1.

Background:

When operating fluid handling cases, it is important to use the best type of pump for

the process, and we must understand how to control the type of pump we are using. Pumps

are the engineering designs motor generated that are used to impel the movement of fluid

from one place (suction) to another place (discharge). For a simple example of why we need

pumping system, we simply apply the fact that there are some processes not spontaneously

occur in nature such as water at a lower level may not, and will not, flow up to higher level

without applying work to it. Therefore, pumps are needed to this type of scenario. In other

cases, pumps are used to accelerate the liquid to higher velocity for a desired flow rate. Some

industries such as refineries, need higher velocity (higher kinetic energy) in pumping system

in order for the liquid to move fast enough that accumulation of solid materials in the pipes is

not possible. Thus, it is extremely important to consider each pump type limitations and what

works best for a specific pumping system, and when developing new processes, it is

particularly opted to know what types of pumps are more controllable to minimize the risks

that could occur from laboratory testing to industrial scales. Pumping system is developed, in

most cases, for flowing liquid. However, many designs can also handle solids in suspension,

dissolved gas, mud, slurries and other substances that physically do not resemble a liquid.

2. Descriptions of Various Pumps:

Pumps are classified into two types based on the manner in which pumps transmit

energy to the pumped location: kinetic (centrifugal) pump or positive displacement. For the

centrifugal pump, the centrifugal force produced by a rotating blade, called the impeller,

impels kinetic energy to the fluid (in most cases, liquid), moving the fluid from pump inlet to
outlet. The other type uses reciprocating action of one or several pistons, rotating lobes, or by

expanding and collapsing cavities to develop flow, with pressure as the result. Positive

displacement pumps also tend to operate at lower rotational speeds.

There is a bunch of classifications of pump types alone in centrifugal pump. We are

opted to consider a few types as follows:

 Overhung Impeller – this classification includes a variety of centrifugal pump types

such as Closed-Coupled Single-Stage Horizontal End Suction where we have closed-

coupled pump that has the impeller mounted directly on the shaft of the driver; this

type eliminates the need for pumping housing. This is used for light duty because it

can be cleaned (flushed) without much disassembly. It can handle liquids and semi-

solids under varying conditions. Other type is Frame Mounted. This type of pump is

used for medium to severe applications, loads and thermal transients tend to

contribute to severe stresses and internal deflection inside the pump. Another one is

Centerline-Mounted Refinery Pump. As the name suggests, it is used for refinery

applications, temperature, pipe loads, product flammability are the primary conditions

in selecting this type of pump, and there are still other more in this category alone.

 Impeller between Bearings - These pumps are grouped into single- or multistage

designs, and each type is available in either axially or radially split configurations.

One example is Single-Stage where the suction and discharge is piping is connected

to the lower half of the casing, and we does not need to be disturbed for rotor

removal. Multistage Designs, axially or radially split constructions are typical in this
 type of pump. Axially split construction offers the advantage of easy maintenance

because of quick rotor removal that is similar to the single-stage type while that of

radially split construction offer the advantage of reduced radial thrust resulting in

longer life of seals and bearings.

 Vertical or Turbine Types – as the name suggests, this type of pump is more

resemble as the turbine because of the nozzle vanes and it resemble diffusers. This

type of centrifugal pump is applied to agricultural irrigation, water drainage, hot well

and booster pumps in power plants, refinery applications and more.

Like centrifugal pump, positive displacement pump comes in a family of several

types under this category alone. Several types are available because of the basic needs for

each case. We have different systems with different scenarios. Therefore, engineers design

the best pump type for a specific system. We will only mention some uses with a few types

of positive displacement pumps here and notes that there are several other not are specified

hereunder.

 Reciprocating Pumps – This type of pump uses energy from the reciprocating

pistons to generate pressure causing the fluid in the chamber to move to the discharge

medium. For a reverse stroke, the liquid flows into the vacated space caused by

retrieving pistons, which is moved by suction of pressure (vacuum pressure). This

mechanism supply necessary openings and closings of ports to provide the overall

transfer of liquid from inlet to discharge.

  Rotary Vane Pumps – These pumps are used for light products such as liquefied

gases, solvents, light oils, and the like. This type of pump is the combination of

centrifugal pump and pressure generated by positive displacement pump. It features

an eccentric rotor with several rotating blades.

 Rotary Lobe Pumps – This type of pumps are used in the food industries because it

has the advantage of non-contacting metal parts by the use of external gears which

reduces the wear but adds complexity. Hence the principle behind this pump is

similar to the Gear Pumps. This type of pump has a typical flow rate of 200-300 gpm.

 Progressive Cavity Pumps – This type of pump is desired for highly viscous

material. It has a capability of handling at least 1 million centipoise of viscosity.

Typical applications of this pump are in water waste sludge, and other highly viscous

fluid.

3. Specifications/Designs:

Before we can select a pump type, we first consider the duty conditions. These may

include the type of fluid, the intensive and extensive properties of the liquid such as density

or specific gravity, temperature, viscosity, flow, inlet and outlet pressures, fixed or variable

operating conditions, presence of solids, corrosive material in the liquid. Also, for

installation, we need to accurately estimate the pumping system starting with the location of

the inlet to the discharge medium. Piping sizes must be considered for suitable velocities for

some slurry liquids. Pressure drops for the entire piping system with potential energy

according to elevation of the suction and discharge media. Calculations are needed to be

made in order to specify the basic needs of a pumping system such as alternative routes,
alternative pressure and temperature changes, varying flow rates, and varying fluid

properties. These considerations help engineers to estimate minimum limitation for pumping

system and when and at what location another pump is needed to be installed in order to

provide the desired flow rate.

