9
www.gjaet.com Page | 308 Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016 ISSN (Online): 2277-6370 & ISSN (Print):2394-0921 TESTING AND VALIDATION FOR VIBRATION REDUCTION OF A CENTRIFUGAL PUMP Suhas Sangle 1 , A. N. Surde 2 1,2 Mechanical Engineering Department, Walchand Institute of Technology, Solapur Abstract: Centrifugal pump plays an important role in industries and it requires continuous monitoring to increase the availability of the pump. The pumps are the key elements in food industry, waste water treatment plants, agriculture, oil and gas industry, paper and pulp industry, etc. It is necessary to be interested in vibration in centrifugal pumps because it has a major effect on the performance. Generally, increasing vibration levels indicate a premature failure, which always means that the equipment has started to destroy itself. It is so because excessive vibrations are the outcome of some system malfunction. It is expected that all pumps will vibrate due to response from excitation forces, such as residual rotor unbalance, turbulent liquid flow, pressure pulsations, cavitations, and/or pump wear. The magnitude of the vibration will be amplified if the vibration frequency approaches the resonant frequency of a major pump, foundation and/or piping component. Generally higher vibration levels (amplitudes) are indicative of faults developing in mechanical equipment. Harmonic analysis performed to correlate physical test results through FEA. All 3 directions are physically tested and correlated for system without isolators. Results plotted initially without isolators are validated with FEA and then in FEA different shapes were tried like round, groove and tapers to find the best isolator mount for specific centrifugal pump application to reduce vibrations in Vertical Direction. Key Words : Isolators, Centrifugal Pump, Vibration Amplitude, FEA I. INTRODUCTION To ensure the safety of pump and associated plant components, the vibration and noise must be kept within safer limits. Higher vibrations ultimately results in decreased component’s life due to cyclic loads, lower bearing life, distortion to foundation, frequent seal failures etc. Higher vibrations ultimately results in decreased component life due to cyclic loads, lower bearing life, distortion to foundation, frequent seal failures etc. Similarly noise has got huge impact on working environment and comfort conditions of an individual. Exact diagnosis of vibration and noise sources is very difficult in centrifugal pumps as this may be generated due to system or the equipment itself. [2]. Vibrations basically are the displacement of a mass back and forth from its static position. The major challenge in diagnosis of vibrations and noise in centrifugal pumps is service of the centrifugal pump itself. In centrifugal pumps the root of vibrations and noise may lie in mechanical or hydraulic aspects. It is very easy to trace the mechanical causes but it becomes very difficult to trace hydraulic causes. This makes pumps vibration and noise diagnostic very complex. A) Sources of Vibrations in Centrifugal Pumps The sources of vibration in centrifugal pumps can be categorized into three types as below: Mechanical causes Hydraulic causes Peripheral causes B) Diagnosis of Vibrations in Centrifugal Pump: Vibration measurement: Mechanical vibrations are most often measured using accelerometers, but displacement probes and velocity sensors are also used. Generally, a portable vibration analyzer is preferred. The analyzer provides the amplification of the sensor signal, it does the analogue to digital conversion, filtering, and conditioning of the signal. Many analyzers also offer advanced processing of the collocated signals as well as storage and display of the data. II. EXPERIMENTAL SETUP Assumptions: The force that will cause the vibration, must overcome the structure’s mass, stiffness and damping properties. Structure’s mass, stiffness and damping properties are inherent to the structure and will depend on the materials and design of the machine. As discussed in introduction, vibrations basically are the displacement of a mass back and forth from its static position. A force will cause a vibration, and that vibration can be described in terms of acceleration, velocity or displacement. It is necessary to be interested in vibration in centrifugal pumps because it has a major effect on the performance. Generally, increasing vibration levels

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Page 1: TESTING AND VALIDATION FOR VIBRATION · PDF fileTESTING AND VALIDATION FOR VIBRATION ... best isolator mount for specific centrifugal pump ... The sources of vibration in centrifugal

www.gjaet.com Page | 308

Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016

ISSN (Online): 2277-6370 & ISSN (Print):2394-0921

TESTING AND VALIDATION FOR VIBRATION

REDUCTION OF A CENTRIFUGAL PUMP Suhas Sangle1, A. N. Surde2

1,2Mechanical Engineering Department, Walchand Institute of Technology, Solapur

Abstract: Centrifugal pump plays an important role in

industries and it requires continuous monitoring to

increase the availability of the pump. The pumps are

the key elements in food industry, waste water

treatment plants, agriculture, oil and gas industry,

paper and pulp industry, etc.

