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    cavity pumps

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    4 views13 pages

    P1247 59

    Uploaded by

    emiljuchiac
    cavity pumps

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 13
    UNDERSTAND PROGRESSING CAVITY PUMPS CHARACTERISTICS AND AVOID ABRASIVE WEAR by Gerhard Vetter Professor and Wolfgang Wirth Research Engineer University of Erlangen-Nuremberg Erlangen, Germany Gerhard Vewer obyained his Dipl_Ing degree (Mechanical Engineering) at Tech hische Universitit Karlsruhe, Germany. Af ter same years as a Research Engineer in ‘urbomachinery a the same university, he Joined Lewa, Leonberg (Germany) as head ‘of the Research and Development Depart ‘ment. He became Chief Engineer ond, in 1970 Technical Managing Director. In 1981, hhe accepted a chair (professorship) for Ap- paratusand Chemical Machineryatthe Uni versity of Etlangen-Murembers. Dr. Veter has dedicated more than 2 yecrsto research, develop: ‘ment and design of pumps and metering equipment. He has been one ofthe pioneers in diaphragm pumps development. His many papers, patents and contributions 10 textbooks have established his reputa Fon as a pump specialist. Wolfgang Wirth obtained his Dipl.-Ing degree (Chemical Engineering) atthe Uni versity of Erlangen-Nuremberg, Germany (1986) and subsequently joined the Intute of Apparatus and Chemlcal Machinery at ¥ thesame insitution Asaresearch engineer, se prepareda thesis about methods for mod. SAGE illng the hydraulic and ribolagic proper- ries of progressing cavitypumpsand received his Dr-Ing. degree (1993), ABSTRACT Progressing cavity pumps develop their pumping action by the mesting of the external threads of the elastomer stator and. the intemal threads of the metallic rotor. The speciah geometcy, as characterized by the different pitches of stator and rotor threads and the eccentric motion of the rotor, is erea displacement chambers, which are periodically superposition, a constant flow against the pressure differential ‘The authors report on tbe influencing parameters on pump performance with respect to flow-speed-characteristcs, voiu mettic and energetic efficiency and starting torque. In all eases, the rotor/stator overlapping is featuring remarkable influences, Clearances between stator and rotor inerease the internal leakag ‘and decrease mechanical friction. Overlapping rotor/stator design yields internally Hight pumps, but increased mechanical ” friction. With theoretical and experimental investigations, an understanding of the pump performance is presented. The tests clearly show an optimum of energetic efficiency to exist for a certain overlapping Tacies. The theoretical modelling of the ‘pump performance proves to be very difficult, due to tolerances ‘onclearance dimensions from manufacture and thermal or chemo- physical expansion as well, But nevertheless, a first rule of ‘thumb for estimating pump efficiency based on leakflow tests ‘and determination of the friction coefficient u by means of & tribometer are given, Furthermore by droabrasive wear ests and possibilities of theoretical modelling are given, AAs progressing cavity pumps sre frequently used for such applications as transporting abrasive suspensions and slurries, this subject is very important and implementing anew scientific approach. The tribological system inthe pump in that service is jominated by sliding hydroabrasive wees. ‘The wear mec isms is explained and a model presented by considering the rermeshing geometry and the relative time interval for contact fof a stator surface element. Field tests with progressing cavity ‘pumps using quartz-suspensions and different material selection ‘emensirate basically good correlation wit the model, indicat ing clearly that the wear rate varies strongly with the local position on the rotorsurface. A large numberof tribological tests conducted with especial rotary sliding tribomtetr chat is simu lating the rotating and oscillating motion in the progressing cavity pump quite closely, delivered wear rates correlating ‘Quantitatvely With field test results and, thus, offer @ rovgh possibility for endurance prediction. Based on tribological esis with the adequate triboreter and the real pumping fluid, the optimum pump design may be elaborated. INTRODUCTION Progressing cavity pumps are capable of handling a wide spectrum of fluids. The range of applications extends ftom pumping water out of deep wells 1, 2] to the transport of