Centrifugal Pumps

1299 Pages·2020·97.705 MB·English

by  Johann Friedrich Gülich

Johann Friedrich Gülich
Centrifugal
Pumps
Fourth Edition
Centrifugal Pumps
ü
Johann Friedrich G lich
Centrifugal Pumps
Fourth Edition
123
JohannFriedrich Gülich
Villeneuve, Switzerland
ISBN978-3-030-14787-7 ISBN978-3-030-14788-4 (eBook)
https://doi.org/10.1007/978-3-030-14788-4
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Preface
Life is linked to liquid transport, and so are vital segments of economy. Pumping
devices - be it the human heart, a boiler feeder or the cooling water pump of a
motorcar - are always part of a more or less complex system where pump failure
can lead to severe consequences. To select, operate or design a pump, some
understanding of the system is helpful, if not essential. Depending on the appli-
cation,acentrifugal pumpcanbeasimpledevicewhichcouldbebuiltinagarage
with a minimum of know-how - or a high-tech machine requiring advanced skills,
sophisticated engineering and extensive testing. When attempting to describe the
state of the art in hydraulic engineering of centrifugal pumps, the focus is neces-
sarily on the high-tech side rather than on less-demanding services even though
these make up the majority of pump applications.
Centrifugal pump technology involves a broad spectrum of flow phenomena
which have a profound impact on design and operation through the achieved
efficiency, the stability of the head-capacity characteristic, vibration, noise, com-
ponent failure due to fatigue, as well as material damage caused by cavitation,
hydro-abrasive wear or erosion corrosion. Operation and life cycle costs of
pumpingequipmentdependtoalargeextentonhowwellthesephenomenaandthe
interaction of the pump with the system are understood.
This book endeavors to describe pump hydraulic phenomena in their broadest
sense in a format highly relevant for the pump engineer involved in pump design
andselection,operationandtroubleshooting.Emphasisisonphysicalmechanisms,
practical application and engineering correlations for real flow phenomena, rather
than on mathematical treatment and theories of inviscid flow.
Vibrations and noise remain among the most persistent pump problems
encountered by manufacturers and operators alike. Major additions in the present
4thEnglisheditionfocusonthistheme.Specifically,additionaltopicsdiscussedin
the 4th edition are as follows:
1. Chapter 10.14 “Vertical-pump vibrations” has been added; it focuses on large
cooling water pumps with power of up to 4000 kW. Time and again, the
approach flow through the large intake structures induces vibrations in spite of
v
vi Preface
sump model testing done to eliminate vortices. The case histories reported
suggest that Froude model testing is not sufficient to guarantee trouble-free
operation since the inertia effects associated with large Reynolds numbers are
not sufficiently modeled. Non-uniform approach flows create forces on the
pump body, and correlations are offered to estimate this type of excitation
forces.
2. With the object of helping with vibration diagnostics, Chap. 10 has been again
significantly enhanced by a more detailed discussion of various unsteady flow
phenomena and their impact on hydraulic excitation forces. Case histories are
provided which afford additional insight into excitation mechanisms.
Experimental data on lateral excitation forces and pressure pulsations at blade
passingfrequencyarepresentedinagenericformatwhichfacilitatesapplication
to other projects.
3. New correlations to estimate the rotordynamic coefficients of annular seals and
the hydraulic impeller interaction are provided in Chap. 10.6.
4. With ever-increasing computing power, steady or unsteady numerical flow
calculations of entire pumps have meantime become state of the art. Chapter 8
has been revised accordingly. A statistical evaluation of the discrepancies
between test and CFD has been done with the object of assessing the accuracy
which can be expected from numerical flow calculations.
5. InChap.7,anewcorrelationforestimatingtherequiredNPSHofinducersfrom
geometric parameters has been developed and methods for designing twin
volutes for multistage pumps and vaned inlet chambers are provided.
6. Anewcorrelationforestimatingtheradialpumpperformanceintwo-phaseflow
has been developed, Chap. 13. The viscosity anomality linked to emulsions is
illustrated by some test data.
