J. Subbiah,: Thermal Power Station-Ii Neyveli Lignite Corporation Limited Neyveli

FACTORS INFLUENCING PERFORMANCE
OF
CENTRIFUGAL PUMPS
J. SUBBIAH, DCE/MECH
OPERATION SERVICES / TURBINE
THERMAL POWER STATION-II

NEYVELI LIGNITE CORPORATION LIMITED
NEYVELI
PERFORMANCE OF PUMPS J. SUBBIAH, DCE/MECH OPERATION SERVICES / TURBINE / TPS-II, N.L.C. LTD., NEYVELI.
PERFORMANCE OF PUMPS
FOCUS
 Pumps
 Cavitation
 NPSH
 Safe Operation
 Protections
Energy
 Greek ενεργός, energos, “active, working’’
 Energy is often defined as the ability to do
work
THE CONSERVATION OF ENERGY
 Energy is converted from one form to

THOMAS YOUNG another, but it is never created nor
destroyed
Energy Conservation
The meaning of energy conservation, energy efficiency as well as energy

cost reduction are different but related concepts
Energy Conservation
 It is achieved when the growth of energy consumption for the product,

process etc., is reduced
 This has simple relation with the reduction in the quantity of energy
consumed over a span of time
 This can be the result of improvement in technology, process, and

efficiency or simply change in habit to reduce the consumption
 This may also result in the quantity of output, consumption and comfort
level achieved out of use of energy
Energy Efficiency
 It is achieved when intensity of energy consumption for the product,

process etc., is reduced, without affecting the output and comfort level
 This can be the result of improvement in technology, process and

efficiency
 This, in simple words, means use less energy to perform same function
Energy Conservation
ENERGY COST REDUCTION
 This means simply smaller energy bill, of course without affecting the
quality of output
 It can be achieved by energy conservation, energy efficiency, better

management (adopting alternative cheaper cost sources, better use of
resources, lower transportation and storage cost, lower wastage etc.)
 The ultimate aim of cost reduction is to achieve reduction in the energy

cost
Energy Efficiency
 Effective operation practices
 Energy Efficient
n Equipment
n Systems
 Energy efficiency means using less energy to perform the same function
 Energy efficiency assumed more importance because of being the most

cost-effective and reliable means of mitigating the global climate change
Energy Efficiency
TRANMISSION DISTRIBUTION
 Transmission and Distribution System efficiency from the output of the
power plant to the end user is 83% in India
 The standard technical losses are around 17%
INDUSTRY
 Transformer – Internal Distribution Network efficiency is 95%
 Motor efficiency is 90%
 Mechanical System, pump efficiency is 70%
 Overall efficiency = 0.83 x 0.95 x 0.9 x 0.7 = 0.5 = 50%
 One Unit (kWhr) saved at the end user level is equivalent to two units
generated in the power plant
Pump
 Pump is a mechanical device to increase the pressure energy

of a liquid
 Pumping is the process of addition of energy to a liquid for

the purpose of moving it from one point to another
 This energy will cause the liquid to do work such as flow

through a pipe or rise to a higher level
Centrifugal Pump
Centrifugal pump transforms mechanical energy from a rotating

impeller into kinetic and potential energy required by the system
 Liquid enters the impeller at its center technically known as the eye
of the pump
 Discharges into the casing surrounding the impeller
 The pressure (head) developed by centrifugal action is entirely due

to the velocity imparted to the liquid by the rotating impeller
 An impeller of a given diameter operating at a given speed can

develop so much head and no more
 Pump shall be started, keeping its discharge valve in close condition
Principles of Pump
 If continuous water supply is maintained at the eye of the impeller,

uninterrupted discharge head will be established at the periphery of
the impeller
 Density of the medium decides the centrifugal head developed by

rotating impeller of a pump
 Density of water is 800 times of that of air
 Impeller that rotates in the medium produces forced vortex
 As long as the impeller rotates in the air, the centrifugal head

developed depends on the density of the air, that will not sufficient to
raise the water level even for a few meter
Pump Affinity Law
 The pump has to be filled with water so that the head developed is
sufficient to lift the water to the required height – called Priming
 Any centrifugal pump is to be started with its discharge valve in

closed condition to reduce starting torque
Affinity Law - Centrifugal Pumps
• Discharge “Q” a D & N
• Head “H” a D2 & N2
• Power “P” a D3 & N3
HEAD OF PUMP
Hd (Delivery Head)
Hs (Suction Head)
Hstat = HS+Hd
Static Head
 It is the sum of suction and delivery heads
 Suction head is the vertical height of the center line of the

pump shaft above the surface of a available liquid
 Delivery head is the vertical height measured from the pump

shaft to where the liquid is delivered
Total Head
 This is the actual head against which the pump has to work
 It is equal to the static head plus all the head losses occurring in
flow before, through and after the impeller
 It is the head measured across the pump inlet and out let flanges
 It is the difference between delivery and suction pressure head
NPSH
The amount of energy at the pump centre line
NPSH available
Characteristics of the system

