Urea Melt Pump Design

Fluid Mechanics of Turbomachinery Dr. Ogut

Figure 1: Actual Urea Melt Pump

Usman Asad Ben Davidson Jared Dodge Hendra Novi

Contents
ABSTRACT ............................................................................................................................................... 3 INTRODUCTION ...................................................................................................................................... 3 DESIGN.................................................................................................................................................... 4 CAVITATION...................................................................................................................................... 6 BASIC EQUATIONS FOR CENTRIFUGAL PUMP DESIGN ................................................................ 5 VELOCITY TRIANGLES ..................................................................................................................... 4

DESIGN ANALYSIS ................................................................................................................................... 8 INITIAL VALUES FOR DESIGN PARAMETERS ....................................................................................... 8 ESTIMATING PUMP LOSSES .............................................................................................................. 13 CONCLUSIONS ...................................................................................................................................... 19 APPENDICIES......................................................................................................................................... 20 APPENDIX A: Performance Calculations ........................................................................................... 20 APPENDIX B: Pipe Loss Calculations ................................................................................................. 21 APPENDIX C: Equations and Iterations ............................................................................................. 22 APPENDIX D: References .................................................................................................................. 23

SYSTEM HEAD LOSSES ..................................................................................................................... 6

ABSTRACT The objective of this project was to design a urea melt pump that adequately met the specifications of the piping system. The specific system in this case provided 125m of head, but designing the pump with 10% factor of safety the system provided 137.5m of head. At a flow rate of 59.1 m3/hr, the pump provides 138.5m of head, uses 53kW at a 56% total efficiency. The final design was found using an iterative design process altering 1, 2, r 1, r 2, b 1, b 2, n B, , and Q. By varying these parameters and observing the results a pump design was found to meet the system specifications. The pump we designed met these specifications thus the project yielded successful results. INTRODUCTION The centrifugal pumps are by far the most commonly used type of pumps. Of all of the installed pumps in a typical petroleum/petrochemical plant, about 8090% are centrifugal pumps. Centrifugal pumps are widely used because of their simplicity, high efficiency, wide range of capacity, head, smooth flow rate, and ease of operation and maintenance. Basic components for centrifugal pump are the: impeller, shaft, casing, and bearings. The others components are shown in Figure 2.

Figure 2: Centrifugal Pump Sectional Drawing

The impeller is the main element in a centrifugal pump. Entire construction of a pump depends upon the impeller. The fundamental equation of impeller, determines the head developed by the impeller with respect to the increase in the momentum of the fluid flowing through the impeller i.e., to get a relation between dynamic and kinematic parameters of impeller. The system is designed as seen in Figure 3:

 Pump performance can be found by = . This equation relates the power required to operate the pump and the head provided by the pump. This is an ideal equation that can be corrected for real life scenarios with slip factors and efficiencies.
Figure 3: Piping Layout

DESIGN

VELOCITY TRIANGLES

Base on impeller dimensions, fluids velocity across the impeller surface can be predicted, Figure 4 below shows that relationship.

Figure 4: Velocity Triangles

The following symbols are used in drawing velocity triangles 2 1 U = Vane or blade tip velocity 60 C = (V) Absolute velocity of flow of fluid. (Velocity of the fluid with reference to the earth or any non-moving object) W = Relative velocity of the fluid in the blade passage. (The velocity of the fluid with reference to the blade or impeller) = Absolute angle: the angle between the absolute velocity C or V and blade velocity u = Vane angle or blade anglethe angle between the relative velocity w and vane or blade velocity u. Cu = (V u ) Tangential velocity of V Vm = (C m ) Radial velocity of V Wu = Tangential velocity of W Q = Flow Rate b1 = Impeller suction side blade width b2 = Impeller discharge side blade width = Impeller eye/suction side radius r1 r2 = Impeller discharge side radius

2 + + = 2 = =

BASIC EQUATIONS FOR CENTRIFUGAL PUMP DESIGN

The Bernoulli equation shows the relationship between pressure, velocity and height that will always be constant.

Based on the Bernoulli equation the total head can be determined. 1 2 2 2 2 [(2 12 ) + (2 1 ) (2 12 )] 2

H E is theoretical head (Euler Head), is base on pump dimensions. 1 ( 1 1 ) 2 2

2 2 = 1 = 2 , = ( )( )

Slip factor is a correction factor to correct the assumption that the pump has infinite blades and include the number of blades in the impeller.

H i,s with slip, is the head that contains slip factor.

