QUALITY CIRCLE PRESENTATIONA PRESENTATION

ON“PUMPS IN POWER PLANTS”

BYM.K. ASTHANA, SR. MANAGER (QA)

COMING UP……..

BRIEF INTRODUCTION OF THERMAL POWER PLANT

EXAMPLES OF MAJOR PUMPS

DEFINITIONS

CLASIFICATION OF PUMPS

FUNDAMENTAL EQUATIONS OF PUMP

TYPES & CHARACTERISTICS OF PUMPS

MATERIAL SELECTION

QUALITY CONTROL & TESTING

P.G. TEST OF CW PUMP – SIPAT – II, KhSTPP - II

SUB - CRITICAL STEAM POWER PLANT

T

1

2

3

56

79

10

11

s

SCHEMATIC DIAGRAM T-s DIAGRAM

1

HPT IPT LPT GEN.

LPH

DEAERATOR

BFPHPH CEP

BOILER

2

34

5

78

91011

CONDENSER

6CWP

Saturated vapor line

CRITICAL POINT

p = 15 Kgf/cm2

p = 1.0332 Kgf/cm2

p =225.65 Kgf/cm2

LIQUID - VAPOR REGION

LIQUID REGION

VAPOR REGION

T

vTemperature - Specific Volume Diagram for Water

Saturated liquid line

PUMPS

CONDENSATE EXTRACTION PUMP

C.W. PUMP

HORIZONTALCENTRIFUGAL PUMP

PUMPS PUMPS DESIGN PARAMETERS

PARAMETERS CW PUMP C.E. PUMP B.F. PUMP

TYPE VERTICAL VERTICAL HORIZONTAL, CENTRIFUGAL

FIVE

1080.3 M3/Hr

2088 MWC

5690 RPM

6765 KW

FORGED CARBON STEEL WITH AUSTENITIC SS INLAY IN HIGH VELOCITY ZONE

13 Cr, SS

13 Cr, SS FORGING

NO. OF STAGES SINGLE FIVE

FLOW 30,000 M3/Hr 810 M3/Hr

DISCHARGE HEAD 20.50 MWC 307 MWC

OPERATING SPEED 331 RPM 1480 RPM

MAX. WATER TEMP. 43.1O C

PUMP INPUT 1903.22 KW

MATERIAL

SUCTION BELL 2% Ni CI CAST IRON

PUMP CASING 2% Ni CI CAST IRON

IMPELLER CF – 8M 12% Cr, SS

SHAFT, SHAFT SLEEVE ASTM A 276 Gr. 410, H&T

12% Cr, SS FORGING

PUMPS PUMPS DESIGN PARAMETERS

PARAMETERS RAW WATER PUMP

MAKE UP WATER PUMP (PT)

MAKE UP WATER PUMP (ASH)

TYPE VERTICAL, MIXED FLOW

VERTICAL, MIXED FLOW

VERTICAL, MIXED FLOW

NO. OF STAGES SINGLE SINGLE TWO

FLOW 5500 M3/Hr 4000 M3/Hr 2200 M3 /Hr

DISCHARGE HEAD 11.5 MWC 25 MWC 40 MWC

OPERATING SPEED 750 RPM 1000 RPM 1000 RPM

SERVICE DUTY CONTINUOUS CONTINUOUS CONTINUOUS

MAX. WATER TEMP. 36O C 36O C 36O C

Categories

• Pumpadds energy to a fluid, resulting in an increase in pressure across the pump.

• Turbineextracts energy from the fluid, resulting in a decrease in pressure across the turbine.

CATEGORIES• For gases, pumps are further broken down into

– FansLow pressure gradient, High volume flow rate. Examples include ceiling fans and propellers.

– BlowerMedium pressure gradient, Medium volume flow rate. Examples include centrifugal and squirrel-cage blowers found in furnaces, leaf blowers, and hair dryers.

– CompressorHigh pressure gradient, Low volume flow rate. Examples include air compressors for air tools, refrigerant compressors for refrigerators and air conditioners.

