A detailed Report on Pumps which are used in refinery

, with focus on the facility at IOCL-Guwahati Refinery.

A Report submitted by:-

Name: MRINMOY JYOTI KALITA
Enrollment Number: MEB17040
Semester and Year: B.Tech 6th Semester ( 3rd Year)
Department : Department of Mechanical Engineering
Institute: School of Engineering, Tezpur Central University,
Napaam,Tezpur
 PREFACE

The stark advantage of humans over other animals is the ability to be inquisitive.
The hunger for knowledge and the curiosity of the unknown is the biggest
driving force of human development. As time passes by, humanity grows in its
ideas, and new skills are acquired.

As engineering undergraduates, with the world ahead of us, it is natural that

practical skills are as important as bookish texts. The real feel of pressure, of
expectations and the rush to meet critical deadlines is what makes an
undergraduate engineering student into a real-life engineer.

This report is the outcome of the things learned and experiences gained by the
author, as an internee in the state-of-the-art virtual internship of 30 days as
organised by the Guwahati Refinery, under IOCL. It rotates around the online
work undertaken by the internship mentor and the author in taking a firsthand
experience of a thermal power plant which powers the entire refinery
establishment, all under the constraints of the global CoVid-19 pandemic.

The internship is a breakthrough initiative by the officials at the L&D Cell,

Guwahati Refinery, and at IOCL, to bring the knowledge earned by the working
engineers at the establishment to the knowledge seeking student fraternity,
breaking all stereotypes and barriers.
 CERTIFICATE OF AUTHENTICITY

This is to certify that Mrinmoy Jyoti Kalita, from the Deparment of Mechanical Engineering
of School of Engineering, Tezpur Central University, has partaken in the state-of-the-art
virtual internship course of Indian Oil Corporation Limited (IOCL), Guwahati Refinery, for a
duration of 30 (thirty) days, under my guidance.

The internee has been meticulous in completing the assignment, and has handed it on time.
The report is not a copy of any existing document, and any references taken have been duly
credited in the Bibliography portion of the report.

The report is up to standard, and I am satisfied with the authenticity and quality of the report
submitted.

Aritra Pramanik
Asst. Manager (Mechanical)
Guwahati Refinery
 ACKNOWLEDGEMENT
At the outset, I would like to thank my institute, Tezpur Central University, for
providing me the opportunity to represent the institute in the virtual training
program of IOCL at Noonmati Refinery, Guwahati.

My parents and the various people involved in my developmental process have

to be especially thanked, as it would be nearly impossible to achieve such
heights without their blessings, support and guidance.

Next, I would like to thank Indian Oil Corporation Limited, especially the L&D
Cell at Guwahati Refinery Limited, for taking the pain of organising a state-of-
the-art virtual internship for the benefit of the student fraternity at large.

Finally, our able mentor and internship guide,Mr. Aritra Pramanik , Assistant
Manager (Mechanical) at IOCL-Guwahati Refinery, has to be highly praised for
his step-by-step evaluation process, his helping attitude and his details to
minutes. It has been a memorable and educational journey with him.

Mrinmoy Jyoti Kalita

MEB17040

6th semester B.Tech

 CONTENTS

Part 1: INTRODUCTION

a) Introduction of IOCL
b) Introduction of the Guwahati Refinery

Part 2: A TECHNICAL APPROACH OF SOME MECHANICAL EQUIPMENT

a) Introduction to Pumps
b) Types and details of positive displacement pumps
c) Positive displacement vs non positive displacements pumps
d) Working of centrifugal pumps
e) Details and functions of different components of centrifugal pumps
f) Bearings used in common centrifugal pumps
g) Types of seals used in industrial common centrifugal pumps
h) Types of couplings used in industrial common centrifugal pumps

Part 3: CONCLUSION

a) Final Overview
b) Bibliography
 Part 1: INTRODUCTION

a)INTRODUCTION OF INDIAN OIL CORPORATION LTD. (IOCL)

Indian Oil Corporation Limited (IOCL) is an Indian state-owned oil and gas corporation, with
its headquarters at the national capital. Counted as one of the giants in the oil and gas
production and distribution market at a global scenario, it is ranked as a Maharatna Company
under the Central Government Umbrella and also is regarded as one of the Fortune 500
companies. In the sector of petroleum products production and distribution, IOCL ranks 18th
in the global ranking as of 2016, and is at the pinnacle of all state owned oil and gas companies
in the Asia-Pacific region.
There are seven major Business Divisions in the organisation:
• • Refineries Division
• • Pipelines Division
• • Marketing Division
• • R&D Division
• • Petrochemicals Division
• • Exploration & Production (E&P) Division
• • Explosives and Cryogenics Division

