DEBRE MARKOS UNIVERSITY

Institute of technology
School of Mechanical and Industrial
Engineering
Turbo-Machinery
MEng3201

Chapter 2
Centrifugal pumps and fans

Prepared by: Birlie Fekadu

Contents of the Chapter

❖ Introduction
 Impeller flow
 Efficiency
 Performance characteristics
 Design of pumps
 Fans
 Introduction
Class of Turbo machines which convert
mechanical energy into fluid energy. include:
Pumps, Compressors, Blowers and Fans.
 If a turbo machine is used to raise the
pressure of a liquid ( water, chemicals,
petroleum,) it is called a Pump.
 If a turbo machine is used to raise the
pressure of a gas it is called a Compressor or
a Blower or a Fan, depending upon the
pressure developed.
Centrifugal Pump: A mechanical device used to
transport fluids by the conversion of rotational
kinetic energy to the hydrodynamic energy of
the fluid flow.
A collection chamber in the casing converts
much of the Kinetic Energy (energy due to
velocity) into Head or Pressure.
 Working Principle of a Centrifugal Pump
 A centrifugal pump is one of the simplest pieces of equipment in any process
plant. Its purpose is to convert energy of a prime mover (an electric motor or
turbine) first into velocity or kinetic energy and then into pressure energy of a
fluid that is being pumped.
 The energy changes occur by virtue of two main parts of the pump, the impeller
and the volute or diffuser. The impeller is the rotating part that converts driver
energy into the kinetic energy. The volute or diffuser is the stationary part that
converts the kinetic energy into pressure energy. All of the forms of energy
involved in a liquid flow system are expressed in terms of height of liquid i.e.
head.
 Generation of Centrifugal Force
 The process liquid enters the suction nozzle and
then into eye (center) of a revolving device
known as an impeller. When the impeller rotates,
it spins the liquid sitting in the cavities between
the vanes outward and provides centrifugal
acceleration. As liquid leaves the eye of the
impeller a low-pressure area is created causing
more liquid to flow toward the inlet.
 Liquid forced into impeller
 Vanes pass kinetic energy to liquid: liquid
rotates and leaves impeller
 Volute casing converts kinetic energy into
pressure energy

How does a Centrifugal pump work _.mp4

Classification of Centrifugal Pumps
1. By the type of energy conversion,

Volute casing with guide blades

Volute casing
4. By the axis o rotation,
2. By the number of stages, • Horizontal
• Single stage • Vertical
• Multi-stage 5. By the method of drive,
3. By impeller type, • Direct ( rigid or flexible
• open couplings)
• Semi-open • Indirect ( gear drive, belt
• Closed, drive, … )
Components or parts and operation of Centrifugal Pumps

A centrifugal pump has two main components:

I. A rotating component comprised of an impeller and a shaft.
II. A stationary component comprised of a casing, casing cover, and
bearings.
 Stationary Components
Casing
Casings are generally of two types: volute and circular.
Volute casings build a higher head.
A volute is a curved funnel increasing in area to the discharge port. One of
the main purposes of a volute casing is to help balance the hydraulic
pressure on the shaft of the pump.
Circular casing have stationary diffusion vanes surrounding the impeller
periphery that convert velocity energy to pressure energy
Suction and Discharge Nozzle
End suction/Top discharge: The suction nozzle is located at the end of, and
concentric to, the shaft while the discharge nozzle is located at the top of the
case perpendicular to the shaft.
Internal circulating device: refers to device located in the seal chamber to
circulate seal chamber fluid through a cooler or barrier/buffer fluid reservoir.
Mechanical Seal:
Bearing housing
 Side suction / Side discharge nozzles: The suction and discharge
nozzles are located at the sides of the case perpendicular to the
shaft
 Seal Chamber and Stuffing Box
 Gland: is a very important part of the seal chamber or the stuffing
box. It gives the packing's or the mechanical seal the desired fit on
the shaft sleeve. It can be easily adjusted in axial direction.
 Throat Bushing: The bottom or inside end of the chamber and
forms a restrictive close clearance around the sleeve (or shaft)
between the seal and the impeller.
 Throttle bushing: refers to a device that forms a restrictive close
clearance around the sleeve (or shaft) at the outboard end of a
mechanical seal gland
 Rotating Components
Impeller: is the main rotating part that provides the centrifugal acceleration
to the fluid. Classified as
Based on major direction of flow in reference to the axis of rotation
 Radial flow ,
 Axial flow and
 Mixed flow
 Based on suction
 Single-suction: Liquid inlet on one side.
 Double-suction: Liquid inlet to the impeller symmetrically from both
sides.
 Based on mechanical construction

 Closed: Shrouds or sidewall enclosing the vanes.