PUMPS

PUMP COMPRESSOR BLOWER FAN

FUNCTION A MACHINE FOR RAISING A LIQUID

A RELATIVELY INCOMPRESSIBLE FLUID

TO A HIGHER LEVEL OF PRESSURE OR HEAD

A MACHINE FOR RAISING A GAS

A MACHINE FOR MOVING VOLUMES OF A GAS

A MACHINE FOR MOVING LARGE AMOUNT OF A GAS

TYPE OF FLUID A COMPRESSIBLE FLUID

COMPRESSIBLE COMPRESSIBLE

END RESULT TO A HIGHER LEVEL OF PRESSURE

WITH MODERATE INCREASE OF PRESSURE

WITH LOW INCREASE IN PRESSURE

PUMPS

PUMPS

POSITIVEDISPLACEMENT

KINETIC

RECIPROCATING

ROTARY

BLOW CASE

CENTRIFUGAL

SPECIAL

PERIPHERAL

PISTON

DIAPHRAGM

PLUNGER

SINGLE ROTOR

MULTIPLE ROTOR

RADIAL FLOW

AXIAL FLOW

MIXED FLOW

PUMPS

RECIPROCATING PUMPGEAR PUMP

JET PUMP PITOT TUBE PUMP

• CENTRIFUGAL PUMPSFluid enters axially, and is discharged radially.

PUMPS

• MIXED FLOW PUMPSFluid enters axially, and leaves at an angle between radially & axially.

• AXIAL FLOW PUMPSFluid enters & leaves axially.

PUMPS CURVES

VOLUME FLOW

PRES

SUR

E IN

CR

EAS E

CENTRIFUGAL PUMP

POSITIVE DISPLACEMENT PUMP

PERIPHERAL PUMP

PUMP CURVES FOR DIFFERENT PUMP TYPES

PUMPS CURVES

VOLUME FLOW

PRES

SUR

E IN

CR

EAS E

POSITIVE DISPLACEMENT PUMP AND SYSTEM CHARACTERISTICS

Normal

System

Res

istan

ce

Increa

sed S

ystem

Res

istan

ce

25%Speed

50%Speed

75%Speed

100%Speed

Pum

p C

hara

cter

istic

s

A1A2

v1

v2

m = ρ1* A1* v1 = ρ2* A2* v2

For an incompressible liquid flow,

Q = A1* v1 = A2* v2

THE CONTINUITY EQUATION

THE CONTINUITY EQUATION

For an incompressible liquid flow,

Q1 = Q2 + Q3

A1* v1 = A2* v2 + A3* v3

A1 A2

v1v2

A3

BERNOULLI’S EQUATION

A1

A2

v1

v2

z1

z2

Horizontal Datum

p1 + v21 + gz1 = p2 + v2

2 + gz2 + Δpf

ρ 2 ρ 2 ρ

p1 + v21 + z1 = p2 + v2

2 + z2 + Δpf

w 2g w 2g w ⇒

STATIC, TOTAL & DYNAMIC PRESSURE HEADSTATIC PRESSURE TAP PITOT TUBE PRANDTL TUBE

pp0

pp0

pv

p1

w STATIC HEAD =

v2

2g VELOCITY HEAD =

z POTENTIAL HEAD =

= p + ρv2

w 2

TOTAL PRESSURE OR STAGNATION PRESSURE

PUMPS

Blade Losses

Impeller frictionInternal Leakages(Slip)

External Losses

Bearing Losses

Sealing friction

Impeller Friction Losses

Blade Losses

P Pi Pblade Puseful

Bearing & Sealing Friction Losses

Internal Leakage (Slip)

External Leakage

Centrifugal Pumps

• Snail--shaped scroll • Most common type of

pump: homes, autos, industry.

Centrifugal Pumps

Side view of impeller blade.Vector analysis of leading and trailing edges.

