Design of Triplex Plunger Pump

Abdullah Al-Jubran
Ali Al-Qahtani
HaitamAl-Mubarak
Project Advisor: Dr. Emad Tanbour
A Design Project Submitted in Partial Fulfillment
of the Requirements for the Course
Assessment III: Graduation Project
College of Engineering
Department of Mechanical Engineering
Statement of Purpose
To design a triplex plunger pump that can be
manufactured using locally available
resources and manufacturing techniques
To practice the application of computer-aided
design program in the design of machines
College of Engineering
Department of Mechanical Engineering
Table of Contents
Introduction
Scope of Project
Pumps Classification
Triplex Pump Basics/Concept
Calculations
Crankshaft Diameter
Bearings
Triplex Pump Prototype
College of Engineering
Department of Mechanical Engineering
Introduction
Triplex Plunger Pump
Positive Displacement Pump
Three Plungers in parallel
High-Pressure Low-Capacity Application
hydrostatic testing
water blasting
surface preparation
car washing
pipe and tube cleaning
oil drilling
College of Engineering
Department of Mechanical Engineering
Scope of Project
Designing of Triplex Plunger Pump
Discharge Pressure: 350 bar (5,076 psi)
Flow Rate: 24 li/min (6.3 gpm)
Crankshaft
Bearings
Material Selection
Fasteners
Making of Digital Prototype
College of Engineering
Department of Mechanical Engineering
Design Approach
Group Brainstorming
Gather Literatures from the web
Design Conceptualization
Identification of Critical Components
Sizing and Strength Calculations
Prototyping by CAD Solidworks
College of Engineering
Department of Mechanical Engineering
Triplex Pump Design GANTT Chart
College of Engineering
Department of Mechanical Engineering
Positive Displacement Pump versus Centrifugal Pump
Classification Diagram of Displacement Pumps
Classification Diagram of Displacement Pumps
Reciprocating Positive Displacement Pumps
1. Piston Pump
2. Plunger Pump 3. Diaphragm Pump
Higher Pressure Suitable for Chemicals
Good packing life
Expensive
Good for slurries
Easier to maintain
Ways to Achieve Reciprocating Motion
1. Crankshaft with crank pin
2. Crankshaft with eccentric sheave or strap
Slider Crank Mechanism
The offset between the shaft center and eccentric
sheave center determines the pump stroke
Plunger Pump with Eccentric Sheave
Critical Components
a. Crankshaft
b. Eccentric Sheave
c. Crankshaft Support Bearing
d. Eccentric Sheave Bearing
e. Wrist Pin
f. Wrist Pin Bearing
g. Fluid End Plunger
Design Calculations
Criteria: Displacement: 24 li/min
Discharge Pressure: 350 bar
# of Plungers: 3
Computation to determine required power
kW = Q Ptd / 36 ME
Where Q = delivered capacity, m3/h
Ptd = differential pressure (discharge suction), bar
ME = mechanical efficiency, %
At 24 liters/minute, 350 bar and typical efficiency of 88%,
(24 liters/min)(60min/hr)(1m3/1000liters)(350bar)
(360.88)
kW =
kW = 15.91 kilowatts, or 21.33 Hp
Computation to determine Pump Speed and Plunger Speed
Q = A m n s 6 10
-8
Sp = s n / 30,000
From Pump Handbook, 3
rd
edition, pages 3.4, 3.6
Where Q = displacement, m
3
/h
Sp = plunger speed, m/s
A = cross-sectional area of plunger, mm
2
M= number of plungers
n = rpm of pump
s = stroke of pump, mm
Preselected Plunger Bore and Stroke
Plunger Bore Size : 18, 19, 20, 21 and 22 mm
Plunger Stroke : 21, 22, and 23 mm
Plunger Bore, mm Plunger Stroke,
mm
Pump Speed, rpm Plunger Speed,
m/s
18
21 1,497 1.05
22 1,429 1.05
23 1,367 1.05
19
21 1,344 0.94
22 1,283 0.94
23 1,227 0.94
20
21 1,213 0.85
22 1,158 0.85
23 1,107 0.85
21
21 1,100 0.77
22 1,050 0.77
23 1,004 0.77
22
21 1,002 0.70
22 957 0.70
23 915 0.70
Table 1 Pump Speed at Different Plunger Bore and Stroke
The obtained plunger speeds above are in accordance with the industry
standard
Computation to determine Pump Required Torque
From Pump Handbook, 3
rd
edition, page 3.8
M = p 9.549 / n
Where M = pump torque, Nm
n = speed, rpm
p = power, W
Plunger Bore, mm Plunger Stroke,
mm
Pump Speed, rpm Torque,
N m
18
21 1,497 102
22 1,429 106
23 1,367 111
19
21 1,344 113
22 1,283 118
23 1,227 124
20
21 1,213 125
22 1,158 131
23 1,107 137
21
21 1,100 138
22 1,050 145
23 1,004 151
22
21 1,002 152
22 957 159
23 915 166
a. Calculation to Determine Crankshaft Diameter
a. Calculation to Determine Crankshaft Diameter
Where D = shaft diameter, mm
K
t
= shock and endurance factor applied to computed twisting
moment
(Table 14-2 Machine Design Data Book, 2
nd
ed. page 14.18)
M
t
= twisting moment or torque, Nm