It is necessary to be interested in vibration in

centrifugal pumps because it has a major effect on the

performance. Generally, increasing vibration levels

indicate a premature failure, which always means that

the equipment has started to destroy itself. It is so

because excessive vibrations are the outcome of some

system malfunction. It is expected that all pumps will

vibrate due to response from excitation forces, such as

residual rotor unbalance, turbulent liquid flow,

pressure pulsations, cavitations, and/or pump wear.

The magnitude of the vibration will be amplified if the

vibration frequency approaches the resonant

frequency of a major pump, foundation and/or piping

component. Generally higher vibration levels

(amplitudes) are indicative of faults developing in

mechanical equipment.

Harmonic analysis performed to correlate physical

test results through FEA. All 3 directions are

physically tested and correlated for system without

isolators. Results plotted initially without isolators are

validated with FEA and then in FEA different shapes

were tried like round, groove and tapers to find the

best isolator mount for specific centrifugal pump

application to reduce vibrations in Vertical Direction.

Key Words: Isolators, Centrifugal Pump, Vibration

Amplitude, FEA

I. INTRODUCTION

To ensure the safety of pump and associated plant

components, the vibration and noise must be kept

within safer limits. Higher vibrations ultimately results

in decreased component’s life due to cyclic loads, lower

bearing life, distortion to foundation, frequent seal

failures etc. Higher vibrations ultimately results in

decreased component life due to cyclic loads, lower

bearing life, distortion to foundation, frequent seal

failures etc. Similarly noise has got huge impact on

working environment and comfort conditions of an

individual. Exact diagnosis of vibration and noise

sources is very difficult in centrifugal pumps as this

may be generated due to system or the equipment itself.

[2]. Vibrations basically are the displacement of a mass

back and forth from its static position. The major

challenge in diagnosis of vibrations and noise in

centrifugal pumps is service of the centrifugal pump

itself. In centrifugal pumps the root of vibrations and

noise may lie in mechanical or hydraulic aspects. It is

very easy to trace the mechanical causes but it becomes

very difficult to trace hydraulic causes. This makes

pumps vibration and noise diagnostic very complex. A) Sources of Vibrations in Centrifugal Pumps

The sources of vibration in centrifugal pumps can be

categorized into three types as below:

Mechanical causes

Hydraulic causes

Peripheral causes

B) Diagnosis of Vibrations in Centrifugal Pump:

Vibration measurement:

Mechanical vibrations are most often measured using

accelerometers, but displacement probes and velocity

sensors are also used. Generally, a portable vibration

analyzer is preferred. The analyzer provides the

amplification of the sensor signal, it does the analogue

to digital conversion, filtering, and conditioning of the

signal. Many analyzers also offer advanced processing

of the collocated signals as well as storage and display

of the data.

II. EXPERIMENTAL SETUP Assumptions:

The force that will cause the vibration, must overcome

the structure’s mass, stiffness and damping properties.

Structure’s mass, stiffness and damping properties are

inherent to the structure and will depend on the

materials and design of the machine.

As discussed in introduction, vibrations basically are

the displacement of a mass back and forth from its

static position. A force will cause a vibration, and that

vibration can be described in terms of acceleration,

velocity or displacement.

It is necessary to be interested in vibration in

centrifugal pumps because it has a major effect on the

performance. Generally, increasing vibration levels

Page 2: TESTING AND VALIDATION FOR VIBRATION · PDF fileTESTING AND VALIDATION FOR VIBRATION ... best isolator mount for specific centrifugal pump ... The sources of vibration in centrifugal

www.gjaet.com Page | 309

Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016

ISSN (Online): 2277-6370 & ISSN (Print):2394-0921

indicate a premature failure, which always means that

the equipment has started to destroy itself. It is so

because excessive vibrations are the outcome of some

system malfunction. It is expected that all pumps will

vibrate due to response from excitation forces, such as

residual rotor unbalance, turbulent liquid flow, pressure

pulsations, cavitation and/or pump wear. The

magnitude of the vibration will be amplified if the

vibration frequency approaches the resonant frequency

of a major pump, foundation and/or piping component.

Generally higher vibration levels (amplitudes) are

indicative of faults developing in mechanical

equipment.

It is also important to know the location to mount the

vibration mounts. We know that a force cause vibration.

If we know what types of forces are generating the

vibration, we will have a good idea how they will be

transmitted through the physical structure of the

machine and where they will cause vibrations. With

rotating machines, this point is almost always directly

on the machine’s bearings.

