Turbo Machinery

Pumps, Turbines...
 Turbo Machinery Overview
Types of Pumps
Dimensionless Parameters for Turbomachines
Power requirements
Head-discharge curves
Pump Issues
Cavitation
NPSH
Priming
Pump selection
 Types of Pumps
Positive Jet pumps
displacement Turbomachines
piston pump axial-flow (propeller
Diaphragm pump pump)
peristaltic pump radial-flow (centrifugal
Rotary pumps pump)
gear pump mixed-flow (both axial
two-lobe rotary and radial flow)
pump
screw pump
 Reciprocating action pumps
Piston pump diaphragm pump
can produce very high pressures
hydraulic fluid pump
high pressure water washers
 Peristaltic Pump

Fluid only contacts tubing

Tubing ___
ID and roller
_______
velocity with respect to the
tubing determine flow rate
Tubing eventually fails from
fatigue and abrasion
Fluid may leak past roller at
high pressures
Viscous fluids may be
pumped more slowly
 Rotary Pumps
Gear Pump
fluid is trapped between gear teeth and
the housing
Two-lobe Rotary Pump
(gear pump with two teeth on each
gear)
same principle as gear pump
fewer chambers - more extreme pulsation
trapped fluid
 Rotary Pumps
Disadvantages
precise machining
abrasives wear surfaces rapidly
pulsating output
Uses
vacuum pumps
air compressors
hydraulic fluid pumps
food handling
 Screw Pump
Can handle debris
Used to raise the
level of wastewater
Abrasive material
will damage the
seal between screw
and the housing
Grain augers use
the same principle
Compressors that
are suspect of
liquid slugging
 Positive Displacement Pumps

What happens if you close a valve on the

effluent side of a positive displacement pump?
What does flow rate vs. time look like for a
piston pump? 2.5

2
1st piston

total flow
1.5 2nd piston
3rd piston
1
3 pistons
0.5

0
0 0.5 1 1.5
revolutions
 Jet Pump
eductor
A high pressure, high velocity jet discharge is used to
pump a larger volume of fluid.
Advantages
no moving parts
self priming
handles solids easily
Disadvantage
inefficient
Uses
deep well pumping
pumping water mixed with solids
Bilge pumps

http://spaceflight.nasa.gov/shuttle/upgrades/ojp.html
 Pressure Developed by Centrifugal
Pumps
Centrifugal pumps accelerate a liquid
The maximum velocity reached is the velocity of the
periphery of the impeller
The kinetic energy is converted into potential energy
as the fluid leaves the pump
The potential energy developed is approximately 2
equal to the velocity
________head____ at the periphery of the hp =
V
impeller 2g
A given pump with a given impeller diameter and
speed will raise a fluid to a certain height regardless
of the fluid density
Theoretical Pressure Development
 Theoretical Pressure Development
In order to develop an expression for the theoretical pressure developed by the impeller, we apply the
principle of angular momentum to the mass of fluid moving through it.

If a mass, m, rotates about an axis at a radius, r, and at a tangential velocity, v, then it has an angular
momentum of mrv. Furthermore, if the mass is a fluid that is continuously being replaced then it
becomes a mass flow, dm/dt, and a torque, T, must be maintained that is equal to the corresponding
continuous rate of change of momentum

In the case of the centrifugal impeller depicted in Figure 3, the peripheral component of fluid velocity
is Cu. Hence the torque becomes

Consider the mass of fluid filling the space between two vanes and represented as abcd on Figure 3. At
a moment, dt, later it has moved to position efgh. The element abfe leaving the impeller has mass
dm and is equal to the mass of the element cdhg entering the impeller during the same time. The
volume represented by abgh has effectively remained in the same position and has not, therefore,
changed its angular momentum. The increase in angular momentum is that due to the elements abfe
and cdhg. Then, from equation above applied across the inlet and outlet locations becomes,
 Theoretical Pressure Development
Extending the flow to the whole impeller instead of merely between two vanes gives dm/dt as the total mass flow, or

where
Q = volume flow (m3/s)
= fluid density (kg/m3)

giving

Now the power consumed by the impeller, Pow is equal to the rate of doing mechanical work,

Pow= T W

where
= speed of rotation (radians/s)

giving

But

r2 = u2 = tangential velocity at outlet

r1 = u1 = tangential velocity at inlet.

