Discharge Pressure P

FIGURE 17 Head-capacity (flow rate) performance curve with viscosity a parameter—for two speeds.

liquids are accordingly known as true or Newtonian liquids, for which the viscosity is constant. Another class of liquids, however, such as cellulose compounds, glues, greases, paints, starches, slurries, and candy compounds, displays changes in viscosity as agitation is varied at constant temperature. The viscosity of these substances depends upon the shear rate at which it is measured, and these fluids are termed non-Newtonian.

If a substance is known to be non-Newtonian, the expected viscosity under the actual pumping conditions should be determined, because it can vary quite widely from the viscosity under static conditions. Since a non-Newtonian substance can have an unlimited number of viscosity values (as the shear rate is varied), the term apparent viscosity is used to describe its viscous properties. The apparent viscosity is expressed in absolute units and is a measure of the resistance to the flow at a given shear rate. It has meaning only if the shear rate used in the measurement is also given.

The grease-manufacturing industry is very familiar with the non-Newtonian properties of its products, as evidenced by the numerous curves that have been published of the apparent viscosity plotted against the rate of shear. The occasion is rare, however, when one can obtain accurate viscosity information when it is necessary to select a pump for handling these products.

It is practically impossible in most instances to give the viscosity of grease in the terms most familiar to the pump manufacturer, such as Saybolt Seconds Universal or Saybolt Seconds Furol, but only a rough approximation would be of great help. For applications of this type, data taken from similar installations are most helpful. Such information should consist of the type, size, flow rate, and speed of the installed pumps; the suction pressure; the temperature at the pump inlet flange; the total working suction head; and, above all, the pressure drop in a specified length of piping. From the latter, a satisfactory approximation of the effective viscosity under the operating conditions can be obtained.

If accurate shear rate-viscosity data are available, they can be used to more accurately predict pump performance. The shear rates in various areas of the pump can be calculated to determine the viscosity changes of the liquid as it passes through the pump. In this way, the effect on suction loss, slip, and friction loss can be analyzed to help predict the NPSH, flow rate, and power.

Speed It was previously stated that viscosity and speed are closely tied together and that it is impossible to consider one without the other. Although rotative speed is the ultimate outcome, the basic speed that the manufacturer must consider is the internal axial velocity of the liquid going through the rotors. This is a function of pump type, design, and size.

Rotative speed should be reduced when handling liquids of high viscosity. The reasons for this are not only the difficulty of filling the pumping elements, but also the mechanical losses that result from the shearing action of the rotors on the substance handled. The reduction of these losses is frequently of more importance than relatively high speeds, even though the latter might be possible because of positive inlet conditions.

Capacity The delivered capacity (flow) of any screw pump, as stated earlier, is the theoretical capacity less the internal leakage, or the slip, when handling vapor-free liquids. For a particular speed, Q = Qt — S, where the standard unit of Q and S is the U.S. gallon per minute (cubic meter per minute).

The delivered capacity of any specific rotary pump is reduced by

• Decreasing speed

• Decreased viscosity

• Increased differential pressure

The actual speed must always be known. Most often, it differs somewhat from the rated or nameplate specification. This is the first item to be checked and verified in analyzing any pump performance. It is surprising how often the speed is incorrectly assumed and later found to be in error.

Because of the internal clearances between rotors and their housing, lower viscosities and higher pressures increase the slip, which results in a reduced flow rate for a given speed. The impact of these characteristics can vary widely for the various types of pumps. The slip, however, is not measurably affected by changes in speed and thus becomes a smaller percentage of the total flow at higher speeds. This is a significant factor in the handling of low-viscosity fluids at higher pressures, particularly in the case of untimed screw pumps that favor high speeds for the best results and best volumetric efficiency. This will not generally be the case with pumps having support-bearing speed limits. Pump volumetric efficiency Ev is calculated as

_ = Q = Q — S Ev Qt Qt with Qt varying directly with speed. As stated previously, the theoretical capacity of a screw pump varies directly as the cube of the nominal diameter. Slip, however, varies approximately with the square of the nominal diameter. Therefore, for a constant speed and geometry, doubling the rotor size will result in an eightfold increase in theoretical flow rate and only a fourfold increase in slip. It follows therefore that the volumetric efficiency improves rapidly with increases in the rotor size.

