Texas A&M University at Qatar

CHEN 432

Fall 2018

Team number: 2

Name of experiment: Pumps

Report number: 2

“On my honor as an Aggie, I have neither given nor received unauthorized aid on

this academic work”

Name Signature

Muhammad Danyal Imam

Omar Mansour

Safeer Hafeez
 Transmittal Letter
Muhammad Danyal Imam
Education City
Doha, Qatar

18th October 2018

Dr. Ghada Salama

Instructional Associate Professor
Chemical Engineering Department
Texas A&M University at Qatar

Dear Dr. Salama:

The purpose of this document is to outline the report prepared by Team 2 on the
Pump experiment, which was carried out on October 4th and October 11th, 2018, as
part of the CHEN 432 course.
The objective of this experiment was to develop the characteristic pump curves of
two different centrifugal pumps, at various RPM values and flowrates. The team
tested the closed impeller and open impeller centrifugal pumps separately, recording
data for 9 different flow rates each for 3 different RPM values for each pump.
The results showed that pump rotational speed is directly proportional to the pump
head developed, while the volumetric flowrate obtained is inversely proportional to
the developed pump head. The results also showed that the efficiency of open type
centrifugal pumps increases with increasing flowrate. The same is true for closed type
centrifugal pumps at low flowrates, however, their efficiency begins to decrease when
the flowrate becomes larger than the optimum value.
For this experiment, Muhammad Danyal Imam was the group leader, and was
primarily responsible for operation of the pump and adjusting flow rates and RPM
values during the experiment, together with Omar Mansour, while Safeer Hafeez was
responsible for data collection and analysis. For report writing, Muhammad Danyal
Imam was tasked with preparing the cover sheet, transmittal letter, title sheet, table
of contents, summary and introduction. Safeer Hafeez prepared the list of figures, list
of tables and experimental plan, while Omar Mansour performed the excel and
sample calculations, wrote up the results and discussion and prepared the
appendices.
In case of any questions or suggestions please do not hesitate to contact us, and we
look forward to your feedback.
Regards,
Muhammad Danyal Imam
 Investigating the Effect on Pump Performance by Varying the
Flowrate and Rotational Speeds for Different Centrifugal Pumps

CHEN 432

Team 2
Muhammad Danyal Imam
Omar Mansour
Safeer Hafeez

18th October 2018

“An Aggie does not lie, cheat or steal or tolerate those who do”
 Table of Contents

Table of Contents ............................................................................................................................. ii

List of Figures .................................................................................................................................. iv
List of Tables ................................................................................................................................... iv
Summary .......................................................................................................................................... 1
Introduction ..................................................................................................................................... 2
Objectives .................................................................................................................................... 2
Background .................................................................................................................................. 2
Centrifugal Pumps .................................................................................................................... 3
Positive Displacement Pumps .................................................................................................. 7
Theory ........................................................................................................................................ 10
Sample Calculations ....................................................................................................................... 12
Experimental Plan .......................................................................................................................... 14
Equipment .................................................................................................................................. 14
Operating Procedure.............................................................................................................. 17
Experimental Procedure ........................................................................................................ 18
Shutdown Procedure ............................................................................................................. 19
Timeline...................................................................................................................................... 19
Error Analysis ............................................................................................................................. 20
Results and Discussion ................................................................................................................... 21
Pump Head................................................................................................................................. 21
Centrifugal Open Type Impeller ............................................................................................. 22
Centrifugal Closed Type Impeller ........................................................................................... 23
Comparison between Closed Type and Open Type Centrifugal Pumps ................................ 24
Pump Efficiency.......................................................................................................................... 25
Efficiency of the Open Type Centrifugal Pump ...................................................................... 25
Efficiency of the Closed Type impeller ................................................................................... 27
Comparison between Closed Type and Open Type Centrifugal Pumps ................................ 28
Conclusion ...................................................................................................................................... 29
Recommendations ......................................................................................................................... 30
Nomenclature ................................................................................................................................ 31
Appendix A: Data Sheets and Spreadsheet Calculations ............................................................... 32

ii
Appendix B: Risk Assessment......................................................................................................... 36
References ..................................................................................................................................... 38

