Prelim Topic

SUBJECT:
AUXILIARY MACHINERY 211

 CO1: Operate, maintain and troubleshoot the following
auxiliary machineries in accordance with its
manufacturer’s specification:
 LO – Leaning Outcomes:
At the end of the course, the student must be able

to;
LO1: Determine the components, function and
operating principle of:
1. Pumps
2. Heat exchanger
3. Air compressor
4. Fresh water generator
5. Deck machineries
Wk 1 / S 1 – Introduction’s
 Auxiliary Machinery:
 The auxiliary machinery may be in support of the

main propulsion engines and include pump’s, heat
exchangers, compressed air, fresh water generator
and deck machinery. (crane, mooring winch and
windlass)
Wk1 / S1 – Pump’s
PUMP’S
Pump:
A Pump is a machine used to raise
liquids from a low point to a high point. A
pumping system on a ship will consist of
suction piping, a pump and discharge
piping. The system is arranged to provide a
positive pressure or head at some point and
discharge the liquid.
 Types of Pump:
1. Gear pump
2. Centrifugal pump
3. Vane pump
4. Screw pump
5. Reciprocating pump
 Thereare two main classes of pump in

marine use:
a.) Displacement pump and

b.) Centrifugal pump
 a. Displacement pump’s:
All the displacement pumps are Self

Priming Pump. The pump like Gear pump,
Reciprocating pump and Screw pump are
included in the positive displacement pump.
 Three Classifications of Rotary Gear Pump:
1. Simple Gear Pump

2. Herringbone Gear Pump
3. Helical Gear Pump
This type of pump’s is generally made according to the

type of rotating element.
(1A)
1. Simple Gear Pump:

(1B)
 The Simple Gear Pump has two spur gears, which

mesh together and revolve the opposite directions.
One is the driving gear (follower) and the other is
the driven (driver) gear. Clearances between the
gear teeth and the casing and between the gear
faces and the casing are only a few thousandths of
an inch.
(1C)
 The action of the un-meshing gears draws the

liquid into the suction side of the pump. The
liquid is then trapped in pocket forms by the gear
teeth and the casing so that it must follow along
with the teeth. On the discharge side, the liquid is
force out by the meshing of the gears.
 Gear Pumps consist of these main
components:
 Functions of each components:
 Drive shaft – a rotating shaft that transmits
mechanical power from a motor of and engine to a
point or a region of application.
 Seal – is a ring shape component that are designed to
obstruct or limit the fluid leakage fro a device.
 Mounting flange – is a mounting support of the
equipment.
 Drive gear – to be used in direct drive and some
others extruders.
 Idler gear - a gear placed between a driving and a
driven gear to transfer motion without change of
direction or gear ratio.
Case seal - is used to join or seal two systems or

mechanisms together.
Bushing - a usually removable cylindrical lining
for an opening (as of a mechanical part) used to
limit the size of the opening, resist abrasion, or
serve as a guide.
Suction port - the inlet location is said to be at
the suction side of the pump.
Discharge port - The outlet location is said to be
at the discharge side of the pump.
Driven (Idler) Gear - a gear placed between a driving and a
driven gear to transfer motion without change of direction or gear
ratio.
2. Herringbone Gear Pump:
(2A)
 Herringbone Gear Pump:

 Herringbone gear pumps eliminate end thrust and
can be used to develop a pressure up to 3000 psi or
(20,000 kPa).
 Herringbone gears consist of two rows of helical
teeth cut into one gear. One of the rows of each gear
is right handed, while the other is left handed. This
arrangement cancel out axial thrust force.
(2B)
 Herringbone Gear Pump operates as a

smoothly as helical gear pumps, and provide
greater flow rates, because they could be run at
higher speeds. They also produce less pulsating
action because of the higher speeds.
In a herringbone gear type one discharge phase
begins before the previous discharge phase is
entirely complete, and this overlapping tends to
give a steadier discharge pressure than is found
in a simple gear pump.
(3C)
3. Helical Gear Pump:

 Helical Gear Pump:

Is a modified simple gear pump, because of the
helical design, overlapping of successive discharges
from spaces between the teeth is even greater than the
herringbone gear pumps, and the discharge flow is
accordingly even smoother. Since the discharge flow is
smooth in the helical gear pump, the gears can be
designed with a small number of teeth, thus allowing
increased capacity without sacrificing smoothness of
flow.
 A gear pump uses the meshing of gears to pump

fluid by displacement.
 Their are two main variation of gear pumps.

1. External Gear Pump
2. Internal Gear Pump
Gear Pump Design:
 External Gear Pump Works:

• External gear pump are similar in pumping
action to internal gear pump in that two gears
come into and out of mesh to produce flow.
• The external gear pump uses to identical
gears rotating against each other – one gear
is driven b a motor and it in turn drives the
other gear.
Cont..
 External gear pump are a popular

pumping principle and ae often used as
a lubrication pumps in machine tools, in
fluid powers transfer units, and as oil
pumps in engines.
 Internal Gear Pump:

Internal gear pump is a non-pulsing, self
priming and can run dry for short periods.
They’re also bi-rotational, meaning that the
same pump can be used to load and un-load
vessels. Because internal gear pumps have
only two moving parts, They are reliable, simple
to operate and easy to maintain.
 Centrifugal Pump:
 Referred as constant pressure pump,

through these the discharge pressure of a
pump cannot be varied without changing the
physical conditions of the pump, (such as
throttling the discharge valve or in – creasing
the size of impeller).
 Centrifugal Pumps:
Centrifugal Pump Main Components:
 Impeller:
The impeller is fitted inside a casing that
collects water and pushes the liquid in the
direction at which the impeller is moving. This
structure reduces exit flow velocity and increases
static pressure, a combination necessary for
overcoming pressure that builds up in the system.
 Classification of Impeller:
 Open Impeller:
• The vane are attached to the hub. There is

no shroud to support the vanes. These are
good design for pumping stringy materials
such as paper stock.
 Thousand of pumps operate with open

impellers and some pump designs have
even standardized on these open impeller
pumps.
 Open face impeller are popular because the
cost less money to manufacture so the
pump cost less.
 Unfortunately these pumps cost more to
operate and wear more quickly.
 Semi-Open Impeller:
• The vanes are attached to the hub with shroud and
on one side of the impeller. The pump efficiency is
maintain by setting a close clearance between the
vanes and the volute or back-plate.
• Some of these semi-open impeller have pump out
vanes on the back of the shrouds that reduce the
pressure on the back of the shrouds and prevent
foreign matters from lodging in back of the impeller,
interfering with its operation.
 Closed Impeller:
• In this design the vanes are attached to the hub with
a shrouds or either side of the impeller.
• Close impellers are sensitive to clogging with solids
so their use is limited to the pumping of reasonably
clear liquid.
• Oil refineries used close impellers because of the
problem of maintaining a closed tolerance between
semi-open impeller and the pump volute. Explosive
products would ignite if the impeller came into
contact with the volute, but with the enclosed
impeller version soft wear rings would make the
contact.
Impeller Clearance
Critical for Open Impellers
• Normal Setting .015” (.38mm) of front cover.
• High temperature requires more clearance:
• Potential rubbing problem causes vibration and high bearing loads.
• Set impeller .002” (.05mm) additional clearance for every 50 deg F (28
deg C) over ambient temperature.
• Important for maximum efficiency.

 A pump diffuser or volute is part of a

centrifugal pump designed to make the
pump more efficient by optimizing the flow
of the liquid being pumped. This makes the
flow more controlled and increases the
liquid pressure, increasing the effect of the
centrifugal pump's motion.
 Pump Diffusers or Volute:
 Vane Pump:
A rotary vane pump
is a positive-displacement
pump that consists of
vanes mounted to a rotor
that rotates inside a cavity.
In some cases these vanes
can have variable length
and/or be tensioned to
maintain contact with the
walls as the pump rotates.
 Vane Pump:
 Principle Operations of Vane Pump:
 Vanes are allowed to slide into and out of

the rotor and seal on all edges, creating
vane chambers that do the pumping work.
On the intake side of the pump, the
vane chambers are increasing in volume.
... Multistage rotary-vane vacuum pumps
can attain pressures as low as 10−6 mbar
(0.0001 Pa).
Cont..
 Vanes or blades fit within the slots of the

impeller. As the rotor rotates (yellow
arrow) and fluid enters the pump,
centrifugal force, hydraulic pressure,
and/or pushrods push the vanes to the
walls of the housing. ... Fluid enters the
pockets created by the vanes, rotor, cam,
and side plate.
 Uses of Rotary Vane Pump:
 Furthermore, vane pumps can be used in

low-pressure gas applications such as
secondary air injection for auto exhaust
emission control, or in low-pressure
chemical vapor deposition systems.
Rotary-vane pumps are also a common
type of vacuum pump, with two-stage
pumps able to reach pressures well below
10−6 bar.
 Screw Pump:
A screw pump is a positive-displacement

pump that use one or several screws to move fluids
or solids along the screw axis. In its simplest form,
a single screw rotates in a cylindrical cavity, thereby
moving the material along the screw's spindle.
Screw Pump Components:

• Bearing - The functions of the bearings are to

support the weight of the shaft (rotor) assembly,
to carry the hydraulic loads acting on the shaft,
and to keep the pump shaft aligned to the shaft
of the driver.
• Drive shaft - The shaft is usually the longest
part of a pump and is made of one piece. Its
function is to transmit the input power from the
driver into the impeller.
 Universal joint - a form of coupling

between two rotating shafts allowing
freedom of angular movement in all
directions.
• Rotor – a rotating part of a mechanical
device or pump.
• Stator – the stationary part of a rotary
machine or pump.
• Pump body - a part designed to shelter,

cover, contain, or support a component,
such as a bearing, or a mechanism, such as
a pump or wheel: a bearing housing; a
motor housing; a wheel housing.
• Pressure mouth - The outlet location is
said to be at the discharge side of the
pump.
Operation Principles:
 These pumps are used for high flow at
relatively low pressure ( max. of 100 bars).
They were used on board ship where a
constant pressure hydraulic system extended
through the whole ship, especially the
control ball valve but also to help drive the
steering gear and other system.
 The advantage of the screw pump is the low
sound level of this pumps; however the
efficiency is not high.
 Reciprocating Pump:
• Reciprocating pump is a positive

displacement pump where certain volume of
liquid is collected in enclosed volume and is
discharged using pressure to the required
application.
Reciprocating Pump:
Types of Reciprocating Pump:

On the basis of mechanism:
1. Single Acting Reciprocating Pump: In this ,only
one side of the piston engages to displace the liquid. Eg :
piston syringe.
2. Double Acting Reciprocating Pump: In this, both
sides of the piston engages to displace the fluid. In each
stroke of the piston, two process i.e. suction and dis
charge carried at the same time. It consists of two
inflow and two outflow pipes.
Single Acting Reciprocating pump:

 During suction stroke, the piston moves

backward and this opens the suction valve
making the water enter into the cylinder.
During suction the delivery valve remains
closed and no water is discharged through
it.
 After suction stroke, the piston moves

forward, delivery valve gets open and
suction valve come into close position. As
the piston moves forward it exerts thrust
force on the liquid and it starts escaping
out of the cylinder through delivery pipe.
The water from the delivery pipes reaches
to its required destination.
 Double Acting Reciprocating Pump:

 As the piston moves to the right hand side as

shown in the fig above. The following
process takes place at left and right side.
 At left side:
 The suction valve opens and delivery valve
gets closed. The water from the water
reservoir is sucked into the cylinder.
 The suction valve is gets closed and delivery valve

gets open. the water sucked in the previous stroke
is discharges out of the cylinder.
 In the same way as the piston moves to left hand
side, the discharge of the liquid takes place at left
side and suction takes at the right side. And in
each stroke of the piston, both suction and
discharge of liquid takes place at the same time. If
suction is taking place at right side than discharge
takes place at left and vice-versa.
 Advantages:
1. High pressure is obtained at the outlet.