Hence
 Theoretical Pressure Development

The power imparted by an impeller to the fluid is given by equation as

where
pft = rise in total pressure across the impeller.

In the absence of frictional or shock losses, must equal the power consumed by the impeller, pow.

Hence

This relationship gives the theoretical total pressure and is known as Euler's equation.

The inlet flow is often assumed to be radial for an ideal centrifugal impeller, i.e. Cu1 = 0, giving
Theoretical Pressure Development
Euler's equation can be re-expressed in a manner that is more amenable to physical
interpretation. From the outlet vector diagram

=
=
or

2u2 Cu2 =

Similarly for the inlet,

Euler's equation then becomes

 Radial Pumps
also called _________
centrifugal pumps
broad range of applicable flows and heads
2
higher heads can be achieved by increasing the h = V
p
_______
diameter or the ________
rotational ______
speed of the impeller 2g

Flow Expansion (volute)

Discharge
Casing
Suction Eye Impeller
Impeller
Vanes
 Axial Flow

also known as
__________
propeller pumps
low head (less than 12
m)
high flows (above 20
L/s)
 Dimensionless Parameters for
Turbomachines

We would like to be able to compare pumps with

similar geometry. Dimensional analysis to the
rescue...
To use the laws of similitude to compare
performance of two pumps we need
exact geometric similitude
all linear dimensions must be scaled identically
roughness must scale
homologous - streamlines are similar
constant ratio of dynamic pressures at corresponding Q
points
also known as kinematic similitude
same
D 3
 Kinematic Similitude:
Constant Force Ratio

Reynolds VD
ratio of inertial to _______
viscous forces

Froude V2 V
ratio of inertial to ________
gravity force
gl gl
Weber
ratio of inertial to _______ ______ forces
surface-tension V 2
l

Mach
ratio of inertial to _______ V
elastic forces
c
 Notes
The Weber Number is a dimensionless value useful for analyzing fluid flows where there is an interface between
two different fluids.
The Weber Number is the ratio between the inertial force and the surface tension force, and can be expressed as
We = v2 l /
Where We = Weber number (dimensionless)
= density of fluid (kg/m3, lb/ft3)
v = velocity of fluid (m/s, ft/s)
L = characteristic length (m, ft)
= surface tension (dyne/cm)
Since the Weber Number represents an index of the inertial force to the surface tension force acting on a fluid
element, it can be useful analyzing thin films flows and the formation of droplets and bubbles.

The Mach Number is a dimensionless value useful for analyzing fluid flow dynamics problems where
compressibility is a significant factor.
The Mach Number can be expressed as
M=v/c
Where M = Mach number
v = fluid flow velocity (m/s, ft/s)
c = speed of sound (m/s, ft/s)
Alternatively the Mach Number can be expressed with the density and the bulk modulus for elasticity as
M = v ( / E)1/2
Where = density of fluid (kg/m3, lb/ft3)
E = bulk modulus elasticity (N/m2 (Pa), lbf/in2 (psi))
The bulk modulus elasticity has the dimension pressure and is commonly used to characterize the fluid
compressibility.
 Turbomachinery Parameters

D flow Q
C p f Re, F ,W , M , , , Where is the fluid?
Dimpeller D flow D flow
3

2p hp g
Cp
hp g
CH = 2 V Dimpeller CH
V 2 V 2 Dimpeller
2

hp g D flow Q
CH f Re, , ,
2 Dimpeller
2 Dimpeller D flow D flow
3

impeller (Impeller is better defined)
 Shape Factor
Related to the ratio of flow passage diameter
to impeller diameter
Defined for the point of best efficiency
What determines the ideal shape for a pump?

S f ( , Q, p, )
 Notes
Specific speed Ns is a quasi non-dimensional number used to classify pump impellers as to their type
and proportions.
In Imperial units it is defined as the speed in revolutions per minute at which a geometrically similar
impeller would operate if it were of such a size as to deliver one gallon per minute against one foot of
hydraulic head. In metric units flow may be in l/s or m/s and head in m, and care must be taken to state
the units used.
Performance is defined as the ratio of the pump or turbine against a reference pump or turbine, which
divides the actual performance figure to provide a unitless figure of merit. The resulting figure would
more descriptively be called the "ideal-reference-device-specific performance." This resulting unitless
ratio may loosely be expressed as a "speed," only because the performance of the reference ideal pump
is linearly dependent on its speed, so that the ratio of [device-performance to reference-device-
performance] is also the increased speed the reference device would need to turn, in order to produce
the performance, instead of its reference speed of "1 unit."
Specific speed is used in engineering design where it is thought of as an index used to predict desired
pump or turbine characteristics; e.g., the general shape of a pump's impeller. Often it is used to predict
the type of pump or turbine required for a design flow rate and head. Once the desired specific speed is
known, basic dimensions of the unit's components can be easily calculated.
Several mathematical definitions of specific speed (all of them actually ideal-device-specific) have been
created for different devices and applications.
 N Q
* Impeller Geometry: w Q
N sp = S=
(h )
p
34
Shape Factor ( gh )
p
34

