdischarge -Psuction (8 ! 5)10 5 kg / m s 2 h pump = = !g (1000 kg / m 3 )(9.81 m / s 2 ) = 30.6 m

Pw = ! gQ H watts = (1000 kg / m 3 )(9.81 m / s 2 )(0.0042 m 3 / s )(30.6 m ) =1260.8 w

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Pump performance
Pump efficiency: the ratio of the power imparted on the fluid by the pump, to the power supplied to drive the pump. Its value is not fixed for a given pump. Efficiency is a function of the discharge, and therefore also the operating head. For centrifugal pumps, the efficiency tends to increase with flow rate up to a point midway through the operating range (peak efficiency) and then declines as flow rates rise further. Pump performance data is usually supplied by the manufacturer for pump selection. Pump efficiencies tend to decline over time due to wear. 32

Pump performance

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Pump selection for the liquid transport system

Total liquid transport system: pipes, valves, fittings, pumps, etc

For this figure: hsystem = z2 - z1 + h1-2 Frictional losses (h1-2): Proportional to the square of velocity. Velocity is proportional to volumetric flow rate

Therefore: h1-2 = Csystem Q2

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hsystem = z2 - z1 + Csystem Q2

z2-z1

This curve depends on the system properties. For example, if the static head changes, the curve shifts up or down. If a valve or elbow is added then the shape of the curve changes. (Csystem will be different)
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When the pump characteristic curve is superimposed on the system curve, the intersection gives the operating point appropriate for this system. From the graph, the flow rate and the head are obtained. The operating point should be near the maximum efficiency of the pump.
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Performance analysis
For a particular pump, there is an optimal flow rate where the efficiency " is maximum. Typical values: "! is maximum at Qdesign Qdesign ! 0.6 Qmax Convention: At the best efficiency point: Q = Q* H = H* " = "*
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Resistance curves (head loss due to friction)

Characteristic curve (head curve) of the pump

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Net positive suction head (NPSH)

Definition: The head required at the pump inlet to keep the liquid from cavitating or boiling.
2 Pvapor Pinlet V inlet NPSH R = + ! !g 2g !g

If cavitation does occur, there will be: -! pump noise and vibration, -! pitting damage to the impeller, and -! a sharp drop-off in pump head and discharge.
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Pump characteristic curves

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Problem
A centrifugal pump is to be located 4 m above the water level in a tank. The pump will operate at a flow rate of 0.02 m3/s. The manufacturer suggests a pump with a NPSHR at this flow rate as 3 m. All frictional losses may be neglected except a heat exchanger between the pipe inlet and the pump suction that has a loss coefficient Kf = 15. The pipe diameter is 10 cm and the water temperature is 30 C. Is this pump suitable for the given conditions?

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Solution
Heat exchanger

Pipe diameter 10 cm = 0.1 m Pump location above water level in tank = 4 m Volumetric flow rate 0.02 m3 /s Loss coefficient due to heat exchanger Kf = 15 Temperature of water 30C NPSHR = 3 m

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Average velocity = volumetric flow rate / cross-sectional area

0.02 m 3 / s Vav = = 2.55 m / s 2 2 ! / 4(0.1) m

We will express the head loss due to the heat exchanger as:
2 Vav [2.55(m / s)] = 4.97 m hf = K f = 15 2g 2(9.81 m / s 2 ) 2

From steam tables, the vapor pressure of water at 30 C = 4.25 KPa The available NPHS is calculated as:

Pvapor Patm NPSH A = ! z1 ! h f ! !g !g = (101.3 ! 4.25)1000 ! 4 m ! 4.97 m = 0.97 m 2 3 (9.81 m / s )(1000 kg / m )

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Since the available NPSH is less than the NPSH required by the pump, we conclude that this pump is not suitable for these conditions. A usable pump should have NPSHR less than 0.97 m

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Valves
Main functions: Control of the flow / flow rate On / off Variable debit

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Gate valve

The gate valve is not designed to regulate flow, but to stop the flow. A gate valve should always be either fully open or fully closed.
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Gate valve

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Globe valve

The globe valve is designed to serve as a regulating valve, meaning that it can adjust the flow by the percentage of the opening.

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Globe valve

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Butterfly valve
Used both for isolating, and regulating flow. Lower cost, and lighter. The disc is always present within the flow, therefore a pressure drop is always induced, regardless of valve position.

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Butterfly valve

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K loss for butterfly valve

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Check valve

Also called non-return valve, or one-way valve

Cracking pressure: the minimum upstream pressure at which the valve will operate.
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Ball check valve

Small, simple, and cheap.

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Angle valve

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Cock

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Problem
A centrifugal pump is being considered for transporting water from tank A to tank B. The pipe diameter is 4 cm. The friction factor is 0.005. The minor losses include a contraction at the pipe inlet, expansion at the pipe outlet, four pipe bends, and a globe valve. The total length is 25 m and the elevation difference between the levels of water in tank A and B is 5 m. The performance curves of the pump supplied by the manufacturer are given in Figure below. Calculate the power requirement of this pump. Kf (elbow) 1.5 Kf (globe valve, fully opened) 10 Kcontraction 0 .5 Kexpansion 1 .0

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Solution
Strategy: We need to develop the system curve and plot it in the graph given, to find the intersection point with of the pump performance curve. Then we can calculate the power requirements. Apply Bernoulli equation, noting that P1 = P2, V1=V2, z2-z1 = 5 m hpump = z2-z1 + major frictional losses + minor frictional losses

! (4)(0.005)(25 m ) $ V2 hpump = 5 m + # + 0.05 + 1.0 + 4(1.5) + 10& 2 0.04 m " % 2(9.81 m / s ) = 5 + 1.53V 2
Since Q = A V, or V = Q/A
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hpump = 5 +

1.53Q 2
2 ! ! (0.04) / 4# " $ 2

= 5 + 968,879.3Q 2

This is the equation of the system curve

Plot this system curve in the pump performance graph

Operating point

The operating point (intersection) is 0.0078 m3/s flow rate and a head of 65 m. Also note that the operating efficiency is about 88%.
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Therefore, the pump head needed at the pump shaft:

hs =

65 m = 73.9 m 0.88

Pw = ! gQ hs watts = (990 kg / m 3 )(9.81 m / s 2 )(0.0078 m 3 / s )(73.9 m ) = 5.6 Kw

Homework: Calculate the NPSHR if the water is at 30 C

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Problem
Oil, with a vapor pressure of 20 kPa, is delivered through a pipeline by equally spaced pumps, each of which increases the oil pressure by 1.3 MPa. Friction losses in the pipe are 150 Pa per meter of pipe. What is the maximum possible pump spacing to avoid cavitation of the oil?

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