Energy in the liquid at the suction of the pump
Above that energy in the liquid due to its vapour pressure
NPSH required
Characteristics of the pump

The energy required to overcome frictional losses from suction opening t
It varies with pump design, size & operating conditions
The available NPSH must always be equal to or greater than the required N
NPSH
Net Positive Suction Head

NPSH=Hp ± Hz – Hvp - Hf
HP - Head corresponding to the absolute pressure
which the pump draws
HZ - Height in meters of the liquid surface above or
below the impeller center line
HVP - Head corresponding to the vapour pressure of
the liquid at the existing temperature
HF - Head lost because of friction and turbulence
between surface of the liquid and the pump
suction flange
Vapour Pressure
 Water boils at 1000c at atmospheric pressure and gets

converted completely into vapour (steam)
 Boiling temperature of a liquid decreases as the pressure

decreases and vice versa
 Corresponding to every temperature there is a pressure at

which the liquid gets converted into its vapour form
 This pressure is known as vapour pressure
Effect of Pumping Temperature on NPSH
 If the temperature of water being pumped is increased e.g., due to

corresponding change in deaerator pressure in case of BFP or condenser
vacuum in case of condensate extraction pump, then the NPSH available will
decrease
 If NPSH available was only marginally higher than NPSH required, a slight
temperature increase would eat away the margin. This is explained in the
below figure
Effect of Pumping Temperature on NPSH
 In the above figure, the pumping system was designed for 1600C. When the
water temperature rose to 1800C, NPSH available was inadequate and severe
cavitation resulted in the pumps
 Process could be controlled maximum up to 1700C for cavitation free

operation
 Therefore, it is extremely important to control the temperature of pumping

liquid for safe operation of the pump
 However, if temperature fluctuations cannot be avoided, arrangements have

to be made to improve the suction conditions or pump impeller may have to
be redesigned
Effect of Pump Location on NPSH
 The effect of changing the location of pump is explained

 This case refers to a re-location of a pump (involving change of elevation and
pipe line length, number of bends etc.,), which resulted in reduced NPSH
available
Effect of Pump Location on NPSH
 Pump cannot run at design flow without cavitation

 The pump is elevated due to change in piping layout, then the static suction
head available to the pump is reduced
 This will subsequently cause the deficiency of the NPSH available as
compared to designed NPSH
Effect of Change in Speed of the Pump
 With speed increase, NPSH required also goes up appreciably and eat away the
margins available in NPSH available
 In the above figure, design flow with low speed has enough margin on NPSH
available over NPSH required
 If the high-speed pump is used in this system, NPSH required curve becomes
steep as compared to low speed pump
 Hence for the same flow the high speed pump will operate in cavitation zone
since the margin between NPSH available and NPSH required gets reduced
 Hence high-speed pump will not be suitable for this configuration
 In such cases the manufacturer has to be given information in the

specification itself as to what speed increase is expected normally, so that it
can be taken care of the design stage itself
 In a given system and operating condition there are certain methods by which
the NPSH available can be improved. In case of BFP they are :
1. Raise the height of the deaerator further, thereby increasing the static
head. But this method is not feasible since the CEP head will also
required to be increased. Further by raising the deaerator the piping
length will increase and hence the friction loss will increase in the same
proportion
2. Incorporate a slow speed booster pump. The pump will have much lower
NPSH requirement than BFP. Booster pump will increase the suction
pressure to cope up with NPSH requirement of the BFP
3. By increasing the suction pipe diameter, there by reducing the head loss
due to friction
Effect of Change in flow rate
 The NPSH requirement increases with the increase of flow rate of the pump
whereas NPSH reduces with flow rate
 While operating the pump, one has to be sure that at the required flow rate,
the NPSH available is more than NPSH required (manufacturers recommended
curve) at that flow
Effect of Change in flow rate
 It can be seen from the above figure that at flow Q1, which is the designed
flow the NPSH available, is substantially higher than the NPSH required
 Generally NPSH available should be 20 to 30 % more than the NPSH required