Indian Oil accounts for nearly half of India's petroleum products market share, 35% national
refining capacity (together with its subsidiary Chennai Petroleum Corporation Ltd., or CPCL),
and 71% downstream sector pipelines through capacity. The Indian Oil Group owns and
operates 11 of India's 23 refineries with a combined refining capacity of 80.7 million tonnes
per year. Indian Oil's cross-country pipeline network, for the transport of crude oil to
refineries and finished products to high-demand centers, spans over 13,000 km. The company
has a throughput capacity of 80.49 million tonnes per year for crude oil and petroleum
products and 9.5 million cubic meters per day at standard conditions for gas. On 19
November 2017, IOC, in collaboration with Ola, launched India's first electric charging station
at one of its petrol-diesel stations in Nagpur.
Servo is the Lubricants brand under which IOCL operates its Lubricant business. Servo is the
Largest selling Lubricant Brand in both Automotive & Industrial segments.
IndianOil has the following refineries under its jurisdiction:
• • Barauni Refinery
• • Bongaigaon Refinery
• • CPCL, Chennai
• • CPCL, Narimanam
• • Digboi Refinery
• • Guwahati Refinery
• • Haldia Refinery
• • Koyali Refinery
• • Mathura Refinery
• • Panipat Refinery
• • Paradip Refinery
As for pipelines, IOCL has a huge network of crude and end product pipelines. The complete
list of the same is as under
• • Salaya - Mathura crude oil pipeline
• • Mundra - Panipat crude oil pipeline
• • Paradip-Haldia-Barauni crude oil pipeline
• • Koyali - Mohanpura product pipeline
• • Koyali - Ahmedabad product pipeline
• • Guwahati - Siliguri product pipeline
• • Barauni - Kanpur product pipeline
• • Haldia - Mourigram - Rajbandh product pipeline
• • Haldia - Barauni product pipeline
• • Panipat - Jalandhar LPG pipeline
• • Dadri - Panipat R-LNG pipeline
• • Koyali - Ratlam product pipeline
• • Koyali - Dahej/ Hazira product pipeline
• • Panipat - Bhatinda product pipeline
• • Panipat - Rewari product pipeline
• • Panipat - Ambala - Jalandhar product pipeline
• • Mathura - Delhi product pipeline
• • Mathura - Bharatpur product pipeline
• • Mathura - Tundla product pipeline
• • Chennai - Trichy - Madurai product pipeline
• • Chennai - Bangalore product pipeline
• • Chennai ATF pipeline
• • Bangalore ATF pipeline
• • Kolkata ATF pipeline
• • Paradip - Raipur - Ranchi product pipeline
• • Jaipur Panipat Naphtha Pipeline
• • Paradip - Hyderabad product pipeline

In short, Indian Oil Corporation Limited is a shining star in the Indian economy, and its open-
minded work environment, supportive employees and high benefits makes it one of the best
employers in the world, and ensures that the zest of the young mind to work and involve their
energies into the nation’s progressive growth is fulfilled.
 b) INTRODUCTION OF THE GUWAHATI REFINERY

Guwahati Refinery is a public sector oil and gas refining establishment, set up in Noonmati,
Guwahati on 1st January, 1962, and is presently under the umbrella of Indian Oil Corporation
Limited (IOCL). It holds the distinction of being the first public sector refinery on the Indian
soil. Inaugurated by Late Pandit Jawahar Lal Nehru, the first Prime Minister of independent
India, the refinery was built with Romanian Collaboration and has a capacity of 1.0 million
metric tonnes per annum. This refinery processes crude oil from Upper Assam Oil Fields, India
and helps cater energy need of the region. As of 2017, crude oil is also being transported into
the facility from other parts of the country, and thus over the past 50 years, it has grown
considerably from being a regional caterer of energy, to a national player.

LPG, Naphtha, Motor Spirit (MS), Aviation Turbine Fuel, Superior Kerosene Oil, High Speed
Diesel (HSD), Raw Petroleum Coke and Sulfur are the products of this Refinery. Auto fuels
MS and HSD supplied by the refinery are of eco-friendly BS-IV grade as per statutory
guidelines of Government of India. The production of these valuable petroleum products is
through a series of different primary and secondary processing units along with the associated
auxiliary facilities like Captive Power Plant installed within the refinery.

In the primary unit of the Refinery i.e. the Crude Distillation Unit (CDU), desalted crude from
the desalter is heated up through a series of heat exchangers and is fed into a pre fractionator
column. Here the lighter gases, LPG and unstabilised gasoline are separated. The outputs from
CDU are gasoline, Kero-I, Kero-II and Straight Run Gas Oil. Reduced Coke Oil (RCO) which is
the bottom product from the main fractionating column, forms the main raw material for
Coking unit and Indmax. In Naphtha Splitter section, total Straight Run Naphtha is separated
into three different fractions namely Light Naphtha (LN), Reformate Naptha (RN) and Heavy
Naptha (HN).