Impeller
Nsp S diameter
500 0.18 pressure low ____
Radial: high _______, flow

1000 0.37 radial

3400 1.25 mixed

6400 2.33 mixed

flow
axial: high _______, pressure
low _______
10000 3.67

*N in rpm, Q in gpm, H in ft
 Notes
Pump specific speed
Low-specific speed radial flow impellers develop hydraulic head principally through
centrifugal force. Pumps of higher specific speeds develop head partly by centrifugal force
and partly by axial force. An axial flow or propeller pump with a specific speed of 10,000
or greater generates its head exclusively through axial forces. Radial impellers are
generally low flow/high head designs whereas axial flow impellers are high flow/low head
designs.
Centrifugal pump impellers have specific speed values ranging from 500 to 10,000
(English units), with radial flow pumps at 500-4000, mixed flow at 2000-8000 and axial
flow pumps at 7000-20,000. Values of specific speed less than 500 are associated with
positive displacement pumps.
As the specific speed increases, the ratio of the impeller outlet diameter to the inlet or eye
diameter decreases. This ratio becomes 1.0 for a true axial flow impeller.
Note that the units used affect the specific speed value and consistent units should be used
for comparisons. Pump specific speed can be calculated using British gallons or using
Metric units (m3/s or L/s and metres head), changing the values listed above.
 Impeller Shape vs. Power Curves

S
Power (% of design)

radial 1 - O.33
2 - 0.81
3 - 1.5
4 - 2.1
axial 5 - 3.4
Discharge (% of design)
 Notes
There are multiple decisions to be made about impeller selection and not all pump suppliers are qualified to make them:
The impeller shape or specific speed number will dictate the shape of the pump curve, the NPSH required and influence
the efficiency of the pump.
Has the impeller configuration been iterated in recent years? Impeller design is improving with some of the newer
computer programs that have become available to the design engineer.
The suction specific speed number of the impeller will often predict if you're going to experience a cavitation problem.
The impeller material must be chosen for both chemical compatibility and wear resistance. You should consider one of
the duplex metals because most corrosion resistant materials are too soft for the demands of a pump impeller.
The decision to use a closed impeller, open impeller, semi-open, or vortex design is another decision to be made.
Closed impellers require wear rings and these wear rings present another maintenance problem.
Open and semi-open impellers are less likely to clog, but need manual adjustment to the volute or back-plate to get the
proper impeller setting and prevent internal recirculation.
Vortex pump impellers are great for solids and "stringy" materials but they're up to 50% less efficient than conventional
designs.
Investment cast impellers are usually superior to sand cast versions because you can cast compound curves with the
investment casting process. The compound curve allows the impeller to pump abrasive fluids with less vane wear.
If you're going to pump low specific gravity fluids with an open impeller, a non-sparking type metal may be needed to
prevent a fire or explosion. You'll be better off choosing a closed impeller design, with soft wear rings in these
applications.
The affinity laws will predict the affect of changing the impeller speed or diameter. You'll want to be familiar with these
laws for both centrifugal and PD pumps.
Additional Dimensionless Parameters

hp g
CH = 2 2 D is the _______
impeller diameter
w D
Q
CQ
D3
Pw = g Qhp
P
CP P is the _____
power
3 D 5

CQ1 2 Alternate equivalent way

S to calculate S.
CH3 4
(defined at max efficiency)
 Head-Discharge Curve
hp g Theoretical head-
circulatory flow - CH = 2 2
w D discharge curve
inability of finite
number of blades to h p
guide flow
friction - ____
V2
shock - incorrect angle
of blade inlet ___V2 Actual head-
discharge curve
other losses
bearing friction
packing friction
disk friction Q
Q
internal leakage CQ
D3
Pump Power Requirements