for the cavitation free operation of the pump
 However, the flow can be increased maximum up to Q2 for short operation
 But in any case flow should never be increased above Q2 value since the
cavitation will take place and there will be severe damage to the pump
Cavitation
 If the pressure at any point inside a pump, particularly at the

suction line drops below the vapour pressure corresponding to
the temperature of liquid, the liquid will vapourize and appear
as cavities of vapour or vapour bubbles
 These cavities are carried up-stream along with liquid until a

region of high pressure is formed inside the impeller where the
cavities may collapse with a tremendous impact on the side
walls of the impeller vanes
This phenomenon is called cavitation
Cavitation
Cavitation causes
 noise
 vibration in pump
 drop in energy conversion(head)
 drop in flow rate (Q)
 drop in efficiency
 pitting
 erosion
 Reducing life of the pump
NPSH
Example 1 : Pumping water from a sump. Water temperature is 30°C .

Friction and turbulence loss in the suction line is 0.3m. Suction lift is
2.4m. What is the NPSH available?
Hf = 0.3m p = atmospheric pressure 1 kg/ cm2
Hz = -2.4m Hp = 10p/s
s = specific gravity = 0.996@300C
Hp = (10x1)/0.996 = 10.05m
2.4M Hz Hp
vapour pressure @ 300C = 0.0429kg/cm2
Hvp= (10 x 0.0429) / 0.996 = 0.431m
NPSH = 10.05-2.4-0.431-0.3 = 6.919m
NPSH
Example 2: A condensate extraction pump at sea level draws water from

condenser in which 0.0856 kg/cm2 (A) (687.5mm Hg vacuum) is
maintained. The friction and turbulence loss in the piping is estimated to be
1.2m. What minimum height of water level in the condenser above the
pump center line must be maintained, if the required NPSH of the pump is
3.6m for the maximum capacity of the pump ?
Condenser Pressure p = 0.0856kg/cm2 (A)

Specific gravity s = 0.991
Hp = (0.0856x10)/0.991 = 0.865m
Hp = 10p/s
Hp
Hvp = (0.086x10)/0.991 = 0.865m
Hf = 1.2m
?
NPSH = Hp+Hz - Hvp - Hf Hz
3.6 = 0.865+Hz - 0.865 - 1.2

Hz = 3.6+1.2 = 4.8m
Multi Stage Pump
 Speed of the pump / Diameter of the impeller is to be increased. Higher

speed will induce stress in the impeller
 Hence to increase the head add number of impellers to the same shaft –
called Multi Stage Pumps
Effect of Specific Gravity
 Specific gravity is the ratio between “Mass of a given volume of

substance” to “ Mass of an equal volume of water”
 Power consumed by a pump is directly proportional to the Specific

gravity of the liquid
 Discharge head in terms of “meter” is not dependant on the Specific

gravity of the liquid
 Discharge head in terms of “bar” is dependant on the Specific gravity

of the liquid
Safe Operation of Pump
 A thumb rule says that, “ for every 100 kW of input power to the pump
3 lps of flow has to be established through the pump”to keep the
water temperature within the acceptable limits
 If there is more liquid leaving the pump faster than the liquid that can
enter into the pump, then the pump is starved of liquid leading to a
condition called “Run Out condition” which facilitates cavitation as the
increased discharge flow reduces the absolute pressure available at the
eye of the impeller
Pump Selection
 It is essential to define required pump parameters with as much

clarity as possible
Flow
Head
 It would be ideal if the pump operation occurs as close to design

point as possible
 Too much of safety margin will result in improper selection i.e. over
design
 Over designed equipment is a commonly noticed phenomenon in the

industry
Pump Selection
 To tackle this issue, system designer should define expected

pump operation in as much detail as possible
 A complete band within which pump is likely to operate most of

the time should be defined
 Pump selection should be optimised to suit the band
 If a particular operating situation is likely to occur for a short

time in a year, it may not be worth to select a pump for that
situation
Pump Selection
 System characteristic curve should be properly prepared
 This will be immensely useful at the time of pump selection
 Operation of pump away from the Best Efficiency Point (BEP) means
 Lower pump efficiency
 High Vibration
 High Noise Level
Pump Efficiency
 In any power plant pumps like boiler feed pumps (BFP), condensate
extraction pumps (CEP), circulating water pumps (CWP) consume
major amount of power and it is a good target to start energy
conservation exercise
 Any reduction in power consumption in these pumps can result in

good deal of power saving
 Energy conservation process will have to be started right from the

power plant designing and detailed engineering
Optimum Pump Design
 It is a well known fact that poor surface finish on hydraulic passages