Centrifugal Pumps: Blade Design

PUMPS

Change in Angular Momentum of fluid from inlet to exit

= Mt = m* (r2C2u – r1C1u)

Mt *δφ= δφ* δm * (r2C2u – r1C1u)δt

Work Done per unit mass = Blade Work = Mt *δφ = Ib = ω * (r2C2u – r1C1u) = gΔHδm ηh

⇒ gΔH = (u2C2u – u1C1u)ηh

ΔH = Differential Headηh = Hydraulic Efficiencyu = peripheral velocityCu = tangential component of

absolute velocity

PUMPS

C1u ≈ 0, ⇒ gΔH = u2C2u

ηh

If ηh = 1, ΔHi = Ideal Differential Head = “Euler Head”

ΔHi = u2C2u/g = u2 [u2 – C2m/tanβ2 ]/g

C2m = Q / (2π * r2 * b2)

ΔHi = u2 u2 – Q g 2π * r2 * b2 tanβ2

Pump Head

• Net Head

• Water horsepower

• Brake horsepower

• Pump efficiency

PUMPS

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

0 20 40 60 80 100FLOW “Q”

CENTRIFUGAL PUMP H – Q CURVE

Hydraulic Losses

Actual Differential Head

Ideal Differential Head

DIF

FER

ENTI

AL

HEA

D “

H”

PUMPS

10

20

30

40

50

60

70

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

0 20 40 60 80 100FLOW “Q” in m3/h

DIF

FER

ENTI

AL

HEA

D “

H”

in m

CENTRIFUGAL PUMP H – Q CURVE

EFFI

CIE

NC

Y “η

”IN

%

170

160

150

170

150

N = 1450 rpmMedium = Water

Pump – Performance CurveCentrifugal Pump

• BEP: best efficiency point

• H*, bhp*, V* correspond to BEP

• Shutoff head: achieved by closing outlet (V=0)$

• Free delivery: no load on system (Hrequired = 0)

Matching a Pump to a Piping System

• Steady operating point:

• Energy equation:

Centrifugal Pumps: Blade Design

PUMPS

4

8

12

16

20

24

28

32

0 120 240 360 480 600

DIF

FER

ENTI

AL

HEA

D “

H”

in m

FLOW “Q” in m3/h

CENTRIFUGAL PUMP H – Q CURVE WITH ISO – EFFICIENCY LINES

5055

6062

6362

6055

50

425

426

427429

430

PUMPS

H

SHUT OFF HEAD(ZERO DISCHARGE)