2. Priming process is not needed in this
pump.
3. It provides high suction lift.
4. It is also used for air.
 Disadvantages:
1. It requires high maintenance because

of more wear and tear of the parts.
2. Low flow rate i.e. it discharges low
amount of water.
3. They are heavy and bulky in size.
4. High initial cost.
 Application:
• It
is used at a place where low
discharge rate is required with high
pressure. It is mostly used to deliver water at
large heights such as in deep well.
 Components of Reciprocating Pump:

 The main components of reciprocating pump are as
follows:
 Suction Pipe
 Suction Valve
 Delivery Pipe
 Delivery Valve
 Cylinder
 Piston and Piston Rod
 Crank and Connecting Rod
 Strainer
 Air Vessel
Components of Reciprocating Pump:
1. Suction Pipe
 Suction pipe connects the source of liquid to
the cylinder of the reciprocating pump. The
liquid is suck by this pipe from the source to
the cylinder.
2. Suction Valve
 Suction valve is non-return valve which
means only one directional flow is
possible in this type of valve. This is
placed between suction pipe inlet and
cylinder. During suction of liquid it is
opened and during discharge it is closed.
3. Delivery Pipe
 Delivery pipe connects cylinder of pump to the
outlet source. The liquid is delivered to desired
outlet location through this pipe.
4. Delivery Valve
 Delivery valve also non-return valve
placed between cylinder and delivery pipe
outlet. It is in closed position during
suction and in opened position during
discharging of liquid.
 5. Cylinder
 A hollow cylinder made of steel alloy or cast iron.
Arrangement of piston and piston rod is inside this
cylinder. Suction and release of liquid is takes place in
this so, both suction and delivery pipes along with
valves are connected to this cylinder.
6. Piston and Piston Rod

 Piston is a solid type cylinder part which
moves backward and forward inside the
hollow cylinder to perform suction and
deliverance of liquid. Piston rod helps the
piston to its linear motion.
7. Crank and Connecting Rod

 Crank is a solid circular disc which is
connected to power source like motor,
engine etc. for its rotation. Connecting rod
connects the crank to the piston as a result
the rotational motion of crank gets
converted into linear motion of the piston.
8. Strainer
 Strainer is provided at the end of suction
pipe to prevent the entrance of solids from
water source into the cylinder.
9. Air Vessel
 Air vessels are connected
to both suction and delivery
pipes to eliminate the
frictional head and to give
uniform discharge rate.
Working Principles of
Reciprocating Pump:
 The working of reciprocating pump is as
follows:
 When the power source is connected to crank,
the crank will start rotating and connecting rod
also displaced along with crank.
 The piston connected to the connecting rod
will move in linear direction. If crank moves
outwards then the piston moves towards its
right and create vacuum in the cylinder.
 This vacuum causes suction valve to open and

liquid from the source is forcibly sucked by the
suction pipe into the cylinder.
 When the crank moves inwards or towards the
cylinder, the piston will move towards its left and
compresses the liquid in the cylinder.
 Now, the pressure makes the delivery valve to open
and liquid will discharge through delivery pipe.
 When piston reaches its extreme left position

whole liquid present in the cylinder is delivered
through delivery valve.
 Then again the crank rotate outwards and piston
moves right to create suction and the whole
process is repeated.
 Generally the above process can be observed

in a single acting reciprocating pump where
there is only one delivery stroke per one
revolution of crank. But when it comes to
double acting reciprocating pump, there
will be two delivery strokes per one
revolution of crank.
Uses of Reciprocating Pump:

Reciprocating pump is mainly used for;
 Oil drilling operations
 Pneumatic pressure systems
 Light oil pumping
 Feeding small boilers condensate return

End of Week 1 / Session 1 – 4.
Thank You
for
LISTENING
Refer to Prelim
Formative Assessment # 1
PRAYER
is the best armor of all trials
Wk2 / S1 – Heat Exchanger
 Competence:
A-III/1 F1.C4: Operate main and auxiliary machinery
and associated control systems.
 KUP:
A-III/1 F1.C4. KUP1.6: Basic construction and
operation principles of machinery system namely
(a) various pumps: (gear pump, centrifugal pump,
vane pump, screw pump, reciprocating pump), (b)
air compressor, (c) fresh water generator, (d) heat
exchanger.
 CO1:
Operate, maintain and troubleshoot the
following auxiliary machineries in accordance with
its manufacturer’s specification:
 LO1: Determine the components, function and operating

principle of:
1. Pumps
2. Heat exchanger
3. Air compressor
4. Fresh water generator
5. Deck machineries
The Basic Principles of Using a Heat

Exchanger;
• A heat exchanger is a special device that assists in heat
transfer through one channel to another usually by
conduction. Basically, in almost all applications, there is a
solid barrier that prevents the media from mixing up with
each other. One side of the wall contains the hot fluid,
while the other side has the cool fluid flowing through the
channels. Depending on the structure, the exchanger can
be more efficient in performing heat transfer. Fins or
corrugations are often included in the exchanger’s design
in order to make this possible.
 The pump shown above is of very common design.

It is used for pumping many types of liquid and gas
and is capable of delivering at very high pressures.
This makes it suitable for hydraulic supply.
The tooth profile is similar involute gear teeth for

liquid pumps. For gas pumps special profiling with
very fine tolerances is employed.
(B)
 Clearances between the gear teeth and the casing and

between the gear faces and the casing are only a few
thousandths of an inch. The action of the un-meshing
gears draws the liquid into the suction side of the
pump. The liquid is then trapped in pocket forms by
the gear teeth and the casing so that it must follow
along with the teeth. On the discharge side, the liquid
is force out by the meshing of the gears.
 3. Screw Pump :
 These pumps are seen in many applications and have a
higher capacity than double row type. Fluid enters the
pump and is screwed by the idler shafts along the
outer edge to the discharge port. Axial thrust of the
idlers is absorbed by the integral thrust collar of the
driven shaft. The axial thrust of the driven shaft is
absorbed by the thrust bearing.
The scroll sits in a replaceable insert which is sealed to
the outer casing by O-rings.
 Centrifugal Pump :
 Water is led to the suction eye of the rotating impeller.
The water gains energy by the centrifugal action of the
pump and is discharged to the volute outlet casing.
The volute is created by increasing the area of the
outlet port and is greatest at outlet from the pump. By
this design the kinetic energy of the water is converted
to pressure energy.
 Sealing is provided by a mechanical seal or by packed
gland.
 For the former cooling water is supplied from the
discharge side of the pump. For the latter cooling is
provided by the allowance of slight leakage,
lubrication is by a grease filled manual lubricator.
 The kinetic energy of the fluid flowing through the
impeller is converted to pressure energy by the shape
of the volute casing. For high pressure pumps such as
boiler feed pumps a diffuser ring is fitted in the casing
which converts a greater portion of the pressure energy
allowing greater pressures to be generated. A scroll
type inducer may be fitted to the inlet which improves
the efficiency of unit and allows the pump to operate
with low suction pressures.
 Water is led to the suction eye of the rotating impeller. The
water gains energy by the centrifugal action of the pump
and is discharged to the volute outlet casing. The volute is
created by increasing the area of the outlet port and is
greatest at outlet from the pump. By this design the kinetic
energy of the water is converted to pressure energy.
 Sealing is provided by a mechanical seal or by packed
gland. For the former cooling water is supplied from the
discharge side of the pump. For the latter cooling is
provided by the allowance of slight leakage, lubrication is
by a grease filled manual lubricator.
 Wear rings
 For efficient operation it is important to ensure that
leakage from the high to low pressure side is kept to a
minimum. This is achieved by the use of wearing rings.
Traditionally these are fitted to the casing, to increase the
longevity of the impeller wear ring tyres may be fitted.
 The clearance given for wear rings is often a source of
contention especially when dealing with on-ship made rings.
A clearance of 1/1000 of the diameter of the bore is often
quoted although this may be very difficult to achieve in
practice.
 Axial force
 Without careful design an axial force is created by the
action of the impeller. This is due to the low pressure
acting on the suction eye while the rest of the impeller
is subjected to discharge pressure.
 One solution is shown above where radial blades are
cast into the back (stuffing box side) of the impeller.
These blades are commonly called pump-out vanes,
and are meant to increase the centrifugal force of the
fluid trapped behind the impeller.
 This causes the fluid to be “thrown” outwards, reducing the
pressure behind the impeller for the same reason that the
impeller causes a reduction of pressure at the suction eye.
 Another method which may be found in conjunction with the
pump-out vanes are the balancing holes. These are holes drilled
near the center of the impeller, connecting the space in the back
of the impeller with the suction eye. This reliefs the pressure
behind the impeller by allowing the high pressure fluid trapped
there to flow to the low pressure region at the suction eye. In
order for this to be effective, there must be a tight clearance
between the impeller and the casing to reduce the flow of fluid
into the back of the impeller.
 Alternately dual back to back impellers may be fitted in common
with a double casing
 b. Centrifugal pump:
Water is led to the suction eye of the

rotating impeller. The water gains energy by
the centrifugal action of the pump and is
discharged to the volute outlet casing. The
volute is created by increasing the area of
the outlet port and is greatest at outlet from
the pump.
Wk1 / S 1 – Pump’s
• As a consequence, the energy level of fluid handled by the

pump or flowing through pump is augmented, making it
possible for the fluid to move from a lower level to a higher
level, against gravity and friction.
• And the liquid horsepower is the input and converted to
velocity energy by impeller, then converted to pressure
energy in the diffuser section of the volute case to push liquid
through the piping through the sprinkler or holding tank or
cooling coils or whatever is attached to it.
(Wk-1) LOSSES OF HEAD IN PUMPING SYSTEM:
 Three causes of Pumping System Losses:
1. Friction loss in bearing and gland, surface of

impeller and casing impellers should be highly
polished to minimize friction loss.
“The resistance to flow is also called head loss due to
friction.”
(Wk-1) LOSSES OF HEAD IN PUMPING
SYSTEM
cont…
 2. Head loss in pump due to shock at each entry and exit to

impeller vane where eddies are formed at vane edges.
 Head loss is the reduction of total head or pressure (sum of
elevation head, velocity head and pressure head) of the fluid as it
moves through the fluid system.
Head loss is unavoidable in real fluids, but it is present because
of; the friction between the fluid and the wall of the pipe; the
friction between the adjacent fluid particles as the moves
relative to one another; and the turbulence caused whenever
the flow is re-directedor affected in anyway by such
components as piping entrances and exits, pumps, valves,
flow reducers, and fittings.
(Wk-1) LOSSES OF HEAD IN PUMPING SYSTEM
Cont…
 3. Leakage loss in thrust balance device, gland sealing,
clearance between cutwater and casing and bearing seals.
 Failure to deliver causes by loss of suction may be due to
insufficient supply head, air leakage suction pipe (e.g. valve
open on empty bilge, etc..), loss of priming facility or leaking
shaft gland.
 Capacity reduction could be the result of a damaged sealing
ring, leaking gland, obstruction (valve partly closed), and
incorrect rotational speed.
 Excessive vibration may be cause by either;