7. Impeller stresses and failure modes have been discussed in more detail and the
correlations developed for estimating the risk offailure.
8. Some additions were made in most of the chapters, and some printing errors
were corrected. The below table gives a detailed list of new items.
Villeneuve, Switzerland Johann Friedrich Gülich
January 2019
Supplements to the 4th Edition
Forreadersfamiliarwiththe3rd(2014-)edition,thefollowingtablemightbehelpful
togetaquickoverviewofthetopicswhichhavebeenaddedinthepresentedition.
Chapter Topic Figs.,Tables,Eqs.
1.6 Pressurerecoveryincurveddiffusers Fig.1.24,Eq.(1.54)
3.2.6 Calculationoffrictionfactors,andoptimization,of Figs.3.14-1to3.14-3,
annularsealswithdeepserrations Table3.7(4)
4.5.1 Designofinletringsandlow-flowimpellers:remedies Eqs.(4.15a),(4.17a)
forover-sizedimpellerinletscausingnoiseand
vibrations
Exponentsfortrimmingimpellers
5.2.6 Additionaltestdataonimpellerinletrecirculation Eq.(5.7c),TableD5.1,
Fig.5.16
5.6.6 Casinggroovesforsuppressionofinstabilitiesinthe Fig.5.43-1
Q-H-curveofsemi-openimpellers(semi-axial)
5.9 Somecommentsonthelimitsofunderstanding
3D-flowphenomena
6.2.4 Sometestdataonthelimitofthesuctionspecific Eq.(6.8a)
speed
6.3.1 EffectofsealclearancesonNPSH
3
6.8.2.3 Unsteadyvolutecavitation Fig.6.47
6.8.3 Inletringsforreducingcavitationproblemsduring Figs.6.48and6.49
partloadoperation
7.2.4 Suctionimpellerdesignwithflatpressuredistributions TableD7.1-1,
Fig.7.10-1
7.3.4 “Double-acting”impellerswithspecificspeedsof
n <10:twoadditionalconceptsreportedinthe
q
literature
7.5 Selectionofspeedandheadforlargesemi-axial Eqs.(7.11a)and(7.11b)
coolingwaterpumps
(continued)
vii
viii Supplementstothe4thEdition
(continued)
7.7.3 Inducerperformancepredictionfromgeometry Eq.(7.23a),
Fig.7.37-1
7.7.4 Inducerdesignsystematic
7.8.2 Multistagepumpswithdoublevolutes Figs.7.42-1to7.42-3
7.13 Designofvanedinletcasingsformultistagepumps Figs.7.51-1to7.51-4
7.14 Updateofimpellerdesignaccordingananalytical Table7.10,Fig.7.53
procedure
8.6.3 UnsteadyCFDcalculationsupdate
8.8.4 Accuracyofnumericalperformancecalculations Table8.3,Figs.8.22to
8.24
8.8.5 CFDset-upparameters Table8.4
9.2.1 Staticpressureattheimpelleroutletforaxialforce Figs.9.14-1to9.14-3
calculations
9.3.4 Radialforcesindoublevolute Fig.9.30-1
9.3.7 Influenceoftheapproachflowonradialforces:new Fig.9.32
testdata
10.6.2 Additionalmethodforcalculatingtherotordynamic Table10.4(1)
reactionforcecoefficientsforannularseals
10.6.3 Asetofcorrelationsforcalculatingtherotordynamic Table10.4(2)
coefficientsforthehydraulicimpellerinteractionhas
beendevelopedbasedontestdata
10.6.6 Twocasehistoriesofsuper-synchronousrotor
instabilitiesarediscussed
10.7.1 Thischapterhasbeenthoroughlyrevised: Figs.10.25-1,10.25-2,
(1)Guidelinesforstaggeringdouble-entryimpellers; 10.26-1and10.28-1
(2)Rotor/statorinteraction:effectofincidenceat
diffuserorvolute;(3)Testdataforpressurepulsations
atbladepassingfrequency;(4)Alternatestallinvaned
diffuser;(5)Testdataforlateralexcitationforcesat
bladepassingfrequency
10.7.3 Vibrationscausedbycavitationinapumpwith Figs.10.32-1to10.32-4
double-entryimpeller
Vibrationscausedbyinletrecirculation
10.12.4 Trailingedgedesignforreducedvortexshedding
10.14 Extensivediscussionofvertical-pumpvibrationsand Figs.10.65to10.78
problemsrelatedtounsteadyandnon-uniform Tables10.14,10.15
approachflowthroughtheintakestructure
13.1.5 Performanceimpairmentwhenpumpingemulsionsof Fig.13.12-1
immiscibleliquids
13.2.4 Anewmodelispresentedforestimatingthehead Eqs.(13.19btod)
reductionwhenpumpinggas-liquidmixtures Figs.13.23and13.24
14.1.2 Impellerfractures-analysisandprediction Figs.14.7-1to14.7-4
Eqs.(14.2a)to(14.2e)
Acknowledgements
The 1st English edition owed its existence to the initiative and sponsoring of the
managementofSulzerPumps.Forthis,IammostgratefultoDr.A.Schachenmann
who initiated the project, R. Paley and Dr. R. Gerdes.
