Pumps - operation

Operational Problems
o Cavitation
o Priming

57
Net Positive Suction Head (NPSH)
• If the suction pressure at pump inlet is less than or equal
to or just slightly greater than the vapor pressure of the
liquid, the liquid may flash into vapors inside the pump.
This is called Cavitation
• It greatly reduces the capacity of pump and also causes
severe Erosion.
• To Avoid Cavitation, the Pressure at the pump inlet must
exceed the vapor pressure of liquid by a certain amount
which is called Net Positive Suction Head (NPSH)
• There are two types of NPSH
– Net Positive Suction Head Available (NPSHa)
– Net Positive Suction Head Required (NPSHr )
Net Positive Suction Head (NPSH)
• NPSHR
– absolute pressure in excess of vapor pressure REQUIRED at pump inlet
to prevent cavitation
– given by pump manufacturer
• NPSHA
– pressure in excess of vapor pressure AVAILABLE at pump inlet
– determined by pump installation (elevation above reservoir, frictional
losses, water temperature)
• If NPSHA is less than NPSHR cavitation will occur
• NPSHA must always be greater than NPSHR

NPSH = Absolute P at Pump suction - Vapor P at pump temp

NPSHr =
Specific Gravity x 0.433
 7.3 Definition of Important Terms

Ha + Hs – Hvap - Hf
Ha

Hs

Hvap

Hf

60
Net Positive Suction Head Available (NPSHa)

Case 1
Positive Suction
from an open tank.
At Ambient Temperature
Net Positive Suction Head Available (NPSHa)

Case 2
Suction lift from an open
tank.
At Ambient Temperature
Net Positive Suction Head Available (NPSHa)

Case 3
Suction from a closed tank
and temperatures greater
than ambient.
 To Increase the NPSHa
• Raise the suction tank (or level in the tank).
• Lower the pump.
• Increase the pressure in the suction tank.
• Cool the liquid to reduce vapor pressure.
• Modify the suction piping. - Increase pipe diameter
• Reduce the piping length - change fittings - modify
valve type - reduce number of fittings.
 Cavitation
Cavitation can be termed as: “The Heart attack of the pump”

It has been described as

A reduction in pump capacity
A reduction in the head of the pump
The formation of bubbles in a low pressure area of the pump
A noise that can be heard when the pump is running
Damaged that can be seen on the pump impeller and volute

Hence Cavitation is an abnormal condition that

can result in loss of production, equipment
damage and worst of all, personnel injury
65
Mechanism of Cavitation

66
Mechanism of Cavitation

Formation of bubbles
Vaporization of Liquid
Increase in Temperature of
Liquid
Decrease in Pressure
Growth of bubbles
Operating Conditions
Collapses of bubbles
Liquid Micro Jet
Impeller Pitting
67
Mechanism of Cavitation

68
Mechanical Deformation due to Cavitation
• Longer duration of cavitation condition can result in
unbalancing of radial and axial thrusts on the impeller.
This unbalancing often leads to following mechanical
problems:
– bending and deflection of shafts,
– bearing damage,
– thrust bearing damage from axial movement,
– breaking of impeller nuts,
– seal faces damage etc

69
 Cavitation Corrosion

• The collapse of bubbles destroys existing protective

layers making the metal surface permanently activated
for the chemical attack.

• The rate of erosion may be increased if the liquid itself

has corrosive tendencies

70
 Preventing Cavitation
• To prevent cavitation the NPSHa must be greater than
the NPSHr
• The methods to increase NPSHa have already been
described

71
 Pump PRIMING
• A pump with air in its casing is AIR BOUND and can
accomplish neither Suction Nor Discharge until the air
is replaced with a liquid.
• Priming is the solution of AIR BOUND pump.
• Priming is the process in which Air/Gas is removed
from the pump.

72
 Pump PRIMING
• Air can be displaced by:
– Priming the pump from an auxiliary priming tank connected to
the suction line
– Drawing the liquid into the suction line by an independent
source of vacuum
• Also several types of Self-Priming centrifugal pumps are
available
• Positive Displacement pumps can compress the gas/air
inside the pump so they are Self-Priming pumps

73
 Pros and Cons of Centrifugal Pump

• Advantages
– Simple in construction and cheap
– Little space requirements
– Handle liquid with large amounts of solids
– No need for internal lubrication
– uniform pressure, without shock or pulsation.
– Uniform flow at constant flow and Head
– Maintenance costs are lower
– Discharge valve closed will not damage pump for
short periods

74
 Pros and Cons of Centrifugal Pump
• Disadvantages
– Cannot handle highly viscous fluids efficiently
– Cannot be operated at very high heads
– Multiple stages needed for high pressures
– Maximum efficiency holds over a narrow range
of conditions
– must be primed
– Backflow
– Impeller damage if pumped liquid is abrasive

75