Delayed Coking Unit (DCU) with a capacity of 0.44 MMTPA is the main secondary unit of
Guwahati Refinery. The unit produces middle distillates from heavy ends. Main feedstock to
DCU is Reduced Crude Oil, which is heated to high temperatures of about 500oC in a furnace.
Due to high temperatures, RCO is thermallycracked and yields various hydrocarbon fractions
like LPG, coker gasoline, coker kerosene, coker gas oil, coker fuel oil, residual fuel oil and coke.
With growing environmental consciousness, Guwahati Refinery, Indian Oil Corporation
Limited has also ventured into ecologically friendly fuel and subsequently installed 3 new
units: the ISOSIV, the Hydrotreater and the INDMAX. The ISOSIV unit produces Lead Free
Petrol by the Molecular Sieve Technology, which separates Octane rich MS components from
feed naphtha. The Hydrotreater Unit (HDT) enables the Refinery to produce High Speed Diesel
of very low sulphur and cetane number conforming to BIS specifications. The HDT also
produces ATF, Superior Kerosene Oil with high smoke point and low sulphur. The Indane
Maximization (INDMAX) technology developed by R&D Centre of Indian Oil installed at the
Refinery is designed to achieve LPG yield as high as 44% through Fluidized Catalytic Cracking
of residual feed stocks like Reduced Crude Oil, Coker Fuel Oil and Coker Gasolene. The
INDMAX unit also enables Guwahati Refinery to upgrade all its residual products to high value
distillate products and make it a zero residue Refinery.
Guwahati Refinery is committed in its responsibility towards the community around it and
the larger society. It is also deeply committed in safeguarding and preserving ecological
balance. It has been taking proactive measures continuously for the improvement of safety,
health and environment standards due to progressive proximity of community settlements
around the Refinery. The measures include tree plantations, improvement in drainage
systems, house-keeping and cleanliness drives as well as substantive programmes adopted
on successive World Environment Days to enhance awareness of the individual and collective
responsibilities towards environment preservation among the employees and their families,
students and the community in general.

The Refinery's concerns for environment protection is further demonstrated by extensive

tree plantation and development of Ecological Park and Sanjeevani Udayan in and around
the Refinery further spearhead its efforts to the cause of ecological balance. Planting and
preserving bio-diversified species are continual efforts in preserving bountiful nature.
Periodic campaigns are also carried out in the neighborhood to bring home the importance
of clean environment.

Emergency planning and response is ensured through well laid out Onsite and Offsite Disaster
Management plans and periodic drills on simulated scenario. All credible scenarios like Fire
and Vapor Cloud Explosion, Oil Spill, Hydrocarbon release, Toxic gas release, flood, and
earthquake and security threats are incorporated in the Disaster Management Plans. To keep
air pollution in check, Guwahati Refinery has installed one Continuous Ambient Air Quality
Monitoring Station (AAQMS), with connectivity to CPCB server which continuously monitors
ambient air quality.

A number of efficient mechanisms for water pollution prevention and control are in place in
the Refinery. It has modified the API Separator by which there will be further improvment of
oil separation efficiency. A Electro chlorinator that is used to combat slime and algae
formation installed to provide continuous treated effluent chlorinated water. On-line
analyzers (pH, COD, BOD, TSS) are installed at Effluent Treatment Plant with connectivity to
CPCB server for continuous monitoring of treated effluent quality. An effluent treatment plant
with continuous system improvement by addition of Dual Media Filters, Dissolved Air
Flotation (DAF), Floating Drum Skimmer, full-fledged pollution control laboratory and reuse
of treated effluent in the Refinery ensures the adherence to applicable standards. The
Refinery has taken up initiatives for solid waste management with processing of Accumulated
Sludge through oil recovery Bio-remediation of Residual Sludge, processing of sludge in DCU.
Moreover, the Refinery has installed solar PV system in Canteen, solar panels at roof tops of
the various location of the refinery, replaced general lighting with LED, processed food waste
generated from canteen and Refinery Township, waste paper processing under sustainability
development.

In tune with IndianOil's commitment as a responsible stakeholder, Guwahati Refinery

implements various developmental initiatives under it CSR interventions for benefiting the
local community, especially in thrust areas like skill-development & education, empowerment
of women, healthcare & sanitation, safe drinking water, among others.
 Part 2: A TECHNICAL APPROACH OF SOME MECHANICAL EQUIPMENT

a) Introduction to Pumps
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical
action, typically converted from electrical energy into Hydraulic energy.Hydraulic energy is
the form pressure energy.
Pumps operate by some mechanism (typically reciprocating or rotary), and
consume energy to perform mechanical work moving the fluid. Pumps operate via many
energy sources, including manual operation, electricity, engines, or wind power, and come in
many sizes, from microscopic for use in medical applications, to large industrial pumps.
Application of Pump:-
Mechanical pumps serve in a wide range of applications such as pumping water from
wells, aquarium filtering, pond filtering and aeration, in the car industry for water-
cooling and fuel injection, in the energy industry for pumping oil and natural gas or for
operating cooling towers and other components of heating, ventilation and air
conditioning systems. In the medical industry, pumps are used for biochemical processes in
developing and manufacturing medicine, and as artificial replacements for body parts, in
particular the artificial heart and penile prosthesis.

