3. 3
IntroductionIntroduction
• 20% of world’s electrical energy
demand
• 25-50% of energy usage in some
industries
• Used for
• Domestic, commercial, industrial and
agricultural services
• Municipal water and wastewater services
What are Pumping Systems
5. 5
IntroductionIntroduction
• Main pump components
• Pumps
• Prime movers: electric motors, diesel engines,
air system
• Piping to carry fluid
• Valves to control flow in system
• Other fittings, control, instrumentation
• End-use equipment
• Heat exchangers, tanks, hydraulic machines
What are Pumping Systems
7. 7
Type of PumpsType of Pumps
Classified by operating principle
Pump Classification
Dynamic
Positive
Displacement
Centrifugal Special effect Rotary Reciprocating
Internal
gear
External
gear
Lobe
Slide
vane
Others (e.g.
Impulse, Buoyancy)
Pumps
Dynamic
Positive
Displacement
Centrifugal Special effect Rotary Reciprocating
Internal
gear
External
gear
Lobe
Slide
vane
Others (e.g.
Impulse, Buoyancy)
Pumps
8. 8
Type of PumpsType of Pumps
Positive Displacement Pumps
• For each pump revolution
• Fixed amount of liquid taken from one end
• Positively discharged at other end
• If pipe blocked
• Pressure rises
• Can damage pump
• Used for pumping fluids other than
water
9. 9
Type of PumpsType of Pumps
Positive Displacement Pumps
• Reciprocating pump
• Displacement by reciprocation of piston
plunger
• Used only for viscous fluids and oil wells
• Rotary pump
• Displacement by rotary action of gear, cam or
vanes
• Several sub-types
• Used for special services in industry
10. 10
Type of PumpsType of Pumps
Dynamic pumps
• Mode of operation
• Rotating impeller converts kinetic energy into
pressure or velocity to pump the fluid
• Two types
• Centrifugal pumps: pumping water in
industry – 75% of pumps installed
• Special effect pumps: specialized conditions
11. 11
Type of PumpsType of Pumps
Centrifugal Pumps
How do they work?
• Liquid forced into
impeller
• Vanes pass kinetic
energy to liquid: liquid
rotates and leaves
impeller
• Volute casing converts
kinetic energy into
pressure energy
12. 12
Type of PumpsType of Pumps
Centrifugal Pumps
Rotating and stationary components
13. 13
Type of PumpsType of Pumps
Centrifugal Pumps
Impeller
• Main rotating part that provides centrifugal
acceleration to the fluid
• Number of impellers = number of pump stages
• Impeller classification: direction of flow, suction type
and shape/mechanical construction
Shaft
• Transfers torque from motor to impeller during pump
start up and operation
14. 14
Type of PumpsType of Pumps
Centrifugal Pumps
Casings
• Functions
• Enclose impeller as “pressure vessel”
• Support and bearing for shaft and impeller
• Volute case
• Impellers inside casings
• Balances hydraulic pressure on pump shaft
• Circular casing
• Vanes surrounds impeller
• Used for multi-stage pumps
Editor's Notes
TO THE TRAINER
This PowerPoint presentation can be used to train people about the basics of pumps and pumping systems. The information on the slides is the minimum information that should be explained. The trainer notes for each slide provide more detailed information, but it is up to the trainer to decide if and how much of this information is presented also.
Additional materials that can be used for the training session are available on www.energyefficiencyasia.org under “Energy Equipment” and include:
Textbook chapter on this energy equipment that forms the basis of this PowerPoint presentation but has more detailed information
Quiz – ten multiple choice questions that trainees can answer after the training session
Workshop exercise – a practical calculation related to this equipment
Option checklist – a list of the most important options to improve energy efficiency of this equipment
Company case studies – participants of past courses have given the feedback that they would like to hear about options implemented at companies for each energy equipment. More than 200 examples are available from 44 companies in the cement, steel, chemicals, ceramics and pulp & paper sectors
Pumping systems account for nearly 20% of the world’s electrical energy demand. Furthermore, they range between 25-50% of the energy usage in certain industrial plant operations.
The use of pumping systems is widespread. They provide domestic, commercial and agricultural services. In addition, they provide municipal water and wastewater services, and industrial services for food processing, chemical, petrochemical, pharmaceutical, and mechanical industries.
