Pump characteristics and applications

502 Pages·2014·33.57 MB·English

by  Volk

Mechanical Engineering
Volk
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Providing a wealth of information on pumps and pump systems, Pump Characteristics np aanndd AApppplliiccaattiioonnss
and Applications, Third Edition details how pump equipment is selected, sized, oper- d
ated, maintained, and repaired. The book identifies the key components of pumps and C

pump accessories, introduces the basics of pump and system hydraulics as well as more
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advanced hydraulic topics, and details various pump types, as well as special materials h
on seals, motors, variable frequency drives, and other pump-related subjects. It uses ex- p
ample problems throughout the text, reinforcing the practical application of the formulae a
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and analytical presentations. It also includes new images highlighting the latest genera-
tion of pumps and other components, explores troubleshooting options, and incorporates l r
relevant additions into the existing chapters.
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What’s NeW iN this editioN: c
• Includes more than 150 full-color images that significantly improve a
the reader’s ability to understand pump drawings and curves t
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• Introduces a new chapter on pump case studies in a format that provides
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case study background, analysis, solutions, and lessons learned i
o r
• Presents important new updates and additions to other chapters
• Includes a ten-step procedure for determining total pump head i
n
• Discusses allowable and preferred operating ranges for centrifugal pumps s
• Provides charts covering maximum and normally attainable pump efficiencies, t
s
performance corrections for slurry pumps, and mechanical seal flush plans
i
c
Pump Characteristics and Applications, Third Edition is appropriate for readers with all
levels of technical experience, including engineering and pump industry professionals,
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pump operators and maintenance technicians, upper-level undergraduate and graduate
students in mechanical engineering, and students in engineering technology programs.
K15984
Michael Volk
6000 Broken Sound Parkway, NW
Suite 300, Boca Raton, FL 33487
711 Third Avenue
an informa business New York, NY 10017
2 Park Square, Milton Park
Abingdon, Oxon OX14 4RN, UK
CAT#K15984 cover.indd 1 8/19/13 12:10 AM
Pump
Characteristics
and Applications
T H I R D E D I T I O N