causes turbulence in the flow pattern resulting in power loss
 High quality surface finish can reduce these losses thus helping in
improving the efficiency
 Smaller clearances between stationery and rotating components also

result in reduced internal circulation thus improving the efficiency.
However this should not be done at the cost of reliability
Pump Optimum Selection
 Define required pump parameters (flow, head, etc.,) with as much

clarity as possible
 It would be ideal if the actual pump operation occurs as close at
design point as possible
 While selecting the pump, pump manufacture is dependent on the
plant designer in the form of pump parameters
 Too much of safety margin will result in improper selection e.g., too
much of buffer in the parameters will result in a pump which is over
designed for the purpose
 Over designed equipment is a commonly noticed phenomenon in the
industry
 A complete band within which pump is likely to operate most of the
time should be defined so that pump selection can be optimized to
suit the band.
 System resistance curve should be properly prepared
 This
PERFORMANCE will be
OF PUMPS immensely
J. SUBBIAH, DCE/MECHuseful at the
OPERATION time
SERVICES of pump
/ TURBINE / TPS-II,selection
N.L.C. LTD., NEYVELI.
Throttling
 The case of partial closure of a regulating valve on the discharge

side is known as throttling and its effect is to increase and steeper
the friction head curve, and thus the total system head curve
 Each throttle position will thus establish its own working point
 The above figure shows the case of a centrifugal pump with a sluice
valve installed on the delivery side
 A practical throttling range is indicated by the limits of the working

envelope of the pump, as further throttling will result in drastic
reduction in efficiency and can be restored to, if lower efficiency is
acceptable
Throttling
 Throttling may be done to create artificial pressure of head

development so as to bring pump’s duty point within its acceptable
limit to H-Q, if head is not sufficient, but this is very much wasteful
method in respect of energy consumption
Pump Characteristics
Pump Head Calculation
Pump capacity
Q = 0.05m3/sec
Q = AV
Where, A = (D2)/4 – pipe cross sectional area in m2
D = diameter of the pipe in m
V = velocity of water in m/s
Assuming velocity, V=0.5m/s
we get diameter of the pipe, D=0.35m
Suction Layout has the following fittings

Straight pipe of length - 7m
Medium radius bend - 1 No.
Foot Valve - 1 No.
Strainer - 1 No.
EQUIVALENT SUCTION PIPE LENGTH
Straight pipe length = 7.0 m

Medium radius bend (25x0.35) = 8.8 m*
Foot valve & strainer (120x0.35) = 42.0 m*
Equivalent suction pipe length = 57.8 m
* Data from pipe frictional loss charts
FRICTIONAL HEAD (Dynamic Head)

Hf = 4flv2 / 2gD
Where, f = coefficient that depends upon the pipe internal surface
l = equivalent pipe length in m
D = pipe diameter in m
v = velocity in m/s
g = gravitational constant in m2/s
Hf = (4 x 0.005 x 57.8 x 52) / (2 x 9.81 x 0.35)
= 0.04m.
Total suction head = Suction lift + frictional head
Total suction head = 1.5 + 0.04 = 1.6m
EQUIVALENT DELIVERY PIPE LENGTH
Straight pipe length = 100.0 m

NRV (80 x 0.15) = 12.0 m
Gate valve (8 x 0.15) x 2 = 2.4 m
Long radius bend (20 x 0.15) x 6 = 7.5 m
Equivalent delivery pipe length = 139.9m
FRICTIONAL HEAD (Dynamic Head)
Hf = 4flv2 / 2gD
Hf = (4 x 0.005 x 139.9 x 2.82)/(2 x 9.81 x 0.15)
= 7.45m
Delivery lift = 70.0m
Total delivery head = Delivery lift + frictional head
Total delivery head = 70 + 7.45 = 77.45m
TOTAL HEAD = Total suction head + Total delivery head
= 1.6 + 77.45 = 79.0m
Pump Efficiency Calculation
PUMP HYDRAULIC POWER

Ph = Q x (hd-hs) x r x g/1000
Where Ph = hydraulic power in kW
Q = flow in m3/s
hd = discharge head in mwcl
hs = suction head in mwcl
r = density of the liquid in kg/m3
g = acceleration due to gravity in m2/s
PUMP SHAFT POWER
Ps = Ph /hpump
Where, Ps =pump shaft power in kW
Ph =pump Hydraulic power in kW
hpump = pump efficiency in %.
Efficiency of Pump
ELECTRIC MOTOR INPUT POWER