iii
 List of Figures

Figure 1: Left: Design of a centrifugal pump.4 Right: Schematic of impeller motion.5 .................... 3
Figure 2: Left: Open impeller.10 Middle: Semi-open impeller.11 Right: Closed impeller.12 .............. 5
Figure 3: Left: Typical characteristic pump curve for closed type centrifugal pumps. Right: Typical
characteristic curve for open type centrifugal pumps.13 ................................................................. 6
Figure 4: Left: Schematic of a positive displacement pump.18 Right: Design of a positive
displacement pump.19 ...................................................................................................................... 8
Figure 5: Typical characteristic pump curve for positive displacement pumps.21 ........................... 9
Figure 6: Multi-pump test rig setup24 ............................................................................................ 15
Figure 7: Multi-pump test rig flow diagram ................................................................................... 16
Figure 8: Pump head as a function of volumetric flowrate for open type centrifugal pumps ...... 22
Figure 9: Pump head as a function of volumetric flowrate graph for closed type centrifugal
pumps ............................................................................................................................................ 23
Figure 10: Pump head as a function of volumetric flowrate comparison between open type and
closed type centrifugal pumps. ...................................................................................................... 24
Figure 11: Pump efficiency as a function of volumetric flowrate for the open type centrifugal
pump. ............................................................................................................................................. 26
Figure 12: Pump efficiency as a function of volumetric flowrate for the closed type centrifugal
pump. ............................................................................................................................................. 27
Figure 13: Pump efficiency vs volumetric flowrate comparison between closed type and open
type centrifugal pumps operating at 2800 RPM. ........................................................................... 28
Figure 14: Data Sheets ................................................................................................................. 35

List of Tables

Table 1: Fluid flowrates per RPM ................................................................................................... 19

Table A. 1: Spreadsheet calculations for open type centrifugal pump.......................................... 33
Table A. 2: Spreadsheet calculations for closed type centrifugal pump........................................ 34
Table B. 1: Risk Assessment ........................................................................................................... 37

iv
 Summary

The objective of this experiment was to develop characteristic pump curves for two

different centrifugal pumps and examine the effect on pump head of varying flowrates

and revolutions per minute (RPM) values. To achieve this objective, a closed impeller

centrifugal pump and an open impeller centrifugal pump were tested separately, and

the values of discharge pressure, inlet pressure and flow rate recorded and exported

to an excel sheet. The pumps were operated with a solution of 50% ethylene glycol

and 50% water.

RPM values of 1000, 2000 and 2800 were tested with data points for at least 7

flowrates recorded for each RPM value. For each flowrate, the equipment recorded

readings for approximately 1 minute, and the readings averaged over the time

interval to reduce the effect of fluctuations. The data obtained was used to plot the

developed pump head as a function of volumetric flowrate to obtain the characteristic

curves for both centrifugal pumps at the three RPM values. In addition, pump

efficiencies were calculated and plotted as a function of volumetric flow rate to

evaluate the effect of increasing rotational speeds and flowrates on pump efficiency.

The results showed that the developed pump head is directly proportional to the

rotational speed, and inversely proportional to the volumetric flowrate. They also

showed that pump efficiency increases with increasing rotational speeds and

increasing flowrates, with the exception of closed type centrifugal pumps at high

flowrates, in which case the pump efficiency decreases as the flowrate increases

beyond a certain optimum value.

 2

Introduction

Objectives

The objective of this experiment was to plot and compare the characteristic pump

head curves of two different centrifugal pumps at varying flow rates and at different

revolutions per minute (RPM) values. The closed impeller and open impeller

centrifugal pumps were tested at RPM values of 2800, 2000 and 1000 each. A

minimum of 7 flowrates were tested for each RPM value, and the results plotted to

obtain the characteristic pump curves.

Background

Pumps are mechanical devices that move fluids from one place to another via

mechanical action or by imparting kinetic energy to the fluid, inducing flow. They are

broadly divided into two main types, based on their mode of operation:1

 Kinetic pumps: Pumps that use fluid velocity and momentum to generate

pumping power. Centrifugal pumps are a form of kinetic pump.

 Positive Displacement pumps: Pumps that use mechanical force to displace

fixed-volume cavities in order to move the fluid.1

Pump performance is evaluated by characteristic pump curves, which are plots of

volumetric flow rates versus the developed pump head. Pump head is defined as the

maximum height above the starting point to which the pump can raise the level of the

liquid.

This experiment studied the performance of two kinds of centrifugal pumps:

 3

1. Closed impeller centrifugal pump

2. Open impeller centrifugal pump

Centrifugal Pumps

Centrifugal pumps are the most common types of pumps used over a variety of

industries, owing to their simple design and high efficiencies. Centrifugal pumps

involve the use of one of more rotary impellers inside the pump housing. These

impellers are connected to the drive shaft that rotates the impellers against the side

of the chamber, decreasing the pressure near the inlet and causing suction. The rotary

motion of the impeller then forces the fluid to rotate as well before it is discharged

through the outlet at higher velocities.3 The figure below outlines the design of a

centrifugal pump and the schematic of impeller motion.