yd
= design yield stress, Pa
From Machine Design Data Book, 2
nd
edition, page 14.3
16

yd
K
t
M
t
D =

1000
For rotating shafts with dynamic load, dynamic effect taken
indirectly into consideration
The diameter of shaft subjected to simple torsion
From Machine Design Data Book, 2
nd
edition, page 14.18
Using AISI 1020 steel which has a yield strength of about 206 MPa,
and using a design factor of 1.5,

max
= 206 MPa 10
^6
Pa/MPa
(2 1.5)

max
= 68,666,666 Pa
From Shigley's Mechanical Engineering Design, 8
th
Edition, page 212

max
= S
y
/ 2n
Where
max
= maximum shear stress, Pa
S
y
= yield stress, Pa
n = design factor
16
3.1415 68,666,666
1.5 M
t D =

1000
Plunger Bore,
mm
Plunger Stroke,
mm
Pump Speed,
rpm
Pump Torque,
Nm
Computed
Shaft
Diameter, mm
18
21 1,497 102 22.4
22 1,429 106 22.8
23 1,367 111 23.1
19
21 1,344 113 23.3
22 1,283 118 23.6
23 1,227 124 24.0
20
21 1,213 125 24.1
22 1,158 131 24.4
23 1,107 137 24.8
21
21 1,100 138 24.9
22 1,050 145 25.3
23 1,004 151 25.6
22
21 1,002 152 25.6
22 957 159 26.0
23 915 166 26.4
Table 1: Computed Shaft Diameter at Different Plunger Bore and Stroke
b. Calculation to Determine Eccentric Sheave Diameter
S
d
2
= (s/2) + (D/2) + s
w
Where S
d
= eccentric sheave diameter, mm
s = plunger stroke, mm
D = shaft diameter, mm
s
w
= minimum sheave width, mm
- pre-selected to be 4.7625 mm (3/16 inch) to facilitate easy
welding of the eccentric sheave to the shaft
Plunger Bore,
mm
Plunger Stroke,
mm
Computed Shaft
Diameter, mm
Ecc. Sheave
Diameter, mm
18
21 22.4 53.0
22 22.8 54.3
23 23.1 55.7
19
21 23.3 53.8
22 23.6 55.1
23 24.0 56.5
20
21 24.1 54.6
22 24.4 56.0
23 24.8 57.3
21
21 24.9 55.4
22 25.3 56.8
23 25.6 58.2
22
21 25.6 56.2
22 26.0 57.6
23 26.4 59.0
Table 2: Eccentric Sheave Diameter at Different Shaft Size
c. Calculation to Determine Strength of Eccentric Sheave Weldment
Stresses in welded joints in torsion
" = Mr / J
Where = shear or torsional stress, Pa
M = torsional moment, Nm
r = distance from the centroid of the weld group to the point in the weld
of interest, m
J = second polar moment of area, m
4
For circular fillet welds
J
u
= 2 r
3
The distance from the centroid of the weld group to the point in the weld of interest,
r, can be taken as the radius of the shaft.
The force exerted by the plunger
F
p
= Pressure Plunger Cross-Sectional Area
Example, 22mm plunger bore
F
p
= (350 bar) (100KPa/bar) (1000Pa/Kpa) (1N/m
2
/Pa)
(22mm/1000mm/m)
2
/4
F
p
= 13,304 N
Maximum moment = F
p
(stroke/2). For 23mm stroke,
M = 13,304 N (23mm/1000mm/m) 2
M = 153 Nm
J = 0.707hJu
By using the results above, the stress on the 3/16 inch fillet weld can be calculated.
(153Nm)(27mm/1000mm/m)2
(0.707)(3/16in.)(1m/39.37in.)(23.1415)((27mm/1000mm/m)2)
3
" =
" = 39,682,448 N/m
2
or 39.7 MPa (5.473 ksi)
c. Calculation to Determine Crankshaft Bearing
Bearing Catalog Load Rating
C
10
=
1/a
F
D
L
D
n
D
60
L
R
n
R
60
Where C
10
= catalog load rating, kN
F
D
= desired radial load, kN
L
D
= desired life, hours
n
D
= desired speed, rev/min
L
R
= rating life, hours
n
R
= rating speed, rev/min
a = constant; a = 3 for ball bearings, a = 10/3 for roller bearings
For most bearing manufacturers L
R
n
R
60 = 10
6
C
10
=
1/a
F
D
L
D
n
D
60
10
6
Forces acting on the crankshaft bearing
Total maximum force acting on the bearing
F
b1
=
1
2
F
p2
+
3
4
F
p1
F
b1
=
5
4
F
p
Where F
p
= Pressure Plunger Cross-Sectional Area
F
p
= (350 bar) (100KPa/bar) (1000Pa/Kpa) (1N/m
