06-pump fundamentals & specialapplications

8/16/2019 06-Pump Fundamentals & SpecialApplications

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Pump Fundamentals& Special Applications

15/30/16



Agenda

• Pump Fundamentals• Head & Pressure (Distinction)

• System Curve (Static / Dynamic Head)

• NPSH & Cavitation (Importance)

• Special Applications• Filter Press Feed (Minimum & maximum conditions)

• Cyclone Feed (Cyclone pressure)

• Slurry with Froth (Froth factor)

• Tailings (Total TDH and eleation

25/30/16



Head versus Pressure

HEAD is

• The elevation of a column ofliquid

• The phsical height a!ove areference point

• "easured in feet or meters

• #ndependent of the liquid $%

• The preferred method ofspecifing pump performance

P!ESS"!E is

• The force per unit area e&erted! the liquid column

• 'sed to specif the equipmentrequirements

• "easured in (%/cm2) *ars) +Pa

• A function of the liquid $%

• 'sed to confirm if pump designpressure rating is suita!le for thedut

5/30/16 3



E##ect o# Speci#ic $ravity on Static Head

30.5 M 30.5 M 30.5 M

30.5 kPa



5

,elocit is the +e-• #mpeller increases the liquid.s velocit

• asing converts velocit to pressure or head

• Head in the casing increases as ou travel around the perimeter

• The larger the impeller or the faster the shaft speed the higher thevelocit

• "ore ,elocit Higher Head

,elocit Head



6

Casing

%mpeller

Single Stage End

Suction Pump



i+e this-Animated %raphic4



Pump undamentals

• $tatic ifferential Head 7levation change i&ed4

• riction Head oss Pipe friction ,aria!le4

• Total namic Head $tatic Head 8 riction loss

• Pressure psi4 TH & $% / 2931

:5/30/16



elocity Head

elocity Head 'hvs( is the energy a li)uid

re)uires to go #rom stationary state to

velocity

elocity Head 'hvd( is the discharge energy ali)uid has as it goes out the discharge

elocity Head * + ,+g

%t is part o# the total head calculation



elocity Head

E-ample

.ater shoots out the top o# a vertical pipe a certain

height 'drin/ing #ountain(

Head in the pipe can 0e measured with a $auge1

The height it shoots out o# the pipe cannot1

That height a0ove the pipe is roughly the elocity

Head1



Pump Per#ormance E)uations

Total Dynamic Head 'TDH(

TDH * 'Hd 2 Hs( 3 Hvs 3 Hvd 3 H#

Hd * Discharge Head '#eet or meters(

Hs * Suction Head '#eet or meters(

Hvs * elocity Head 2 Suction

Hvd * elocity Head 2 DischargeH# * Friction loss



System Friction Curve

S4STE5 F!%CT%6N C"!E

A $raph which represents the Total Head that a pump

must produce to deliver various )uantities o# li)uid to a

given discharge location in the System

1 Consists o#

• The Static Head 'elevation di##erence(

• The Frictional Head 'resistance to #low(



System Friction Curves



System Friction Curves

F!%CT%6NA7 TA87ES 9: Std1 Steel Pipe



The System TDH

TDH = (Hddisch - Hssuct

) + Hvent + Hvexit +

Hf pipe



System Head Curve

Static Head

Selected flow: 250

New Pt. at 6.0 Ø 210 @ 155 Ft.

Original Pt: 150 GPM @ 100 Ft.



The Head 'a0solute( re)uired at the impeller eye #or the

pump operating at !P5 necessary to deliver the #low

rate at speci#ied TDH

%t is roughly e)ual to 0arometric pressure 'in #eet , meters

o# slurry( plus or minus static head less #riction losses

in te piping and vapor pressure o# the li)uid

NPSH! * hatm 3 Hssuct 2 hvent 2 hvp 2 h# suct 'All values at the impeller eye(

S$

Net Positive Suction Head



Net Positive Suction Head

Constant Flow

o

t

a

l

H

e

a

d

F

e

e

t

of Total

Head

NPSH at 3% drop = 8 ft.