Pump
Characteristics
and
Applications
T H I R D E D I T I O N
Michael Volk
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2014 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20130507
International Standard Book Number-13: 978-1-4665-6309-4 (eBook - PDF)
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Contents
Preface to the Third Edition ................................................................................xv
Preface to the Second Edition ...........................................................................xvii
Preface to the First Edition .................................................................................xix
Acknowledgments ............................................................................................xxiii
Author ..................................................................................................................xxv
1. Introduction to Pumps ...................................................................................1
I. What Is a Pump? ...................................................................................1
II. Why Increase a Liquid’s Pressure? .....................................................2
III. Pressure and Head ................................................................................3
IV. Classification of Pumps ........................................................................4
A. Principle of Energy Addition ......................................................4
1. Kinetic ..................................................................................4
2. Positive Displacement ........................................................4
B. How Energy Addition Is Accomplished ...................................6
C. Geometry Used .............................................................................6
V. How Centrifugal Pumps Work ...........................................................6
VI. PD Pumps .............................................................................................12
A. General .........................................................................................12
B. When to Choose a PD Pump ....................................................12
C. Major Types of PD Pumps ........................................................15
1. Sliding Vane Pump ...........................................................19
2. Sinusoidal Rotor Pump ....................................................20
3. Flexible Impeller Pump ...................................................20
4. Flexible Tube (Peristaltic) Pump .....................................21
5. Progressing Cavity Pump ...............................................22
6. External Gear Pump .........................................................23
7. Internal Gear Pump..........................................................25
8. Rotary Lobe Pump ...........................................................26
9. Circumferential Piston, Bi-Wing Lobe Pumps ...............27
10. Multiple-Screw Pump ......................................................28
11. Piston Pump ......................................................................29
12. Plunger Pump ...................................................................31
13. Diaphragm Pump .............................................................32
14. Miniature PD Pumps .......................................................35
2. Hydraulics, Selection, and Curves ............................................................39
I. Overview ..............................................................................................39
II. Pump Capacity ....................................................................................41
III. Total Head ............................................................................................42
© 2008 Taylor & Francis Group, LLC v
vi Contents
A. Static Head...................................................................................43
B. Friction Head ..............................................................................46
C. Pressure Head .............................................................................57
D. Velocity Head ..............................................................................58
IV. Performance Curve .............................................................................60
V. Horsepower and Efficiency ...............................................................68
A. Hydraulic Losses ........................................................................70
B. Volumetric Losses ......................................................................70
C. Mechanical Losses .....................................................................70
D. Disk Friction Losses ...................................................................70
VI. NPSH and Cavitation .........................................................................76
A. Cavitation and NPSH Defined .................................................76
1. NPSH .................................................................................81
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2. NPSH .................................................................................84
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B. Calculating NPSH : Examples ..................................................85
a
C. Remedies for Cavitation ............................................................86
D. More NPSH Examples ..............................................................89
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E. Safe Margin NPSH versus NPSH ..........................................92
a r
F. NPSH for Reciprocating Pumps ..............................................96
VII. Specific Speed and Suction Specific Speed......................................97
VIII. Affinity Laws .....................................................................................103
IX. System Head Curves .........................................................................107
X. Parallel Operation .............................................................................116
XI. Series Operation ................................................................................122
XII. Oversizing Pumps ............................................................................126
XIII. Pump Speed Selection ......................................................................128
A. Suction Specific Speed .............................................................129
B. Shape of Pump Performance Curves.....................................129
C. Maximum Attainable Efficiency ............................................129
D. Speeds Offered by Manufacturers .........................................133
E. Prior Experience .......................................................................133
3. Special Hydraulic Considerations ...........................................................135
I. Overview ............................................................................................135
II. Viscosity .............................................................................................135
III. Software to Size Pumps and Systems ............................................150
A. General .......................................................................................150
B. Value of Piping Design Software ...........................................151
C. Evaluating Fluid Flow Software ............................................152
D. Building the System Model .....................................................153
1. Copy Command ..............................................................154
2. Customize Symbols ........................................................154
3. CAD Drawing Features .................................................154
4. Naming Items ..................................................................154
5. Displaying Results ..........................................................155
© 2008 Taylor & Francis Group, LLC
Contents vii
6. The Look of the Piping Schematic ................................155
E. Calculating the System Operation .........................................155
1. Sizing Pipe Lines ............................................................156
2. Calculating Speed ...........................................................156
3. Showing Problem Areas ................................................156
4. Equipment Selection.......................................................156
5. Alternate System Operational Modes ..........................157
F. Communicating the Results ...................................................157
1. Viewing Results within the Program ..........................157
2. Incorporating User-Defined Limits .............................157
3. Selecting the Results to Display ...................................157
4. Plotting the Piping Schematic .......................................158
5. Exporting the Results .....................................................158
6. Sharing Results with Others .........................................158
7. Sharing Results Using a Viewer Program ...................158
G. Conclusion .................................................................................158
H. List of Software Vendors .........................................................159
IV. Piping Layout .....................................................................................159
V. Sump Design ......................................................................................165
VI. Field Testing .......................................................................................166
A. General .......................................................................................166
B. Measuring Flow ........................................................................167