Types of Pump :-
1) Positive displacement pump:-
2) Non positive displacement pump:-
 b) Types and details of positive displacement pumps:-

A positive displacement pump provides a constant flow at fixed speed, regardless of changes
in pressure.
The pump makes the fluid move by trapping a fixed amount and forcing the volume into the
discharge pipe. The liquid flows into the pump as the cavity on the suction side opens or
expands, whilst the liquid flows into the discharge as the cavity closes or decreases. Through
every cycle of operation, the volume is the same.
Different types of Positive displacement Pump:-
i) Gear pumps,
ii) Screw pumps,
iii) Vane pumps,
iv) Axial piston pumps.

i) Gear pumps:-
A gear pump is a type of positive displacement (PD) pump. It moves a fluid by repeatedly
enclosing a fixed volume using interlocking cogs or gears, transferring it mechanically using a
cyclic pumping action. It delivers a smooth pulse-free flow proportional to the rotational
speed of its gears.

Fig:- Gear Pump

ii) Screw Pumps:-

A screw pump, also known as a water screw, is a positive-displacement (PD) pump that use
one or several screws to move fluids or solids along the screw(s) axis. In its simplest form (the
Archimedes' screw pump), a single screw rotates in a cylindrical cavity, thereby moving the
material along the screw's spindle.
 Fig :- Screw Pumps

iii) Vane Pumps:-

Vane pumps are hydraulic pumps that operate at very low noise levels. Hydraulic vane pumps
operate with much lower flow pulsation, i.e. constant flow. As such, vane pumps produce less
noise while maintaining a relatively high speed of up to 3,000 rpm The hydraulic vane pump
finds its use in die casting and injection moulding machines in industry, as well as in land and
road construction machinery.

Fig:- Vane Pumps

iv) Axial piston pumps :-

An axial piston pump has a number of pistons (usually an odd number) arranged in a circular
array within a housing which is commonly referred to as a cylinder block, rotor or barrel. This
cylinder block is driven to rotate about its axis of symmetry by an integral shaft that is, more
or less, aligned with the pumping pistons (usually parallel but not necessarily).
 Fig:- Axial Piston Pump

Types of Non positive displacement pump:-

A non-positive displacement pump’s output flow rate can change in response to the pressure
on the outlet. They use Newton’s first law of motion to move fluid against the system
resistance. Although they provide smooth and continuous flows - their flow output is reduced
as the system resistance is increased.
Types of Non positive displacement pump:-

i) Centrifugal pumps

ii) Multi-stage pumps

iii) Axial (propeller) pumps

c) Specific application of Positive displacement pumps and

Centrifugal pumps:-
There are two main families of pumps; positive displacement and centrifugal (rotodynamic),
both of which have their uses and best areas of application. It is important however to be able
to identify when each pump type should be selected, which ultimately comes down to their
working principle and the application at hand.

Positive displacement pumps are characterised by an operation that moves fluid by trapping
a fixed volume, usually in a cavity, and then forces that trapped fluid into the discharge pipe.
A centrifugal pump transfers the kinetic energy of the motor to the liquid by a spinning
impeller; as the impeller rotates it draws in fluid causing increased velocity that moves the
fluid to the discharge point.
A quick comparison table:-

Below is a quick comparison table that highlights the main performance differences
between centrifugal (rotodynamic) pumps and positive displacement pumps.
Performance curve comparison :-

For visual reference of the performance comparisons between the two working principles see
below performance curves that show how both centrifugal and positive displacement pumps'
duty are affected by different factors.

What applications are centrifugal pumps used for?

Centrifugal pumps are the most common pump type for the transfer of low viscosity fluids
in high flow rate, low pressure installations, which makes them ideal for applications that
require the pump to deal with large volumes. The centrifugal pump design is often
associated with the transfer of water, but is also a popular solution for handling thin fuels
and chemicals:

 General water supply

 Sea water transfer

 Water circulation
 Air conditioning

 Boiler feed

 Light fuel transfer

 Petrochemical

 Washing and firefighting

 Irrigation

Whilst generally speaking centrifugal pumps are used with clean liquids, if the correct
impeller is selected i.e. a vortex impeller, some solids are able to be handled.

Centrifugal pumps benefit from a simple design with few moving parts, resulting in lower
maintenance requirements and costs. This makes them suited to applications where the
pump is used often or is even continuously run. The simplicity of the construction also
makes centrifugal pumps easy to produce in many different materials including plastics
and cast iron for lighter duties, and bronze and stainless steels for more corrosive or
hygienic application. Hence the multiple fluids that centrifugal pumps are suitable for use
with.

The centrifugal pump design is also very compact in comparison to other pump types that
produce the same output levels, making them a good option when space saving is an
issue.

When to use a positive displacement pump?

Positive displacement pumps are usually selected for their ability to handle high viscosity
fluids at high pressures and relatively low flows as their efficiency isn’t affected by
pressure. Whilst centrifugal pumps are the most common type of pump installed due to
their simplicity, positive displacement pumps are a solution that can handle more difficult
conditions where centrifugal pumps may fail, thanks to their ability to be run at any point
on their curve.