Question - What happens when NPSHA dops !e"ow NPSH# $



Cavitation occurs when the Pressure

'NPSHAvaila!le( at the impeller eye drops 0elow

the apor Pressure 'NPSH!equired(

Cavitation is the continuous #ormation and

collapse o# apor 8u00les as the li)uidtravels through the impeller

This collapse '%mplosion( o# the 0u00les

releases a lot o# energy causing damage tothe impeller and other wear components

Cavitation



Cavitation Damage



Special Applications

Filter Press Feed• 'suall the final or ;aste slurr product is fed into a filter cloth

press to !e de;atered and form a ca+e for transport / disposal

• Pressure or vacuum is applied to reduce the moisture content

• Pump starts at high flo;) lo; head < lo; =P" , control4

• As the press starts to fill up flo; starts to decrease and pump=P" is increased to overcome the increased resistance

• ilter presses run in ccles per hour > 3) ?) 5 or 6

• @eed to +no; the t;o e&treme dut points along ;ith slurrdetails to correctl select and sie the pump

5/30/16 21




Filter Press Feed

• ut Points-• "a& flo;- 1)3?5 gpm 305 m3/hr4 :195 ft 2?9: m4 60 psi ?1? +Pa4

• "in flo;-1B? gpm ?? m3/hr4 2??95 ft ?95 m4 1:0 psi 12?2 +Pa4

• $lurr- ;65C) $%$olids29) d:020B D") $%$lurr19

• ilter presses ccles per hour E 5

• Pac+ed !o& ;ith seal ;ater9 Fften dr gland e&pellers used

• , controlled motor < end of ccle recirculation mode

• $elect pump model) sie) =P" and motor sie

• Pump ?&6>21 "odel 5500

5/30/16 22



9-;2+< 5odel ==>> 2 Duty Points

5/30/16 23




Cyclone Feed• 'suall used to separate the coarse and fine solid factions in

the slurr E P:0 split

• Tpicall used primar and secondar grinding circuits li+e the

$A% mill and !all mill• The required cclone pressure converted to head must !e

added to the TH9 @o discharge velocit head is included inthe TH calculation

• clone inlet pressure usuall 12>15 psi or :3>10? +Pa4 isconverted to head and added to the TH

• As pump ;ears) ,s often used to maintain cclone pressure

5/30/16 2?




Cyclone Feed

• ut Point-• ut- 1)100 gpm 250 m3/hr4 6592 ft 1B9B m4 ?: psi 331 +Pa4

• clone-12 psi :3 +Pa4 1693 ft 590 m4

• $lurr- ;65C) $%$olids29) d:02000 D") $%$lurr19

• TH 50 hstatic4 8 ?9: hentrance4 8 109? hfriction4 8 1693 hcclone4 :195 ft

• Pac+ed !o& ;ith seal ;ater9 $ometimes dr gland e&pellers used

• Ghat happened to the hdischarge

• Pump 6&6>21 "odel $=>IT) @= lined

• "etal impellers preferred

5/30/16 25



;-;2+< 5odel S!72?T

5/30/16 26




Slurry with Air , Froth• =eagents are used to form !u!!les to float mineral sulfide of

some ores for recover9 7&ample- "o$2 "ol!denum isulfide4

• roth is difficult to pump and can cause performance issues li+e

• Air !inding of the impeller ee• =educed flo;) TH and efficienc

• $ome of the options to handle froth include

• 'sing an oversie pump for the larger volume

• $pecial forth pump ;ith a larger inlet an inducer tpe impeller • %oulds $=>$ pump ;ith $hearpeller J

• $=>$ pump can handle up to 295 froth factor ;ithout over siing

5/30/16 2



Shearpeller TM

• 'nique impeller design to handleslurries ;ith froth / entrained airor long / string particles