Pw = g Qhp Water power

Subscripts
Pw
eP
Ps
w = _______
water
Ps p = _______
pump
em
Pm s = _______
shaft
g Qhp m = motor
_______
Pm =
eP em
 Affinity Laws
Volume Capacity
The volume capacity of a centrifugal pump can be expressed like
q1 / q2 = (n1 / n2)(d1 / d2)
where
q = volume flow capacity (m3/s, gpm, cfm, ..)
n = wheel velocity - revolution per minute - (rpm)
d = wheel diameter
Head or Pressure
The head or pressure of a centrifugal pump can be expressed like
dp1 / dp2 = (n1 / n2)2 (d1 / d2)2
where
dp = head or pressure (m, ft, Pa, psi, ..)
Power
The power consumption of a centrifugal pump can be expressed as
P1 / P2 = (n1 / n2)3 (d1 / d2)3
where
P = power (W, bhp, ..)
 Notes
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 %
SO If we want to increase the volume flow
capacity of an existing system by 10%
we have to increase pressure head by 21%
and the power supply by 33%.
 Affinity Laws
Changing the Wheel Velocity

If the wheel diameter is constant - change in pump wheel

velocity can simplify the affinity laws to
Volume Capacity
q1 / q2 = (n1 / n2) (1a)
Head or Pressure
dp1 / dp2 = (n1 / n2)2 (2a)
Power
P1 / P2 = (n1 / n2)3 (3a)
 Affinity Laws
Volume Capacity
q1 / q2 = (n1 / n2)
Head or Pressure
dp1 / dp2 = (n1 / n2)2
Power
P1 / P2 = (n1 / n2)3

Volume Capacity
q 1 / q2 = d 1 / d2
Head or Pressure
dp1 / dp2 = (d1 / d2)2
Power
P1 / P2 = (d1 / d2)3
 Pumps in Parallel or in Series

Parallel
Flow ________
adds
Head ________
same

Series
Flow ________
same
Head ________
adds

Multistage
 Pumps in Series Pressure added
When two (or more) pumps are arranged in series, their resulting pump
performance curve is obtained by adding their heads at same flow rate as
indicated in the figure below.

Centrifugal pump in series are used to overcome larger system head loss than one pump can
handle alone. For two identical pumps in series the head will be twice the head of a single
pump at the same flow rate. With constant flowrate the combined head moves from 1 to 2. In
practice the combined head and flow rated moved along the system curve to 3.
If one of the pumps stops, the operation point moves along the system resistance curve from
point 1 to point 2 - head and flow rate are decreased.
Series operation of single stage pumps is seldom encountered - more often multistage
centrifugal pumps are used.
 Pumps in Parallel Flow added
When two or more pumps are arranged in parallel their
resulting performance curve is obtained by adding their
flowrates at the same head as indicated in the figure below.

Centrifugal pumps in parallel are used to overcome larger volume flows than one pump can
handle alone. For two identical pumps in parallel the flowrate will double (moving from 1 to
2) compared to a single pump if head is kept constant. In practice the combined head and
volume flow moves along the system curve as indicated from 1 to 3.
If one of the pumps in parallel or series stops, the operation point moves along the system
resistance curve from point 3 to point 1 - the head and flow rate are decreased.
 Cavitation in Water Pumps

water vapor bubbles 8000

form when the 7000

Vapor pressure (Pa)

pressure is less than 6000

the vapor pressure of 5000

4000
water 3000
very high pressures 2000
(800 MPa or 115,000 1000
0
psi) develop when the
0 10 20 30 40
vapor bubbles collapse Temperature (C)
 Net Positive Suction Head
NPSHR - absolute pressure in excess of vapor
pressure required at pump inlet to prevent cavitation
given by pump manufacturer
determined by the water velocity at the entrance to the
pump impeller
NPSHA - pressure in excess of vapor pressure
available at pump inlet
determined by pump installation (elevation above
reservoir, frictional losses, water temperature)
If NPSHA is less than NPSHR cavitation will occur
 Net Positive Suction Head

2 Elevation datum
Absolute pressure
z
ps Vs2 pv s = suction
NPSH R = + - Total head -pv!
1 g 2g g

2
peye pv Veye
NPSH R = - + At cavitation!
g g 2g
NPSHR increases with Q2!
How much total head in excess of vapor pressure is available?
 NPSHA
p1 V12 p2 V22
+ + z1 = + + z2 + hL
g 2g g 2g

patm ps Vs2
+ zreservoir = + + hL
g g 2g

patm ps Vs2
- Dz - hL = +
g g 2g

patm pv ps Vs2 pv
- Dz - hL - = + - Subtract vapor pressure
g g g 2g g
patm p
- Dz - hL - v = NPSH A
g g
 NPSHr Illustrated

Pv
Pressure in excess of
vapor pressure required
NPSHr to prevent cavitation

NPSHr can exceed atmospheric pressure!