Generally speaking positive displacement pumps are designed for the transfer of high
viscosity fluids such as thick oils, slurries, sewage and pastes. Thanks to their internal
clearances, some types such as progressive cavity pumps and peristaltic pumps, are also
excellent at applications handling mediums containing high levels of solids including
dewatering ground water and waste oils. Screw and vane pumps on the other hand and
are ideal for pumping relatively clean fluids such as fuels and lubrication oils.

Being lower speed pumps than the centrifugal design, rotary positive displacement pumps
with larger pumping chambers such as progressive cavity, lobe and peristaltic pumps are
typically low shear pumps that provide a smooth flow. This allows them to pump shear
sensitive products that need their structure to remain intact such as olives that cannot be
squashed and adhesives that cannot lose their stickiness and gels that need to retain their
gel-like property.
 Positive displacement pumps are able to handle variations in pressure, flow and viscosity
and remain efficient, unlike centrifugal pumps which do not operate well off the centre of
their curve. As their flow rate remains constant (proportional to the speed of operation),
smooth and low pulsating despite changes in the pressure, positive displacement pumps
such as peristaltic, piston and diaphragm pumps are ideal solutions for dosing applications
as it allows accurate metering to be carried out.

d) Working of Centrifugal pumps:-

Centrifugal pumps are used to induce flow or raise a liquid from a low level to a high level.
These pumps work on a very simple mechanism. A centrifugal pump converts rotational
energy, often from a motor, to energy in a moving fluid.

The two main parts that are responsible for the conversion of energy are the impeller and the
casing. The impeller is the rotating part of the pump and the casing is the airtight passage
which surrounds the impeller. In a centrifugal pump, fluid enters into the casing, falls on the
impeller blades at the eye of the impeller, and is whirled tangentially and radially outward
until it leaves the impeller into the diffuser part of the casing. While passing through the
impeller, the fluid is gaining both velocity and pressure.

The following chief factors affect the performance of a centrifugal pump and need to be
considered while choosing a centrifugal pump:

 Working Fluid Viscosity – can be defined as resistance to shear when energy is

applied. In general, a centrifugal pump is suitable for low viscosity fluids since the
pumping action generates high liquid shear.
 Specific density and gravity of working fluid – The density of a fluid is its mass per
unit of volume. A fluid’s mass per unit volume and gravity of a fluid is the ratio of a
fluid’s density to the density of water. It directly affects the input power required to
pump a particular liquid. If you are working with a fluid other than water, it is
important to consider the specific density and gravity since the weight will have a
direct effect on the amount of work performed by the pump.
 Operating temperature and pressure – Pumping conditions like temperature and
pressures are an important consideration for any operation. For example - High-
temperature pumping may require special gaskets, seals and mounting designs.
Similarly, an adequately designed pressure retaining casing may be required for high-
pressure conditions.
 Net Positive Suction Head (NPSH) and Cavitation – NPSH is a term that refers to the
pressure of a fluid on the suction side of a pump to help determine if the pressure is
high enough to avoid cavitation. Cavitation refers to the formation of bubbles or
cavities in liquid, developed in areas of relatively low pressure around an impeller and
can cause serious damage to the impeller and lead to decreased flow/pressure rates
 among other things. One must ensure that the system’s net positive suction head
available (NPSHA) is greater than the pump’s net positive suction head required
(NPSHR), with an appropriate safety margin.
 Vapour pressure of the working fluid – The vapor pressure of a fluid is the pressure,
at a given temperature, at which a fluid will change to a vapor. It must be determined
in order to avoid cavitation as well as bearing damage caused by dry running when the
fluid has evaporated.

Fig-Working of centrifugal pump

e) Details and functions of different components of
centrifugal pumps:-
The following are the main components of a centrifugal pump:

1. Impeller

2. Casing

3. Suction pipe with a foot valve and a strainer

4. Delivery pipe

5. Pump Shaft

6. Diffuser

All the main parts of the centrifugal pump are shown in the above figure.

1. Impeller:- The rotating part of a centrifugal pump is called "impeller", It consists of a series
of backward curved vanes. The impeller is mounted on a shaft which is connected to the shaft
of an electric motor.

2. Casing:- The casing of a centrifugal pump is similar to the casing of a reaction turbine. It is
an air tight passage surrounding the impeller and is designed in such a way that the kinetic
energy of the water discharged at the outlet of the impeller is converted into pressure energy
before the water leaves the casing and enters the delivery pipe. The following three types of
the casings are commonly adopted:-

a) Volute casing

b)Vortex casing

c) Casing with guide blade

(a) Volute Casing. Figure shows the volute casing, which surrounds the impeller. It is of spiral
type in which area of flow increases gradually. The increase in area of flow decreases the
velocity of flow. The decrease in velocity increases the pressure of the water flowing through
the casing. It has been observed that in case of volute casing, the efficiency of the pump
increases slightly as a large amount of energy is lost due to the formation of eddies in this
type of casing.

