Centrifugal pump(various air handling methods)

Air Handling and Priming of Centrifugal Pumps: Because of roll and pitch, marine pumps at times have to handle very highly aerated water, even under flooded suction conditions in only moderate weather; the amount of air can be sufficient to air-lock a non-self-priming pump if the water inlets or suctions are not well-placed. Expansion of the air at the pump entry and its subsequent compression in the pump, gives rise to noise similar to cavitation, especially in positive displacement pumps, where compression is rapid. Also, it can be very destructive of pump and pipe materials, by corrosion, erosion or both. Pumps may be mounted above the level of the liquid to be pumped even though placed low in the ship, and they must be equipped with means to create a vacuum in the pipeline. Some others must be similarly equipped so that the maximum amount of liquid can be extracted from the tanks, bilges, etc. To achieve this, the air handling facilities must be good. As the velocity of the outer tips of the impeller of a centrifugal pump is relatively low, the suction effort of the pump, when empty, rarely exceeds 12 mm water gauge and a centrifugal pump must be primed with water, as it cannot exhaust the contained air as a displacement pump can. When the pump is placed below the level of the water, as in marine circulating sets, the filling is effected by opening the injection valve on the ship's side and the air-cock on the top of the pump casing. The pump is fully primed whensolid water emerges from the aircock.

Centrifugal pump(various air handling methods) contd 2

Air Handling Methods: Air extraction on most pumps is required, especially on all bilge pumps. Early designs of circulating pumps employed a steam ejector on the volute easing together with a steam jet into the easing to condense and prime, or a direct water-priming valve. Later designs of centrifugal pump incorporated a separate air-pump. In the first types the air is separated from the water in the suction chamber, it rises and is withdrawn by the air pump via a float-operated valve. Twin single-acting air pumps are fitted, driven by worm and wheel from the pump spindle, and are crank driven. The pumps are capable of operating flooded should the float gear break down but in normal operation the flooded water suction closes the float valve and the air pumps idle. In the more modern designs rotary types usually replace the reciprocating air pumps. Types of air pumps are:

Centrifugal pump(various air handling methods) contd 3

Types of air pumps are: Recirculation of discharge. This is a very inefficient method. Liquid ring primer (see figure below). This type is most frequently used. Its air handling capacity is good, the extracted air being vented to atmosphere, although it can be used to pump against pressure. It is used as a gas compressor and as an air exhausted.

Liquid Ring Primer unit.

Liquid Ring Primer unit.

Air gulps are quickly cleared, small air leakages and aerated water are continuously handled with out fall in pump performance.

Liquid Ring Primer unit.contd

The liquid ring air pump consists of a bladed circular rotor shrouded on the underside, rotating in an oval casing. Sealing water is drawn into the whirlpool casing through a make up supply pipe, The water follows the periphery of the casing due to the centrifugal force Imparted to it by the rotor and the water-ring, revolving eccentric to the blade recedes from and re-approaches the rotor boss twice in one revolution, thus producing in effect a series of reciprocating water pistons between the blades. The inner edge of the water-ring forms the boundary of two eccentric cores round the rotor boss, while the blades run full of water.

Liquid ring air pump

See A and B in the figure below. Liquid ring air pump

Liquid ring air pump contd

Assuming the space between each blade to be a cylinder, then in one-half revolution the water is thrown from F out to G and back again to F, constituting one suction and one discharge stroke and this occurs twice in one revolution. It will be understood therefore, that if shaped suction and discharge ports are provided in way of the path of the eccentric cores formed by the rotating water, air will be drawn through the suction ports and expelled through the discharge ports, as each blade passes the ports. Such ports are arranged in the stationary rotor plate fitted in the cover above the rotor. In each revolution, therefore, the water recedes from the rotor boss drawing air through the suction ports in the rotor plate into the eccentric cores of the water-ring, from whence it is forced through the discharge ports in the rotor plate after the points of maximum throw-out at G have been passed and the water re-approaches the rotor boss

Liquid ring air pump contd

. A continuous supply of sealing water is circulated from the reservoir to the whirlpool casing, and is discharged with the air back to the reservoir. (The air passes to atmosphere through the overflow pipe.) This circulation ensures that a full water-ring is maintained, and the cooling coil incorporated in the reservoir limits the temperature rise of the sealing water during long periods of operation. The supply for the cooling coil can be taken from any convenient seawater connection. About 0.152 litres/sec is required at a pressure not exceeding 2 bar. The reservoir has a cooling coil through which passes seawater and this cools the fresh water which gets heated due to the churning action of the air pump impeller.

Liquid ring air pump contd

Line diagram showing Water ring air pump principle.

Liquid ring air pump contd

Alternative explanation: The usual suction separating chamber and ball float are provided but the air connection from the top of the ball float chamber is taken to the rotary air pump which is directly driven by an extension of the motor spindle on top of the pump. The rotor revolves in a special variable shaped chamber, which is supplied with fresh water from a reservoir in the air pump casing. Due to the casing shape the water is made to flow from and towards the rotor centre during each revolution. The water motion is utilised to act as suction and discharge for the air through appropriate sets of ports. The air pump can be placed in or out of operation by a control cock on the front of the Air pump casing. The principle of operation is referred to as the 'water ring principle'. Figure in page 61 shows this in simplified form. As the impeller vanes pass the suction port air is drawn in and trapped between the water ring and the pump shaft. This 'slug' of air is carried around and delivered to the discharge-port hence this pump is a positive displacement type. In some ship plants all the priming connections for all pumps, etc., are led to a central exhausting system, this system under the operation of auto compressors functions to give priming from a central control station to all units in the engine room as required.