Figure 1: Left: Design of a centrifugal pump.4 Right: Schematic of impeller motion.5

Open Impellers

Centrifugal pumps can be run with open, semi-open and closed impellers. The open

impeller consists of a series of vanes attached to a central unit, with the vanes open

on both sides. Due to the lack of support on either side, this type of impeller is the
 4

weakest, and tends to only be used in smaller and less powerful centrifugal pumps to

avoid breakage. They are also the least efficient due to the open design, as the fluid

flowing into the casing interacts with the fluid already inside. However, they can

handle fluids with suspended solids, and are much easier to clean than semi-open and

closed impellers.6

Semi-open Impellers

Semi-open impellers have a plate attached to the vanes on one side, leaving the other

side exposed. This type of impeller is less likely to be clogged with suspended

particles than the closed impeller, and its efficiency can be maintained via impeller

clearance adjustment. Since the impeller is open from one side, it can be easily

inspected for damage, and the vanes can be cut/adjusted to increase capacity and

range of operational speeds. However, semi-open impellers cannot be used with

volatile or explosive fluids, have a limited operating temperature range and are less

efficient than closed impellers.7

Closed Impellers

Closed impellers involve the vanes being attached to plates on either side, with the

fluid travelling in channels between the vanes and between the plates. This is the

most commonly used type of impeller in industry, as it is capable of handling volatile

and explosive fluids. This design creates the most efficient flow within the pump,

however, the efficiency can decrease over time, due to an increase in the clearance of

the wear ring.8 The wear ring clearance is the gap between the tip of the rotating

vanes and the pump casing, to allow the impeller to rotate freely. To maximize
 5

efficiency, this clearance must be minimized, to reduce the amount of liquid leaking

through this clearance towards the suction end. Over time, due to corrosion as some

liquid leaks through, the gap can get larger, decreasing efficiency. Wear rings are

usually incorporated in the design of the impeller, to reduce damage to the vanes.9

However, due to the closed design, inspection of the wear rings requires disassembly

of the pump, making maintenance difficult. Closed impellers can also not be used for

fluids with suspended particles, and usually require a filter to clear the liquid before

use in the centrifugal pump.8

The figure below illustrates the design of the three different kinds of impellers.

Selection of impellers is based on the application of the pump, fluid velocity required,

and type of fluid involved.

Figure 2: Left: Open impeller.10 Middle: Semi-open impeller.11 Right: Closed impeller.12

Characteristic pump curves of centrifugal pumps typically resemble Figure 3 below.

 6

Figure 3: Left: Typical characteristic pump curve for closed type centrifugal pumps. Right: Typical
characteristic curve for open type centrifugal pumps.13

Advantages of centrifugal pumps:

 They have a very simple design with few moving parts, giving them a long life

and requiring minimal maintenance.14

 Flow rate can be easily adjusted via rotational speed or inlet valve.14

 Centrifugal pumps allow steady, continuous fluid flow output.14

 They are much smaller compared to other types of pump that generate the

same output.15

 There is an air gap between the motor and chamber, removing the risk of

damage to the motor due as fluid cannot leak into the motor. The air gap also

prevents heat loss to the surroundings by conduction.16

Disadvantages of centrifugal pumps:

 They need to be primed before use; the pump chamber must be filled with

liquid before any suction can be generated.14

 7

 Centrifugal pumps may develop cavitation, which is the vaporization of the

fluid in areas of high velocity and low pressure, particularly around the

impeller blades. Therefore, the pressure of the fluid drops below its vapor

pressure. This results in the formation of bubbles that may implode on the

surface of the impeller blades and cause corrosion and damage.15

 They are unsuitable for use with highly viscous fluids.15

Applications of centrifugal pumps:17

 Pumping crude oil for use by oil refineries.

 Wastewater processing plants

 Drainage

 Gas processing

 Pharmaceutical, Food and chemical industries

 Manufacturing

Positive Displacement Pumps

Positive displacement pumps operate in a series of working cycles. One cycle involves

intake of fluid into a compartment inside the pump, followed by the next cycle

discharging the fixed volume of fluid at the outlet via a rotary or reciprocating
 8

method. The figure below outlines the schematic and design of a positive

displacement pump.18

Figure 4: Left: Schematic of a positive displacement pump.18 Right: Design of a positive

displacement pump.19

As the piston moves backwards, suction is created, drawing fluid into the

compartment. The next cycle involves the piston pushing the volume of fluid out as a

discharge. This kind of pump produces discontinuous flow as opposed to the

continuous flow produced by a centrifugal pump. There are many different kinds of

positive displacement pumps that differ based on different pumping mechanisms.20

The figure below illustrates a typical characteristic curve for positive displacement

pumps. The dashed line shows the actual pump performance. This results from the

fact that as discharge pressure increases, some of the fluid leaks back towards the

suction end, reducing the effective flowrate of the discharge.21

 9

Figure 5: Typical characteristic pump curve for positive displacement pumps.21

Advantages of positive displacement pumps:19

 They maintain a constant speed and flow regardless of what the inlet pressure

is.

 They can handle a wide variety of fluids, fluids of very high or very low

viscosities.

 They are self priming.

 Suitable for use in high pressure applications.

 Flowrate can be adjusted very precisely.

Disadvantages of positive displacement pumps:22

 Pressure relief and safety valves are necessary to prevent damage.

 They are not very suitable for high speeds due to the oscillating movement.
 10

 There are a greater number of wear parts when compared to centrifugal

pumps.