 Pumps in Pipe Systems
system operating point
120

100

80 Head vs. discharge

Head (m)

pump
curve for ________
hp 60

40 Could you solve this

Static head with a dimensionless
20
performance curve?
0 hp g
CH = 2 2
0 0.2 0.4
3
0.6 0.8 w D
Discharge (m /s)

What happens as the static head changes (a tank fills)?

 Priming
hp g
The pressure increase created is CH = 2 2
w D
proportional to the _______
density of the
p
fluid being pumped. CH
2 D 2
A pump designed for water will be
unable to produce much pressure p CH 2 D 2
increase when pumping air
Density of air at sea level is __________
1.225 kg/m3
Change in pressure produced by pump is
about 0.1% of design when pumping air
rather than water!
 Priming Solutions

Applications with water at less than

atmospheric pressure on the suction side of
the pump require a method to remove the air
from the pump and the inlet piping
Solutions priming tank to vacuum pump
foot valve
priming tank
vacuum source
self priming

foot valve
 Self-Priming Centrifugal Pumps
Require a small volume of liquid in the pump
Recirculate this liquid and entrain air from the
suction side of the pump
The entrained air is separated
from the liquid and discharged
in the pressure side of the pump
 Variable Flows?

How can you obtain a wide range of flows?

__________________________
Valve
__________________________
Multiple pumps (same size)
__________________________
Multiple pumps (different sizes)
__________________________
Variable speed motor
__________________________
Storage tank
Why is the flow from two identical pumps
usually less than the 2x the flow from one
pump?
 RPM for Pump (motors)
60 cycle
number of
Other options poles
2
sync
3600
full load
3500
rad/sec
367
variable speed 4 1800 1750 183
6 1200 1167 122
belt drive 8 900 875 92
10 720 700 73
12 600 583 61
14 514 500 52
16 450 438 46
18 400 389 41
20 360 350 37
22 327 318 33
24 300 292 31
26 277 269 28
28 257 250 26
30 240 233 24
 Estimate of Pump rpm

The best efficiency is obtained when S=1

Given a desired flow and head the
approximate pump rpm can be estimated!

34
S=
w Q
34 w
( gh )
p

( gh )
p Q
 Pump Selection
Material Compatibility
Solids
Flow
Head
NPSHa
Pump Selection software
A finite number of pumps will come close to meeting
the specifications!
 Selection of Pump Type

1000 Positive
displacement
Radial
100 6000
Pumping head (m)

4000

Power (kW)
2000
hp Mixed 1000
10 600
400
200
100
1 Axial 60
40
1 2 4 6 20
10
0.1
0.0001 0.001 0.01 0.1 1 10
Flow (m3/s)
 Pump Selection Chart

http://www.pricepump.com/

Model M

Model X
 End of Curve Operation

Right of the BEP (Best Efficiency Point)

is sufficient NPSH available for the pump to operate
properly?
fluid velocities through the suction and discharge
nozzles of the pump could be extremely high, resulting
in increased pump and system noise (and wear)
Left of BEP operation
high thrust loads on the pump bearings and
mechanical face seals result in premature failure.
The pump is oversized, resulting in lower efficiency and
higher operating and capital costs.
 w Q
S=
Goulds Pump Curves ( gh )
p
34

890 rpm = 93.2 rad/s

Splitcase double suction

BEP = 1836 L/s

S=0.787

Check the Power!

 Pump Installation Design

Why not use one big pump?

Can the system handle a power failure?
Can the pump be shut down for
maintenance?
How is the pump primed?
Are there enough valves so the pump can
be removed for service without disabling
the system?
 Pump Summary
Positive displacement vs. turbomachines
Dimensional analysis
Useful for scaling
Useful for characterizing full range of pump performance
from relatively few data points
Turbomachines convert shaft work into increased
pressure (or vice versa for turbines)
The operating point is determined by where the
pump and system curves intersect
NPSH