 Open: No shrouds or wall to enclose the vanes.
 Semi -open or vortex type
 Wear rings: Wear ring provides an easily and economically renewable
leakage joint between the impeller and the casing
 Shaft: The basic purpose of a centrifugal pump shaft is to transmit the
torques encountered when starting and during operation while supporting
the impeller and other rotating parts.
 Shaft Sleeve : Pump shafts are usually protected from erosion, corrosion
, and wear at the seal chambers, leakage joints, internal bearings , and in
the waterways by renewable sleeves.
 Coupling: Couplings can compensate for axial growth of the shaft and
transmit torque to the impeller.
 Impeller flow

An impeller has vanes which are blades that

push the liquid through the impeller. The
center of the impeller where the liquid enters
the impeller is called the eye.
The impeller is the most important part of the
pump since it is where the work is taking
place. To obtain useful work, the impeller is
contained in a casing which directs the
accelerated fluid along a desired path.
 There are two different impeller types
used in the process industry. They differ
by the type of flow through the impeller.
The most common type is a “radial flow”
impeller where the liquid makes a 90° turn
as it passes through the impeller
 In a turbine type impeller, the liquid
also makes a turn as it passes through
the pump,, but less than 90◦. Since the
liquid makes less of a turn, a turbine
style impeller may be slightly more
efficient than a similar “radial flow”
impeller
 Velocity triangle in impeller flow of centrifugal pump
In the case of centrifugal pumps, work is
done by the impeller on the fluid
(water). The expression for work done
by the impeller on the water is obtained
by drawing a ‘velocity triangle’ at the
inlet and outlet of the impeller, as shown
in the figure, in a similar way as for a
‘Francis turbine’.
In the design of such pumps, it is better
to consider a radial flow of fluid (water)
at the inlet for best efficiency of the
pump.
The subscripts r and f represents the
absolute velocities and radial velocities
of fluid respectively. The subscript w
represent the tangential components of
the absolute velocity of the flow.
  The specific work is given by:
where
 Therefore, the head developed by the pump is:
Also called Euler’s head
 From the inlet and exit triangles, applying cosine law:

 Subtracting the second expression from the first

 Maximum head can be developed by the pump if the fluid
approaches the blade inlet radially. Therefore, ,

 From the exit velocity triangle shown

for a backward curved blade,
 The volume flow rate given by parameters at the impeller
exit is:

Substituting

 This is an important piece of equation which shows the

degree of dependence of head on discharge,
quantitatively.
 The effect of impeller blade shape On performance
There are three possible orientation of the blade at the outlet: forward curved,
radial and backward curved arrangements. The velocity triangles for the three
arrangements are as shown in the figure below.

In case of forward curved, V2t > U2 and V2 is larger comparatively. In the

case of radial, V2t is equal to U2. In the case of backward curved, V2t < U2.
The plot H versus Q is as shown in the figure. 2 on the curve.
The rising characteristics of the forward curved leads to increase of
power input with increase of Q. The power curve is not self-limiting
and damage to motor may occur. As a result, the backward curved is
preferable.
 head developed by the impeller
 Heads
 Static head : the head gained as a
result of elevation from a
reference datum.
 Pressure head : the head as a
result of static pressure
possession of the fluid.
 Velocity head: the head as a
result of kinetic energy
Possession of the fluid.
  Manometric head
Manometric head is the head the pump should develop in
order to get the desired elevation or distance of fluid by also
overcoming the friction and different pipe losses.
Applying conservation of energy for the pump system:
 Losses and Efficiencies of centrifugal pump
  Pipe losses