Flow through the pump, inlet and outlet will always constant 5

Specific speed is a number that characterizes the type of impeller in a unique and coherent manner. Specific speed are determined independent of pump size and can be useful comparing different pump designs. The specific speed identifies the geometrically similarity of pumps. =

= = = (2 2 1 1 ) 0.5 0.75

= (21 )(1 )(1 ) = (22 )(2 )(2 )

= (1 1 ) = (2 2 )

Power required to pump the liquid will depend on flow rate and head

A low pressure condition at the suction side of a pump can cause the fluid to start boiling called cavitation. Cavitation is a danger to the entire pump. Failure of pump components such as: rubbing in wearing ring, shaft brake can occur if there is a cavitation. To avoid cavitation, number of net positive suction head NPSH A > NPSH R NPSH R The NPSH R is the required net positive suction head by the pump in order to prevent cavitation for safe. The NPSH R for a particular pump generally determined experimentally by the pump manufacturer and is part of the documentation of the pump. NPSH A The net positive suction head made available the suction system for the pump is often named NPSH A . The NPSH A can be determined during design and construction, or determined experimentally from the actual physical system using the following equation. =

CAVITATION

SYSTEM HEAD LOSSES

h loss where h loss h major_losses h minor_losses

The head loss of a pipe, tube or duct system, is the same as that produced in a straight pipe or duct whose length is equal to the pipes of the original systems plus the sum of the equivalent lengths of all the components in the system. This can be expressed as = h major_losses + h minor_losses = total head loss in the pipe or duct system = major loss due to friction in the pipe or duct system = minor loss due to the components in the system 6

Friction Coefficient - f The friction coefficient depends on the flow - if it is laminar, transient or turbulent and the roughness of the tube or duct. To determine the friction coefficient we first have to determine if the flow is laminar, transient or turbulent - then use the proper formula or diagram, see Figure 5 for details. The flow is

= 1 2 4 = = 1 2 4 2 = 2 2 = 2 =

System Head losses from Piping, elbow and Valve

Where Re = Renould Number V = Fluid Velocity = Fluid Density = Dynamic or absolute viscosity =

laminar when Re < 2300 transient when 2300 < Re < 4000 turbulent when Re > 4000

Figure 5: Moody Diagram

DESIGN ANALYSIS
Our design approach is: 1. Select starting values for pump speed and all impeller geometry aspects. 2. Refine initial parameters so that the pump gives close to desired performance, in terms of flow and head, at design point. 3. Use numerous techniques and assumptions to find approximate equations and values for all losses and loss coefficients. 4. Combine loss factors and design parameters in Excel and use an iterative process to optimize design parameters according to our system requirements.

INITIAL VALUES FOR DESIGN PARAMETERS

Conventionally, pump design is done on the experience basis. Manufacturers have extensive records of existing performance data on families of pumps. Similarity analysis and non-dimensional groups are often used to design new pumps based on existing pumps with known hydraulic and mechanical performance. Such data for existing pumps has been compiled and plotted by numerous authors using non-dimensional parameters. These parameters is used to give starting values of The most important of these parameters is the Specific Speed (N s ) defined as:

Specific speed can be used to determine our pump type and efficiency as shown in figure below.

0.5 = 0.75

Figure 6: Pump efficiency and type against Specific Speed Ns

To meet our head and capacity requirement, first we need to select our pump speed. The pump speed will depend on the type of driver we select. Our requirement is for a small size pump for constant operation at non-fluctuating loads. Therefore a motor-driven pump meets our requirement and there is no requirement for the added complexity and cost of a turbine driver. The rotational speed of motors depend on the frequency of the electrical supply and number of poles as per below equation: = 120

where N synchronous is the synchronous speed of the motor in rpm F is frequency of AC supply in Hz P is number of motor poles.

Using a supply frequency of 50 Hz (Standard for Europe and Asia), our options for rotational speed are: 1500 Hz for 4 pole motor and 3000 Hz for 2 pole motor. It is clear from Figure 6, that higher speed favors more efficient operation. So the driving speed including motor slip is selected as 2900rpm, which is common for industrial motors. Now, our system requirements are: 9

Flow Head Speed

Table 1: System Requirements

59.1 m3/hr 137 m 2900 rpm

260.2 GPM 449.5 ft 303.7 rad/s

The specific speed (N s ) of our pump now comes out be roughly 500. Figure 6 shows our impeller will be purely radial having efficiency in the range of 50-55%. Next, we select the blade number and discharge blade angle. Our desired performance curve gives ~ 8% rise from BEP to shut-off head. Using Figure 7, we select an initial value of 7 vanes with 2 of 27.