Figure 1: Radial locations of probe mounting

Figure 2: Axial locations of probe mounting

The reason for this is that the various dynamic forces

from a rotating machine must be transmitted to the

foundation through the bearings. As a rule of thumb,

vibration readings on rotating machines must be taken

in the horizontal, vertical and axial direction on each

bearing as shown in figures as mentioned.

Experimental Setup available at client location as

shown in schematic below:

Figure 3: Overall system schematic

Experimental Setup available at client location as

shown below:

(a) Probe at Horizontal (b) Probe at Horizontal direction

direction

Figure 4: Experimental setup at client’s location

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Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016

ISSN (Online): 2277-6370 & ISSN (Print):2394-0921

III. HARMONIC ANALYSIS

Harmonic analysis (HA) is a technique to determine the

response of a structure to sinusoidal (harmonic) loads of

known frequency.

Input: Harmonic loads (forces, pressures, and

imposed displacements) of known magnitude

and frequency. Loads may be multiple loads,

in-phase or out-of-phase, all at the same

frequency.

Output: Harmonic displacements at each

DOF, usually out of phase with the applied

loads and other derived quantities, such as

stresses and strains.

Harmonic analysis is used in the design of supports,

fixtures, and components of rotating equipment such as

compressors, engines, pumps, and turbo-machinery.

And structures subjected to vortex shedding (swirling

motion of fluids) such as turbine blades, airplane wings,

bridges, and towers. A harmonic analysis is used to

make sure that a given design can withstand sinus oidal

loads at different frequencies (e.g.: an engine running at

different speeds) and to detect resonant response and

avoid it if necessary (by using dampers, for example).

Assumptions and Restrictions of HA

Valid for structural, fluid, magnetic, and

electrical degrees of freedom (DOFs).

Thermal DOFs may be present in a coupled

field harmonic analysis using structural

DOFs.

The entire structure has constant or frequency-

dependent stiffness, damping, and mass effects.

All loads and displacements vary sinusoidally

at the same known frequency (although not

necessarily in phase).

Element loads are assumed to be real (in-

phase) only, except for current density and

pressures in SURF153, SURF154, SURF156,

and SURF159 elements

Following are locations of probes for which Response

of Pump will be measured.

Figure 5: Locations at Probe

FEA Validation with Physical Testing:

Harmonic Analysis performed to correlate Physical test

results through FEA. Which will reduce the

experimentation with different isolators and some finite

quantity of isolator can be chosen for physical test.

Different isolator models were tried in FEA from which

4 best isolator models were taken for physical testing.

Below are correlation graphs for FEA and Physical

Testing without Isolator.

Graphs shows better correlation of FEA results and

Physical Test results considering the excitation

frequency and amplitude of vibration.

Frequency domain:

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 200 400 600 800

A1-Axial-Freq Vs Acceleration

comparative Test and FEA

0

5

10

15

0 200 400 600 800

A1-Vertical-Freq Vs Acceleration

comparative Test and FEA

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Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016

ISSN (Online): 2277-6370 & ISSN (Print):2394-0921

With Isolators:

Isolator Dampers are used to minimize the

vibration levels. Different types of isolators are chosen

to get minimum vibration acceleration and vibration

displacement levels.

Circular type isolators are used with different

shapes to investigate the required stiffness and optimum

stiffness for mounting purpose. Different shapes of

isolators such as Round (Circular) diameter 2.5”, round

isolator diameter 1.5”, Circular with grooves, Tapered,

were chosen for experiment.

2.5” diameter Circular Isolator:

Fig. 6 2.5” diameter circular Isolator

While experimenting, 2.5” diameter circular

isolators (as shown in figure 6) are used as dampers to

minimize the vibration levels. Using these isolators,

vibration acceleration and vibration displacement

readings were taken.

Acceleration: Vertical

Graph 1 Vertical position: Acceleration Vs Frequency

Acceleration is measured with Vertical

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

48 Hz is lowest frequency with 3.5 m/s^2 amplitude

whereas without isolator it was 10.28 m/s^2 at 278.4

Hz.

Acceleration: Transverse

Graph 2 Transverse position: Acceleration Vs Frequency

0

2

4

6

8

10

12

14

16

0 200 400 600 800

A1-Transverse-Freq Vs Acceleration

comparative Test and FEA

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Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016

ISSN (Online): 2277-6370 & ISSN (Print):2394-0921

Acceleration is measured with Transverse

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

48 Hz is lowest frequency with 1.67 m/s^2 amplitude

whereas without isolator it was 12.5 m/s^2 at 277 Hz.