Pumps have two main purposes:
Transfer of liquid from one place to another place (e.g. water from an underground aquifer into a water storage tank)
Circulate liquid around a system (e.g. cooling water or lubricants through machines and equipment)
The main components of a pumping system are:
Pumps (different types of pumps are explained in section 2)
Prime movers: electric motors, diesel engines or air system
Piping, used to carry the fluid
Valves, used to control the flow in the system
Other fittings, controls and instrumentation
End-use equipment, which have different requirements (e.g. pressure, flow) and therefore determine the pumping system components and configuration. Examples include heat exchangers, tanks and hydraulic machines
This section include various types of pumps. Pumps come in a variety of sizes for a wide range of applications. They can be classified according to their basic operating principle as dynamic or displacement pumps. Dynamic pumps can be sub-classified as centrifugal and special effect pumps. Displacement pumps can be sub-classified as rotary or reciprocating pumps. In principle, any liquid can be handled by any of the pump designs. Where different pump designs could be used, the centrifugal pump is generally the most economical followed by rotary and reciprocating pumps. Although positive displacement pumps are generally more efficient than centrifugal pumps, the benefit of higher efficiency tends to be offset by increased maintenance costs.
Pumps come in a variety of sizes for a wide range of applications. They can be classified according to their basic operating principle as dynamic or positive displacement pumps
In principle, any liquid can be handled by any of the pump designs.
Centrifugal pump is generally the most economical but less efficient.
Positive displacement pumps are generally more efficient than centrifugal pumps, but higher maintenance costs.
Positive displacement pumps are distinguished by the way they operate: liquid is taken from one end and positively discharged at the other end for every revolution.
In all positive displacement type pumps, a fixed quantity of liquid is pumped after each revolution. So if the delivery pipe is blocked, the pressure rises to a very high value, which can damage the pump.
Positive displacement pumps are widely used for pumping fluids other than water, mostly viscous fluids.
Positive displacement pumps are further classified based upon the mode of displacement:
Reciprocating pump if the displacement is by reciprocation of a piston plunger. Reciprocating pumps are used only for pumping viscous liquids and oil wells.
Rotary pumps if the displacement is by rotary action of a gear, cam or vanes in a chamber of diaphragm in a fixed casing. Rotary pumps are further classified such as internal gear, external gear, lobe and slide vane etc. These pumps are used for special services with particular conditions existing in industrial sites.
Dynamic pumps are also characterized by their mode of operation: a rotating impeller converts kinetic energy into pressure or velocity that is needed to pump the fluid.
There are two types of dynamic pumps:
Centrifugal pumps are the most common pumps used for pumping water in industrial applications. Typically, more than 75% of the pumps installed in an industry are centrifugal pumps. For this reason, this pump is further described on the next slides.
Special effect pumps are particularly used for specialized conditions at an industrial site
A centrifugal pump is one of the simplest pieces of equipment in any process plant. The figure shows how this type of pump operates:
Liquid is forced into an impeller either by atmospheric pressure, or in case of a jet pump by artificial pressure.
The vanes of impeller pass kinetic energy to the liquid, thereby causing the liquid to rotate. The liquid leaves the impeller at high velocity.
The impeller is surrounded by a volute casing or in case of a turbine pump a stationary diffuser ring. The volute or stationary diffuser ring converts the kinetic energy into pressure energy.
A centrifugal pump has two main components. First, a rotating component comprised of an impeller and a shaft (click once and circles will appear). And secondly, a stationary component comprised of a casing, casing cover, and bearings (click once and circles will appear).
Impeller
An impeller is a circular metallic disc with a built-in passage for the flow of fluid. Impellers are generally made of bronze, polycarbonate, cast iron or stainless steel, but other materials are also used.
The number of impellers determines the number of stages of the pump. A single stage pump has one impeller and is best suited for low head (= pressure)
Impellers can be classified on the basis of (which will determine their use):
Major direction of flow from the rotation axis
Suction type: single suction and double suction
Shape or mechanical construction: Closed impellers have vanes enclosed by shrouds; Open and semi-open impellers; Vortex pump impellers. The figure shows an open type impeller and a closed type impeller
Shaft
The shaft transfers the torque from the motor to the impeller during the startup and operation of the pump.
Casings have two functions
The main function of casing is to enclose the impeller at suction and delivery ends and thereby form a pressure vessel.
A second function of casing is to provide a supporting and bearing medium for the shaft and impeller.
(Click once) There are two types of casings
Volute casing (see figure) has impellers that are fitted inside the casings. One of the main purposes is to help balance the hydraulic pressure on the shaft of the pump.
Circular casing has stationary diffusion vanes surrounding the impeller periphery that convert speed into pressure energy. These casings are mostly used for multi-stage pumps. The casings can be designed as solid casing (one fabricated piece) or split casing (two or more parts together)