On the other hand, viscosity changes affect the slip inversely to a certain power, which has been determined empirically. An acceptable approximation for the range of 100 to 10,000 SSU is obtained by using the 0.5 power index. Slip varies approximately with the differential pressure, and a change from 400 SSU to 100 SSU will double the slip in the same way as will a differential pressure change of 100 to 200 lb/in2 (7 to 14 bar):


Figure 18 shows the flow rate and volumetric efficiencies as functions of pump size.

Pressure Screw pumps do not in themselves create pressure; they simply transfer a quantity of fluid from the inlet to the outlet side. The pressure developed on the outlet side is solely the result of resistance to the flow in the discharge line. The slip characteristic of a particular pump type and model is one of the key factors that determine the acceptable operating range, and it is generally well defined by the pump manufacturer.

Power The brake horsepower (bhp), or, in SI units, the brake kilowatts, required to drive a screw pump is the sum of the theoretical liquid horsepower (kilowatts) and the internal power losses. The theoretical liquid power twhp (tkW) is the actual work done in moving the fluid from its inlet pressure condition to the outlet at the discharge pressure.

FIGURE 18 Flow rate and volumetric efficiency as functions of pump size.

Note that this work is done on all the fluid of the theoretical capacity, not just the delivered capacity, as the slip does not exist until a pressure differential DP occurs. Screw pump power ratings are expressed in terms of horsepower (550 ft-lbf/sec) in USCS units and in terms of kilowatts in SI units. The theoretical liquid horsepower (kilowatts) can be calculated as follows:

It should be noted that the theoretical liquid horsepower (kilowatts) is independent of the viscosity and is a function only of the physical dimensions of the pumping elements, the rotative speed, and the differential pressure.

The internal power losses are of two types: mechanical and viscous. The mechanical losses include all the power necessary to overcome the frictional drag of all the moving parts in the pump, including rotors, bearings, gears, and mechanical seals. The viscous losses include all the power lost from the fluid drag effects against all the parts in the pump as well as from the shearing action of the fluid itself. It is probable that the mechanical loss is dominant when operating at low viscosities and high speeds, and the viscous loss is the larger of these two losses at high-viscosity and slow-speed conditions.

In general, the losses for a given type and size of pump vary with the viscosity and the rotative speed and may or may not be affected by pressure, depending upon the type and

DISCHARGE PRESSURE, BAR 0 50 100 150 200

DISCHARGE PRESSURE, BAR 0 50 100 150 200


FIGURE 19 Typical overall efficiency curves.


FIGURE 19 Typical overall efficiency curves.

model of pump under consideration. These losses, however, must always be based upon the maximum viscosity to be handled since they will be highest at this point.

The actual pump power output, whp (wkW), or the delivered liquid horsepower (kilowatts), is the power imparted to the liquid by the pump at the outlet. It is computed similarly to theoretical liquid horsepower (kilowatts) using Q in place of Qt. Hence, the value will always be less. The pump efficiency Ep is the ratio of the pump power output to the brake horsepower (see Figure 19).

Renewable Energy 101

Renewable Energy 101

Renewable energy is energy that is generated from sunlight, rain, tides, geothermal heat and wind. These sources are naturally and constantly replenished, which is why they are deemed as renewable. The usage of renewable energy sources is very important when considering the sustainability of the existing energy usage of the world. While there is currently an abundance of non-renewable energy sources, such as nuclear fuels, these energy sources are depleting. In addition to being a non-renewable supply, the non-renewable energy sources release emissions into the air, which has an adverse effect on the environment.

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