Acceleration: Axial

Graph 3 Axial position: Acceleration Vs Frequency

Acceleration is measured with Axial

accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

863 Hz is lowest frequency with 1.04 m/s^2 amplitude

whereas without isolator it was 0.43 m/s^2 at 425 Hz.

Displacement: Vertical

Graph 4 Vertical position: Displacement Vs Frequency

Displacement is measured with vertical

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

it reaches 17 Hz is lowest frequency with 0.274µm

amplitude.

Displacement: Transverse

Graph 5 Transverse position: Displacement Vs

Frequency

Displacement is measured with Transverse

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

15 Hz is lowest frequency with 0.49 µm.

Displacement: Axial

Graph 6 Axial direction: Displacement Vs Frequency

Displacement is measured with Axial

Accelerometer setting to get Frequency and Amplitudes

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Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016

ISSN (Online): 2277-6370 & ISSN (Print):2394-0921

respectively. From Above graph it can be observed that

11 Hz is lowest frequency with 0.229 µm amplitude.

NOTE: For the other isolators, only values of

acceleration amplitudes and displacement amplitudes

are discussed without graphs.

Grooved Isolator:

Fig.7 Grooved Isolator

While experimenting, grooved isolators (as shown in

figure 7) are used as dampers to minimize the vibration

levels. Using these isolators, vibration acceleration and

vibration displacement readings were taken.

Acceleration: Vertical

Acceleration is measured with Vertical

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

48 Hz is lowest frequency with 4.48 m/s^2 amplitude

whereas without isolator it was 10.28 m/s^2 at 278.4

Hz.

Acceleration: Transverse

Acceleration is measured with Transverse

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

48 Hz is lowest frequency with 1.58 m/s^2 amplitude

whereas without isolator it was 12.5 m/s^2 at 277 Hz.

Acceleration: Axial

Acceleration is measured with Axial

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

48 Hz is lowest frequency with 7.33 m/s^2 amplitude

whereas without isolator it was 0.43 m/s^2 at 425 Hz.

Displacement: Vertical

Displacement is measured with Vertical

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

16 Hz is lowest frequency with 0.347 µm amplitude.

Displacement: Transverse

Displacement is measured with Transverse

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

14 Hz is lowest frequency with 0.423 µm amplitude.

Displacement: Axial

Displacement is measured with Axial

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

13 Hz is lowest frequency with 0.557 µm amplitude.

Tapered Isolator:

Fig.8 Tapered Isolator

While experimenting, tapered isolators (as

shown in figure 8) are used as dampers to minimize the

vibration levels. Using these isolators, vibration

acceleration and vibration displacement readings were

taken.

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Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016

ISSN (Online): 2277-6370 & ISSN (Print):2394-0921

Acceleration: Vertical

Acceleration is measured with Vertical

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

48 Hz is lowest frequency with 17.8 m/s^2 amplitude

whereas without isolator it was 10.28 m/s^2 at 278.4

Hz.

Acceleration: Transverse

Acceleration is measured with Transverse

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

48 Hz is lowest frequency with 6.56 m/s^2 amplitude

whereas without isolator it was 12.5 m/s^2 at 277 Hz.

Acceleration: Axial

Acceleration is measured with Axial

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

241 Hz is lowest frequency with 3.56 m/s^2 amplitude

whereas without isolator it was 0.43 m/s^2 at 425 Hz.

Displacement: Vertical

Displacement is measured with Vertical

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

16 Hz is lowest frequency with 0.726 µm amplitude.

Displacement: Transverse

Displacement is measured with Transverse

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

12 Hz is lowest frequency with 0.595 µm amplitude.

Displacement: Axial

Displacement is measured with Axial

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

14 Hz is lowest frequency with 0.17 µm amplitude.

1.5” Diameter Circular Isolator

Fig.9 1.5” diameter circular Isolator

While experimenting, 1.5” diameter circular

isolators (as shown figure 9) are used as dampers to

minimize the vibration levels. Using these isolators,

vibration acceleration and vibration displacement

readings were taken.

Acceleration: Vertical

Acceleration is measured with Vertical

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

47 Hz is lowest frequency with 10.2 m/s^2 amplitude

whereas without isolator it was 10.28 m/s^2 at 278.4

Hz.

Acceleration: Transverse

Acceleration is measured with Transverse

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

48 Hz is lowest frequency with 3.67 m/s^2 amplitude

whereas without isolator it was 12.5 m/s^2 at 277 Hz.