1. Loose coupling
2. Loose impeller
3. Bearing damaged
4. Impeller imbalance
(Wk-1) Viscosity of the fluid to be pump:
 Oil are much more difficult for pump to handle than

water. Losses increase within the pump and pump
lines. Both head and capacity are reduced; therefore
more power is required for operation.
 Both hot and thick liquids should flow to the pump
under a positive suction head for satisfactory
operation. But the pump will then be kept properly
primed in case of thick liquids. Vaporization and vapor
binding due to hot water inside the pump casing is
avoided. (it can cause of pump damaged due to dry run
or running without liquid).
(Wk-1) Permission should be obtain
before any fluids move:
 Removing or transferring of fluids, might affect the
stability of the ship and it can cause of marine
pollution overboard. (that’s why before removing or
transferring of fluid from one tank to another, we
should inform that activity into the deck officers or to
our engine OIC for proper distribution of ballast tank
water to maintain the ship stability).
(Wk-1) Types of pump generally
used on ships and its purpose:
 Types of Pump’s:
There are three main classes of pump in
marine use.
1. Positive Displacement Pump
2. Axial Flow Pump
3. Centrifugal Pump
(Wk-1) Positive Displacement Pump
 Positive Displacement Pump (Reciprocating

Pumps/Piston Pumps):
moving a fluid by capturing and then discharging a fixed amount

of fluid. A piston pump is one example of a positive displacement
pump. and referred as constant discharge pump because the
volume of gap between the piston and cylinder in this pump are
constant. It can increase the pressure by closing the discharge
valve and increasing the stroke length of the piston. This increase
in stroke length will continuously increase the discharge pressure.
Positive-displacement pumps frequently are used in
hydraulic systems at pressures ranging up to 5000 psi.
(Wk-1) Positive displacement Pump (Cont.)
(Wk-1) Positive Displacement Pump (Cont.)
(Wk-1) Types of pump (Cont.)
 Axial Flow Pump:

 Axial flow pumps are generally used for low head/high
flow and especially for slurry application.
 An axial flow pump, or AFP, is a common type of pump
that essentially consists of a propeller in a pipe. The
propeller can be driven directly by a sealed motor in the
pipe or mounted to the pipe from the outside or by a
right-angle drive shaft that pierces the pipe.
 The main advantage of an AFP is that it can easily be
adjusted to run at peak efficiency at low-flow/high-
pressure and high-flow/low-pressure by changing the
pitch on the propeller (some models only).
(Wk-1) Axial Flow Pump (Cont.)
(Wk-1) Centrifugal Pump (Cont.)
 Centrifugal Pump:
Referred as constant pressure pump, through
these the discharge pressure of a
pump cannot be varied without changing
the physical conditions of the pump, (such
as throttling the discharge valve or in –
creasing the size of impeller).
(Wk-1) Centrifugal Pumps (cont.)
(Wk-1) Basic Action of Displacement Pump
 The positive displacement pumping action is to

achieved by the reduction or increase in volume of a
space causing the liquid or gas to be physically moved.
(A pumping action to prevent pumping rate reduction
or to maintain the pump delivery).
 The methods employed is either a piston in a cylinder
using a reciprocating motion, or rotating unit using
vanes, gears or screw.
(Wk-1) Necessity for a relief valve to be
fitted in the discharge of any
displacement pump:
 A relief valve is always fitted between the pumps

suction and discharge chambers to protect the pump
should it be operated with the valve closed in the
discharge line.
 Normally relief valve should be fitted at the
discharge ports of the pump, to protect the pump
sealing parts damaged due to high pressure, and
also the protection of the drive equipment
imparted for the pumps operation due to high
ampere.
(Wk-1) Necessity for a relief valve to be
fitted in the discharge of any
displacement pump:
Pump handling oil or other hazardous materials:
It is requirements that a pump’s handling hazardous
materials and oil should be fitted with relief valve on
the discharge side, to prevent explosion due to high
pressure along the line. (meaning to say safety, the
relief valve would automatically open to release the
excess pressure if incase high pressure occur along
the line during pump operation). We do not know
the pipe and gasket condition, due to wear and tear it
might happened explosion due to prolonged use .
(WK-1) How Reciprocating Displacement
Pump Works:
Prelim Assessment 1
Wk 2 – Intended Learning
Outcome
 Atthe end of the course, the
student must be able to;
 Know the basic construction, parts and

operation principle’s of various type of
pump’s.
(Wk-2) The Purpose of an Air Vessel fitted to
the Discharge:
 An air vessel is usually fitted to the discharge

pipework’s to dampen out the pressure variation
during discharge. As the discharge pressure rises the
air is compressed in the vessel and when the pressure
falls the air expand. ( meaning the importance of air
vessel fitted along the discharge pipeline is only the
storage of air, where the air is used to help pushing of
liquids going to discharge).
(Wk-2) - Characteristics of a Reciprocating
Pump:
 Referring to suction lift, priming, discharge pressure,

vapour or gas in the fluid being pumped.
 Reciprocating pumps are particularly adapted, for
low capacities and high pressures, and in every cycle
certain volume of fluid being displace. (reciprocating
pump is commonly used in even manufacturing
because of their accuracy, “particularly in light and
high viscos materials”)
(Wk-2) Characteristics of reciprocating pump.
(cont)
 Suction Lift Pump installed above water
level
Pump installed below
water level
(cont.)
Priming
Pump priming is when water, or some other liquid, is used to
draw up more liquid from a well that has already been tapped.
While priming is not necessary with many modern pumps,
there are times when it may be required, especially with older
devices. Therefore, knowing what to do and when to do it may
be essential in some situations to ensure proper water supply.
When air has seeped down into the pump, replacing fluid and
causing a loss of pressure, priming is usually needed. Most
pumps use fluid, usually water, to create the pressure and
suction needed to pull up more liquid from below ground.
Therefore, when air seeps into the system, there is a loss of
pressure.
In order to prime the pump, often all that is needed is another

source of the liquid being sought. This is usually accomplished
simply by pouring some of that liquid down the well. Once
that is done, simply turning on the pump or using a hand
crank, depending on the type of pump, is usually all that is
required.
In most cases, once water starts to flow from a pump, more

priming in the future should be unnecessary. In cases where
(cont.)
Discharge
Pressure:
(cont.)
Discharge
pressure:
(Wk-2) - Characteristics of a Reciprocating
Pump: (cont.)
 Referring to suction lift, priming, discharge

pressure, vapour or gas in the fluid being pumped.
 Reciprocating pumps are particularly adapted,

for low capacities and high pressures, and in every
cycle certain volume of fluid being displace.
(reciprocating pump is commonly used in even
manufacturing because of their accuracy,
“particularly in light and high viscosity fluids”)
(Wk-2) Principle of Rotary Displacement Pump:
Rotary displacement pumps for various
flow rates.
 Rotary displacement pumps are ideal as feed and metering pumps in
an extensive range (long & wide) of flow rates. They are often a cost-
effective alternative, especially in the food, pharmaceutical, and
biotechnology industries, as well as in low pressure requirements. (it is
commonly used in the food processing plant, pharmaceutical, and
biotechnology industries, intended for chemical and acid used, it
needs low pressure requirements)
 Rotary pumps are suitable for flow rate ranges from a few l/h up to
several hundred m³/h and are available as gear pumps, rotary lobe
pumps, screw spindle pumps and progressive cavity pumps.
(progressive cavity pump is a type of pump can handle airy liquid)
(Wk-2) Sketched and principle of parts.
Gear
Pump.
(Wk-2) Sketched and principle of parts. (cont.)
Gear Pump.
 Drive shaft – a rotating shaft that transmits mechanical power from a
motor of and engine to a point or a region of application.
 Seal – is a ring shape component that are designed to obstruct or limit
the fluid leakage fro a device.
 Mounting flange – is a mounting support of the equipment.
 Drive gear – to be used in direct drive and some others extruders.
 Idler gear - a gear placed between a driving and a driven gear to
transfer motion without change of direction or gear ratio or a gear for
support or guidance instead of power transmission.
 Case seal - is used to join or seal two systems or mechanisms together.
 Bushing - a usually removable cylindrical lining for an opening (as of
a mechanical part) used to limit the size of the opening, resist abrasion,
or serve as a guide.
 Suction port - the inlet location is said to be at the suction side of the
pump.
 Discharge port - The outlet location is said to be at the discharge side
of the pump.
(Wk-2) Sketched and principle of parts.
(cont.)
Rotary vane
pump.
An eccentric rotary
vane pump. Note that
modern pumps have an
area contact between
rotor and stator (and
not a line contact). 1.
pump housing 2. rotor
3. vanes 4. spring
Screw Pump.
 Bearing - The functions of the bearings are to support the weight of the
shaft (rotor) assembly, to carry the hydraulic loads acting on the shaft,
and to keep the pump shaft aligned to the shaft of the driver.
 Drive shaft - The shaft is usually the longest part of a pump and is made
of one piece. Its function is to transmit the input power from the driver
into the impeller.
 Universal joint - a form of coupling between two rotating shafts
allowing freedom of angular movement in all directions.
 Rotor – a rotating part of a mechanical device or pump.
 Stator – the stationary part of a rotary machine or pump.
 Pump body - a part designed to shelter, cover, contain, or support a
component, such as a bearing, or a mechanism, such as a pump or
wheel: a bearing housing; a motor housing; a wheel housing.
 Pressure mouth - The outlet location is said to be at the discharge side
of the pump.
(Wk-2) Operation of an Axial Flow Pump:
 The axial flow pump is used where large quantity of

water at a low head is required, e.g., in condenser
circulation. The efficiency is equivalent to a low lift
centrifugal pump where the higher speed allows a
smaller driving motor.
 A type of pump is efficient, simple in design and
available in a wide range of capacity. (this type of
pump is commonly name as booster pump. It is
installed in an in-lined of the pipe and it has a double
functions impeller)
(Wk-2) Operation of an Axial Flow Pump:
(cont.)
 Axial flow pump
impeller.
 Axial Flow pump
casing.
(Wk-2) Principle of Centrifugal Pump:
 Centrifugal pumps are a sub-class of dynamic asymmetric

work-absorbing turbo machinery. Centrifugal pumps are
used to transport fluids by the conversion of rotational
kinetic energy to the hydro dynamic energy of the fluid
flow. The rotational energy typically comes from an engine
or electric motor. The fluid enters the pump impeller along
or near to the rotating axis and is accelerated by the
impeller, flowing radially outward into a diffuser or volute
chamber (casing), from where it exits.
 Common uses include air, water, sewage, petroleum and

petrochemical pumping. The reverse function of the
centrifugal pump is a water turbine converting potential
energy of water pressure into mechanical rotational energy.
(Wk-2) Principle of Centrifugal Pump: (cont.)
(Wk-2) Principle of Centrifugal Pump: (cont.)
 The impeller is fitted inside a casing that collects water and
pushes the liquid in the direction at which the impeller is
moving. This structure reduces exit flow velocity and increases
static pressure, a combination necessary for overcoming pressure
that builds up in the system.
 A pump diffuser or volute is part of a centrifugal pump

designed to make the pump more efficient by optimizing the
flow of the liquid being pumped. This makes the flow more
controlled and increases the liquid pressure, increasing the
effect of the centrifugal pump's motion. (to maximized the flow
of pump due to this diffuser, the diffuser is installed closely to
the impeller to prevent losses of liquid due to a big clearance
between impeller and casing).
(Wk-2) Sketch of Single Entry Vertical Centrifugal
Pump:
Wk 3 - ILO
 At the end of the session the student must be
able to;
 Demonstrate / Describe the arrangement and