Q

UNSTABLE PART OF THE CURVE

Q

H

STABLE UNSTABLE

STABLE AND UNSTABLE PUMP CURVES

PUMPS

FLAT AND STEEP PUMP CURVES FOR CENTRIFUGAL PUMPS

H

QO

H H

Q Q QQO QO

HO

Hmax

PUMPS

THE EFFECT ON PUMP PERFORMANCE DUE TO WEAR IN SEALS & CLEARANCES

H

Q

DIFFERENTIAL HEAD

WORN PUMP

NEW PUMP P

Q

POWER REQUIREMENTS

WORN PUMP

NEW PUMP

Q

H

DIFFERENTIAL HEAD

WORN PUMP

NEW PUMP P

Q

POWER REQUIREMENTS

WORN PUMP

NEW PUMP

THE EFFECT ON PUMP PERFORMANCE DUE TO WEAR ON PUMP BLADES

PUMPS

ROTODYNAMIC PUMP CURVES RELATIVE TO BEP

REL

ATI

VE D

IFFE

REN

TIA

L H

EAD

RELATIVE VOLUME FLOW

1

1

0RELATIVE VOLUME FLOW

1

1

0

REL

ATI

VE P

OW

ER

PUMPS

THE EFFECT OF VISCOSITY ON SMALL CENTRIFUGAL PUMP

DIF

FER

ENTI

AL

HEA

D IN

M

VOLUME FLOW IN M3/Hr

200 40 60 80 100 120 140

10

20

30

40

50

150 mm2/s

100 mm2/s

50 mm2/s

1 mm2/s

SHA

FT P

OW

ER IN

KW

VOLUME FLOW IN M3/Hr

200 40 60 80 100 120 140

10

20

30

40

50

1 mm2/s

30 mm2/s

50 mm2/s

100 mm2/s

150 mm2/s

PUMPS

PERFORMANCE CURVE OF A PERIPHERAL PUMP

50

SHA

FT P

OW

ER IN

KW

VOLUME FLOW IN M3/Hr

0 10 20 30

1

2

3

4

5

DIF

FER

ENTI

AL

HEA

D IN

M

VOLUME FLOW IN M3/Hr

0 10 20 30

10

20

30

40

OPTIMUM POINT

PUMPS

PERFORMANCE CURVE OF A POSITIVE DISPLACEMENT PUMP

75

DIS

CH

AR

GE

PRES

SUR

E B

AR

g

VOLUME FLOW IN M3/Hr

0 20 40 60

30

15

45

60

90

105

80 100 120 140

50

POW

ER IN

KW

VOLUME FLOW IN M3/Hr

0 20 40 60

20

10

30

40

60

70

80 100 120 140

PUMPS

120

VOLU

ME

FLO

W IN

M3 /H

r

DISCHARGE PRESSURE BAR g

PERFORMANCE CURVE OF A POSITIVE DISPLACEMENT PUMP

0 15 30 45

105

100

110

115

125

130

60 75 90 10590

70

MEC

HA

NIC

AL

EFFI

CIE

NC

Y %

DISCHARGE PRESSURE BAR g

0 15 30 45

40

30

50

60

80

90

60 75 90 10520

POW

ER IN

KW

40

10

0

20

30

50

60

70ηmech

POWER

PUMPS

p2

p1p3

Pumped Medium mp

Motive Medium md

mp + md

DIFFUSER (VENTURI)

c4

c5

q = mp / md

Pressure relationship = z = (p03 – p02) / (p01 – p03) = Hp/Hd

Pump Efficiency = η = q*z

DIAGRAMATIC PRINCIPLE OF A JET PUMP

PUMPS

FLOW RELATIONSHIP “q”

PRES

SUR

E R

ELA

TIO

NSH

IP “

z”

PERFORMANCE CURVE FOR A JET PUMP

z

η

EFFI

CIE

NC

Y η

Blade number affects efficiency and introduces circulatory losses (too few blades) and passage losses (too many blades)

Centrifugal Pumps: Blade Design

Axial Pumps

Open vs. Ducted Axial Pumps

Pump Specific Speed

Pump Specific Speed is used to characterize the operation of a pump at BEP and is useful for preliminary pump selection.

Propeller has radial twist to take into account for angular velocity (=ωr)

Blades generate thrust like wing generates lift.

Open Axial Pumps

• Tube Axial Fan: Swirl downstream

• Counter-Rotating Axial-Flow Fan: swirl removed. Early torpedo designs

• Vane Axial-Flow Fan: swirl removed. Stators can be either pre-swirl or post-swirl.

Ducted Axial Pumps

Absolute frame of reference Relative frame of reference

Ducted Axial Pumps - Blades

Dimensional Analysis

Π analysis gives 3 new non-dimensional parameters– Head coefficient

– Capacity coefficient

– Power coefficient• Reynolds number also appears,but in terms of angular

rotation– Reynolds number

• Functional relation is– Head coefficient

– Power coefficient

Dimensional Analysis

• If two pumps are geometrically similar, and

• The independent Π’s are similar, i.e., CQ,A = CQ,BReA = ReBεA/DA = εB/DB

• Then the dependent Π’s will be the sameCH,A = CH,BCP,A = CP,B

• When plotted in non-dimensional form, all curves of a family of geometrically similar pumps collapse onto one set of non-dimensional pump performance curves

• Note: Reynolds number and roughness can often be neglected,

Dimensional Analysis

AFFINITY LAWS

SUMP

WIER

FLOWMETER

FLOW NORMALIZER TRASH RACK

C.W. PUMP

CREST

TEST BED

PUMPS

LAY OUT OF CW PUMP TEST BED

PUMPS

H

Q = 0.4046 + 0.003607 √2gLH1.5

L = LENGTH OF WEIR “M”

H = HEIGHT OF LIQUID “M”

Q = VOLUME FLOW IN M3/SEC.