 Friction loss: Given by the most known Darcy – Weisbach equation
is friction factor which can be read from the Moody diagram for different
pipe relative roughness and Reynolds number for turbulent flow. For
laminar flow an approximate value can be found by using
 Elbow loss
 Cross section change loss
 Pump losses
 Mechanical loss: are friction losses in mechanical components (shafts,
bearings, seals, etc…)
 Hydraulic loss: Friction loss in rotor and casing, incidence loss,
diffusion loss, impeller tip leakage, etc..
 Leakage: is due to the loss of liquid in-between the impeller and the
pump.
Efficiencies
 Cavitation
  When a working pressure becomes less than the vapor pressure of
the liquid at some temperature, vapors begin to form.
 Once vapor bubbles form it is only a matter of very short time
before they implode and strikes the metal surfaces of the turbo
machine components. Doing so the enormous burst out pressure is
instantaneously changed to the high velocity of the fluid element
enough to pit the metal surface.
 In turbomachines there are different occasions in which low
pressure regions may form where the pressure can even down
below the vapor pressure of the liquid.
 Regions of Cavitation
 Consequences of cavitation
 Suction region (Impeller eye in
• Low efficiency pump operation
pumps)
• Pitting and erosion of metal
 Regions of adverse pressure gradient
surface and premature pump
 Regions near air leakage (causes air
failure
cavitation)
• Misalignment of shaft and
 Causes that pronounce cavitation in
bearing as a result of vibration
pumps  Symptoms of cavitation in pumps
 Suction side losses
o High noise
 Leakage
o Vibration
 High impeller speed
o Erratic pump operation (power
 To reduce the possible occurrence of
fluctuation)
cavitation
o Pressurizing reservoir
o Reducing negative suction head
o Reducing losses in the suction side
o Working at low temperature
 Net Positive Suction Head (NPSH)

NPSH is an important parameter in dealing with the formation of

cavitation in suction side or impeller eye of a centrifugal pump.
𝑁𝑃𝑆𝐻 is the minimum criteria for the pump to work above for
cavitation free operation.
NPSH is the pressure head difference between the impeller eye
absolute pressure and the vapor pressure of the liquid.
 NPSHr and NPSHa
NPSH required is the NPSH value that is set by the pump
manufacturer in which the pump should operate above this value to
avoid potential cause of cavitation. It is obtained by a thorough
experimental investigation.

NPSH available is the NPSH value of the actual working condition.

The same pump may face different systems and working conditions
so that NPSHa varies. Pump users should always make sure that
NPSHa > NPSHr.
 Minimum speed for starting a centrifugal pump
 The centrifugal pump will start delivering water or liquid if and only if
the pressure rise in the impeller is more than or equal to the manometric
head ( Hm ). In order to start delivering water or liquid, the pump has to
rotate at least at a minimum speed ( Nmin ).
 when the impeller is rotating, the water in contact with impeller also starts
to rotate. this is the cause of forced vortex flow. In case of forced vortex
flow, the head (H) due to the pressure rise in the impeller is given by

For proper delivery H ≥ Hm and for minimum speed

H ≥ Hm
 Slip factor ( s )
 In the actual flow through the impeller, the pressure at the leading edge is
higher than the trailing edge of the impeller, that means the velocity is lower
at the leading edge and higher at the trailing edge. This leads to a non-
uniform velocity distribution. As a result, the fluid is discharged from the
impeller at an angle relative to the impeller less than the vane angle. The
result is a reduction in the exit whirl or tangential velocity from C w2 to Cw2’.
This is illustrated in the figure below.
The dotted lines represent the
velocity diagram without slip. The
angle 2 (2) is the vane angle. The
solid line represents the velocity
diagram with slip. The angle 2’< 2.
It may be seen that Cw2’ < Cw2 . The
ratio of Cw2’/Cw2 is known as slip
factor ( s ).
 Pump priming
 Centrifugal pumps are not capable of pumping air. It is because the
density of water is almost 1000 times greater than that of air. It
means when some air is trapped between the water and the pump
suction, the pump needs to develop a head 1000 times in order to
create the same suction effect to the liquid which is impossible.
Therefore, it is inevitable to remove the air.
 Pump priming is a manual way of removing air by filling water
inside the impeller casing which displaces the air.
 Pumps which can automatically prime themselves are called self –
priming pumps.
 Centrifugal pump characteristics and system curves
 It is important to identify the difference between pump and
system and the corresponding characteristic curves.
 When we say pump we are considering the process between the
pump suction eye to the pump outlet.
 The system is the whole piping system both in the suction and
delivery sides.
 Therefore, pump performance and system performance are
different but needs to be compromised for best overall
performance.
 From dimensional analysis of incompressible flow in pumps and
turbines, the head coefficient, power, and efficiency are the
functions of volumetric flow coefficient only for geometrically
similar machines. Therefore, most of the performance curves in
pumps are given by discharge versus head, break horse power
and efficiency.
 Such curves for pump and system are plotted in a single graph
shown below.
 Characteristics curve plotted against pump discharge
 