Fig:- Main parts of centrifugal Pump

b)Vortex Casing. If a circutar chamber is introduced between the casing and the impeller as
shown in Fig, the casing is known as Vortex Casing. By introducing the circular chamber. the
loss of energy due to the formation of eddies is reduced to a considerable extent. Thus the
efficiency of the pump is more than the efficiency when only volute casing is provided.
c) Casing with Guide Blades. This casing is shown in Fig in which the impeller is surrounded by
a series of guide blades mounted on a ring which is known as diffuser. The guide vanes are
designed in such a way that the water from the impeller enters the guide vanes without
stock.Also the area of the guide vanes increases, thus reducing the velocity of flow through
guide vanes and consequently increasing the pressure of water. The water from the guide
vanes then passes through the surrounding casing which is in most of the cases concentric
with the impeller as shown in Fig.

3. Suction Pipe with a Foot valve and a Strainer:- A pipe whose one end is connected to the
inlet of the pump and other end into water in a sump is known as suction pipe. A foot valve
which is a non-return valve or one-way type of valve is fitted at the lower end of the suction
pipe. The foot valve opens only in the upward direction. A strainer is also fitted at the lower
end of the suction pipe.

4. Delivery Pipe:- A pipe whose one end is connected to the outlet of the pump and other
end delivers the water at a required height is known as delivery pipe.

5. Pump Shaft:-The impeller is mounted on a shaft. The shaft is usually made of steel or
stainless steel and is sized to support the impeller. Shafts have to be sized carefully. An
undersized shaft can result in increased pump vibration, shorter bearing life, the potential for
shaft breakage , and an overall reduced pump life. However, an oversize shaft can increase
the cost of the pump unnecessarily.
6. Diffuser:- Some centrifugal pumps contain diffusers. A diffuser is a set of stationary vanes
that surround the impeller. The purpose of the diffuser is to increase the efficiency centrifugal
pump by allowing a more gradual expansion and less turbulent area for the liquid to reduce
in velocity.

Fig- Diffuser in Centrifugal Pumps

 f) Bearings used in common centrifugal pumps:
All types of bearings have been used in centrifugal pumps, even magnetic bearings. The same
pump type (or model) is frequently even offered with two or more different bearing types,
dictated either by varying service conditions or by the preference of the purchaser. Most
pumps use either antifriction or oil film (sleeve-type) bearings, such as those listed below:

• Antifriction bearings
– Single-row, deep-groove ball bearing
– Double-row, angular contact ball bearing
– Single-row, angular contact ball bearing pair
– Cylindrical roller bearings
– Spherical roller bearings
– Taper roller bearings set
• Sleeve bearings*
• Pivoted-shoe thrust bearings*

These bearings are typically used for large pumps and motors with high thrust and/or radial
loads (exceeding antifriction bearing capabilities).

Antifriction Bearings
Antifriction bearings -- and especially ball bearings -- are most commonly used in small- and
medium-sized pumps because of their high speed capability and low friction. Most municipal
applications use antifriction bearings.

Bearing Cages:-
It is essential that the balls (or rollers) in antifriction bearings be equally spaced. For this
reason, a retaining cage is used between the balls and between the inner and outer races .
This cage carries no load, but the contact between it and the ball produces sliding friction that
generates a small amount of heat. Ball bearings are generally produced with glass fiber-
reinforced polyamide, pressed metallic (of either steel or brass) or machined brass.
All cage types can be used for a large variety of pump applications. However, reliability-
focused pump users will not allow the procurement and installation of bearings with
polyamide cages, especially for bearing applications above 212˚F. This stance is taken because
cage degradation will not appear on the most widely-used vibration data collectors and
portable vibration analyzers, and also because these cages have low temperature limitations.
Further, reliability-focused users avoid, or even disallow, bearings with riveted, two-piece
steel cages. Rivet heads can be a weak link on some pump applications if they pop off.

Radial Bearing:-
The purpose of a radial bearing, also known as a deep groove bearing, is to reduce rotational
friction and support loads. This is achieved by using two races to hold the balls and to spread
the load through the balls. As the bearing race rotates it causes the balls to rotate.

Shaft Bearing:-
A thrust bearing is a particular type of rotary bearing. Like other bearings they permanently
rotate between parts, but they are designed to support a predominantly axial load. Thrust
bearings come in several varieties.

Fig- Shaft Bearing

Ball Bearings:-
The most common antifriction bearings used in centrifugal pumps are the various types of
ball bearings. The most common ball bearings used on centrifugal pumps are single-row,
deep-groove; double-row, deep-groove; double-row, angular contact; and universally-
matchable, single-row, angular contact ball bearings. All except the double-row, self-aligning
bearings are capable of carrying thrust loads as well as radial loads.

Fig- Ball Bearings

Of these, the single-row, deep-groove ball bearing is the most commonly used bearing on
centrifugal pumps (except for larger size pumps). They are ideal for both radial thrust and
combined loads but require careful alignment between the shaft and the housing in which
the bearing is mounted. They are also sometimes used with seals built into the bearing in
order to exclude dirt, retain lubricant or both. The double-row, deep-groove ball bearings --
in effect, two single-row bearings side-by-side -- have greater capacity for both radial and
thrust loads.