FLOW MEASUREMENT BY RECTANGULAR WEIR

D

PUMPS FLOW MEASUREMENT BY ORIFICE PLATE

d

p1 p2

PUMPS

MATERIAL & MATERIAL

COMBINATION

COST

MANUFACTURING TECHNIQUES

STRENGTH

CORROSION

EROSION

CAVITATION

PROCESS UPSET

CONDITIONS

PROCESS VARIATIONS

FACTORS AFFECTING MATERIAL SUITABILITY FOR PUMPS

PUMPS

TYPICAL MATERIALS

MATERIAL WITH IRON AS ITS MAIN CONSTITUTENT

MATERIAL WITH SIGNIFICANT PROPORTIONS OF Cr & Ni

MATERIAL WITH Cu OR Al AS ITS MAIN CONSTITUENTS

OTHER METALLIC MATERIALS

NON – METALLIC MATERIALS

PUMPS COMMONLY USED MATERIAL COMBINATIONS FOR CENTRIFUGAL PUMP

CASING IMPELLER SHAFT APPROX. RELATIVE COST

GREY CAST IRON GREY CAST IRON STAINLESS STEEL 0.97

GREY CAST IRON GUN METAL STAINLESS STEEL 1.0

GREY CAST IRON PLASTIC STAINLESS STEEL 0.95

GREY CAST IRON STAINLESS STEEL STAINLESS STEEL 1.08

S. G. IRON STAINLESS STEEL STAINLESS STEEL 1.25

CAST STEEL GREY CAST IRON STEEL 1.1

CAST STEEL CAST STEEL STEEL 1.2

CAST STEEL BRONZE STEEL 1.25

CAST STEEL 13 Cr STEEL STEEL 1.3

CAST STEEL STAINLESS STEEL STAINLESS STEEL 1.5

13 Cr STEEL 13 Cr STEEL 13 Cr STEEL 1.4

TITANIUM TITANIUM TITANIUM 10

STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL 1.8

PUMPS MATERIAL STANDARDS

EQUIVALENT INTERNATIONAL STANDARDMATERIAL IS

BS ASTMCAST IRON IS 210, Gr. FG 260 BS 1452 Gr. 250 ASTM A – 48 CL 35

Ni RESIST IS2749, Gr. AFG Ni 15Cu 6 Cr3

BS 3468 AUS 102 Gr. B

ASTM A – 436 TYPE – 2

CARBON STEEL IS 1570 Gr. 40C8 BS 970 080M40 ASTM A 107 Gr. 1040

SS 304 BS 970 304S15 ASTM A – 276 TYPE 304

SS 316 IS 1570 Gr. 05Cr18Ni11Mo3 BS 970 304S16 ASTM A – 276 TYPE 316

SS 410 GREY CAST IRON BS 970 410S21 ASTM A – 276 TYPE 410

K MONEL IS 3444 Gr. 22 STEEL ASTM A 743 Gr. M-35

BRONZE IS 318 Gr. LTB 2 BS 1400 LG 2C ASTM B – 62, B145 ALLOY 4A

CF8M IS 3444 Gr. 9 BS 1632 Gr. B ASTM A 351 Gr. CF8M

CF8C ASTM A 351 Gr. CF8C

CA 15 BS 3100 – 410 C 21 ASTM A 217 Gr. CA 15

Al. BRONZE IS 305 Gr.2 ASTM B 148, B271 ALLOY 9A

CAST STEEL BS 1504 101A ASTM A216 Gr. WCB

PUMPS MATERIAL OF CENTRIFUGAL PUMP & MAIN AREAS OF APPLICATION

MATERIALS APPLICATIONSCAST STEELCAST STEEL DEDE--AERATED HOT WATER, BOILER FEED PUMPSAERATED HOT WATER, BOILER FEED PUMPS

SG IRON, NODULAR SG IRON, NODULAR IRONIRON

AS ABOVE. BETTER RESISTANCE TO CORROSION AT HIGH LIQUID AS ABOVE. BETTER RESISTANCE TO CORROSION AT HIGH LIQUID VELOCITIES THAN CAST STEEL BUT NOT AS GOOD AS CIVELOCITIES THAN CAST STEEL BUT NOT AS GOOD AS CI

