ME 4880 Experimental Design Lab

Centrifugal Pump Performance Experiment

Instructors:

Dr. Cyders, 294A Stocker, cyderst@ohio.edu

Dr. Ghasvari, 249B Stocker, ghasvari@ohio.edu

Spring 2014

1
 Part I.
• General topics on Pumps
• Categories of Pumps
• Pump curve
• Cavitation
• NSPH
 Pumps
– Basic definitions to describe pumps and pumping
pipe circuits
– Positive displacement pumps and centrifugal
pumps
– The ‘Pump Curve’
– Net Positive Suction Head
Pump analysis: energy equation
P1 V12 P2 V2 2
  z1    z2  h friction  hpump
 g 2g  g 2g

Q
1 2

• Shaft work delivered by pump is translated into a

pressure rise across the pump: P2 > P1
• How does hpump vary with Q?
– Typically data is gathered from experiments by
manufacturer and is presented in dimensional form
(pump curve)
Definitions in a typical pump system:
• Liquid flows from the P1 V12 P2 V2 2
suction side to the   z1    z2  h friction  hpump
 g 2g  g 2g
discharge side
• Suction head is head P
available just before hs  zs  s  h fs
pump, hs: g
• Discharge head is head at Pd
the exit from pump, hd: h  z  h
d d
 g fd
• Pump head, hp:
hp  hd  hs
= head required
from pump
• Flow rates affect
terms hfd & hfs
 Positive Displacement Pumps
• Properties of a PD pump:
– Pumps fluid by varying the dimension of an inner chamber.
Volumetric flow rate determined size of chamber + RPM of
pump.
– Nearly independent of back pressure.
• Application for metering fluids (example, chemicals into a process,
etc.)
– Develops the required head to meet the specified flow rate
• Head limit is due to mechanical limitations (design/metallurgy).
Catastrophic failure at limit.
• High pressure applications
– Able to handle high viscosity fluids.
– Often produces a pulsed flow
 Types of Positive Displacement
Pumps
A. Reciprocating piston (steam pumps)
B. External gear pump
C. Double-screw pump
D. Sliding vane
E. Three lobe pump
F. Double circumferential piston
G. Flexible tube squeegee
H. Internal gear
Positive Displacement Pumps
 Centrifugal pumps
• Characteristics
– Typically higher flow rates
than PDs.
– Comparatively steady
discharge.
– Moderate to low pressure
rise.
– Large range of flow rate
operation.
– Sensitive to fluid viscosity.
 Efficiency of centrifugal pumps:
• From the energy P1 V12
 z 
P2 V2 2
 z h h
 g 2 g 1  g 2 g 2 friction pump
equation, pumps
P
increase the pressure H
g
head
• The power delivered to
Pw  QP Pw   gQH
the water (water horse
power) is given by
• The power delivered by
the motor to the shaft Pbhp  T
(breaking horse power)
is given by
Pw  gQH
• Therefore, efficiency is:  
PBHP T

Note: 1HP = 746W

Centrifugal pumps – pump curves
• Real pumps are never ‘ideal’ and the
performance of the pumps are determined
experimentally by the manufacturer and
typically given in terms of graphs or pump
curves.
• Typically performance is given by curves of:
• Head versus capacity
• Power versus capacity
• NPSH versus capacity
– As Q increases the head developed by the screen
decreases.
– Maximum head is at zero capacity
– The maximum capacity of the pump is at the point where
no head is developed.
 Centrifugal pumps – Sample Pump
Curve
• 3500 is the RPM
• Impeller size 6¼ to 8¾ in. are shown
• Maximum efficiency is ~50%.
– Note that pumps can operate at 80-90% eff.
• Maximum normal capacity line
– Should not operate in the region to the right
of the line because pump can be unstable.
• Semi-open impeller
– Max sphere 1¼”
– This pump is designed for slurries /
suspensions and can pass particles up to
1¼”. This is why efficiency is relatively low.
• Motor horse power.
– Remember to correct for density using
previous equation
• Operating line (system curve)
– This is dependent on the system you are
putting the pump into. It is a plot from the
energy equation.
– That is, analyze the system to determine the
pump head required as a function of flow
rate through the pump … This will form the
P2  P1  L  Q
2 system line.
H pump   z2  z1   f  hm 
g  D  
 2 g  D2
2
4
 Pump cavitation and NSPH
• Cavitation should be avoided
due to erosion damage to
pump parts and noise.
• Cavitation occurs when P <
Pv somewhere in the pump
• Since pump increases
pressure, to prevent
cavitation we ensure suction
head is large enough
compared to vapour
pressure Pv Ps  Pv
NPSH  zs   h fs
g
• Net positive suction head

• Often we evaluate NPSH

using energy equation and
reference values – don’t
measure Pinlet
 NSPHrequired
• Manufacturers determine
conservatively how much
NPSH is needed to avoid
cavitation in the pump
– Systematic experimental
testing
• NSPHrequired (NPSHR) is
plotted on pump chart
– Caution: different axis scale
is common – read carefully
• Plot NPSH vs NSPHrequired Qmax Q
to give safe operating
range of pump
 Part II.
• Dimensional analysis
• Affinity Laws
 Dimensionless pump performance