principle’s of single and double entry impeller.
(Wk-3 / day1) Single and Double Entry
centrifugal Pump:
 Single Entry Pump – Fluid enters the impeller axially

through the eye of the impeller by centrifugal action,
continues radially and discharge around the entire
circumstances. The fluids passes through the impeller
from the vane is giving and increase pressure and
velocity.
 Double Entry Pumps – Fluid enters from the two

sides of the impeller eye as if there are two back to
back impellers giving twice the discharge at a given
head.
Wk-3 / day 1) Single and Double Entry
Centrifugal Pump:
Wk-3 / day 1) Single and Double Entry
Centrifugal Pump:
 Principle of double and single entry
impeller.
(Wk-3 / day 1) Single and Double Entry
Centrifugal Pump: (cont.)
 Single entry  Double entry
impeller impeller
(Wk-3 / day2) Vertical Multi Stage Single Entry
Impeller:
A – Electric motor
B – Drive coupling
C – Lantern
D – Radial bearing
E – Outer column
F – Shaft sleeve
G – Ceramic bushing
H – Impeller
I – Delivery duct
L – Intake duct
M - Bushing
(Wk-3 / day 2) Vertical Multi Stage Single Entry
Impeller: (cont.)
 The fluid from one impeller is discharge via suitable

passages to the eye of the next impeller so that the total
head developed is the product of the head per stage,
such a pump is often used for high pressure discharge at
a moderate speed.
(single entry but multi stage impeller, it is
commonly used for boiler water feed pump
where in the pressure should be higher than the
boiler operating pressure for filling up of water into the
boiler shell)
(Wk-3 / day2) Purposed of a diffuser.
 Also, while an impeller is placed
in the center of a volute, an
impeller generally sits directly
adjacent to a diffuser and pushes
water into the diffuser vanes.
 The basic function of a diffuser is

similar to that of a volute.
Diffuser vanes are positioned
such that they begin close to the
outer edge of the impeller and
then gradually extend away from
the impeller periphery.
(Wk-3 / day 3) Characteristics of centrifugal
pump.
 Suction lift
Suction lift exists when the
source of supply is below the
centerline of the pump.
Suction and lift are important considerations when
pumping fluids. Suction is the vertical distance
between the fluid to be pumped and the center of the
pump, while lift is the vertical distance between the
pump and the delivery point. The depth from which a
hand pump will suck is limited by atmospheric
pressure to an operating depth of less than 7 meters.
The height to which a hand pump will lift is governed
by the ability of the pump and the operator to lift the
weight in the delivery pipe. Thus the same pump and
operator will be able to achieve a greater lift with a
smaller diameter pipe than they could with a larger
diameter pipe.
pump
Suction lift.
A Suction Lift exists when the liquid is taken

from an open to atmosphere tank where the
liquid level is below the centerline of the
pump suction.
(Wk-3 / day 3) Characteristics of centrifugal pump.
 Priming
pump. (cont.)
 Centrifugal pump priming.
 Most centrifugal pump are not self priming. In other
words, the pump will not be able to function. If the pump
casing becomes filled with vapour or gasses. To ensure that
a centrifugal pump remains primed and does not become
gas bound, most centrifugal pump are located below the
level of the source from which the pump is to take the
action.
 In some systems the pump is primed by utilizing a priming
pump control by a float switch. Priming the pump and
venting the pump casing during system start up should
prevent gas build up.
pump. (cont.)
Discharge pressure.
 Discharge pressure describes the pressure of a liquid as it

leaves a pump. Higher discharge pressures equal greater
force behind the release while lower pressure means less. A
pump’s discharge pressure is influenced, but not
determined, by other aspects of the pump. While this term
is independent of other descriptions for a pump, the overall
combination of flow rate, suction pressure and capacity
will determine the total power of the system.
pump. (cont.)
Vapour or gas in the fluids being pump.
 The vapor pressure of a fluid is the pressure at a given

temperature, at which a fluid will change to a vapor. Each
fluid has its own vapor pressure/temperature relationship.
(Wk-3 / day4) Why and When air extraction is
necessary.
 Venting the pump casing or in the pipelines during
the system start up to prevent gas build up. At this
point it can cause; damage of the pump, thermal
degradation of the fluid or oil, thermal cracking and
sludge formation.
 Why air or gas present in the system?
- this is because of creating bubbles due to
sudden valve opening and closing, shock
wave due to sudden opening of valve,
inadequate (NPSHA) net positive suction head
available and nearly dry operation of pump due to
insufficient fluid or liquid volume.
(Wk-3 / day 4) Sketch of reciprocating air pump.
 Sketch of reciprocating air

pump.
(Wk-3 / day 4) Sketch of water ring air pump.
Water ring air

pump.
A liquid-ring pump is a rotating positive-
displacement pump.
They are typically used as a vacuum pump,
but can also be used as a gas compressor.
The function of a liquid-ring pump is similar
to a rotary vane pump, with the difference
being that the vanes are an integral part of
the rotor and agitate a rotating ring of liquid
to form the compression-chamber seal. They
are an inherently low-friction design, with
the rotor being the only moving part. Sliding
friction is limited to the shaft seals. Liquid-
ring pumps are typically powered by an
induction motor.
(Wk-3 / day 5 ) Single line sketch of central priming
system.
CENTRAL PRIMING SYSTEMS
 If there is more than one centrifugal pump to be

installed, one priming device can be made to serve all
the pumps. Such an arrangement is called a central
priming system. If the priming device and the venting
of the pumps are automatically controlled, the system
is called a central automatic priming system.
(Wk-3 / day 5) Single line sketch of central
priming system. (cont.)
 Sketch of central piping system.
This system is more efficient than the

single pipe loop. The heated water from
the boiler is fed to one side of every
radiator (the feed pipe) while the other
end of each radiator is connected to a
separate common return pipe. This
means that the temperature of the
water entering each radiator is more or
less the same so each radiator should
heat the local environment by the same
amount.
(Wk-3 / day 5)Principle of Ejector:
 An Ejector is a form of pump that has no moving parts.

A high pressure liquid or vapor such as steam
discharges from the nozzle as high velocity jet and
entrains any gasses or liquids surrounding the nozzle.
Ejector can be arranged as single or multi stage units
and have particular application for examples: the air
ejector in a closed feed system. (this type of pump is
used for Waste water aeration or for mixing)
(Wk-3 / day 5)Principle of Ejector. (cont.)
(Wk-3 / day 5) Principle of Ejector: (cont.)
Ejector Design
 Very simply, an ejector is a pumping device. It has no moving parts.
Instead, it uses a fluid or gas as a motive force. Very often, the motive
fluid is steam and the device is called a “steam jet ejector.” Basic ejector
components are the steam chest, nozzle, suction, throat, diffuser and
they discharge.
 Steam jet ejectors offer a simple, reliable, low-cost way to produce

vacuum. They are especially effective in the chemical industry where an
on-site supply of the high-pressure motive gas is available.
 Ejectors are considered an alternative to mechanical vacuum pumps for

a number of reasons:
 No source of power is required other than the motive gas;

 Because they have no moving parts, they are reliable vacuum producers;
 They are easy to install, operate and maintain.
Prelim Assessment 2
Pre-lim (wk3/D3) – Heat
Exchanger:
 ILO – Intended Learning
Objectives:
 At the end this chapter the student must be able to ;
 Demonstrate the functional and purpose of heat

exchanger.
 Know the construction and operation of
evaporator and distillers.
 Described the air compressor and system
principles.
(Wk 3 / day 3) – Heat Exchanger
The Basic Principles of Using a Heat Exchanger;
 A heat exchanger is a special device that assists in heat transfer through one channel to
another usually by conduction. Basically, in almost all applications, there is a solid
barrier that prevents the media from mixing up with each other. One side of the wall
contains the hot fluid, while the other side has the cool fluid flowing through the
channels. Depending on the structure, the exchanger can be more efficient in
performing heat transfer. Fins or corrugations are often included in the exchanger’s
design in order to make this possible.
 In general, the two most commonly used heat exchangers are the shell-and-tube
and flat plates devices.
 A shell-and-tube exchanger involves several tubes that are often collectively called a
bundle. This bundle is contained inside a “shell” or a pressure vessel. Whether the
purpose is to heat or cool the fluid, the end result would be the exact opposite of the
temperature of the fluid being fed through the tubes. This type of exchanger is usually
adopted in industries that require high-pressure applications.
 Cont.
The flat plate heat exchanger, on the other hand, involves the use
of several sheets of stainless steel that are assembled in a stack.
Unlike its main counterpart, which is the shell-and-tube exchanger,
the flat plate device offers higher heat transfer coefficients. Its
structure is purposely designed to allow more surface area that is
deemed beneficial for the increased efficiency of the said heat
transfer device. Another good addition is its weight, which is actually
five times lighter than the shell-and-tube variety. Gasketed plates are
often preferred for most industry applications simply because they
can be disassembled conveniently for cleaning and tune-ups. The fact
that the plate exchanger is both cost-efficient and compact makes it a
practical choice for use in power plants and other similar industries.
 Cont;
 A majority of the heat exchangers today are made from durable materials such
as iron, steel, copper and aluminum. In order for an exchanger to transfer heat
effectively, it must be equipped with corrosion-resistant parts. Due to the
amount and frequency of the liquids being transferred through the exchanger,
oxidization and damage are simply inevitable.
 Some of the home appliances that use heat exchangers in their systems are the
air- conditioning units and refrigerators. On the other hand, large industries
such as the food processing firms and oil refineries make use of huge heat
exchangers that include the cooling towers and water chillers. Actually, the
application of heat transfer devices varies greatly on purpose. They are capable
of heating and cooling both the air and water for specific purposes. Industrial-
purpose exchangers are always mammoth-sized because they have to be
efficient enough to meet certain temperature levels. Residential heat
exchangers are rarely seen as separate units, but they are otherwise found in
some cooling appliances.
 How a simple heat exchanger works. A hot fluid (shown in red) flows
through a tube coiled inside a larger shell through which another, colder
fluid (shown in blue) is running in the opposite direction. Heat is
exchanged by the fluids: the hot fluid cools down and the cold fluid
warms up, without them actually coming into contact and mixing. This
is a simplified example of a shell and tube exchanger: generally, heat
exchangers of this design have many thin tubes running through a large
shell.
(Wk 10/day 5) – Heat Exchanger
 Marine Heat Exchanger;
 - A heat exchanger is a device used to transfer heat

between one or more fluids. The fluids may be
separated by a solid wall to prevent mixing or they may
be in direct contact. They are widely used in space
heating, refrigeration, air conditioning, power stations,
chemical plants, petrochemical plants, petroleum
refineries, natural-gas processing, and sewage
treatment.
Wk 10 (Day 5) – Heat Transfer
 The energy always moves from a warmer system to a