 Suction and Suction Specific Speed – net positive suction head (NSPH)

characterizes the suction performance. The pump only operates if the fluid is at a

liquid state, and little to no vaporization should occur during pumping operation.

Vaporization occurs when the liquid pressure drops below the vapor pressure of the

flowing liquid. Thus, either the pump cease to operate or the liquid is having a head

loss. Vaporization often occurs at the suction since high velocities cause pressure

drop where bubbles begin to form. Hydraulic losses must also be calculated between

the vessel surface and pump inlet in order to determine total head at the pump suction.

 Pump Characteristics Curves

Fig. 1. Head–capacity curve, where A represents the minimum allowable capacity; B,

the best efficiency point (BEP); and C, the maximum allowable capacity
 Fig. 2. Cavitation phenomenon in pumps showing cavitation bubble distribution and
rate of weight loss as a function of cavitation coefficient at constant speed where ( __)
represents actual and (---) theoretical measurements and L is bubble length growth

 Problems:

Cavitation is of great importance in pumping system. Vaporization happens

because of the velocity is to high causing the pressure drops of the liquid below that of its

vapor pressure, localized velocities increases often near the inlet, pressure drop across the

valve, and temperature increase causes the vapor pressure of the liquid to increase. Thus,

manufacturer provides the adequate NPSH to reduce the risk of cavitation. Other

complication includes the cavitational occurrence somewhere between incipient

cavitation and at the point of complete loss. So the effective way to prevent cavitation is

to consider the material of the pump or the metallurgy of it. If a specific material is not
 good enough for the desired pumping system, we may upgrade the pump by looking for a

better material such as those made of stainless steel.

Impeller wearing is also important to consider. A tight gap between the impeller

and the diffuser can result in high pressure pulsation, vibration, noise, and may lead to

vane breakage. Corrosion must also take into account. some pumping liquids are

materially corrosive or temperature corrosive. Corrosion often occurs because of the

cyclic process that is operating at the pump, and corrosive liquid may ruin the pumping

system by gradually destroying the pump or piping system. High temperature corrosion,

or overheating, is also problem since first, it can cause the liquid to vaporize, and other

problem due to high temperature is that it will damage the pump by either melting it or

giving too much pressure.

Design considerations include the application of Bernoulli’s equation, power,

efficiency, and pump head.

Power – moving a liquid from one the inlet to the outlet location, from the lower

elevation to higher elevation must account for the total amount of energy (work) needed to

supply for a desired flow rate or velocity of a moving liquid. The power of the pump is then

considered by considering the entire system and calculate the work input, or work supplied by

the pump per unit of time. And two methods to upgrade the performance or power of the pump

are first, we might install a torque meter between the pump and the drive, with the given

equation

T x rpm
BHP= … … …(1)
5252
 T x rpm
Power ( kW )= … … …(2)
9545

Where T is the torque measured in N.m and BHP is the brake horsepower. The disadvantages of

this method are the needs to install the torque meter and therefore having a longer length

pumping system and are prone to misalignment and vibrations. Another method is the pump and

motor are coupled directly. To determine the power transmitted to the pump, efficiency (Effmotor)

and power factor (PF) must be know.

I x U x √3 x PF x Eff motor
kW = … … …(3)
1000

kW
BHP= … … …( 4)
0.746

Where I is the current and U is the voltage,

We need to calibrate the pump first before we perform any calculation for the power

needed.

Efficiency – a portion of the power delivered by the pump is spent to overcome the

hydraulic losses, it is necessary to obtain the most efficient pump economically and favorably.

The difference between the driver power and the pump losses equals the power delivered to the

liquid.

kW fluid =kW −kW losses … … … ( 5 ) metric

HP fluid =BHP−HPlosses … … … ( 6 ) U . S

Therefore,

HP fluid Q x H x SG
Eff = = … … … ( 7)
BHP kW x 0.12

Where Q is the flow rate in (m3/s) and H is the pump head in (m),

HP fluid Q x H x SG
Eff = = … … … ( 8 ) for centrifugal pumps
BHP BHP x 3960
 GPM x PSI
Eff = … … … ( 9 ) for positive displacement pumps
BHP x 3960

Pump Head – the meaning of the pump head is the total energy received by the unit of

mass per unit of time. And the pump head is obtained from the Bernoulli’s equation where g is

gravitational acceleration constant, SG is specific gravity, γ is the density, Hs is the suction head,

Hd is the discharge head, and H is the pump head. And the difference of Hd and Hs is as follows,

p d , g−P s , g 1 2 2
H=H d−H s= + ( V d −V s ) + ( Z d −Z s ) … … … (10)
γ 2g

From the equation above, the head pump is the combination of static pressure head, velocity

head, and elevation head.

REFERENCES:

Nelik, L. 2001. Pumps. Kirk-Othmer Encyclopedia of Chemical Technology.

Hall, J.. (2010). Process Pump Control. Chemical Engineering, 117(12), 30-33.  Retrieved

November 28, 2010, from ABI/INFORM Global. (Document ID: 2197575331).