Acceleration: Axial

Acceleration is measured with Axial

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

1044 Hz is lowest frequency with 0.88 m/s^2 amplitude

whereas without isolator it was 0.43 m/s^2 at 425 Hz.

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Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016

ISSN (Online): 2277-6370 & ISSN (Print):2394-0921

Displacement: Vertical

Displacement is measured with Vertical

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

10 Hz is lowest frequency with 1.91 µm amplitude.

Displacement: Transverse

Displacement is measured with Transverse

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

21 Hz is lowest frequency with 0.29 µm amplitude.

Displacement: Axial

Displacement is measured with Axial

Accelerometer setting to get Frequency and Amplitudes

respectively. From Above graph it can be observed that

10 Hz is lowest frequency with 0.947 µm amplitude.

IV.CONCLUS ION

Investigation lead results best for 2.5” diameter circular

Isolator in which the vibration levels are well below the

vibration levels when no isolator and are gives quite

good results compared to all other isolator. Grooved

isolator is used as baseline isolator which shows better

vibration results compared to tapered isolator and 1.5”

diameter circular isolator.

Below are the tables to understand vibration and

frequency levels.

REFERENCES

[1] Stefano, Marco, Giordano and Stojmenovic,

“Mobile ad-hoc networking- The cutting-edge

directions”, John-wiley, 2013.

[2] Wornell and Laneman, “An efficient protocol for

realizing cooperative diversity in wireless networks”,

IEEE ISIT, 2001, page 294.

[3] N.R. Sakthivel a, V. Sugumaran b, S. Babudeva

senapati a, “vibration based fault diagnosis of

monoblock centrifugal pump using decision tree”expert

systems with applications 37(2010),pages 4040-4049.

[4] A.A. Nasser, M.A.Nasser, E.H.T. El-Shirbeeny, and

S.M.Abdel-Rahman “Modal analysis of a centrifugal

pump” undergoing research for ph.D research titled

"Dynamic Analysis and Control of lrrigation and

Drainage Pumping System in Egypt, Faculty of

witho

ut

2.5"

dia.

Circu

lar

Groov

e Taper

1.5"

dia.

Circul

ar

Freq.

(Hz) 278.4 48 48 48 47

Acc.

Amp.

(m/s2)

10.28 3.5 4.48 17.8 10.2

Vibr.

Red

(%)

- 65.95 56.42 -73.15 0.778

Freq.

(Hz) 425 863 48 241 1044

Acc.

Amp.

(m/s2)

0.43 1.04 7.33 3.56 0.88

Vibr.

Red

(%)

- -

141.8

-

1604.6 -727.9 -104.6

Freq.

(Hz) 277 48 48 48 48

Acc.

Amp.

(m/s2)

12.5 1.67 1.58 6.56 3.67

Vibr.

Red

(%)

- 86.64 87.36 47.52 70.64

Isolator

Vertical Axial Transverse

Freq

(Hz)

Disp.

Amp (µm)

Freq

(Hz)

Disp

Amp

(µm)

Freq

(Hz)

Disp.

Amp (µm)

2.5” dia Circular

17 0.274 11 0.229 15 0.49

Groove Round

16 0.347 13 0.557 14 0.423

Taper Round

16 0.726 14 0.17 12 0.595

1.5”

dia.

Circular

10 1.91 10 0.947 21 0.29

T

r

a

n

s

v

e

r

s

e

a

x

i

al

v

e

r

t

i

c

a

l

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Global Journal of Advanced Engineering Technologies Volume 5, Issue 3- 2016

ISSN (Online): 2277-6370 & ISSN (Print):2394-0921

Engineering, Shebin El-Kom, Menoufia University,

Egypt, pages 550-557.

[5] A Syam Prasad, BVVV Lakshmipathi Rao, A Babji,

Dr P Kumar Babu, “Static and dynamic analysis of a

centrifugal pump impeller”, International Journal of

Scientific & Engineering Research, Volume 4, Issue 10,

October-2013.

[6]Karthik Matta, Kode Srividya, Inturi Prakash,

“Static and Dynamic Response of an Impeller at

Varying Effects”, IOSR Journal of Mechanical and

Civil Engineering (IOSR-JMCE), (Vol. 11, Issue 1, Jan.

2014), pp. 101-106.

[7]https://www.google.co.in/search?q=images+of+cen

trifugal+pump&biw.

[8] Mukesh sahdev, “Centrifugal pumps: Basic

concepts of operation, maintenance and

troubleshooting(Part-1)”