colder system. The energy which is moving from one
system to another is known as heat transfer.
 Three main mechanism of heat transfer are;
 Conduction
 Convection
 Radiation
Wk4/S 1 - Conduction
 CONDUCTION:
It is the flow of heat through solids and liquids by vibration
and collision of molecules and free electrons. The molecules of a
given point of a system which are at higher temperature vibrate
faster than the molecules of other points of the same system -or
of other systems- which are at lower temperature. The molecules
with a higher movement collide with the less energized
molecules and transfer part of their energy to the less energized
molecules of the colder regions of the structure. For example, the
heat transfer by conduction through the bodywork of a car.
 CONDUCTION:
 Touching a stove and being burned
 Ice cooling down your hand
 Boiling water by thrusting a red-hot piece of iron into it
Conduction
Wk 4 / Day 1 - Convection
CONVECTION: Flow of heat through currents within a fluid (liquid or
gas).
Convection is the displacement of volumes of a substance in a liquid or
gaseous phase. When a mass of a fluid is heated up, for example when it is in
contact with a warmer surface, its molecules are carried away and scattered
causing that the mass of that fluid becomes less dense. For this reason, the
warmed mass will be displaced vertically and/or horizontally, while the colder
and denser mass of fluid goes down (the low-kinetic-energy molecules displace
the molecules in high-kinetic-energy states). Through this process, the
molecules of the hot fluid transfer heat continuously toward the volumes of the
colder fluid.
 For example, when heating up water on a stove, the volume of water at the
bottom of the pot will be warmed up by conduction from the metallic bottom
of the pot and its density decreases. Given that it gets lesser dense, it shifts
upwards up to the surface of the volume of water and displaces the upper -
colder and denser- mass of water downwards, to the bottom of the pot.
Convection:
 Hot air rising, cooling, and falling (convection currents)
 An old-fashioned radiator (creates a convection cell in a room by emitting
warm air at the top and drawing in cool air at the bottom).
Convection
WK 4 (Day 1) - Radiation
 RADIATION: It is heat transfer by electromagnetic waves.
It does not need a propagating medium. The energy
transferred by radiation moves at the speed of light. The
heat radiated by the Sun can be exchanged between the
solar surface and the Earth's surface without heating the
transitional space.
 For example, if I place an object (such as a coin, a car, or
myself) under the direct sunbeams, I will note in a little
while that the object will be heated.
Radiation:
 Heat from the sun warming your face
 Heat from a light bulb
 Heat from a fire
 Heat from anything else which is warmer than its
surroundings.
(Wk 4 / day 1) – Heat Transfer
 Radiation
The heat exchange process is accomplished by having
the two liquids pass on either side of a conducting
surface. The heat from the hot liquid passes to the cold
liquid and the conducting surface of the tube wall is at a
temperature between the two. It is usual for marine heat
exchanger’ s to have the two liquids flowing the opposite
directions, counter or contra flow. This arrangement
provides a fairly constant temperature difference
between the two liquids and therefore the maximum
heat transfer for the available surface area.
A shell and tube heat exchanger is a usual heat exchanger
designs. It is the most common type of heat exchanger in oil
refineries and other large chemical processes, and is suited for
higher-pressure applications. As its name implies, this type of heat
exchanger consists of a shell (a large pressure vessel) with a bundle
of tubes inside it. One fluid runs through the tubes, and another
fluid flows over the tubes (through the shell) to transfer heat
between the two fluids. The set of tubes is called a tube bundle, and
may be composed of several types of tubes: plain, longitudinally
D2
(Wk10 – D2) – Heat Exchanger

 Two fluids, of different starting temperatures, flow through the heat
exchanger. One flows through the tubes (the tube side) and the other
flows outside the tubes but inside the shell (the shell side). Heat is
transferred from one fluid to the other through the tube walls, either
from tube side to shell side or vice versa. The fluids can be either
liquids or gases on either the shell or the tube side. In order to transfer
heat efficiently, a large heat transfer area should be used, leading to the
use of many tubes. In this way, waste heat can be put to use. This is an
efficient way to conserve energy.
 Heat exchangers with only one phase (liquid or gas) on each side can be
called one-phase or single-phase heat exchangers. Two-phase heat
exchangers can be used to heat a liquid to boil it into a gas (vapor),
sometimes called boilers, or cool a vapor to condense it into a liquid
(called condensers), with the phase change usually occurring on the
shell side. Boilers in steam engine locomotives are typically large,
usually cylindrically-shaped shell-and-tube heat exchangers. In large
power plants with steam-driven turbines, shell-and-tube surface
condensers are used to condense the exhaust steam exiting the turbine
into condensate water which is recycled back to be turned into steam
in the steam generator.
 Types of Heat Exchangers on a Ship.
 1) Shell and Tube Type Heat Exchanger

This is the most popular type design with a shell
accompanying several tubes and the flow of liquid to
be cooled is mainly through tubes, whereas the
secondary liquid flows over the tube inside
shell.
Shell & Tube type heat
exchanger
Shell and tube type heat exchanger is extremely economical to install and
easy to clean; however the frequency of maintenance is higher than other
types.
(Wk 10/day2) – Heat Exchanger
 2) Plate Type Heat Exchanger
Plate type exchanger consists of thin corrugated
plates joined parallel together, creating cavity for fluid
flow inside it. Alternate sides of the plate carries
two different fluids, between which, heat transfer is
carried out.
(Wk10/day 2) – Heat Exchanger
Flat Plate Heat Exchanger
 Installation of this type

of heat exchanger is
expensive than shell and
tube type, but
maintenance cost is
much lower.
 Efficiency of plate type
is higher than shell and
tube type for same size
of unit and can
withstand high
pressure.
Wk 10/ D2 - Flat Plate Type Heat Exchanger.
 This type of heat exchanger uses "sandwiched" passages containing fins to increase the
effectiveness of the unit. The designs include cross flow and counter flow coupled with
various fin configurations such as straight fins, offset fins and wavy fins.
 Plate and fin heat exchangers are usually made of aluminum alloys, which
provide high heat transfer efficiency. The material enables the system to operate at a
lower temperature difference and reduce the weight of the equipment. Plate and fin heat
exchangers are mostly used for low temperature services such as natural gas, helium and
oxygen liquefaction plants, air separation plants and transport industries such as motor
and aircraft engines.
 Advantages of plate and fin heat exchangers:

High heat transfer efficiency especially in gas treatment
Larger heat transfer area
Approximately 5 times lighter in weight than that of shell and tube heat
exchanger.
Able to withstand high pressure
 Disadvantages of plate and fin heat exchangers:

Might cause clogging as the pathways are very narrow
Difficult to clean the pathways
Aluminum alloys are susceptible to Mercury Liquid Embrittlement Failure
Wk 10 (D2)-Example of Plate type Heat Exchanger
WK 10/ D2 - Single Pass Heat Exchanger
In nuclear power plants called pressurized water reactors, large heat exchangers called
steam generators are two-phase, shell-and-tube heat exchangers which typically have
U-tubes. They are used to boil water recycled from a surface condenser into steam to
drive a turbine to produce power. Most shell-and-tube heat exchangers are either 1, 2, or
4 pass designs on the tube side. This refers to the number of times the fluid in the tubes
passes through the fluid in the shell. In a single pass heat exchanger, the fluid goes in
one end of each tube and out the other.
Surface condensers in power plants are often 1-pass straight-tube heat exchangers (see
Surface condenser for diagram). Two and four pass designs are common because the
fluid can enter and exit on the same side. This makes construction much simpler.
Wk 10/ D2- Double Pass Heat Exchanger
Two and four pass designs are common because the fluid can enter and exit on the
same side. This makes construction much simpler.
There are often baffles directing flow through the shell side so the fluid does not take a
short cut through the shell side leaving ineffective low flow volumes. These are
generally attached to the tube bundle rather than the shell in order that the bundle is
still removable for maintenance.
Counter current heat exchangers are most efficient because it allow the highest log
mean temperature difference between the hot and cold streams. Many companies
however do not use single pass heat exchangers because they can break easily in
addition to being more expensive to build. Often multiple heat exchangers can be used
to simulate the counter current flow of a single large exchanger.
WK10 / D3 - Example of lubricating oil cooler
Lobe oil cooler
The primary function of the Lube Oil Cooler is to transfer heat from the hot fluid to
the cold fluid most efficiently. A combination of space, cost and pressure drop
limitations results in a preference for the compact shell and tube type heat exchanger.
Here the baffles provided not only increase the residual time of the shell fluid but
also create extra turbulence.
We are engaged in manufacturing high precision oil coolers/heat exchangers that are
generally heat exchangers for cooling oil. In our company, we are mainly fabricating
shell and tube type heat exchangers. These oil coolers/heat exchanger can be located
outside the power pack or lubrication system or press for efficient cooling results.
Also, we provide customized solutions to our clients as per their specifications.
It is recommended that the heat exchanger’s shell side contain the process fluid with
the cooling fluid on the tube side. Also it is recommended that the cooling fluid inlet
be at the lower end and the outlet at the upper end for effective cooling.
WK 10/ D3 - List of Fuel Oil Heaters
 Fuel Oil Heaters and Assemblies
- For Internal and External Tank Applications
- Maintains Fuel Oil Temperature During Standby and Cold Starting Conditions
 Cross Flow Steam Heaters

- Steam To Oil Heat Exchanger designed to provide a dependable and economical means
of preheating fuel oil.
 Electric Oil Heater
-Model L, Electric Oil Heater - Installed on the discharge side of oil heaters that use
steam or hot water as the heating medium to maintain oil temperatures during standby and cold
starting conditions.
 Safety Type Oil Heaters
-Hot Water or Steam To Double Wall Heat Exchanger - Six pass design, utilizes a tube
within a tube construction.
 Suction Bells
-Model SB, Suction Bell - Allows a loop system to be brought up to temperature with a
small electric heater at the pump and heating set.
 Suction Stub Heater
-Model SS, Suction Stub Heater - Stocked for 230/208 VAC single phase current in a
variety of sizes.
 Tank Heating Coils
-Model B, Tank Heating Coils - Used on underground storage tank applications where
excessive ground water, unusually cold ground conditions, or high pour point oils dictate the need
for reserve heating capacity.
WK 10/ D3 - Example of Fuel Oil Heater
Wk / day 1 – Evaporator & Distiller
(a)
 ILO:
 At the end of the course the student must be able to;
- explain the operation principle of
evaporator and distiller machine.
Wk / day1 – Evaporator and
Distiller
 Evaporator;
 An evaporator is a device used to turn the liquid

form of a chemical into its gaseous form. The liquid is
evaporated, or vaporized, into a gas.
Wk / day1 – Evaporator & Distiller’s
Evaporator (marine).
Large ships usually carry evaporating plants to
produce fresh water, thus reducing their reliance
on shore-based supplies. Steam ships must be
able to produce high-quality distillate in order to
maintain boiler-water levels.
Diesel-engine ships often utilize waste heat as
an energy source for producing fresh water. In
this system, the engine-cooling water is passed
through a heat exchangers, where it is cooled by
concentrated seawater (brine). Because the
cooling water (which is chemically treated fresh
water) is at a temperature of 70–80 °C (158–
176 °F), it would not be possible to flash off any
water vapour unless the pressure in the heat
exchanger vessel was dropped.
Wk / day1 – Evaporator &
Distiller’s
 To alleviate this problem, a brine-air
ejector venturi pump is used to create a
vacuum inside the vessel. Partial
evaporation is achieved, and the vapour
passes through a demister before
reaching the condenser section. Seawater
is pumped through the condenser section
to cool the vapour sufficiently to
precipitate it. The distillate gathers in a
tray, from where it is pumped to the
storage tanks. A salinometer monitors salt
content and diverts the flow of distillate
from the storage tanks if the salt content
exceeds the alarm limit. Sterilization is
carried out after the evaporator.
Wk / day - Evaporator and
Distiller’s
 Evaporators are usually of the shell-and-tube
type (known as an Atlas Plant) or of the plate
type (such as the type designed by Alfa Laval).
Temperature, production and vacuum are
controlled by regulating the system valves.
Seawater temperature can interfere with
production, as can fluctuations in engine load.
 For this reason, the evaporator is adjusted as

seawater temperature changes, and shut down
altogether when the ship is maneuvering. An
alternative in some vessels, such as naval ships
and passenger ships, is the use of the reverse
osmosis principle for fresh-water production,
instead of using evaporators.
SF Week 11 (D2) – Evaporator and Distiller are Pressure
Vessel32
 The simple form of evaporator consists of an open pan