• =eplaces standard impeller

• arger pump not required

• ,ariet of materials availa!le



Model SRL - S

@ $ies

•

2&2>10• 3&3>10• 5&?>15•

:&6>1:• 10&:>21• 12&10>25• 1?&12>2B• 16&1?>3?

lo;s to +>>>> %P"Heads to <+= eetroth factors to +1=



Slurry with Air , Froth• $cavenger oncentrate Fverflo; pump

• $lurr flo; 00 usgpm9 TH 5>ft9 roth factor 390• $lurr- ;30C $%$olids39? $%$lurr1926

5/30/16 30



=-92<9 5odel S!72S

5/30/16 31



=-92<9 5odel S!72S

5/30/16 32

•Ghen using the $=>$ pump) please note the follo;ing-• Githout froth) a 5&?>1? $=> pump is suita!le for the service

• Gith 390 froth factor) the larger 10&:>21 $=> pump is required $election KAL4

• The 10&:>21 $=> pump efficienc has !een corrected for losses due to high froth

• Ho;ever) a standard 5&?>1? $=> pump can !e easil retrofitted in the field to a

KShearpeller TM

L arrangement ;ith no modifications to the piping and/or foundations• *oth the 5&?>1? $=>$ $election K*L4 and 10&:>21 $=> $election KAL4 require 5

HP motors

• The 5&?>1? $=> dut point is left of *7P ;hereas the 10&:>12 $=> is past the*7P

• apital cost for 5&?>1? $=>$ pump is much lo;er than the 10&:>21 $=> pump

• Al;as select $=>$ dut point left of *7P

• Prefera!le range is 50C > B5C of *7P



3?

Tailings Pumps

• Nou can calculate the sstem head if static head)

pipeline length) diameter < material are +no;n• $ometimes) pipe sie recommendation is requested

• #mportant to +no; critical carring velocit• Ge use !et;een ?95 fps 195 mps4 E 12 fps 39 mps4

• Haen < Gilliams formula is the easiest method tocalculate sstem friction loss



35

"ulti>$tage Tailings ine

• @ote the follo;ing for Tailings pipeline-

• Account for highest point in sstem ;hendetermining static head

• High densit polethlene ;ith appropriate pressurerating is commonl used

• $peed adOustment is often required due to changesin flo; < elevation

• Fne or more pumps ma have , control




5ulti2Stage Tailings

• ut Point-• ut- 5000 gpm 1)136 m3/hr4 50 ft 22:96 m4 3B3 psi 2)12 +Pa4

• $uction pipe 1?L # 350 mm4 ength 10 ft 393 m4 ,s 109? fps 392 mps4

• ischarge pipe 16L # ?00 mm4 ength 1:)300 ft 596 +m4 ,d :90 fps 29? mps4

• opper tailings- ;2:C) $%$olids2965) d:0100 D") $%$lurr1921

• TH 550 hstatic4 8 19 hentrance4 8 1B93 hfriction4 8 190 he&it4 50 ft

• A single stage centrifugal pump cannot produce this TH

•Fptions include ?) 5 or 6 pumps in series

• =u!!er impeller can !e used ;ith 6 pumps in series

• Pump 1?&12>2B "odel $=>IH ?00 psi4 @= lined

5/30/16 36



3

"'T#>$TA%7 P'"P#@%7IA"P7

• #f ;e go ;ith ru!!er and 6 pumps in series)

• onditions for single pump ;ith 125 ft TH should!e entered into ePrism

• $ometimes !etter to enter si& individual pumps ;ith

same TH !ut different suction pressures9 This;a the correct motor sies can !e selected

• ePrism cannot currentl differentiate !et;een asingle and multi>stage service9 Nou must manuall

select the high pressure ?00 psi4 version of the1?&12>2B $=>IH pump

• Al;as !etter to have at least t;o pumps ;ith ,



3B

"'T#>$TA%7 P'"P#@%



?0

"'T#>$TA%7 P'"P#@%



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