• Previous part: everything dimensional

– Terminology used in pump systems
– Pump performance charts
– NPSH and avoiding cavitation (NPSH vs NPSHR)
• This part :
– Discuss how centrifugal pumps might be scaled
– Best efficiency point
– Examples
 Dimensionless Pump Performance
• For geometrically similar pumps we expect
similar dimensionless performance curves
• Dimensionless groups? Q
CQ 
– Capacity coefficient nD 3

gH
CH  2 2
– Head coefficient n D
Pbh 
– Power coefficient CP 
 n3 D 5
CH CQ
– Efficiency 
g  NPSH  C
– NPSH? C NPSH 
n2 D 2
• What to use for n (units 1/time): rad/s (), rpm, rps
Dimensional Analysis
• If two pumps are geometrically similar,
and
• The independent ’s are similar, i.e.,
CQ,A = CQ,B
ReA = ReB
A/DA = B/DB
• Then the dependent ’s will be the
same
CH,A = CH,B
CP,A = CP,B
 Affinity Laws
• For two homologous states A and B, we can use 
variables to develop ratios (similarity rules, affinity
laws, scaling laws).
3
Q  D 
CQ , A  CQ , B  B  B  B 
QA  A  DA 

• Useful to scale from model to prototype

• Useful to understand parameter changes, e.g.,
doubling pump speed.
Dimensional Analysis: ideal situation
• If plotted in nondimensional
form, all curves of a family of
geometrically similar pumps
should collapse onto one set of
nondimensional pump
performance curves
• From this we identify the best
efficiency point BEP
• Note: Reynolds number and
roughness can often be
neglected
Dimensionless Pump Performance
• In reality we never achieve true
similarity
– E.g. manufacturers put different
impeller into same housing
– Following figure illustrates a typical
example of 2 pumps that are ‘close’ to
similar
• Note:
• See that at BEP: max = 088
• From which we get
CQ* , CH* , CHS
*
, C* x
• From which you can calculate
Q, H, NPSH, P
 Part III.
• More on Centrifugal Pumps
• Pump selection
 Pump selection
• Previous part :
– Other types of pumps
– Centrifugal and axial ducted
– Pump specific speed
• This part
Non-dimensional Pi Groups for pumps
– Application to optimize pump speed (BEP)
– Scaling between pumps
g  NPSH  Pbh  gH Q
CNPSH  CP  CH  CQ 
n2 D 2  n3 D 5 n2 D2 nD3
Dynamic Pumps
• Dynamic Pumps include
– centrifugal pumps: fluid enters
axially, and is discharged radially.
– mixed--flow pumps: fluid enters
axially, and leaves at an angle
between radially and axially.
– axial pumps: fluid enters and
leaves axially.
Centrifugal Pumps

• Snail--shaped scroll
• Most common type of
pump: homes, autos,
industry.
Centrifugal Pumps
Centrifugal Pumps: Blade Design
Centrifugal Pumps: Blade Design

Vector analysis of leading and

trailing edges.
 Centrifugal Pumps: Blade Design

Blade number affects efficiency and introduces circulatory losses (too

few blades) and passage losses (too many blades)
 Axial Pumps

Open vs. Ducted Axial Pumps

 Open Axial Pumps

Blades generate thrust like Propeller has radial twist to

wing generates lift. take into account for angular
velocity (=r)
Ducted 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.
 Pump Specific Speed

Pump Specific Speed is used to characterize the

operation of a pump at BEP and is useful for
preliminary pump selection.
 Centrifugal pumps-specific speed
Use Dimensionless ‘specific speed’ to help choose. Dimensionless speed is
derived by eliminating diameters in Cq and Ch at the BEP.

 
1 1/ 2
n Q*
Proper CQ* 2

N s'  
 gH 
3
* 3/ 4
CH * 4

Lazy Ns 
Rpm(Gal / min) 2
1

 H ( ft ) 
3/ 4

N s  17,182 N s'
 What we covered:
• Characteristics of positive displacement
and centrifugal pumps
• Terminology used in pump systems
• Head vs flow rate: pump performance
charts
• NPSH and avoiding cavitation (NPSH vs
NPSHR)
• Examples
 What we covered:
• Today we
– Developed dimensionless pump Q
CQ 
variables nD3

– Extrapolate existing pump curve CH 

gH
n2 D2
to different pump speeds, Pbh 
CP 
diameters, and densities  n3 D 5
g  NPSH 
– Examples CNPSH 
n2 D 2
 What we covered
• Today we:
– Examined axial, mixed, radial
ducted and open pump designs
– Used specific speed to determine
which type is optimal
 Part IV.
• Lab procedure
• Venturi Measurements
• Summary of equations and calculation way
• Preparing graphs
 Lab Objectives
• Understand operation of a dc motor
• Analyze fluid flow using
– Centrifugal pump
– Venturi flow meter
• Evaluate pump performance as a function of
impeller (shaft) speed
– Develop pump performance curves
– Assess efficiencies
 Lab Set-up
Paddle meter Valve