in which the liquid is boiled. Heat can be supplied
through a steam jacket or through coils, and scrapers
or paddles may be fitted to provide agitation.
 Such evaporators are simple and low in capital cost,

but they are expensive in their running cost, as heat
economy is poor.
Week 11 (D2) – Example of Evaporator Machine
Week / Day – Evaporators is a pressure vessel
Long tube Evaporators
 Tall and slender vertical tubes may be used for evaporators

as shown in b drawing. The tubes, which may have a length to
diameter ratio of the order of 100:1, pass vertically upward
inside the steam chest. The liquid may either pass down
through the tubes, called a falling- film evaporator, or be
carried up by the evaporating liquor in which case it is called a
climbing-film evaporator. Evaporation occurs on the walls
of the tubes. Because circulation rates are high and the surface
films are thin, good conditions are obtained for the
concentration of heat sensitive liquids due to high heat
transfer rates and short heating times.
Wk / day – Evaporator is a
pressure vessel
 Generally, the liquid is not re-circulated, and if sufficient
evaporation does not occur in one pass, the liquid is fed to
another pass. In the climbing-film evaporator, as the liquid
boils on the inside of the tube slugs of vapour form and this
vapour carries up the remaining liquid which continues to
boil. Tube diameters are of the order of 2.5 to 5 cm, contact
times may be as low as 5-10 sec. Overall heat- transfer
coefficients may be up to five times as great as from a
heated surface immersed in a boiling liquid. In the falling-
film type, the tube diameters are rather greater, about 8
cm, and these are specifically suitable for viscous liquids.
Week / Day – Distillation Process
Reflux is a distillation
technique involving the
condensation of vapors
and the return of this
condensate to the system
from which it originated.
It is used in industrial
and laboratory
distillations. It is also used
in chemistry to supply
energy to reactions over a
long period of time.
Week / Day – Methods of Obtaining Vapour from
Seawater
 Two Main Methods of Obtaining Vapour.
Direct Boiling - "The boiling point of an element or a

substance is the temperature, at which the vapor pressure of the
liquid is equals to the environmental pressure surrounding the
liquid.“
Flash Evaporation - takes place normally in a number of

stages at different pressures and the salts are eliminated as the
water is evaporated and re condensed.
Wk / day1 – Flash Evaporator
ILO
 At the end of this session the student
must be able to;
Demonstrate the operation of flash evaporator

and it’s principles
Wk / day - Flash Evaporation
 Flash evaporation;
 Today the flash evaporator is the most cost-effective type of
evaporator regarding the operation cost.
 Unlike conventional circulation evaporators with one heater circuit
per stage, the flash evaporator has several stages and heaters which
are installed circulatory; however the investment cost are quite
considerable and this type of evaporator is suited for operation
capacities of more than abt. 5 t/h.
 The solution may be fed into any stage of the evaporator and also
drained from any stage, i.e. in EBNER plants the outlet temperature
is allowed to be higher than the inlet temperature. The specific
steam consumption of flash evaporation plants is low. The
consumption depends on both, the number of stages and the total
temperature drop in the evaporator stages.
Week / day – Flash Evaporation
 Flash Evaporation:
 Flash (or partial) evaporation is the partial vapor
that occurs when a saturated liquid stream undergoes
a reduction in pressure by passing through a throttling
valve or other throttling device. This process is one of
the simplest unit operations. If the throttling valve or
device is located at the entry into a pressure vessel so
that the flash evaporation occurs within the vessel,
then the vessel is often referred to as a flash drum.
Wk / day – Flash Evaporator
 If the saturated liquid is a single-component liquid (for example,

liquid propane or liquid ammonia), a part of the liquid
immediately "flashes" into vapor. Both the vapor and the residual
liquid are cooled to the saturation temperature of the liquid at
the reduced pressure. This is often referred to as "auto-
refrigeration" and is the basis of most conventional vapor
compression refrigeration systems.
 If the saturated liquid is a multi-component liquid (for example,

a mixture of propane, isobutane and normal butane), the
flashed vapor is richer in the more volatile components than is
the remaining liquid.
 Uncontrolled flash evaporation can result in a boiling liquid

expanding vapor explosion (BLEVE).
Wk / day – Flash Evaporation
 What exactly is flash evaporation?

- When a saturated liquid undergoes a sudden
reduction in pressure- decreases its boiling point,
therefore it forms vapor.
- Flash evaporation and reverse osmosis are the
two principal types (another is ion exchange). Flash
evaporation takes place normally in a number of
stages at different pressures and the salts are
eliminated as the water is evaporated and re
condensed. Reverse osmosis is where a pressure is
applied across a membrane which allows the fresh
water through but not the salt ions.
Week / day – Construction of Shell and Coil
Evaporator
Week / day – Shell and Evaporator
 Shell of the Evaporator;

- The primary purpose of shell and tube chillers is
that of heat exchange, in vessel form, to cool a closed
circuit, recirculating fluid flow, using refrigerant as the
cooling medium.
- Shell and tube chillers are extremely efficient.
Moreover, they are very compact, requiring only a small
footprint and overall height. Maintenance, an
important consideration in costs terms, is also
fairly straightforward.
Week / day – Shell and Tube Evaporator
 The concept of the shell and tube chiller is based

on a large number of tubes formed into what is
known as a tube bundle. Refrigerant flowing from
the expansion device is passed into the tubes and
progressively evaporates thereby producing a
cooling effect through the latent heat of
vaporization.
SF Week 11 (D3) – Shell and Coil Evaporator
 The tube bundle is mounted within a steel shell and end

caps are fitted to both ends of the shell. Water is passed
over the tubes and gives up heat energy to the surface of
the tubes at lower temperature. The water therefore leaves
the shell and tube chiller several degrees lower than the
entering water temperature. This is known as a or dirty dry
type effect expansion evaporator. The water enters the
side of the shell at one end and leaves the side of the shell
at the other. Shell and tube chillers are supplied with
screwed or flanged water connections. A drain connection
is normally incorporated to allow the water in the shell to
be removed.
Week 11 (D3) – Shell and Heat Tube Exchanger
- Water is normally used as the recirculating medium for

transferring heat energy from the building to the shell and tube
chiller. There are many applications however that require both the
entering and leaving water temperature to be sub-zero.
- It may also be necessary to have the entering water temperature
above zero and the leaving water below zero. In either case, the
water must contain an additive that will prevent freezing and severe
damage to the shell and tube chiller.
Week 11 (D3) - Baffle
- However, if the water were forced to change direction over a

series of semi-circular baffle plates, the resulting turbulence
will ensure thorough mixing of the water throughout the
length of the heat exchanger thus leading to maximum
performance and freeze protection.
- The baffles also increase the velocity of the water
throughout the exchanger, thereby increasing heat transfer
coefficient. The velocity of the water flowing perpendicular to
the tubes should be at least 0.6m/s (2ft/s) to continually clean
the tubes and less than 3m/s (10ft/s to avoid tube erosion.
Week 11 (D3) – Baffle Spacing
 Baffle plate spacing:
 The number of baffles and baffle plate spacing is

varied to produce different capacities from the
same tube bundle assembly. An increase in the
number of baffles increase the performance and
capacity of the evaporator. The pressure drop
experienced at the water pumps and subsequent
pump input energy level increases.
Wk5/ day 5 – Multi-Effect
Evaporator
I.L.O.
At the end of this session the
student must be able to;
Know the operation principle of
multi-effect evaporator
Wk 5/ day5 – Listed of Mounting Fitted in a
Simple Shell and Coil Evaporator
 The single effect vertical evaporator is still in
commonly use. It operates with a vapour pressure
between 1.34 to 1.48 bar. And steam for the heating
coils is supplied direct from the boiler. The initial cost
of such an evaporator is relatively low, it is also
compact and thereby, space savings. The shell and
dome of the evaporator is made of solid drawn
copper. Mounting provided are; 1.) vapour outlet
valve, 2.) steam inlet coil drain valve, 3.) feed check
valve, 4.) blow-down valve, 5.) brine ejector, 6.) safety
valve, 7.) gauge glass with fittings, 8.) salinometer cock
and a 9.) compound pressure gauge.
Wk 5 / day5 – Multiple effect evaporator’s
Multiple-effect evaporators
 Unlike single-stage evaporators, these evaporators can be

composed of up to seven evaporator stages (effects). The
energy consumption for single-effect evaporators is very
high and is most of the cost for an evaporation system.
Putting together evaporators saves heat and thus requires
less energy. Adding one evaporator to the original
decreases energy consumption to 50%. Adding another
effect reduces it to 33% and so on. A heat-saving-percent
equation can be used to estimate how much one will save
by adding a certain amount of effects.
 The number of effects in a multiple-effect evaporator is
usually restricted to seven because after that, the
equipment cost approaches the cost savings of the energy-
requirement drop.
Wk5 / day 5 - Multiple effect evaporator’s
 There are two types of feeding that can be used when dealing
with multiple-effect evaporators. Forward feeding takes place
when the product enters the system through the first effect,
which is at the highest temperature. The product is then
partially concentrated as some of the water is transformed into
vapor and carried away. It is then fed into the second effect
which is slightly lower in temperature. The second effect uses
the heated vapor created in the first stage as its heat source
(hence the saving in energy expenditure). The combination of
lower temperatures and higher viscosities in subsequent effects
provides good conditions for treating heat-sensitive products,
such as enzymes and proteins. In this system, an increase in the
heating surface area of subsequent effects is required.
Wk 5 / day5 - Multiple effect evaporator’s
 Another method is using backward feeding. In this

process, the dilute products are fed into the last effect
which has the lowest temperature and are transferred from
effect to effect, with the temperature increasing. The final
concentrate is collected in the hottest effect, which
provides an advantage in that the product is highly viscous
in the last stages, and so the heat transfer is better. Since
some years there are also in operation multiple-effect
vacuum evaporators with heat pump, well known to be
energetically and technically more effective than systems
with mechanical vapor recompression (MVR) because due
to the lower boiling temperature they can handle highly
corrosive liquids or which may form incrustations.
Wk 5/day5 – Piping Arrangement of Shell and Coil
Evaporator
Wk 5/day5 – Mounting Fitted Functions and Operations
Salinometer is a device designed to measure the salinity, or dissolved salt content, of
a solution.
Fresh water generators (Evaporators) use salinometers on the distillate discharge
in order to check the quality of the water. Water from the evaporator can be destined for
potable water supplies, so salty water is not desirable for human consumption. And on
board-ship extremely high quality water is required for the use of boiler and main
propuslion engine.
Salinometer cock -fitted to the water drum to allow samples to be taken.
Compound gauge is a device that can display both positive and negative (vacuum)
pressures.
Feed check valve, non-return valve or one-way valve is a
valve that normally allows fluid (liquid or gas) to flow through it in only one direction.
Blow-down valve is a manual de-pressurization by operator when he wants to
release pressure quickly before it reaches to abnormal conditions.
Safety valve is to release the excess pressure, especially for the
high pressure vessel. And it’s capacity should be sufficient to prevent a
pressure in excess of 6% above the maximum allowable working pressure.
Gauge glass is a transparent tube through which the operator of a tank can observe
the level of liquid contained within.
Wk 5/day5 – Purpose of Reducing Orifice Fitted in the
Steam Supply of an Evaporator
 A reducing Orifice fitted is shown on the steam inlet.