Applications of positive displacement pumps:23

 Food and beverage industries

 Wineries

 Dairy and meat processing

 Sewage treatment

Theory24

Applying Bernoulli’s equation on a pump installed between points 1 and 2:

𝑊𝑠 𝑃 𝑣2 2 𝑃 𝑣1 2
𝐻𝑝 = = (𝜌𝑔2 + + 𝑧2 ) − (𝜌𝑔1 + + 𝑧1 ) (1)
𝑔 2𝑔 2𝑔

Where

J
𝑊𝑠 = work done by fluid per unit mass (kg)

m
𝑔 = graviational acceleration (s2 )

𝐻𝑝 = pump head (m)

𝑃2 = Pressure at discharge (Pa)

𝑃1 = Pressure at inlet (Pa)

m
𝑣2 = fluid velocity at discharge ( s )

m
𝑣1 = fluid velocity at inlet ( s )
 11

𝑧2 = height of fluid at discharge (m)

𝑧1 = height of fluid at inlet (m)

kg
𝜌 = density of fluid (m3 )

Since velocity and height do not change between the inlet and discharge of the pump,

the above equation can be further simplified to:

∆𝑃
𝑊𝑠 = = 𝑔𝐻𝑝 (2)
𝜌

Where

∆𝑃 = pressure difference (Pa)

The hydraulic power of the pump is given by the rate of mechanical energy input to

the fluid:

𝑃ℎ𝑦𝑑 = 𝜌𝑄𝑔𝐻𝑝 (3)

Where

kg
𝜌 = density of fluid (m3 )

𝑚3
𝑄 = 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 ( 𝑠
)

m
𝑔 = graviational acceleration ( 2 )
s

𝐻𝑝 = pump head (m)

 12

The efficiency of a pump is defined as the ratio of the total output power of the pump

(hydraulic power of the pump) to the total input power to the pump (power of the

motor). It is calculated as follows:

𝑃
𝜂 = 𝑃ℎ𝑦𝑑 (4)
𝑒𝑙𝑒𝑐

Where

𝜂 = 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

𝑃𝑒𝑙𝑒𝑐 = 𝑝𝑜𝑤𝑒𝑟 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟 (𝑊)

𝑃ℎ𝑦𝑑 = ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑝𝑜𝑤𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑜𝑡𝑜𝑟 (𝑊)

Sample Calculations

The subsequent sample calculations were performed for a closed type impeller

̅̅̅̅
operating at a flowrate of 78.56 L/min. The suction pressure (P 1 ) is averaged to .032

̅̅̅̅
Bar and the discharge pressure (P 2 ) is 1.819 Bar. The motor operates at a current of

3 amps and a voltage of 205 V.

1. Calculation of average values on excel, e.g. for average value of P1:

1 0.0322+0.036234+0.03685+.03284…+0.029138
P1 = ∑ni=1(P1 )i = = 0.032 bar (5)
n 78

This same method was used to calculate the average value of Q, P2, I, and V.

2. Unit conversion of pressure from bar to Pascal:

104 Pa
P1 = 0.032 bar × = 3200 Pa (6)
bar

3. Unit conversion of flowrate from L/min to m3/s:

 13

78.56 L min m3 𝑚3
Q= × × 1000 L = 1.3 × 10−3 (7)
min 60 s 𝑠

4. Unit conversion of density from g/mL to kg/m3:

g kg 1000 mL 1000 𝐿 kg
ρ = 1.044 × 1000 g × × = 1044 (8)
mL 1L 1𝑚3 𝑚3

5. Calculation of work done by fluid per unit mass:

∆P 181959 Pa−3298 Pa J
Ws = = = 171.13 (2)
ρ 1044 kg/m3 kg

6. Calculation of pump head:

Ws 233.93 J/kg
Hp = = = 17.4 m (1)
g 9.81 m/s2

7. Calculation of hydraulic power of the pump:

1044kg 0.0013m3 9.81m

Phyd = ρQgHp = × × × 17.4 m = 233.93 W (3)
L s s2

8. Calculation of Electric Power

𝑃𝑒𝑙𝑒𝑐 = 𝐼 × 𝑉 = 205 𝑉 × 3 𝐴 = 615 𝑊 (9)

9. Calculation of pump efficiency:

P 233.93 W
η = efficiency = P hyd × 100% = × 100% = 38.03% (4)
elec 615 W
 14

Experimental Plan

The objective of this experiment was to develop characteristic curves and determine

efficiencies for two centrifugal pumps at three different rotational speeds (RPMs).

The two pumps used were:

 Open type impeller pump

 Closed type impeller pump with an impeller diameter of 156 mm

To develop characteristic curves of the pump, the suction and discharge pressures of

the pump were recorded along with the flowrate of fluid through the pump. The

pressure drops for the pump were used to calculate pump head for different flowrates

and create a characteristic curve.

The input power to the system and hydraulic power of the pump were calculated

using Equation 9 and 3, and used to evaluate efficiencies. The characteristic curves

and efficiencies for different RPMs for each pump were plotted and compared to

determine which pump gave the highest and lowest head, flowrate ranges and

optimal efficiency conditions for each pump.