Figure 7: Number of blades and discharge blade angle against Ns

K u can be determined using Figure 8, which comes out to be around 0.95

2 = (2)0.5

Next, we determine the Head Constant K u defined as :

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Where H is required head in ft and N is speed in rpm. This gives an initial value for D 2 of 12.8 in or 325mm Next, we determine the capacity coefficient K m2 defined as:

(1860 )0.5 2 = 2 2 = (2)0.5

Figure 8: Head constant against specific speed Ns

The Head constant is used to estimate, impeller tip diameter D 2 by the following relation:

K m2 comes out to be 0.06 using Figure 9

Figure 9: Capacity Constant vs. Specific Speed

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 2 = (2 )(2)0.5 2 =
from here b2 can be evaluated as:

and V m2 is evaluated using the relation:

Where Z is the number of blades and S u is the vane thickness (assumed to be 0.127mm) This gives b 2 ~ 6mm. Clearly, this value of b2 is perhaps too small. So a value of 10mm is chosen Next, the eye diameter D s1 is evaluated using Figure 10.

0.321 2 (2 )

Figure 10: Diameter ratio against Specific Speed

Using D s1 /D 2 = 0.35, we get D s1 = 114 mm A similar approach is used to find b 1 . Using K m1 which comes out to be ~ 0.08 at N s = 500 and

1 = (1 )(2)0.5 1 = 1 1

which is evaluated to be ~12mm. A summary of the starting values of impeller parameters are as follows: 12

Rotational Speed () Impeller tip radius (r 2 ) Discharge blade angle ( 2 ) Number of blades (Z) Impeller inlet hub radius (r s1 ) Impeller inlet shroud radius (r h1 ) Discharge width (b 2 )
Table 2: Starting Values

2900 rpm 324 mm 27 7 113 mm 100 mm 13 mm

Using these values, an excel sheet is developed which evaluates all pump velocities, Euler head, slip, ideal head including slip, power consumed and plots these values against flow rate.

ESTIMATING PUMP LOSSES

As previously described, losses in centrifugal pumps may be classified as: 1. Leakage loss 2. Disk Friction 3. Mechanical loss 4. Hydraulic loss

Estimating these losses analytically is not practical considering the complexity of flows in pumps. In order to estimate these losses, a mathematical model of the pump was created in Engineering Equation Solver (EES) initially using the previously determined impeller dimensions. Equations for all losses were entered into the model and values for loss coefficients were estimated using numerous assumptions and simplifications as detailed below for each category of losses. The complete set of equations for the pump model is given in Appendix C. a. Leakage Loss

= (2 )0.5 = + 1.5
0.5

Leakage losses in the wearing ring are given by:

A is the clearance area HL is the head drop across the clearance. 13

A simplified empirical formula based on experimental measurements for H L is presented by Stepanoff as:

Assuming a leakage loss of 4% of design flow at bep, and clearance area A = 2R h1 , where =0.5mm or 0.0005m, values for H L and C were found as: H L =98m and C=0.1 b. Disk Friction Disk friction is normally considered a power loss, as it has a retarding effect on motor torque. It is normally given as:

2 1 (2 1 ) 8

() = 3 5
() = 3 2

Where D is impeller diameter in feet, N is speed in rpm and K is an experimentally derived factor. An alternative equation for power loss due to Disk friction is presented by Pfliederer as:

Where K is plotted against Reynolds number and is the density of the fluid. A simpler chart is presented by H. H. Anderson which relates impeller diameter and disc friction.

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Figure 11: Disk friction against Impeller Diameter for various speeds

Using this chart, power loss due to disk friction for our pump using 300mm diameter and 3000 rpm comes out to be around 5 KW. This is a constant power loss of the pump. c. Mechanical Efficiency Mechanical efficiency for our model is simply assumed to be 94%. d. Hydraulic Losses Hydraulic losses can be separated into three types: i. Incidence / Shock losses ii. Diffusion Losses iii. Friction

2 = 2

The general equation for friction loss is:

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Combining these two losses, we can write

= 1 2

It can be seen that friction loss varies as a square of the flow rate. Diffusion in the impeller can be stated as:

Incidence loss, or shock loss is given by:

= + = 2
= ( )2
= 1 tan 1

Where Q sl is the flow assuming no incidence shock i.e. V u2 =0. The flow rate with no shock Q sl is a function of impeller geometry and operating conditions. It is given by

where A is the inlet area. The combined effect of shock, diffusion and friction losses is represented as:

Figure 12: Hydraulic Loss vs Flow Rate

The values of K sl and K dl were selected after an iterative process. It is clear from the above figure that our best efficiency point will be close to the point where shock losses and equal to diffusion/friction losses. So, first K sl and K dl were selected such that at our design flow (Q=59.1 m3/hr), we have h dl =h sl and actual head = H th H losses = 137m. Using these values as a starting point, different parameters of the model were tweaked so the performance curves obtained were similar to the desired performance curve of the pump. The final selected values for K sl and K dl are: K sl = 70000 K sl =35000 16

Figure 13: Hydraulic losses and Actual Head vs Flow

The final performance curves from the Engineering Equation Solver (EES) model are shown below:

Figure 14: Flow vs. Efficiency, Head, and Power

Once initial starting values and loss coefficients were chosen, each dimension was individually isolated and plotted across a range of values to evaluate the ranges that give the highest head and efficiency. These plots were iterated until physically reasonable values were reached.

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160 140 120 100 Head (m) Efficiency (%) 80 60 40 20 0 0 20 40 60 80 100 2 (degrees)
Figure 15: Outlet Blade Angle vs. Efficiency and Head

Head Efficiency

The above plot is from the last iteration, and shows the head and efficiency versus the outlet blade angle.
300 250 200 Head (m) 150 Efficiency (%) 100 50 0 0 20 40 60 80 100 1 (degrees)
Figure 16: Outlet Blade Angle vs. Efficiency and Head

Head Efficiency

As seen, the inlet blade angle greatly affects head as long as we do not assume Vu 1 to be zero.

Name Impeller Inlet radius

Symbol r1

Value

Units

Alternative Units

0.040 m 18

Impeller Outlet radius Vane Inlet Width Vane Oulet Width Inlet Angle Outlet Angle Number of Blades Angular Velocity Volumetric Flow Rate Density

r2 b1 b2 1 2 nB Q

0.125 m 0.010 m 0.010 m 5.000 30.000 8.000 303.687 rad/s 0.016 m /s 1220.000 kg/m3
3

0.087 rad 0.524 rad 2900.000 rpm 59.100 m3/h

Figure 17: Final Pump Dimensions

Figure 18 shows the system performance curves for our designed pump.

Pump Performance
200 180 160 140 120 Head (m) Efficiency (%) 100 Power Required (KW) 80 60 40 20 0 0 20 40 60 80 100 120 Volumetric Flow Rate (cubic meters per hour)
Figure 18: Pump Performance Curves

Design Flow Pump Head

System Head Required

Pump Efficiency

Power Required

CONCLUSIONS

The pump was designed for a system requiring urea melt to be pumped 100 m vertically. Head losses in the pipes were estimated at 125 m and it was designed to provide a 10% buffer over what would be needed, bringing the total pump head to 137.5 m. The final pump design provides 138.5 m of head at a

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design flow rate of 59.1 m3/h. The pump requires 53 KW to run at its design flow rate and runs at a total efficiency of 56%.

APPENDICIES

APPENDIX A: Performance Calculations See attached 20

APPENDIX B: Pipe Loss Calculations

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Where is Pa = Disharge Pressure (N/m2) Pe = Suction Pressure (N/m2) Ca=Vd = Fluid Discharge Velovity (m/s) Ce=Vs = Fluid Suction Velocity (m/s) Hvd = Total Loss form discharge side (m) Hvs = Total Loss form suction side (m) Za = Elevation of Discharge end Ze = Elevation of Suction End

APPENDIX C: Equations and Iterations See attached

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APPENDIX D: References Anderson, H.H. Centrifugal Pumps and Allied Machinery. 4th. Oxford, UK: Elsevier, 1994. Print.

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Dixon, S.L., and C.A. Hall. Fluid Mechanics and Thermodynamics of Turbomachinery. 6th. Burlington MA: Elsevier, 2010. Print. Girhar, Paresh. Practical centrifugal pumps: design, operation and maintenance. 1. Burlington MA: Elsevier, 2004. Print. Kurokawa, J. "Simple formulae for hydraulic efficiency and mechanical efficiency of hydraulic machinery." 3rd China-Japan Joint Conference. Kurokawa: Osaka, 1990. Print. Lobanoff, Val, and Robert Ross.Centrifugal Pumps: Design and Application. 2nd. Gulf Professional, 1992. "Moody Diagram." Graphic.Engineering Toolbox. First Last. 2011. Web. 10 Nov 2011. <http://www.engineeringtoolbox.com/moody-diagram-d_618.html>. Srinivasan, V.M. Rotodynamic Pumps. 1. New Deli,India: Newage International, 2008. Print. Stepanoff, A.J. Centrifugal and Axial Flow Pumps. 2nd. 1993. Print.

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