It’s purpose is to reduce the pressure of the steam
entering in an evaporator shell in the event of heating
coil failure.
Wk 5/day5 – Purpose of Reducing Orifice Fitted
in the Steam Supply of an Evaporator
 An orifice plate is a device used for measuring flow

rate, for reducing pressure or for restricting flow (in
the latter two cases it is often called a restriction
plate). Either a volumetric or mass flow rate may be
determined, depending on the calculation associated
with the orifice plate. It uses the same principle as a
Venturi nozzle, namely Bernoulli's principle which
states that there is a relationship between the pressure
of the fluid and the velocity of the fluid. When the
velocity increases, the pressure decreases and vice
versa.
wk 5 / day 5
End of PRE-LIM
THANK YOU
Wk 4 – Intended learning objectives (ILO)
 At the end of the lesson, the student should be
able to;
 Traced the marine refrigeration cycle and state it’s

principle, demonstrate the function of refrigerating
system components, and stated refrigeration system
brines and cold storage system.
(Wk-4 / day 1) Marine Refrigeration Cycle.
What is Refrigeration?
 Is the process of keeping an item below room temperature by

storing the item in a system or substance designed to cool or
freeze.
 Refrigeration System – it is a defined as a systems which can

reduce the temperature or heat of a substance under a
controlled condition. Therefore the systems which keep it
cold body at it’s cold state which obtain by the processing of
refrigerant.
(Wk-4 / day 1) Marine Refrigeration Cycle.
Refrigeration Cycle.
1st. Compressor – compress the
refrigerant producing a high temperature
and high pressure vapor.
2nd Condenser - from the word itself
condense the HT l HP refrigerant/ vapor
turning it to high pressure and low
temperature in liquid state.
3rd Expansion valve – it allow the liquid
to expand in area and attain a low
pressure and low temperature in liquid
state.
4th Evaporator – It is where heat
exchange happens. The heat is being
absorb by the refrigerant , the cold gas /
vapor will then be distributed by the
blower. Producing low pressure with high
temperature in gas state.
Then goes back to cycle again.
(Wk 4- day 1) Refrigeration cycle operates on a
reversed heat engine cycle.
 The conversion of primary energy (e.g. heat generated by the

combustion of a fuel) into useful work most often involves a working
fluid operating in a thermodynamic cycle, which is a series of 3 main
properties; temperature, pressure & specific volume.
 Carnot Cycle
 Carnot cycle is a reversible cycle where a working

fluid goes under a cycle with working process;
Isothermal heat addition, Isentropic expansion,
Isothermal heat rejection and finally Isentropic
compression.
 Carnot cycle has the most efficiency of all the working
cycle present in the world because its each process is
nearly reversible. Heat Engines work on the Carnot
Cycle while Refrigerator and Heat Pumps work on
reverse Carnot engine.
reversed heat engine cycle. (cont.)
Heat Engine.
 In a heat engine, an input of heat

causes an increase in the
temperature of the working
substance, allowing the working
substance to perform work. In this
schematic diagram, the working
substance is water. At high
temperature, gaseous water
(steam) pushes a piston, which
causes a wheel to turn. This is the
essential mechanism by which
steam-powered trains operate.
reversed heat engine cycle. (cont.)
 Reverse Heat
Engine.
 In a reverse heat engine, a
work input is converted to a
heat output. In this case,
the work (generated by
electricity) condenses
gaseous water (steam) and
pushes it into a heat-
exchange coil. In the coil,
the temperature of the
water lowers as it liquefies,
releasing heat to the
environment.
(Wk-4/day1) Working fluids for this cycle as
refrigerant’s:
 Chemical used in a cooling mechanism, such as an air
conditioner or refrigerator, as the heat carrier which
changes from gas to liquid and the back to gas in the
refrigeration cycle.
 Most common commercial refrigerants are the chlorofluorocarbons (CFCs) which,
because of their high ozone damaging potential, are being phased out.
 A refrigerant is a substance or mixture, usually a fluid, used in a heat pump and

refrigeration cycle. In most cycles it undergoes phase transitions from a liquid to a gas
and back again. Many working fluids have been used for such purposes.
Fluorocarbons, especially chlorofluorocarbons, became common place in the 20th
century, but they are being phased out because of their ozone depletion effects. Other
common refrigerants used in various applications are ammonia, sulfur dioxide, and
non-halogenated hydrocarbons such as propane.
 The ideal refrigerant would have favorable thermodynamic properties, be noncorrosive

to mechanical components, and be safe, including free from toxicity and flammability.
It would not cause ozone depletion or climate change. Since different fluids have the
desired traits in different degree, choice is a matter of trade-off.
(Wk-4/day1) Working fluids for this cycle as refrigerant’s
Replacements for the CFC and HCFC Refrigerants.

 Refrigeration and air-conditioning have become essential in our
economy. For much of the 20th century the refrigerants (i.e.
working fluids) used in the vast majority of refrigeration and air-
conditioning equipment contained chlorine.
 R-12 (dichlorodifluoromethane or CFC-12) was abundant in
home refrigerators and automobile air conditioners.
 R-22 (chlorodifluoromethane or HCFC-22) was used in most
small domestic and commercial air-conditioning systems.
 R-11 (trichlorofluoromethane or CFC-11) was used in many
large systems.
 In the 1970s it was first suggested that chlorine could, if transported to the
stratosphere, destroy ozone that protected the earth's surface from harmful
solar ultraviolet radiation. This hypothesis was proven in the 1980s, leading in
1987 to an international treaty known as the Montreal Protocol that regulated
CFCs and HCFCs. An intense industry-wide effort to find and implement
alternatives with zero ozone-depletion potential continued throughout the
1990s.
(Wk-4/day2) Properties for Working Fluids
must obtain from the Table of
thermodynamic properties:
 For an easy way to find the fluid properties for both

liquid and vapor, must obtain from the table of
thermodynamic properties.
(Wk-4/day2) Four main Components of the
Refrigeration Plant:
Refrigeration Plant: (cont.)
Four Main Components.
 Compressor – in which the low cold pressure vapour is

compressed to a high pressure super-heated vapor.
 Condenser - a device used for changing a gas into a
liquid.
 Expansion valve – where the cool high pressure
liquid is throttled and expanded to a low pressure
cold liquid.
 Evaporator – in which the low pressure refrige-
rant enters as a cold liquid and is evaporated to
a cold low pressure vapor.
Definitions.
 The definition of refrigeration is The Removal and Relocation of Heat. So if something
is to be refrigerated, it is to have heat removed from it. If you have a warm can of pop
at say 80 degrees Fahrenheit and you would prefer to drink it at 40 degrees, you could
place it in your fridge for a while, heat would somehow be removed from it, and you
could eventually enjoy a less warm pop. (oh, all right, a cold pop.) But lets say you
placed that 40 degree pop in the freezer for a while and when you removed it, it was at
35 degrees. See what I mean, even "cold" objects have heat content that can be reduced
to a state of "less heat content".
 The working fluid properties are essential for the full description of thermodynamic
systems. Although working fluids have a very large number of physical properties
which can be defined, the thermodynamic properties which are often required in
engineering design and analysis are few. Pressure, temperature, enthalpy, entropy,
specific volume and internal energy are the most common.
Evaporator.
Evaporator
 Evaporator – to
evaporate from liquid to
gas while absorbing heat
in the process. It can also
be used to remove water
or other liquids from
mixtures.
 (by evaporation of
liquids or vaporized into
gas is the process of low
refrigerant pressure
circulation).
Evaporator.
 Refrigeration is simply cooling by removing heat.

Heat is a form of energy that can’t be destroyed.
Therefore to remove heat we can only transfer from
one place to another. Even though it is easier to
think of refrigeration as the process of making
things cold, it actually is the process of transferring
heat from one place to another.
 In this diagram illustrates the four basic
components of every refrigeration system. These
include the Evaporator, the Compressor, the
Condenser, and a Metering Device or Expansion
valve. A refrigerant is then circulated through
each component for the sole purpose of removing
heat.
Evaporator.
 A low refrigerant reading is usually indicative of a leak somewhere. While the
leak may be small or large, “topping up” with extra refrigerant is nothing more
than a temporary fix that won’t even get you through the next cooling season. A
properly sealed and well-maintained A/C system will typically not require any
extra refrigerant even after more than a decade of hot summers on the job.
Identifying potential causes of evaporator coil leaks is usually a straightforward
procedure, once a visual inspection and utilization of leak detection
technology have evaluated all possibilities.
 Indoor and outdoor coils, as well as the conduits that convey pressurized
refrigerant back and forth between them, are composed mostly of copper
tubing with brazed joints and screw-type connections. As such, defective welds
or loose connections are often suspected in cases of low refrigerant. However,
leaks from defective welds or loose joints normally manifest very soon after a
new air conditioner is installed and typically account for less than 5 percent of
the cases of low refrigerant. Causes of evaporator coil leaks that occur in the
four- to seven-year time frame of an air conditioner’s service life – a much more
common occurrence – most often are due to degradation of the copper tubing
inside the coil.
(Wk-4 /day3) Four main Components of the
 Compressor.
 Compressor – The compressor is a

vapor compression pump which
uses pistons or some other method
to compress the refrigerant gas and
send it on it's way to the condenser.
 it compresses the refrigerant to a

particular pressure, temperature &
reduces the volume. And also
promote circulation of the
refrigerant by pumping it around
the system. (in which the low
pressure vapor is compressed into a
high superheated vapor).
(Wk-4 /day3) Four main Components of the
Compressor.
 The function of a compressor is to increase the
pressure, and corresponding saturation temperature
(boiling point) of the refrigerant vapor to high enough
level so the refrigerant can condense by rejecting its
heat through the condenser.
(Wk 4 / Day 3) Four main Components of
Refrigeration Plant. (cont.)
 Four types of
Compressor.
 Various types of compressors used in the refrigeration and air conditioning
machines, these are: reciprocating, rotary, screw, and centrifugal. All these
have been described below briefly:
 1) Reciprocating Compressors:
 They have piston and cylinder arrangement like the automotive engine.
 2) Screw Compressors:
 screw compressors comprise of the pair of meshing screws between which the
refrigerant gets compressed. They can produce high pressure for small quantity
of gas
 3) Rotary Compressors:
 The rotary compressors have two rotating elements, like gears, between which
the refrigerant is compressed. Since they can handle small volume of the gas
and produce lesser pressure, they are used in fewer applications.
 4) Centrifugal Compressor:
 The centrifugal compressors comprise of the impeller or the blower that can
handle large quantities of gas but at relatively lower condensing pressure. It is
suitable for working with refrigerants like R-11, R-113 etc.
(Wk-4 / day 4) Four main Components of the
 Condenser.
 Condenser – is an apparatus
that convert vapor into liquid. (
by reducing the temperature
and pressure of the refrigerant).
In which the hot high pressure
vapour is cooled and condensed
of a cooled liquid.
Maintenanc
e.
Step 1
Disconnect. Shut off the circuit

breaker, remove the fuse or slide the
refrigerator away from the wall as
needed to remove the refrigerator's
plug from the electrical outlet. Shut
off water supply lines if equipped
with ice maker or water dispenser.
Maintenanc
Step 2. e.
Locate the condenser coil. There are

two sets of coils for cooling appliances
like refrigerators, they are called the
evaporator3 and condenser1 coils.
Because the condenser coil is exposed to the

ambient air on the refrigerator, it requires
regular cleaning.
 Maintenance
Step 3
Disconnect power. Seriously. Make sure the
power to the refrigerator is disconnected.
 Maintenance
Step 4
Vacuum the coil. With a plastic crevice

or brush attachment, carefully vacuum
dirt and dust wherever it is seen. Use
care not to damage the fins or coil. A
breach created in the coil will allow the
refrigerant to escape and will likely
result in an expensive repair.
 Maintenance
Step 5
Vacuum the fan. If the fan is visible and

accessible, cleaning it will help it move air
across the condenser coil as designed. Dirt
and dust, if allowed to accumulate on the
fan blades, decreases airflow, affects balance
and can contribute to early failure of the
compressor.
 Maintenance
Step 6
Brush away stubborn dirt and dust. Use a

narrow paint brush to gently remove
stubborn dirt and dust from the coil and fan
if able to get sufficient access.
 Maintenance
Step 7
 Slide refrigerator back into position. Plug the refrigerator back into wall
outlet. Arrange any water supply lines and power cords so that they will
not be kinked or crushed by the refrigerator.
Note: Routine maintenance plans reduce

service calls, save electricity and extend the
life of refrigeration equipment.
Maintenance
 Problems caused by failure to maintain refrigeration

equipment.
 Increased utility bills

 Burnt wiring due to increased amp draw
 Failure of fan motors caused by dirty coils
 Failure of thermostat due to increased amp draw
 Failure of compressor due to dirty coils
 Restriction of metering device caused by overheated & damaged
refrigerant oil
 and more!
 Maintenance
 Benefits of routine maintenance
 Reduced electrical consumption