Equipment

The experiment was conducted on a multi-pump test rig shown in Figures 6-7. The

test rig consisted of five centrifugal pumps and two positive displacement pumps.

These pumps were connected singly and are listed below with the corresponding

labels for Figures 6-7.

 Centrifugal pumps
 15

o Multistage (1)

o Closed type impeller with an impeller diameter of 156 mm (2)

o Open type impeller (3)

o Closed type impeller with a reduced impeller diameter of 132 mm (4)

o Flexible impeller (5)

 Positive displacement pump

o Lobe pump (6)

o Membrane pump (7)

Figure 6: Multi-pump test rig setup24

 16

Figure 7: Multi-pump test rig flow diagram

The fluid supplied to these pumps is stored in tank (8) and consists of 50% ethylene

glycol- 50% water. The storage tank has its own temperature sensor (T), supply valve

(V1), and a drain valve (V3). The setup is powered on by switching on the main power

switch (9). The digital display (10) loads up once the setup is activated. The pump

type and pump RPM can be selected on the digital display. The digital display also

displays temperature, flowrate and pressure readings for the fluid as well as

operational pump RPM. Furthermore, the digital display is used to initiate and

terminate the recording of data. The data recorded is stored on the adjacent

connected PC.

The flowrate for the system is controlled by an inlet valve (QV). Pressure readings for

each pump are taken by pressure transducers installed at inlet (P1) and outlet (P2)

of the pumps. Similarly, a flowrate sensor is used to record flowrates for centrifugal

pumps (F1) and positive displacement pumps (F2), respectively. A pressure relief

valve is provided for the system and is set at 3.5 bars. Additionally, check or ball

valves (V2) are provided for open impeller, closed impeller and flexible impeller
 17

pumps. When running a selected pump such as open impeller, the valve leading to the

open impeller pump is opened and the rest are closed to ensure fluid only flows to

the selected pump. A Y– strainer (V4) is also present in the system to remove any

unwanted solids from the fluid stream and prevent clogging of the system.

Operating Procedure24

1. Open the valves V1 (which controls the fluid supply from the tank) and QV

before switching on the system.

2. Switch on the main power switch (9) and allow the system to initialize.

3. If using one of the pumps marked 2, 3, 4, or 5, open their respective valve

(V2) to ensure fluid flow.

4. Select the following from the control panel touch screen (10):

a. Pump type,

b. Maximum RPM of the pump.

5. Press start on the control panel to switch on the pump.

6. Adjust valve (QV) to get the desired flowrate.

7. Press “start save” to record data after the pump is allowed to reach steady

state condition.

8. Press “stop save” after a minute has elapsed and save the date.

Note: Do not run positive displacement pumps (6 and 7), above 3.0 bar pressure or

when QV is closed to prevent equipment damage. Similarly, do not run centrifugal

pumps with QV closed for more than a minute.

 18

Experimental Procedure

For the first run of the first experiment the aforementioned operating procedure was

followed and the open type impeller pump was selected. The flowrate was varied

from 24 L/min to 3 L/min for the RPM value of 1000. The flowrates were to start from

the highest possible flowrate and end with the lowest possible one. Taking the

maximum and minimum flowrates as well as several ones in between is important to

fully capture the performance of the pump across the entire range that it can cover.

At least 7 different flowrates were tested for each RPM value, i.e. 7 runs at each RPM.

Data for each run was recorded for a minute and averaged to reduce the impact of

fluctuations on readings.

In the second and third experiment the RPM was changed to a value of 2000 and 2800

respectively and the (QV) valve was fully opened again for each one. The drop of 800

rpm was chosen to get a broader idea of the performance of the pump at different

speeds. The runs of each new RPM value followed the same principle as for the first

experiment. The flowrates were again decreased in a way that ensured there were no

less than 7 runs. Data was recorded and averaged for runs of each experiment.

The same operating procedure was followed in the testing of the closed type impeller

pump with the diameter of 156 mm. Three experiments with different RPMs were

again conducted for the pump and the same principles in determining the runs were

followed. Data for each experiment were recorded and averaged. The flowrates and

RPMs used for each pump are mentioned in Table 1 below.

 19

Table 1: Fluid flowrates per RPM

Fluid Flowrate (L/min)

Pump RPM Run 1 Run 2 Run 3 Run 4 Run 5 Run 6 Run 7 Run 8 Run 9

Open Type 1000 2.94 7.08 7.58 12.55 15.55 18.48 25.15 - -
Impeller
2000 4.00 10.59 15.71 19.97 23.30 27.50 33.65 38.18 42.98

2800 23.84 30.94 36.05 38.20 44.04 49.59 55.68 61.02 66.27

Closed Type 1000 2.56 4.81 7.45 10.41 12.76 15.78 16.04 20.52 -
Impeller
2000 16.14 21.21 24.53 30.47 35.58 40.63 45.30 50.01 53.75
(d=156 mm)
2800 40.95 44.52 50.68 54.42 60.56 65.90 70.24 74.49 78.56

Shutdown Procedure

The following shutdown procedure was followed after the data for several flowrates

for each one of the three RPMs for a pump was collected:

1. The pump is switched off through pressing “stop pump” on the control panel

(9).