Minput = Ps/ hmotor
Where, Minput = motor input power in kW
Ps = shaft power in kW
hmotor = motor efficiency in %
DESIGN CONDITIONS
Q = 678 m3/hr H = 225m wcl r = 989 kg/m3 g = 9.81 m2/s
HYDRAULIC POWER
Ph = Q x H x r x g / 1000
= [(678/3600) x 225 x 989 x 9.81]/1000
= 411.12 kW
Efficiency of Pump
PUMP SHAFT POWER

Ps = Ph/ hpump
= 411.12/0.81
= 507.86 kW
MOTOR INPUT POWER

Pm = Ps/hmotor
= 507.56/0.93 [assume hmotor = 93%]
 550 kW
Efficiency of Pump
OPERATING CONDITIONS
Q = 540 m3/hr
H = 264 mwcl
r = 989 kg/m3
g = 9.81 m2/s
HYDRAULIC POWER
Ph = Q x H x r x g / 1000
= [(540/3600) x 264 x 989 x 9.81] / 1000
= 384.20 kW
PUMP SHAFT
PS = Ph / hpump
= 384.20/0.795
= 483.27 kW
Efficiency of Pump
MOTOR INPUT POWER

Pm = Ps / hmotor
= 483.27/0.93 [assume hmotor = 93%]
 520 kW
Energy Conservation
Performance of Pumps
Thank you!

J. Subbiah,: Thermal Power Station-Ii Neyveli Lignite Corporation Limited Neyveli

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

J. Subbiah,: Thermal Power Station-Ii Neyveli Lignite Corporation Limited Neyveli

Загружено:

Авторское право:

Доступные форматы

FACTORS INFLUENCING PERFORMANCE

THERMAL POWER STATION-II

 Greek ενεργός, energos, “active, working’’

 Energy is often defined as the ability to do

THE CONSERVATION OF ENERGY

 Energy is converted from one form to

The meaning of energy conservation, energy efficiency as well as energy

 It is achieved when the growth of energy consumption for the product,

 This can be the result of improvement in technology, process, and

 It is achieved when intensity of energy consumption for the product,

 This can be the result of improvement in technology, process and

ENERGY COST REDUCTION

 It can be achieved by energy conservation, energy efficiency, better

 The ultimate aim of cost reduction is to achieve reduction in the energy

 Effective operation practices

 Energy efficiency assumed more importance because of being the most

 Pump is a mechanical device to increase the pressure energy

 Pumping is the process of addition of energy to a liquid for

 This energy will cause the liquid to do work such as flow

Centrifugal pump transforms mechanical energy from a rotating

 Discharges into the casing surrounding the impeller

 The pressure (head) developed by centrifugal action is entirely due

 An impeller of a given diameter operating at a given speed can

 Pump shall be started, keeping its discharge valve in close condition

 If continuous water supply is maintained at the eye of the impeller,

 Density of the medium decides the centrifugal head developed by

 Density of water is 800 times of that of air

 Impeller that rotates in the medium produces forced vortex

 As long as the impeller rotates in the air, the centrifugal head

 Any centrifugal pump is to be started with its discharge valve in

Affinity Law - Centrifugal Pumps

• Discharge “Q” a D & N

• Head “H” a D2 & N2

• Power “P” a D3 & N3

 It is the sum of suction and delivery heads

 Suction head is the vertical height of the center line of the

 Delivery head is the vertical height measured from the pump

 It is the difference between delivery and suction pressure head

The amount of energy at the pump centre line

Characteristics of the system

Characteristics of the pump

Net Positive Suction Head

 Water boils at 1000c at atmospheric pressure and gets

 Boiling temperature of a liquid decreases as the pressure

 Corresponding to every temperature there is a pressure at

 This pressure is known as vapour pressure

 If the temperature of water being pumped is increased e.g., due to

 Process could be controlled maximum up to 1700C for cavitation free

 Therefore, it is extremely important to control the temperature of pumping

 However, if temperature fluctuations cannot be avoided, arrangements have

 The effect of changing the location of pump is explained

 Pump cannot run at design flow without cavitation

 Hence high-speed pump will not be suitable for this configuration

 In such cases the manufacturer has to be given information in the

 Generally NPSH available should be 20 to 30 % more than the NPSH required

 However, the flow can be increased maximum up to Q2 for short operation

 If the pressure at any point inside a pump, particularly at the

 These cavities are carried up-stream along with liquid until a

This phenomenon is called cavitation

Example 1 : Pumping water from a sump. Water temperature is 30°C .

Hf = 0.3m p = atmospheric pressure 1 kg/ cm2

s = specific gravity = 0.996@300C