1. Magnetic Flowmeter ......................................................168
2. Mass Flowmeter ..............................................................168
3. Nozzle ...............................................................................168
4. Orifice Plate .....................................................................168
5. Paddle Wheel ...................................................................169
6. Pitot Tube .........................................................................169
7. Segmental Wedge ...........................................................169
8. Turbine Meter ..................................................................169
9. Ultrasonic Flowmeter .....................................................169
10. Venturi ..............................................................................170
11. Volumetric Measurement ..............................................170
12. Vortex Flowmeter ...........................................................170
C. Measuring TH ...........................................................................171
D. Measuring Power .....................................................................173
E. Measuring NPSH .....................................................................173
4. Centrifugal Pump Types and Applications ..........................................175
I. Overview ............................................................................................175
II. Impellers .............................................................................................176
A. Open versus Closed Impellers ...............................................176
B. Single versus Double Suction .................................................182
C. Suction Specific Speed .............................................................183
D. Axial Thrust and Thrust Balancing ......................................185
© 2008 Taylor & Francis Group, LLC
viii Contents
E. Filing Impeller Vane Tips ........................................................187
F. Solids Handling Impellers ......................................................189
III. End Suction Pumps ...........................................................................190
A. Close-Coupled Pumps .............................................................190
B. Frame-Mounted Pumps ..........................................................193
IV. Inline Pumps .....................................................................................195
V. Self-Priming Centrifugal Pumps ....................................................197
VI. Split-Case Double Suction Pumps ..................................................199
VII. Multistage Pumps .............................................................................203
A. General .......................................................................................203
B. Axially Split-Case Pumps .......................................................203
C. Radially Split-Case Pumps .....................................................207
VIII. Vertical Column Pumps ...................................................................208
IX. Submersible Pumps ..........................................................................213
X. Slurry Pumps .....................................................................................215
XI. Vertical Turbine Pumps ....................................................................218
XII. Axial Flow Pumps ............................................................................226
XIII. Regenerative Turbine Pumps ..........................................................227
XIV. Pump Specifications and Standards ...............................................228
A. General .......................................................................................228
1. Liquid Properties ............................................................229
2. Hydraulic Conditions .....................................................229
3. Installation Details .........................................................229
B. ANSI ...........................................................................................230
C. API ..............................................................................................232
D. ISO ..............................................................................................233
XV. Couplings ...........................................................................................234
XVI. Electric Motors ...................................................................................240
A. Glossary of Frequently Occurring Motor Terms .................240
1. Amps ................................................................................240
2. Code Letter ......................................................................241
3. Design Letter ...................................................................241
4. Efficiency ..........................................................................242
5. Frame Size ........................................................................242
6. Frequency.........................................................................242
7. Full-Load Speed ..............................................................242
8. High Inertial Load ..........................................................242
9. Insulation Class ...............................................................242
10. Load Types .......................................................................242
11. Phase .................................................................................243
12. Poles ..................................................................................243
13. Power Factor ....................................................................243
14. Service Factor ..................................................................244
15. Slip ....................................................................................244
16. Synchronous Speed ........................................................244
© 2008 Taylor & Francis Group, LLC
Contents ix
17. Temperature ....................................................................244
18. Time Rating .....................................................................244
19. Voltage ..............................................................................245
B. Motor Enclosures......................................................................245
1. Open Drip-Proof .............................................................245
2. Totally Enclosed Fan Cooled .........................................245
3. Totally Enclosed Air Over .............................................246
4. Totally Enclosed Nonventilated ...................................246
5. Hazardous Location .......................................................246
C. Service Factor ............................................................................246
D. Insulation Classes ....................................................................247
E. Motor Frame Size .....................................................................247
1. Historical Perspective ....................................................247
2. Rerating and Temperature ............................................250
3. Motor Frame Dimensions ..............................................251
4. Fractional Horsepower Motors .....................................251
5. Integral Horsepower Motors .........................................251
6. Frame Designation Variations ......................................251
F. Single-Phase Motors ................................................................257
G. Motors Operating on Variable Frequency Drives................261
H. NEMA Locked Rotor Code .....................................................262
I. Amps, Watts, Power Factor, and Efficiency ..........................263
1. Introduction .....................................................................263
2. Power Factor ....................................................................263
3. Efficiency ..........................................................................264
4. Amperes ...........................................................................265
5. Summary .........................................................................265
5. Sealing Systems and Sealless Pumps .....................................................267
I. Overview ............................................................................................267
II. O-Rings ...............................................................................................267
A. What Is an O-Ring? ..................................................................268
B. Basic Principle of the O-Ring Seal .........................................268
C. The Function of the O-Ring ....................................................268
D. Static and Dynamic O-Ring Sealing Applications ..............270
E. Other Common O-Ring Seal Configurations .......................270
F. Limitations of O-Ring Use ......................................................271
III. Stuffing Box and Packing Assembly ..............................................272
A. Stuffing Box ...............................................................................273
B. Stuffing Box Bushing ...............................................................273
C. Packing Rings ...........................................................................273
D. Packing Gland ...........................................................................274
E. Lantern Ring .............................................................................275
IV. Mechanical Seals ...............................................................................276
© 2008 Taylor & Francis Group, LLC