Angular-contact ball bearings operate on a principle that makes them ideal for heavy thrust
loads. The single-row type is ideal for thrust in only one direction, whereas the double-row
type, which is basically two single-row bearings placed back-to-back (or face-to-face), can
carry thrust in either direction. A single-row, angular contact ball bearing can only be used
singly on centrifugal pumps if the thrust is always in one direction. This type of bearing is thus
primarily limited to vertical pump thrust bearing applications.

Single-row, angular contact bearing pairs are frequently matched, and the faces of the races
are ground by the manufacturer, so they can be used in tandem for large, one-directional
thrust loads or back-to-back for two-directional thrust loads. Double-row, angular contact
bearings, or their equivalent (a matched pair mounted back-to-back), have been found to be
very satisfactory for pumps that generate a high thrust load in either direction. The life of a
back-to-back bearing is about twice that of the comparable double-row bearing. Some
preload is required with angular contact bearings.

Roller Bearings:-
Roller bearings are used less often, although the spherical roller bearing is frequently used for
large shaft sizes. Since most roller bearings are suitable only for radial loads, their use on
centrifugal pumps tends to be limited.

Fig- Roller Bearing

Other Rolling Element Bearings Considerations:-

Now let's look at specific ways of reducing bearing failures and increasing bearing life:

 Excessive shaft fits increase bearing preload, which shortens their life. Follow
manufacturer shaft and bearing bore fit specifications.
 Angular contact bearing cage inclination generates outward through flow of lubricant,
which could oppose the lubricant flow.
 Face-to-face mounting promotes inward flow.
 Back-to-back mounted angular contact bearings are less sensitive to preloading from
hot shaft.
 Temperature difference between inner and outer bearing races increases the preload.
  Do not cool the exterior of an antifriction bearing housing since it will also cool the
bearing outer race, which will reduce the internal radial bearing operating clearances,
thus increasing the bearing load and reducing the bearing life.
 Do not use polyamide cages, especially above a bearing temperature of 212˚F.
 Avoid damage due to external causes (such as vibration and/or stray electric currents,
such as from a variable frequency drive).
 Avoid high-bearing loads from extended (single volute pump) high- or low-flow
operation and/or high-suction pressures. Bearing fatigue life is proportional to the
third power of the bearing load.
 Avoid unequal flow of the liquid into the two suction eyes of a split-case, double-
suction pump, due to an improper suction piping arrangement, to minimize the thrust
load.
 Users should be mindful in selecting original or replacement antifriction bearings,
because the interchangeable dimensional envelope of an AFBMA bearing does not
ensure that the size or number of balls are the same from one manufacturer to
another, thereby resulting in a possible change in the rating of the bearing.

Spherical Bearing :-

A spherical plain bearing is a bearing that permits angular rotation about a central point in
two orthogonal directions (usually within a specified angular limit based on the bearing
geometry). Typically these bearings support a rotating shaft in the bore of the inner ring that
must move not only rotationally, but also at an angle.

Self-aligning spherical bearings were first used by James Nasmyth around 1840 to support line
shaft bearings in mills and machine shops. For long shafts it was impossible to accurately align
bearings, even if the shaft was perfectly straight. Nasmyth used brass bearing shells between
hemispherical brass cups to align the bearings to self-align.

Fig- Spherical Bearing

 g) Types of seals used in common industrial centrifugal pumps:-
Mechanical seals are critical components in centrifugal pump systems. These devices preserve
the integrity of the pump systems by preventing fluid leaks and keeping contaminants out.
Mechanical seal systems are used on various seal designs to detect leakage, control the seal
environment and lubricate secondary seals.

Depending on the pump type and the process variables, there are various mechanical seal
types to choose from. Each seal variant has its unique design and characteristics which make
it suitable for a specific application.

This article highlights the benefits and drawbacks of the different types of mechanical seals
used in centrifugal pumps.

Different Types of Mechanical Seals for Centrifugal Pumps:-

Mechanical seal types vary in design, arrangement, and how they disperse the hydraulic
forces acting at their faces. The most common seal types include the following:

 Balanced seals
 Unbalanced seals
 Pusher seals
 Non-pusher seals
 Conventional seals
 Cartridge seals

Balanced Seals and Unbalanced Seals:-

Balanced mechanical seal arrangements refer to a system where the forces acting at the seal
faces are balanced. As a result of the lower face loading, there is more even lubrication of the
seal faces and longer seal life. Learn about our mechanical seal lubrication systems today.
Balanced mechanical seals are particularly suited to higher operating pressures, typically
above 200 PSIG. They are also a good choice when handling liquids with low lubricity and
higher volatility.
Unbalanced mechanical seal types are commonly employed as a more economical option to
the more complex balance seal. Unbalanced seals may also exhibit less product leakage due
to tighter control of the face film, but as a result can exhibit much lower mean time between
failure. Unbalanced seals are not recommended for high pressure or most hydrocarbon
applications.