2. All the pump valves (V2), the valve (QV) and the supplying valve (V1) must

be completely closed.

3. Turn the main switch (9) off.

Timeline

All the experiments were completed over the two lab sessions. In the beginning of

each lab, ten minutes were dedicated for a quick meeting to review the session’s plan.

Fifteen minutes were then given for the initial operating procedure. Recording data
 20

for every RPM took thirty minutes each. At the end of the session ten minutes were

spent on the shutdown procedure and cleaning up. Five minutes were given to discuss

our progress with the lab coordinators and discuss the report. The experiment was

conducted on the closed type impeller pump during the first lab session and on the

open type impeller pump during the second lab session.

Error Analysis

Sources of error in this experiment were primarily the fluctuating readings for

pressure and flowrate in the system. In addition to allowing the system to reach a

pseudo-steady state, the readings were collected for 60 seconds and averaged to

remove the effect of fluctuations. Due to these measures, this error is not considered

significant. The readings were used in simple calculations and not in a long chain of

calculations, so propagation of error is minimum.

Error was also induced due to inaccuracies in the control of flow. The flowrate was

controlled manually and involved constant fluctuations, hence, was not always

precisely set the required point. However, since the flowrates were used to create a

characteristic curve, and averaged over a set of multiple readings for every data point,

the slight inaccuracies were negligible.

 21

Results and Discussion

The characteristic performance curves for two different types of centrifugal pumps,

open-type and closed-type impellers, were developed to measure their performance.

The variables analyzed for each pump were the fluid volumetric flow rate, and the

rotational speeds at which the pumps operate and the corresponding effect on the

pump head, and efficiency. These results will then be compared to similar

experiments performed in literature in order to validate the legitimacy of the results.

From the Multi-Pump Test Rig, values for the pressure difference between the inlet

and outlet of each single investigated pump were gathered, allowing for the

calculation of pump head, and thereby hydraulic power and efficiency on Microsoft

Excel.

Pump Head

Hydraulic head is an important parameter in measuring the performance of the

pump. Envisioning that from the discharge of the pump, the fluid is exposed vertically

to the atmosphere; pump head quantifies the height at which the fluid would rise.

This happens by the pump motor converting electrical to mechanical energy,

therefore pump head is also directly related to the potential energy the fluid has

obtained from the pump. Pump head is preferred to characterize pumps, rather than

pressure difference, since most industrial applications of pumps require them to

move a fluid vertically through piping. Therefore with knowledge of pump head, one

may be able to easily determine if the selected pump meets the specifications of the

process.
 22

Centrifugal Open Type Impeller

In order to develop the characteristic curve for the open type impeller centrifugal

pump, the flowrate was varied for the pump at three different rotational speeds,

1000, 2000, and the maximum of 2800 RPM. The characteristic curve with the pump

head as a function of volumetric flowrate for the three different revolution speeds

were developed as seen in Figure 8.

Pump Head vs Volumetric Flowrate

Open Type Centrifugal Pump
12

10
Pump Head (m)

8
1000 RPM
6

4 2000 RPM

2 2800 RPM

0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
Volumetric Flowrate (m3/h )

Figure 8: Pump head as a function of volumetric flowrate for open type centrifugal pumps

As seen in Figure 8, pump head increases with rotational speed. As previously

mentioned, pump head is directly proportional to potential energy imparted to the

fluid; and as the motor’s revolution speed increases more electrical energy may be

converted to mechanical energy.

Furthermore it is seen in Figure 8 that pump head generally decreases with

increasing flowrate. The maximum obtained pump head was 10.7 meters at a flowrate

of 1.43 m3/h. It is seen that by increasing the revolution speed from 1000 to 2800
 23

RPM the pump head increases by a factor of 10; and from 2000 to 2800 RPM a factor

of 2.

CUI Baoling et al.25 investigated a straight-blade and curved-blade impeller pump

operating at 2900 RPM, resulting in similar almost linear characteristic curve for the

straight-blade impeller, as shown in Figure 3.

Centrifugal Closed Type Impeller

The characteristic curves for the closed type impeller were developed in a similar

manner as the open type impeller. Impeller rotational speed was once more varied

between 1000, 2000, and 2800 RPM, and the subsequent data was processed on

Microsoft Excel as seen in Figure 9.