The book benefited from the help which I got from many colleagues at Sulzer
Pumps in the USA and the UK to whom my sincere thanks are extended. Most
importantwerethereviewsoftheEnglishtext.M.Cropperwasinstrumentalinthis
activity. S. Bradshaw, R. Davey, Dr. J. Daly, D. Eddy, M. Hall, Dr. A. Kumar,
P. Sandford, D. Townson and C. Whilde reviewed individual chapters.
J. H. Timcke meticulously checked most of the 1st English edition for consis-
tencywiththe2ndGermaneditionandmademanysuggestionsformakingthetext
and figures easier to understand. Mrs. H. Kirchmeier helped with the figures and
computer problems. Last but not least, my wife Rosemarie Gülich was a tremen-
dous help in checking and improving the final text.
I am grateful to various individuals who provided me with the literature and
granted permission for using figures: Prof. Dr.-Ing. F. Avellan, Dr. M. Farhat,
Dr. O. Braun and Dr. S. Berten from the Ecole Polytechnique Lausanne;
Prof. Dr.-Ing. D.H.Hellmann,Prof. Dr.-Ing. M.BöhleandDr.-Ing. H.Roclawski
from the Technical University of Kaiserslautern; Prof. Dr.-Ing. G. Kosyna,
Prof. Dr.-Ing. habil. U. Stark, Mrs. Dr.-Ing. I. Goltz, Mrs. P. Perez, Dr.-Ing.
H. Saathofffrom the Technical University of Braunschweig; C. H. van den Berg,
MTI Holland; Prof. Dr.-Ing. H. Wurm, A. Töws, Wilo, Dortmund; Dr. P. Dupont,
Sulzer; U. Diekmann, Wilo-Emu; A. Nicklas, Sterling Fluid Systems, T. Folsche,
CP Pumpen AG; and H. Bugdayci, IHC Merwede. I am especially grateful
R. Palgrave for sharing with me a number of instructive photographs of pump
components which have been subject to abrasive wear.
The 1st and 2nd editions benefited from the reviews of individual chapters
provided by: Dr.-Ing. G. Scheuerer, ANSYS München; Dr. P. Heimgartner,
W. Bolliger, W. Schöffler, Dr.-Ing. W. Wesche, Dr. P. Dupont, Dr. S. Berten,
G. Caviola, E. Leibundgut, T. Felix, A. Frei, E. Kläui, W. Handloser (all from
Sulzer); and J. H. Timcke.
ix
x Acknowledgements
The following organizations or individuals kindly granted permission for using
figures:
– Sulzer Pumps Ltd, Winterthur
– T. McCloskey, Electric Power Research Institute, Palo Alto, CA, USA
– VDMA, Frankfurt
– VDI Verlag, Düsseldorf
– Mr. J. Falcimaigne, Institut Français du Pétrole, Paris
– ASME New York
The appropriate references are given in the figure captions.