ENGINEERING CASE HISTORIES
Case 52: Problems with a
blocked-in centrifugal pump
The potential for overheating is one of many concerns
T. SOFROWAS, Consulting Engineer, Houston, Texas
© • ... if a pump must be operated blocked
ver the years I've analyzed several centrifugal pump fail-
ures that were the result of a blocked-in discharge. The
cause was usually a procedural or initial design error and
was corrected after the damage was done. Cracked mechanical
seals and vibration occurred in some instances and a total seizing
of the pump in others. Most pump books' recommend not to run
pumps blocked in.
When a centrifugal pump is in a no-flow condition, it is still
developing horsepower to the trapped liquid. Roughly the no-
flow horsepower is 40% to 60% of full flow. This power has to go
somewhere and much of it goes into heating the conflned liquid
in the casing.
An approximation of the liquid temperature rise in the casing
of a blocked-in centrifugal pump can be calculated from the fol-
lowing equation:
here:
= Liquid temperature rise in pump casing, °F
= No flow or blocked-in horsepower
= Time pump operates at blocked-in condition, minutes
D = Impeller diameter, ft
p = Liquid density, lb/ft^
C = Speciflc heat of liquid, Btu/lb-°F
This is just a rearrangement of the specific heat equation.^
Instead of trying to determine the weight of liquid being heated,
the pump casing is considered to be spherical. Since the piping
contains liquid too and that by using a sphere we only need to
consider the impeller size, this approximation seems adequate for
educational purposes.
Consider the example of a 100 hp-centrifugal water pump with a
one-foot-diameter impeller, using a 50% average blocked-in horse-
power. It is blocked-in for two minutes to switch remote pumps.
A r = 8 1 x 5 0 x 2 / l ^ x 62.4 x 1 = 130°F
The water trapped in the casing would rise 130° F which may
or may not cause problems depending on the pump. What is
important is that there are five variables in this simple equation.
Just saying a pump can be run for some time with no flow would
be irresponsible. As can be seen by the equation, a pump with a
low no-flow horsepower and a large casing probably won't seize,
but a high-energy pump with a smaller volume might. Hydrocar-
bons would have a larger temperature rise than water since they
in for any length of time the safest
approach is to discuss this with the
pump manufacturer. It has experience in
determining how long its pump can be
operated in this condition or if a by-pass
arrangement is required.
have smaller p and C values. Vaporization in the casing and run-
dry conditions would be a concern.
Eventually the heat is dissipated through the casing, piping and
shafting to the atmosphere and the temperature becomes steady
state and doesn't keep increasing, which isn't considered here. This
model only considers a blocked-in discharge for a short time and
is based on the casing being filled with a liquid. Remember that
this article only applies to a radial-flow centrifugal pump, not a
mixed-flow, axial-fiow or other type pump since they can have
completely different blocked-in characteristics.
Starting up with a slightly cracked discharge valve is standard
practice on many low- and medium-specific-speed pumps.^
However, if a pump must be operated blocked in for any length
of time the safest approach is to discuss this with the pump
manufacturer. It has experience in determining how long its
pump can be operated in this condition or if a by-pass arrange-
ment is required. HP
LITERATURE CITED
' Karassik, I. J., Centrifiigal Pump Clinic, p. 334, ISBN: 0-8247-1016-9,
Marcel Dekker, Inc.
^ Sofronas, A., Analytical Troubleshooting of Process Machinery and Pressure
Vessels: Including Real-World Case Studies, p. 153, ISBN: 0-471-73211-7, John
Wiley & Sons.
' Bloch, H. P. and A, R. Budris, Pump User's Handbook Life Extension, p. 375,
ISBN 0-88173-452-7, Fairmount Press, Inc.
•. T o n y S o f r o n a s , P.E., was worldwide lead mechanical
engineer for ExxonMobil before his retirement. The case studies
are from companies the writer has consulted for. Information on
his books, seminars and consulting are available at the Website
http://www.mechanicalengineeringhelp.com.
HYDROCARBON PROCESSING SEPTEMBER 2009 117