GREY CAST IRONGREY CAST IRON HAS GOOD RESISTANCE TO MANY FLUIDSHAS GOOD RESISTANCE TO MANY FLUIDS120120OO C MAXIMUM, pH > 5.5C MAXIMUM, pH > 5.5

13 Cr STEEL13 Cr STEEL DE DE –– AERATED HOT WATER, BOILER FEED PUMPSAERATED HOT WATER, BOILER FEED PUMPS360360OO C, A GOOD REPLACEMENT OF CAST STEEL ABOVE 200C, A GOOD REPLACEMENT OF CAST STEEL ABOVE 200OO C C BETTER THERMAL STABILITYBETTER THERMAL STABILITYHIGHER PRESSURE CAPABILITIESHIGHER PRESSURE CAPABILITIES

SiSi IRON 14SiIRON 14Si RESISTANT TO ACID CORROSION, HCL, H2SO4 AND STRONG SALT RESISTANT TO ACID CORROSION, HCL, H2SO4 AND STRONG SALT SOLUTIONSSOLUTIONSNOT SUITABLE FOR THERMAL SHOCKNOT SUITABLE FOR THERMAL SHOCK

Ni Ni –– RESIST, 20Ni3CrRESIST, 20Ni3Cr HOT, SEA WATERHOT, SEA WATER

GUN METAL, GUN METAL, BRONZEBRONZE

SALT WATER, SEA WATER, BRINE & OTHER MODERATELY CORROSIVE SALT WATER, SEA WATER, BRINE & OTHER MODERATELY CORROSIVE WATER SOLUTIONSWATER SOLUTIONS

MONELMONEL SEA WATER, BRINESEA WATER, BRINE

AUSTENITIC SSAUSTENITIC SS BFP, GENERAL CORROSIVE APPLICATIONS, POOR IN CHLORIDE BFP, GENERAL CORROSIVE APPLICATIONS, POOR IN CHLORIDE SOLUTIONSOLUTION

HAST ALLOY CHAST ALLOY C VERY RESISTANT TO CORROSIONVERY RESISTANT TO CORROSION

TITANIUMTITANIUM CHLORIDE SOLUTIONSCHLORIDE SOLUTIONS

PUMPS

1 101 102 103 104 105 106 107 106 105 104 103 102 101 1

pH 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

STRONG ACID WEAK ACID WEAK ALKALINE STRONG ALKALINE

H+ CONCENTRATION mol/l OH- CONCENTRATION mol/l

ION CONCENTRATION, pH VALUE, DEGREE OF ACIDITY AND ALKALINITY

NEUTRAL

PUMPS1

2

3

4

5

6

7

8

9

10

11

12

13

14

STA

INLE

SS

STE

EL,

P

LAS

TIC

BR

ON

ZEB

RO

NZE

,CA

ST

IRO

N,S

TEE

L A

LLO

YS

STA

INLE

SS

STE

EL,

P

LAS

TIC

,Ni-S

iALL

OY

S,C

AS

T IR

ON

ACID HCL , H2SO4, HNO3 CONCENTRATED

SULPHURIC ACID 10%FORMIC ACID

WINE – CITRIC ACID 10%ACETIC ACID CONCENTRATED

CARBONIC ACID

AMMONIUM CHLORIDE

BORIC ACID

HUMUS ACID

SODIUM BICARBONATE 10%NATRON SOAP MAGNESIA

BORAX 1%

MAGNESIUM HYDROXIDE

AMMONIA 1%

AMMONIA CONCENTRATED, NaOH 1%NaOH 10%KOH 10%

NaOH CONCENTRATEDKOH CONCENTRATED

CIDER

BEER

DRINKINGWATER

HOUSE HOLD WASHING UP & CLEANING PREPARATIONS

WINE

TOMATO

COW’S MILK

CABBAGE

MOTHER’S MILK

EGG WHITE

LEMON

VINEGAR

SALIVA

GRAPEFRUIT

STOMACH ACID

ORANGE

SEWAGE

NEUTRAL

OH

-C

ON

CE

NTR

ATI

ON

H+

CO

NC

EN

TRA

TIO

N