Pusher and Non-Pusher Seals:-

Pusher seals utilize one or multiple springs to maintain seal closing forces. The springs can be
in the rotating or stationary element of the mechanical seal. Pusher type seals can provide
sealing at very high pressures but have a drawback due to the elastomer under the primary
seal face that can be subjected to wear as the face moves along the shaft/sleeve during
operation.

Non-pusher seals utilize a metal or elastomeric bellows to maintain seal closing forces. These
seals are ideally suited to dirty and high temperature applications. Bellows seals are limited
to medium/lower pressure applications.

Both pusher and non-pusher designs are available in balanced and unbalanced configurations.
Conventional Mechanical Seals:-
Conventional seals are typically lower cost and often installed on general service
equipment. These seals require higher operator skill to service as they installed as individual
components.

Cartridge Type Seals:-

Cartridge type mechanical seals incorporate all of the seal elements into a single assembly.
This dramatically reduces the potential for assembly error and the time require for seal
replacements. Learn more about the difference between cartridge and non-cartridge
mechanical seals today.
h)Types of couplings used in common industrial centrifugal pumps:-

Split Couplers - This is a solid metal coupler that connects the pump shaft to the motor
shaft. The picture on the left shows a split coupled inline pump. A close-up of the interior
coupling mechanism is shown on the right. A split coupler can make the pump easier to
service but notice that the coupling is made of steel and thus does not provide any flexion
whatsoever. The sole purpose of the split coupling is to connect a standard frame motor to
the pump end. If the motor shaft starts to vibrate due to motor bearing wear, the vibration
and movement will be transferred directly to the pump. If the pump end starts to vibrate due
to cavitation, operation off the end curve, mechanical seal wear due to water quality, or
simply age, the vibration will be directly transferred to the motor bearings and shaft.

Fig-Split couplers

Flexible Couplers - Flexible couplers are the type of couplers we usually see in base-
mounted pumps. These couplers are typically made of a rubber material sandwiched between
two metal hubs. This type of coupler joins the standard frame motor to the pump end but
also provides a certain amount flexion or bending movement. The flexion of the rubber insert
helps to protect motor bearings from pump borne damage mentioned above and protects
the pump from motor borne damage. This is important with the non-constant torque
associated with HVAC pumps and especially variable-speed systems.

Flexible couplers act as a sacrificial fuse that breaks to protect the motor bearings and the
pump shaft. (It is much less expensive to replace a flexible coupler than a shaft or bearing!) A
flexible coupler helps compensate for various types of misalignment that occur during typical
operation as shown here:

Fig-Flexible Couplers

Closed Coupled or Direct Coupled HVAC Pumps - Of course, there are some pumps
that do not have couplers at all. These are referred to as close coupled pumps. Close-coupled
pumps have a single shaft (instead of two connected shafts) that extends from the motor to
the pump body through an opening in the cover plate. The mechanical seal, shaft sleeve, and
impeller are all mounted on the motor shaft. There is no bearing assembly in the pump
section, so the motor bearings must absorb all of the torsional load. This means the bearings
have to be large, which makes the motors somewhat special and not as readily available on
larger sizes as motors on split or flexible coupled pumps.
 Fig-Close Couple Pump

While close-coupled pumps often take up less floor space, they can be tricky to service
because the motor must be removed for seal change and maintenance. An overhead gantry
and crane may be required to lift the motor away from the pump for servicing if the motor is
large and there is not enough horizontal space available to remove the motor. One advantage
of closed coupled pumps is they do not need to be aligned. This can be helpful if you have a
high speed (3600 rpm) application where the alignment tolerance are tight.
FINAL OVERVIEW:-
Pump is one of the important part of a industry. It is used to transportation of
fluid, relatively with high speed. Centrifugal pumps mostly used for Commercial
purpose. Centrifugal pumps has simple shape , So, it is cost effective.

By this internship, we learned the basics of different mechanical equipment such

as types of Pump, Centrifugal pump and the various components involved in
running a massive refinery as Guwahati Refinery.
BIBLIOGRAPHY:-
1) https://en.wikipedia.org/wiki/Pump

2) A textbook of fluid mechanics and hydraulic machines- R.K.Bansal

3)https://www.watertechonline.com/wastewater/article/16192812/centrifugal-pump-
bearings-tips-for-improving-reliability-and-reducing-
failure#:~:text=The%20most%20common%20ball%20bearings,as%20well%20as%20radial
%20loads.

4)http://jmpcoblog.com/hvac-blog/how-to-pick-a-centrifugal-pump-part-4-pump-
coupling-types-close-split-or-flexible-
coupled#:~:text=Centrifugal%20HVAC%20and%20plumbing%20pumps,the%20efficient%2
0transfer%20of%20power.&text=Split%20Couplers%20-
%20This%20is%20a,shaft%20to%20the%20motor%20shaft.

5) https://www.castlepumps.com/info-hub/positive-displacement-vs-centrifugal-pumps/

6) https://theconstructor.org/practical-guide/centrifugal-pump-working-types/2917/

7) https://momentumsys.com/different-mechanical-seal-types-for-centrifugal-pumps/

8) https://www.engineersedge.com/pumps/diffuser.htm
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