The point at which the pump curve and system
curve meets is the operating point or duty point.
Shut off head point is the point at which the pump
develops the highest head but no discharge.
Run out point is the point at which the pump
delivers maximum discharge with zero head. The
theoretical run out and shut off head points can be
estimated from
Performance curve incorporating NPSHr as a function of
discharge (capacity)
 Multi – Staging in Pumps
Pumps in serious: When we need to increase the head we should connect
pumps in serious: The volume flow rate remains constant since similar pumps
are connected usually. A single pump failure results in system failure.

Pumps in parallel: This is applied when more discharge is needed. The head
remains constant when similar pumps are connected.
But the point where the multi–staged pump curve intersects the system curve
should be the duty point.
Performance curves for multi – staged
Preliminary Design of a Centrifugal Pump
Design procedure:
Step-1:-
• Determine the specific speed of the pump (Ns).
Eg. H=35m, N=1450rpm, Q=1020LPM

N Q
Ns  3
H4

1450 0.017
 3
35 4

 13.14 rpm

• Estimate the pump efficiency (o) from

the curve for a specific speed of 13.14
rpm and discharge of 1020 LPM (Liter
Per Minute).
 o  65 %
Preliminary Design of a Centrifugal (Radial) Pump…
Step-2:-
• Determine the Maximum Shaft Power (Psmax).
This can be determined from the performance curve.

Q(m3/sec) Hp(m) Ps(HP) o(%) Hsys(m)

0 46.2 4.2 0 26
0.005 42.9 7 40.07 26.77
0.01 39.6 9.4 55.21 29.09
0.015 36.3 11.4 62.87 32.96
0.02 33 12.9 67.21 38.38
0.025 29.6 14 69.73 45.34
0.03 26.3 14.6 71.05 53.85
0.035 23 14.8 71.44 63.91
0.04 19.7 14.6 70.97 75.52

• Determine shaft diameter (Ds) using stress theory.

16 Ts 30 Ps max
Ds  3 Where, Ts  and ,  s is the permissibl e shear
s N
stress  30 MPa
Preliminary Design of a Centrifugal (Radial) Pump…
Step-3:-
• Determine the Hub diameter (DH) and the diameter of suction flange (Dsu).
a) Hub diameter (DH) can be assumed 1 cm larger than the shaft diameter.
DH  Ds  1 cm

b) Suction flange diameter (Dsu).

4 Q
Dsu  Where, Vsu is suction velocity  3 m / s
 Vsu

Step-4:-
• Determine Impeller dimensions.
a) Impeller eye diameter (Do).
4 Q
D1  Do   DH2
 Vsu
Preliminary Design of a Centrifugal (Radial) Pump…
b) Impeller inlet passage width (b1).
Q
b1  Where, V1r is flow velocity  Vsu  0.25 m / s
 D1V1r  1
Zt
 D1 
sin 1
and ,  1 is the contractio n factor  0.85 or 1 
 D1

c) Inlet vane angle (1).

For a radial inlet , from the velocity diagrams
V  D1 N
tan 1  1r Where, u1  and , D1  Do
u1 60
d) Impeller outside diameter (D2).
84.5 H
D2  Where,  is the head coefficien t  1.05
N
e) Impeller outlet passage width (b2). Q
b2  and 2 may be assumed 300 to 400
 D2 V2 r  2

Vr2 is kept equal to or slightly less (up to 15 per cent) thanVr1 to avoid any sudden
change of velocity.
Preliminary Design of a Centrifugal (Radial) Pump…

Step-5:-
• Design vanes of the impeller.
a) The radius of arc (), defining the shape between any two rings having radius ra and rb is
given by,
rb2  ra2
 Where,    is the vane angle
2(rb cos  b  ra cos  a )

b) The number of vanes (Z) is given by,

D2  D1 (   2 )
Z  6. 5  sin 1 Where , 1  1 and  2  2
D2  D1 2

c) The thickness of vanes ( t ) can be determined from stress analysis. In actual design a
uniform thickness of 3 mm is adopted.
Preliminary Design of a Centrifugal (Radial) Pump…

d) Plot or generate the curves of vanes.