 Less equipment breakdown
 Lower service and repair costs
 Longer equipment life
 Fresher product
 Reduced product spoilage
 Decreases chance of emergency service due to neglect
 Decreases stress
 and more!
Note: When it comes to reliability of any equipment, preventive maintenance is a

crucial factor. Failure to properly maintain commercial refrigeration will almost
always lead to costly repairs and loss of product.
Wk-4 / day 4) Four main Components of the
Expansion Valve.
 It is placed in-between the condenser and evaporator solely

decreases the pressure into low pressure liquid for the next
compression cycle. (basically refrigerant from the
condenser is pressurized and automatically decreases of
pressure after passing the expansion valve for the next
cycle, so meaning the expansion valve is to regulate the
pressure of refrigerant on the system to fit the required
pressure intake of the evaporator). ( or is to regulate the
refrigerant flow from high pressure side to low pressure
side.
(Wk 4 / day 5) Evaporate the low pressure liquid refrigerant
to a low pressure vapor at constant low temperature. (cont.)
Expansion
valve.
 The thermostatic expansion valve
(TXV) is a precision device, which is
designed to regulate the rate at
which liquid refrigerant flows into
the evaporator. This controlled flow
is necessary to maximize the
efficiency of the evaporator while
preventing excess liquid refrigerant
from returning to the compressor
(flood back). TXV Pressure Balance EquationTXV
P1+P4 = P2+P3
P1 = Bulb Pressure (Opening Force)
P2 = Evaporator Pressure (Closing Force)
P3 = Superheat Spring Pressure (Closing
Force)
P4 = Liquid Pressure (Opening Force)
(Wk 4 / day 5) Evaporate the low pressure liquid refrigerant
to a low pressure vapor at constant low temperature. (cont.)
Expansion valve
maintenance
 Valve overhaul can be time consuming and expensive.
 General guidelines
• Use only original spare parts from the valve manufacturer

• Make sure that springs and stroke of suction and discharge valves are correct –
Do not mix if different.
• Do not grind valve plates.
• Do not change valve stroke and spring type without consultation of the
manufacturer.
• Renew sealing surfaces. Install new sealing elements and rework the valve seats.
• Follow the manufactures specs. for max. wear of parts.
• Consider dimensions that must not be changed especially on timed suction
valves.
• If in doubt always replace parts. Premature failure of a valve is much more
expensive than savings are possible by using worn parts.
• If valves are to be shipped to a repair shop pack them properly to avoid damage
during transport.
(Wk-4 / day 5) – Four main components of
refrigeration system: (cont.)
Refrigeration - Basic Cycle Concepts

 Heat energy always flows naturally from a higher to a lower
temperature level. That is, hot areas naturally cool off and cold areas
naturally warm up. Therefore, moving heat from a lower to a higher
temperature requires the input of work (or heat), usually to create a
pressure differential in the cycle refrigerant.
 The refrigerant (acting as a heat transfer fluid) is used to transfer heat
energy from a lower temperature to a higher temperature. The
refrigerant is evaporated at a temperature lower than the desired
temperature in the freezer or cooler. The condensing temperature of
the refrigerant is increased by compression so that it can either be
rejected to the environment or recovered as useful heat. The basic
refrigeration cycle, with all steps combined, is shown:
(Wk-4 / day 5) – Four main components of
refrigeration system:
 Cycle of
Refrigeration
 Step One, Evaporation: Liquid refrigerant at a sufficiently low pressure is brought into contact
with the heat source (the medium to be cooled). The refrigerant absorbs heat and boils, producing a
low-pressure vapor. The heat exchanger used for this process is called the evaporator.
 Step Two, Compression: The compressor raises the pressure of the refrigerant vapor, normally
using an electric motor drive. This increases the temperature at which the vapors will condense to a
temperature above the temperature of the heat sink. Most common compressors are reciprocating
(piston and cylinder) or screw (looking much like an old meat grinder) compressor designs.
 Step Three, Condensing: The high-pressure refrigerant gas now carrying the heat energy
absorbed at the evaporator plus the work energy from the compressor, enters the condenser. Since
the refrigerant's condensing temperature is higher than that of the heat sink, heat transfer will take
place, condensing the refrigerant from a high-pressure vapor to a high-pressure liquid.
 Step Four, Expansion: The condensed liquid's pressure is reduced (called "throttled") to the lower
pressure evaporator using a valve, orifice plate or capillary tube device. In actual practice, the
condenser cools the refrigerant a bit more, sub-cooling it below the condensing temperature. This is
an important efficiency improving attribute to the cycle, since it reduces the amount of refrigerant
liquid that has to evaporate (it is called flashing at this stage in the cycle) to a gas in the expansion
valve to reduce the pressure and temperature of the liquid entering the evaporator. This reduction
in flash gas is important to improve system performance.
components of refrigeration system:
(cont.)
Prelim - Assessment 3
(Wk 5 / day 1 ) – Intended Learning
Objectives
 ILO; - at the end of the session the student’s should be
able to;
Calculate the performance of the refrigerator.
Draw and label’s a line diagram of the refrigeration plant

using block for the main components and arrow’s to
indicate the flow of working fluid and indicating the
energy values at important points of this cycle.
(Wk 5 / day 1) – Refrigeration Plant performance is
measured by the quantity of energy extracted
from the refrigerated chamber.
The term ‘refrigeration’ in a broad sense is used for

the process of removing heat(i.e. cooling) from a
substance. It also includes the process of reducing
and maintaining the temperature of a body below
the general temperature of its surroundings. In
other words, the refrigeration means a continued
extraction of heat from a body, whose temperature
is already below the temperature of its
surroundings.
 For example, if some space (say in cold storage) is to be kept at -2

ºC, we must continuously extract heat which flows into it due to
leakage through the wall sand also the heat, which is brought
into it with the articles stored after the temperature is one
reduced to -2 ºC. Thus in a refrigerator, heat is virtually being
pumped from a lower temperature to a higher temperature.
According to second law of thermodynamics, this process can
only be performed with the aid of some external work. It is thus
obvious, that supply of power (say electrical motor) is regularly
required to drive a refrigerator. Theoretically, the refrigerator is a
reversed heat engine, or a heat pump which pumps heat from
cold body and delivers to a hot body . The substance which
works in a heat pump to extract heat from a cold body and to
deliver it to a hot body is called refrigerant.
 When people hear the word refrigeration they immediately think of the
refrigerator in their kitchen. However there are actually quite a few different
kinds of refrigeration out three and they each have their own methods of
functioning. One particular type of refrigeration is industrial refrigeration.
This type of refrigeration is typically used for cold storage, food processing,
and chemical processing.
 The equipment is very large and made of industrial stainless steel. Industrial
refrigeration, which frequently uses ammonia refrigeration to maintain
temperature, is necessary for computer, foodstuffs, blood, vaccines, and
quite a few other goods that must maintain a constant and steady
temperature at all times. Temperatures that are too high or too low may
spoil certain goods or ruin them. As a result industrial refrigeration is
especially important maintaining temperature is as well. Since temperature
is so important into industrial refrigeration companies offering this service
must pay attention at all times to the temperature of the industrial
refrigerators.
measured by the quantity of energy extracted from the
refrigerated chamber.
 UNITS OF REFRIGERATION
 Domestic and commercial refrigerators may be rated in kj/s, or Btu/h of

cooling . Commercial refrigerators in the US are in tons of refrigeration, but
elsewhere in kw. One ton of refrigeration capacity can freeze one short ton of
water at 0 ºC (32 ºF) in 24hours.
 Latent heat of ice (i.e. heat of fusion) = 333.55 kj/kg≈ 144 Btu/lb,
 One short ton = 2000lb
 Heat extracted = (2000)*(144)/24 hr = 288000 Btu/24 hr

= 12000 Btu/hr
= 200 Btu/min
 1 tonne of refrigeration = 200 Btu/min

= 3.517 kj/s
= 3.517 kw
(Wk 5 / day 2)
(Wk 5 / day 2)
(wk 5 / day 2)
(wk 5 / day 2)

Prelim Topic

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SUBJECT:

AUXILIARY MACHINERY 211

At the end of the course, the student must be able

 The auxiliary machinery may be in support of the

 Thereare two main classes of pump in

a.) Displacement pump and

All the displacement pumps are Self

 Three Classifications of Rotary Gear Pump:

1. Simple Gear Pump

This type of pump’s is generally made according to the

1. Simple Gear Pump:

 The Simple Gear Pump has two spur gears, which

 The action of the un-meshing gears draws the

Case seal - is used to join or seal two systems or

 Herringbone Gear Pump:

 Herringbone Gear Pump operates as a

3. Helical Gear Pump:

 Helical Gear Pump:

 A gear pump uses the meshing of gears to pump

 Their are two main variation of gear pumps.

 External Gear Pump Works:

 External gear pump are a popular

 Internal Gear Pump:

 Referred as constant pressure pump,

• The vane are attached to the hub. There is

 Thousand of pumps operate with open

• Potential rubbing problem causes vibration and high bearing loads.

• Important for maximum efficiency.

 A pump diffuser or volute is part of a

 Vanes are allowed to slide into and out of

 Vanes or blades fit within the slots of the

 Furthermore, vane pumps can be used in

A screw pump is a positive-displacement

Screw Pump Components:

Screw Pump Components:

• Bearing - The functions of the bearings are to

 Universal joint - a form of coupling

• Pump body - a part designed to shelter,

• Reciprocating pump is a positive

Types of Reciprocating Pump:

Single Acting Reciprocating pump:

 During suction stroke, the piston moves

 After suction stroke, the piston moves

 Double Acting Reciprocating Pump:

 As the piston moves to the right hand side as

 The suction valve is gets closed and delivery valve

1. High pressure is obtained at the outlet.

1. It requires high maintenance because

 Components of Reciprocating Pump:

6. Piston and Piston Rod

7. Crank and Connecting Rod

 This vacuum causes suction valve to open and

 When piston reaches its extreme left position

 Generally the above process can be observed

Uses of Reciprocating Pump:

 Pneumatic pressure systems

 Light oil pumping

 Feeding small boilers condensate return

End of Week 1 / Session 1 – 4.

 LO1: Determine the components, function and operating

The Basic Principles of Using a Heat

 The pump shown above is of very common design.

The tooth profile is similar involute gear teeth for