2
/Pa)
(bore in mm/1000mm/m)
2
/4
= F
bmax
Plunger Bore, mm
18 19 20 21 22
F
P
, k N
8.91 9.92 11.0 12.12 13.30
F
bmax
11.13 12.40 13.74 15.15 16.63
Table 3: Maximum Bearing Load at Different Plunger Bore Sizes
Plunger Bore, mm
18 19 20 21 22
F
P
, (kN)
8.91 9.92 11.0 12.12 13.30
F
bmax
, (kN)
11.13 12.40 13.74 15.15 16.63
n
D
, (rpm)
1,497 1,344 1,213 1,100 1,002
L
D
, (hours)
5,000 5,000 5,000 5,000 5,000
C
10
, (kN)
(ball bearing)
85.25 91.64 98.12 104.71 111.40
C
10
, (kN)
(roller bearing)
69.55 75.03 80.61 86.31 92.11
Computed Shaft
Dia, (mm)
23.1 24.0 24.8 25.6 26.4
Std. Shaft
Dia., (mm)
25 25 25 30 30
Available
Bearing
- - - - -
Table 4: Shaft Bearing Load Rating
Plunger Bore, mm
18 19 20 21 22
F
P
, (kN)
8.91 9.92 11.0 12.12 13.30
F
bmax
, (kN)
11.13 12.40 13.74 15.15 16.63
n
D
, (rpm)
1,497 1,344 1,213 1,100 1,002
L
D
, (hours)
5,000 5,000 5,000 5,000 5,000
C
10
, (kN)
(ball bearing)
85.25 91.64 98.12 104.71 111.40
C
10
, (kN)
(roller bearing)
69.55 75.03 80.61 86.31 92.11
Computed Shaft
Dia, (mm)
23.1 24.0 24.8 25.6 26.4
Initial Std. Shaft
Dia., (mm)
25 25 25 30 30
Adjusted Std.
Shaft Dia., (mm)
30 30 30 30 30
Available
Bearing, SKF
NU 2306
NJ 2306
NU 2306
NJ 2306
NU 2306
NJ 2306
- -
Table 4: Shaft Bearing Load Rating
Available SKF Bearing for the crankshaft
Plunger Bore, mm
18 19 20
F
P
, (kN)
8.91 9.92 11.0
n
D
, (rpm)
1,497 1,344 1,213
L
D
, (hours)
5,000 5,000 5,000
C
10
, (kN)
(ball bearing)
68.20 73.31 78.50
C
10
, (kN)
(roller bearing)
55.64 60.02 64.49
Eccentric Sheave
Internal Dia., (mm)
30 30 30
Eccentric Sheave
Outside Dia., (mm)
60 60 60
Available Bearing,
SKF
NKIS 60
NA 4912
NKI 60/35
NKIS 60
NA 4912
NKI 60/35
NKIS 60
Table 5: Eccentric Sheave Bearing Load Rating
e. Pump Driver Selection
e. Pump Driver Selection
e. Pump Driver Selection
Manufacturer Hp Speed, rpm
Efficiency,
%
Cost, $ Cat. No.
GE
25 1,200 91.7 2,312 S279
25 1,200 93.0 2,800 M7549
Baldor 25 1,200 93.0 5,090 ECP4111T
Siemens 25 1,200 91.7 2,480
1LE29313A
C116AA3
TECO
Westinghouse
25 1,200 91.7 3,438 N0256
25 1,200 93.0 4,456 EP0256
25 1,200 93.0 4,635 HH0256
Table 6: List of Applicable Drive Motors
e. Pump Driver Selection
Manufacturer Hp Speed, rpm
Efficiency,
%
Cost, $ Cat. No.
GE
25 1,200 91.7 2,312 S279
25 1,200 93.0 2,800 M7549
Baldor 25 1,200 93.0 5,090 ECP4111T
Siemens 25 1,200 91.7 2,480
1LE29313A
C116AA3
TECO
Westinghouse
25 1,200 91.7 3,438 N0256
25 1,200 93.0 4,456 EP0256
25 1,200 93.0 4,635 HH0256
Table 6: List of Applicable Drive Motors
Plunger
Bore,mm
Plunger
Stroke, mm
Speed, rpm Remarks
18
21 1,497
Disregarded. Motor speed is only
1,200 rpm.
22 1,429
23 1,367
19
21 1,344
Disregarded. Motor speed is only
1,200 rpm.
22 1,283
23 1,227
20
21 1,213
Disregarded. Motor speed is only 1,200 rpm
22 1,158 Selected Plunger Bore & Stroke
23 1,107 Disregarded. Not optimal.
21
21
Disregarded. No crankshaft bearing available. 22
23
22
21
Disregarded. No crankshaft bearing available. 22
23
Selected Plunger Bore and Stroke
Since the standard shaft diameter chosen is 30mm, and the eccentric
sheave diameter is 60mm, the minimum sheave thickness, s
w
, is
recalculated.
S
d
2
= (s/2) + (D/2) + s
w
From
s
w
=
S
d
- s - D
2
s
w
=
60 - 22 - 30
2
= 4 mm
f. Calculation to determine wrist pin size
AISI 1030 steel is chosen because of higher yield strength than AISI
1020 steel.
Based on maximum shear stress theory, the maximum allowable shear
stress,