Venturi
(P)
Dynamometer

E I
Pout
Pump
Motor
T Pin

Water Tank
 D.C motor

•Armature or rotor
•Commutator
•Brushes
•Axle
•Field magnet
•DC power supply

Figure 1. dc motor (howstuffworks.com)

 Centrifugal pump operation
• Rotating impeller delivers energy to fluid

• Governing equations or Affinity Laws relate

pump speed to:
– Flow rate, Q
– Pump head, Hp
– Fluid power, P
 24
1400 0.6
22

20 1200
0.5
18

pump efficiency, 
1000
16

fluid power (W)

0.4
14
Head (m)

800
12 0.3
10 600

8 operating point 0.2

400
6

4 pump head 1709 rpm 0.1

fluid power 1709 rpm 200
2 pump efficiency 1709 rpm
system load - head
0 0 0.0
0.000 0.002 0.004 0.006 0.008 0.010 0.012
3
Flow Rate (m /s)
 Pump Affinity Laws
N1 Q1
• NQ 
• N2  Hp
N 2 Q2
• N3  P  N1 
2
H p1
  
 N2  H p2
3
 N1  P1
  
 N2  P2
 Determination of Pump Head

Pout  Pin V22  V12

Hp    Z 2  Z1
g 2g

Pout  Pin
Hp 
g
 Determination of Flow Rate
• Use Venturi meter to determine Q

• Fluid is incompressible (const.  )

Q = Vfluid Area
 Venturi Meter

• As V , kinetic energy 
• T = 0
•  Height = 0
• Pv or P 
 Calculate Q from Venturi data

Q  Cd A2V2
• V1 = inlet velocity
• V2 = throat velocity
• A1 = inlet area
• A2 = throat area
 Throat Velocity
2 2
V1 P1 V2 P2
  Z1    Z2
2g g 2g g
A2 P  P1  P2
Z  0 V1  V2  V2 B 2
A1
. . 
m 1  m 2  A v

V2  f (P, B,  )
 Discharge Coefficient

B D2
Cd  0.907  6.53 B
ReD D1

V1D1
ReD 
 A2 2
V1  V2  V2 B
A1
 Solve for Q
• Use MS EXCEL (or Matlab)
• Calculate throat velocity
• Calculate discharge coefficient using
Reynold’s number and throat velocity
• Calculate throat area
• Solve for Q
 Power and Pump Efficiency
• Assumptions
– Q  0
– No change in elevation
– No change in pipe diameter
– Incompressible fluid
– T = 0
• Consider 1st Law (as a rate eqn.)

  
 2
 2
 
Q  W  m h2  h1   V2  V1  g Z 2  Z1 
1 2

 Pump Power Derivation
h  u  Pv
 u2  P2v   u1  P1v 
 h2  h1   m
W  m
W  m  vP2  P1 

m v  AV  Q

W  QP2  P1 

 Efficiencies
output QP2  P1 
 pump  
input T
T
 motor 
EI
QP2  P1 
 overall 
EI
 Summary of Lab Requirements
• Plots relating Hp, P, and pump to Q
• Plot relating P to pump
• Regression analyses
• Uncertainty of overall (requires unc. of Q)
• Compare Hp, P, Q for two N’s
– For fully open valve position
– WRT affinity laws
 905 rpm
1099 rpm
1303 rpm
1508 rpm
1709 rpm
Pump Head (m)

3
Flow Rate (m /s)
 905 rpm
1099 rpm
1303 rpm
Power Delevered to Fluid (W)

1508 rpm
1709 rpm

3
Flow Rate (m /s)
 905 rpm
1099 rpm
1303 rpm
1508 rpm
1709 rpm
pump efficiency

3
Flow Rate (m /s)
Pump Efficiency

905 rpm
1099 rpm
1303 rpm
1508 rpm
1709 rpm

pump power delivered to fluid (W)

 Start-up Procedure
1. Fill pvc tube with water (3/4 full)
2. Bleed pump
3. Switch breaker to “on”
4. Push main start button
5. Make sure variac is turned counterclockwise
6. Make sure throttle valve is fully open
7. Turn lever to “pump”
8. Push “reset” button
9. Push “start” button
10. Adjust variac to desired rpm using tach.
 Pump lab raw data
Shaft DC DC Inlet Outlet Venturi DP Dyna
speed voltage current Pressure Pressure (kPa) (lbs)
(rpm) (volts) (amps) (in Hg) (kPa)
 Shut-down Procedure

1. Fully open throttle valve

2. Turn variac fully counterclockwise
3. Push pump stop button
4. Turn pump lever to “off”
5. Push main stop button
6. Switch breaker to “off”