Procedure:-
• Divide the distance between the impeller internal radius r 1 and r2 into a number of
equal parts (say 4 or 5) as shown in the figure.
• For each division determine the values of r, ra, rb,  and  as shown in the table.
Preliminary Design of a Centrifugal (Radial) Pump…
• Draw all concentric circles with O as center and radius r 1,rx,rY,rZ and r2.
• Draw a radial line OJ = r1 from the center of rotation O to the point J.
• With J as center and angle OJK = 1 and radius 1, get point K .
• With K as center and radius 1, draw the arc JL .
• Draw a line through points L and K of length 2 = LM.
• With M as center and radius 2, draw the arc LN.
• Draw a line through points N and M of length 3 = NP.
• With P as center and radius 3, draw the arc NQ.
• Draw a line through points Q and P of length 4 = QR.
• With R as center and radius 4, draw the arc QS.
Preliminary Design of a Centrifugal (Radial) Pump…
Step-6:-
• Compute data for determining the passage width.
Similarly, the following data can be obtained and the side view of the impeller is
drawn as shown.
Preliminary Design of a Centrifugal (Radial) Pump…

Both the front and side views are as shown below.

Preliminary Design of a Centrifugal (Radial) Pump…

Step-7:-
• Design the volute.
Preliminary Design of a Centrifugal (Radial) Pump…

The following relations are used in designing the volute.

Assumption s : 
 The water in the volute assumed to have nearly spiral flow.
 The effect of slip and losses are assumed to be neglected .
R
3600 R2 vu 2 dR
t 
Q  R Where, t is the angle measured from the tongue
R2
b

The base width of the volute b3 is assumed as,

b3  2b2
The average width b is given by,

b  b3  2 x tan Where, x is the dis tan ce between any radius R and R2
2
and ,   600
The basic cross  sec tional shape of the volute is assumed to be trapezoid
having an angle of 300 with the radial lines or   600.

The relation for R is given by,

R  R2 e tan 2 Where,  2 is the guide vane angle of the impeller vane
 is the angle measured in radian
e is the base base of natural log arithm  2.718
Preliminary Design of a Centrifugal (Radial) Pump…

The output of the mathematical relations for the volute is as shown in the table.
Preliminary Design of a Centrifugal (Radial) Pump…

Using the values in the table, the volute can be drawn as shown in the figure.
Preliminary Design of a Centrifugal (Radial) Pump…

This is generally a preliminary design, but the results of a complete design is similar
to the design shown in the figures.
 Fan
Fans produce very small pressure heads measured in inches of water
pressure differential, and of course are employed to move air or other
gases. A compressor also handles gases, but with large enough
pressure rises that significant fluid density changes occur; i.e., if
density is increased by 5 percent, then the turbomachine may be
called a compressor.
A centrifugal fan, as compared with a pump, requires a much smaller
increase in impeller blade speed, i.e., a smaller radius ratio R2 /R 1,
as
may be inferred from centrifugal pump. It requires a volute, of
course, but no diffuser is needed to enhance pressure rise. The flow
passages between impeller vanes are quite short, as indicated in
Figure below.
 The analysis and design of the impeller proceeds as with the
centrifugal pump. The small changes of gas density are ignored, and
the incompressible equations are applied as with pumps.
Performance curves are qualitatively the same as for pumps, except
that the units of head are customarily given in inches of water, and
those of capacity are typically in cubic feet per minute.
 Other differences are that both total head and static (pressure) head
are usually shown on performance curves, and a fan static
efficiency, based on equation below, is calculated using static head
(P2 –P1 )/pg in place of total head H. Similarity laws for pumps are
applied and are known as fan laws; these are represented by