Pump Head vs Volumetric Flowrate

Closed Type Centrifugal Pump
35

30

25
Pump Head (m)

1000 RPM
20 2000 RPM
15 2800 RPM

10

0
0 1 2 3 4 5
Volumetric Flowrate (m3/s )

Figure 9: Pump head as a function of volumetric flowrate graph for closed type centrifugal
pumps

The characteristic curves for the closed type centrifugal pump show similar

correlations to those of the open type. Once more, the pump head increases with the
 24

rotational speed, and decreases as the volumetric flowrate increases. The maximum

pump head obtained for this impeller type was 26.25 m. By increasing the revolution

speed from 1000 to 2800 RPM the pump head increased by a factor of 9, and from

2000 to 2800 RPM by a factor of 2.

The shape of these curves for the closed type impeller centrifugal pump is consistent

with those found in literature as seen in Figure 3.

Comparison between Closed Type and Open Type Centrifugal Pumps

In order to compare the performance of these two different types of centrifugal

pumps, both performance curves at 2800 RPM were plotted as seen in Figure 10.

Pump Head vs Volumetric Flowrate (2800 RPM)

35

30

25
Pump Head (m)

20
Closed Type Impeller
15
Open Type Impeller
10

0
0 1 2 3 4 5
Volumetric Flowrate (m3/s )

Figure 10: Pump head as a function of volumetric flowrate comparison between open type and
closed type centrifugal pumps.

From Figure 10, it is evident that the closed type impeller produces greater pump

head than the closed type impeller. The shape of each characteristic curve is also

noticeably different. The closed type impellers’ pump head has a much greater
 25

dependence on flowrate than the open type impeller. If the data is fit to a linear trend

line, the closed type impeller has a slope of -3.7, while the open type impeller only has

a slope of -0.25.

Although the closed impeller has an inverse relationship with volumetric flowrate, it

can still be seen in the figure above that the closed impeller maintains higher pump

head than the open impeller at high flowrates. At low flowrates, i.e. 2.5 m3/h, the

closed impeller generates 2.5x the head than the open impeller. At high flowrates, i.e.

4 m3/h, this diminishes to a factor of 1.7. Therefore when choosing which impeller

type the centrifugal pump should have, along with the aforementioned advantages

and disadvantages discussed earlier, the difference in pump head and dependence on

volumetric flowrate is an important parameter to study.

Pump Efficiency

The pumps’ efficiency is also an important parameter to measure its performance.

Pump efficiency, as calculated in Equation 4, is simply the ratio of hydraulic power

and electric power. This information will help to determine the most energy efficient

pump to achieve a desired pressure head; as pressure head is directly proportional to

hydraulic power as seen in Equation 3.

Efficiency of the Open Type Centrifugal Pump

By calculating the hydraulic power from Equation 3, the change in pump efficiency by

varying flowrate for the open type impeller was developed as shown in Figure 11.
 26

Pump Efficiency vs Volumetric Flowrate

Open Type Centrifugal Pump
35

30

25
Efficiency (%)

1000 RPM
20
2000 RPM
15

10 2800 RPM

0
0 1 2 3 4 5
Volumetric Flowrate (m3/h )

Figure 11: Pump efficiency as a function of volumetric flowrate for the open type centrifugal
pump.

As seen in Figure 11, the pump efficiency increases with the rotational speed. As

opposed to the characteristic curves developed which compare pump head, the pump

efficiency is directly proportional to volumetric flowrate. There is therefore a tradeoff

between pump head and pump efficiency when choosing the optimal flowrate at

which the pump operates.

By analyzing the pump efficiency at 1.3 m3/h, it can be seen that the pump efficiency

increases by factor of roughly 3 and 0.25 when operating at 1000 and 2000 RPM

respectively, compared to when operated at 2800 RPM. The advantage of operating

the pump at greater rotational speeds, is that greater volumetric flowrate may be

achieved. Therefore the maximum efficiency operating at 2800 RPM yields an

efficiency increase by a factor of 2 and 6 compared to operating at 2000 and 1000

RPM respectively. It is also evident that operating the pump at low rotational speeds
 27

significantly reduces the efficiency of the pump. At 1000 RPM the maximum obtained

efficiency was 4%, and reaching as low as 1% at low flowrates.

Efficiency of the Closed Type impeller

The pump efficiency curve for the closed type centrifugal pump was also developed

as seen in Figure 12 below.

Pump Efficiency vs Volumetric Flowrate

Closed Type Centrifugal Pump
45
40
35
1000 RPM
30
Efficiency %

25 2000 RPM

20 2800 RPM
15
10
5
0
0 1 2 3 4 5
Volumetric Flowrate (m3/h

Figure 12: Pump efficiency as a function of volumetric flowrate for the closed type centrifugal
pump.

The efficiency curves for the closed type impeller once more show similar trends as

those previously noted for the open type impeller. The pump efficiency is directly

related to the rotational speed, and also the volumetric flowrate at which the pump

operates. However, for the closed type impeller the pump efficiency eventually levels

off and decreases as flowrate increases past 90% of the maximum operating flowrate.