max
= S
y
/ 2n
Where the yield strength, S
y
, for 1030 steel is equal to 260 Mpa. Using a
design factor of 1.5,

max
= 260 / (21.5) = 86.7 Mpa
f. Calculation to determine wrist pin size (contd)
Wrist pin will fail by shearing on sections a and b.

max
= Fp / (A
a
+ A
b
)
But since the cross-sectional area of the wrist pin is the same, therefore
A
a
=A
b
, then,
Where A = cross-sectional area of wrist pin.

max
= F
p
/ 2A = F
p
2(d
w
2
/4) ; d
w
= wrist pin diameter
By transposing the equation above
d
w
= (4F
p
/2
max
)
1/2
411kN1000N/kN
23.141586.7Mpa10
6
Pa/Mpa
d
w
=
d
w
= 0.00899m or 8.99mm
The next preferred size is chosen which is 10 mm.
g. Computation to determine the wrist pin bearing
The bearing size is selected based on the static load rating, C
0
, because
the wrist pin
Basic static load rating C
0
a. makes a slow oscillating or alignment movements under load
b. rotates under load at very low speed
C
0
= S
0
P
0
Where C
0
= basic static load rating, kN
P
0
= equivalent static bearing load, kN
S
0
= static safety factor
Based on SKF guideline, for non-rotating roller bearing with normal
operations, S
0
=1. Since P
0
=11kN, then
C
0
= 111kN
C
0
= 11kN
From SKF catalogue, a drawn cup needle roller bearing with C
0
=11.4kN is
available. The bearing designation is HN1010.
h. Bill of Materials
Item Description Specifications Quantity
1 Crankshaft 30 mm O.D., AISI 1020 steel 1
2
Crankshaft Suppport
Bearing
SKF NU 2306 or NJ 2306 2
3 Eccentric Sheave 60 mm I.D., AISI 1030 steel 3
4 Eccentric Sheave Bearing SKF NKIS 60 3
5 Wrist Pin 10 mm O.D., AISI 1030 1
6 Wrist Pin Bearing SKF HN 1010 1
7 Motor GE M7549 1
j. Triplex Pump Solidworks Digital Prototype
j. Triplex Pump Solidworks Digital Prototype
j. Triplex Pump Solidworks Digital Prototype
j. Triplex Pump Solidworks Digital Prototype
i. Triplex Pump Solidworks Digital Prototype
j. Triplex Pump Solidworks Digital Prototype