Dry ring primer

Dry ring primer: This type of a priming pump may be either the reciprocating or rotary type, but they cannot accommodate mixtures of air and water Therefore, when this type is used, some sort of a protective device must be incorporated between the centrifugal pump and the primer pump so as to prevent water from entering the primer pump.

Ejector / Eccentric vane primer

Ejector: If sized correctly these are effective but their efficiency is low. Priming ejectors work on the jet principle, using steam, compressed air or water as the operating medium. The operating medium is fed in as shown and as it passes into the divergent part, there is a fall in pressure, which sucks up the medium to be pumped. If an ejector is used with a centrifugal pump, it is mounted at the base of the pump near the suction eye. Eccentric vane primer: Has good air handling but life can be short due to wear of vane tips and jamming in slots.

ROTARY AIR EXTRACTION PUMP

ROTARY AIR EXTRACTION PUMP contd

Main pump under priming condition
1. At the initial start of main pump, there is no discharge pressure - the spring keeps operating piston towards "A" thereby keeping friction clutch engaged. 2. Engagernent of friction clutch runs air extraction pump, which sucks air from the suction side of the main pump and also water from the vessel.

ROTARY AIR EXTRACTION PUMP contd

Main pump under operation

ROTARY AIR EXTRACTION PUMP contd

Main pump under operation contd 3. As the main pump fills up and discharge pressure builds up, water pressure acts at "A", pushing operating piston towards "B", thereby disengaging friction clutch and thus cutting off the air extraction pump. 4. The rotor casing is continuously cooled by a closed water circuit from the pump discharge round the air pump jacket and returns to the pump suction.

ROTARY AIR EXTRACTION PUMP contd

Line diagram of the above priming system.

Ejector Type.

Ejector Type contd

Working system
1. Pump starts but no discharge. 2. Pressure transmitter sends signal to pressure controller. 3. Controller sends signal to selector/transmitter relay. 4. Two output signals from selector/transmitter relay:

To open solenoid valve "B" To open solenoid valve "A"

5. Solenoid valve "B" allows air to flow through venturi.

Ejector Type contd

Working system:contd
6. Venturi or ejector creates vacuum and sucks up the air in the pump casing through solenoid valve A. 7. Pump fills up with water and discharges pressure builds up.

Central Priming System

This system is often used when more than four pumps require priming facilities. It gives a large air exhausting reservoir as well as a capacity greater than individual pumps can carry and the pump casings can be filled with liquid before starting. The air exhausting units can be of any type but are usually of the liquid ring type

Central Priming System:contd

The advantages of this system are: Lower initial cost or reduced capital cost. Saving in total power since each pump does not have its own exhauster or priming unit operating all the while the pump is operating. Easier or simpler maintenance. Automatic - takes care of any minor leaks that may be present in the suction side of a centrifugal pump. Very effective. Easy to operate.

central priming system

Out-line diagram of central priming system

central priming system

Operation: Above shows diagrammatically a central priming system arranged to give automatic priming to four pumps. The system can be used for as many pumps of the centrifugal type that would be used in an engine room. Water ring exhausters maintain a vacuum condition between pre-set limits in the vacuum tank. Opening the priming cock, or solenoid-driven non-return valve, for a pump causes priming to take place. To prevent water entering the vacuum tank after priming, float-operated air release valves will automatically close.

central priming system contd

Line diagram of central priming system.

central priming system contd

For essential services a solenoid valve would be fitted instead of a priming cock so that if the valve is inadvertently left open, and due to maloperation or a defect the vacuum in the tank is lost, air is not drawn into the pump and its suction lost with possible serious consequences to plant. Two water ring type of exhausters mounted on top of a water supply tank are shown, one would act as a stand by unit, but both could operate together in the event of heavy demand.

Materials used in pumps

The construction of the pump varies according to the purpose for which the pump is to be used

Non-salt water pumps (potable, engine cooling water etc. but excluding boiler feed pumps): High grade cast iron is used for the casings with bronze internals, the shaft material being either bronze or stainless steel (18 Cr/ 2 Ni) the latter material giving the better wear life

Materials used in pumps contd

1. Seawater pumps: Examples: seawater pumps, ballast pumps, general service pumps, bilge pumps. (These must, of course, also handle port, river and canal water.) It is normal to use all-bronze pumps (zinc free), the casing being gunmetal or cast and machined bronze; the impeller aluminium bronze (5 Fe/ 5.5 Ni) and the shaft material either stainless steel (EN57) for soft packed stuffing boxes, nickel-copper alloys (suitably hardened) or EN58J (18/10/3 Cr/Ni/Mo) under, mechanical seals or bearings. Sleeves and wear rings are of bronze or nickel copper alloys, depending on the severity of service conditions. Stainless steel shafts and stainless steel impellers for certain duties are becoming more appreciated.

Materials used in pumps contd

1. Boiler feed pumps: Because of the high pressures and temperatures involved these invariably have cast steel casings (0.25% carbon steel) with stainless steel shafts and impellers. Highly rated turbodriven pumps have 3% Ni-Cu-Mo forged alloy steel shafts.

Materials used in pumps contd

1. Fresh water pumps: For fresh water services, cast iron is sometimes used for casings, but bronze is the most common casing material for condensate and other low-pressure pumps. Various grades of stainless steel are used for high-pressure boiler feed pump casings. Impellers for low-pressure services are of bronze or nickel-copper alloys and are of stainless steel for boiler feed service. Shafts for low-pressures are of carbon steel or stainless steel and of stainless steel for boiler feed services. Sleeves and wearing rings are of bronze, nickel-copper alloys or stainless steel depending on the severity of the service.