The maximum efficiency for operation at 2800 RPM was nearly 40%, which is 1.25

and 7 times greater than those for the 2000 and 1000 RPM cases respectively. It is
 28

also apparent that operating at low flowrates, as seen in the 1000 RPM curve, is

disadvantageous in terms of pump efficiency.

Comparison between Closed Type and Open Type Centrifugal Pumps

In order to compare the energetic efficiencies of open and closed type centrifugal

pumps, the curves at 2800 RPM are compared in Figure 13.

Pump Efficiency vs Volumetric Flowrate

Comparison Between Closed Type and Open Type
Centrifugal Pumps Operating at 2800 RPM
45
40
Closed Type Impeller
35
30
Efficiency %

Open Type Impeller

25
20
15
10
5
0
0 1 2 3 4 5
Volumetric Flowrate (m3/h )

Figure 13: Pump efficiency vs volumetric flowrate comparison between closed type and open
type centrifugal pumps operating at 2800 RPM.

As seen in Figure 13, the closed type impeller has greater efficiencies than that of the

open type. At a flowrate of 4 m3/h the efficiency of the open type impeller is 75% of

the closed type impeller. Notably, the closed type impeller’s efficiency levels off as the

flowrate increases, however the open type impeller’s efficiency maintains a relatively

linear relationship with respect to flowrate.

 29

Conclusion

In conclusion, by generating the characteristic curves for open type and closed type

impellers for centrifugal pumps, several relationships can be noted. Primarily, pump

head increases as the revolution speed increases. However, as the flowrate increases,

the pump head decreases as theoretically supported by Bernoulli’s’ equation. The

closed type impeller was found to generally produce greater pump head than the

open type impeller. The closed type impeller was also found to operate at higher

efficiencies than that of the open type impeller. Energy efficiency was found to

increase with volumetric flowrate, and therefore there is a trade-off between

efficiency and pump head when optimizing the flowrate at which the pump operates.

Designing an energy efficient pump is important in minimizing energy costs in an

industrial process. Knowledge of pump head is crucial in any engineering design in

industry, in order to determine whether or not a selected pump could achieve the

desired requirements according to the process specifications.

 30

Recommendations

During the duration of this experiment; several ideas for improving the lab’s safety,

procedure, and outcomes were developed.

 The group believed that the equipment description was not adequate in

the laboratory manual. Although the steps to run the equipment were

provided, students did not have a prior understanding of the risks and

hazards resultant of failing to comply with proper valve control may

result in.

 Safety Data Sheets should be provided or required to be researched prior

to the experiment in order to better understand any associated risks and

hazards with the 50% ethylene glycol and water mixture.

 Operating the pumps at high RPM tended to produce an irritating sound

which may be detrimental if exposed to for long periods of time.

 Flowmeters were found to fluctuate within a +/- 1 L/min range for high

flowrates and between a +/- 2 L/min range for low flowrates resulting,

perhaps resulting in inaccurate average values.

 It was difficult to obtain data at low flowrates, therefore a more

automated method of controlling flowrate may be beneficial in obtaining

data at low flowrates.

 31

Nomenclature

Symbols Description Units

g Acceleration due to gravity m⁄s2

Q Fluid volumetric flowrate m3 ⁄s

d Diameter m

∆P Pressure difference Pa

ρ Fluid density kg⁄m3

η Pump efficiency -

𝐻𝑝 Pump head m

𝑊𝑠 Work done by fluid per unit mass J⁄kg

P2 Pressure at discharge Pa

P1 Pressure at inlet Pa

v2 Fluid velocity at discharge m⁄s

v1 Fluid velocity at inlet m⁄s

z2 Height of fluid at discharge m

z1 Height of fluid at inlet m

Phyd Hydraulic power of pump W

Pelec Power of motor W

 32

Appendix A: Data Sheets and Spreadsheet Calculations

 33

Table A. 1: Spreadsheet calculations for open type centrifugal pump

 34

Table A. 2: Spreadsheet calculations for closed type centrifugal pump

 35

Figure 14: Data Sheets

 36

Appendix B: Risk Assessment

 37

Table B. 1: Risk Assessment

Hazard Causes Consequences Safeguards

Electric shock Exposed wire Skin burns, Ensure electric wires
Wet floor neuropathy, or are well sealed and
death in the severe wires are routed away
cases from dangerous place
Slippage Wet floor Concussion, bone Clean up spill as soon
fracture as it occurs
Overheated Overheating of Skin burns, injury Main switch for
components the channel from the heat emergency shutdown

Rotary parts Pump motor Tearing of skin, Tie hair back, don’t
cutting of fingers, wear loose clothing
pulling of hair/loose and stand a certain
clothing distance away from the
machine, don’t insert
finger in fan
Pump Flow regulating Damage to the Flowrate displayed on
operation valve fully pump the screen for constant
with no flow closed monitoring
Build-up of Pressure relief Damage to the Pressure relief valve
pressure valve fully closed equipment always fully open
during pump during operation; flow
operation regulating valve never
fully closed
 38

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