highly viscous fluids intermixed with particles, even to pumping of ready-mixed stucco and plaster at construction sites (Figure 1) Foran econatnical employment ofthese pumps, itis essential to understand the different potential influences on the transport ‘capacity, the efficiencies and the service life of the pump. ‘The pump is characterizedby the following favorable features + typical pump for low flow/high head conditions, + single eee pumps are distinguished by an almost nonpul- sating discharge + sliding internal sealing line. + clearance between the transport elements quasi elastic -> qualified forthe transport of abrasive fluids. PROCEEDINGS OF THE TWELFTH INTERNATIONAL PUMP USERS SYMPOSIA 4 2 34 5 Figure I. Design of a Modern Progressing Cavity Pump (3). 1), stator; 2) rotor: 3) cardan coupling: 4) eardan shaft; 5) drive ‘Shaft; 6) discharge flange; 7} pump housing: 8) bearing hous- ing; and 9) seal housing. + tribological system: metaljclastomer. The progressing cavity pump delivers against pressure differ. entials up to six bae (Single stage design) and up to 72 bar (12 stage design). The pump can be run within systems operating at pressute levels of maximum 160 bar. The pump is selfpriming. for suction conditions up to approximately 9.0 m suction head. ‘The discharge flow ranges from 10 ljh to 600 ma at drive speeds between 30 and 3000 rpm. Large pumps may need 100, KW of drive power. Fiuids with a viscosity between 1 and 1,000,000 mPas, even containing considerable amounts of sol ids, can be handled. Temperatures between 40°C and 300°C are acceptable, the limits depending on the properties ofthe material tused forthe stator. Using highly chemically resistant types of elastomers for the stator the pump shows extended serviee life handling even corrosive fluids. ‘The pump fora certain case of application is characterized by the pump geometry, the materials involved, the Muid to be ‘transported and the operating point on the characteristic. “The authors” intent isto provide an understanding about the Influences on the hydraulics and the power requirements of the pump. Additionally, @ procedure for a wear prognosis and lifetime estimation based on tibometrc tests will be presented. ‘Contrasting with centrifugal pumps, the transport of fluid does not rely on hydrodynamic effects, but is accomplished by hydrostatic displacement of defined volumes of fluid. Accord: ingly, the pump achieves significantly higher delivery pres: sures, The economical volume flow is, however, substantially lower than in centrifugal pumps. The discharge Flow is largely independent of the head, a typical feature of the pump. The characteristic is stiff with respect tothe head. Consequently, the ‘pump is able to transport fluid across the entire range of the Totational speed, Principat Designs In most cases, the ra‘or is driven via a cardan coupling Depending on the head, single, and multiple stage pumps are built. In addition to the horizontal arrangement of pump and ‘motor, vertical features, sometimes with submergible motors, are passible. For exceptionally high viscosity, a feeding helix preceding the pump is necessary to improve the NPSH,, The housing will then show an especially large rectangular feeding cross Section Media unableto flow as,¢.g., neatly dry substances from filter presses or decanters, requite in addition to the feeding helix, stuiing paddles in the feed erase section to avoid bridging, In te food industry, the pump is employed in a configuration allowing apid cleaning. Such pumpsare characterized by stream. tine design without dead end o inaccessible pockets toelim- inate hiding places for bacteri. They can be disassembled without requiring special tools. Special. designs within this Concept are cleaning in place pumps (CTP-pumpe) and pumps that canbe sterilized for the wse im biotechnology or in the pharmaccticl industry (SIP sterilizing in place) Elements ofthe Pump Rotor/Stator Design Usually «hard rotor operates against a oft elastomer stator Inanow pomp, some postive overiapping te rorr larger than ator) exist Between these tanspor clement asute good hydraulic efficiency. For high pressure diferences multistage configurations are used In exceptional cass, up to 12 stages ae employed in & Dump, AS a general rie, each stage is able 1o handle approx Tately sx bar pressure difference ‘The pump ismormally equipped with a solid elastomer stator offerings large caste volume for deformations. The adjustable stator (Figure 2 () and () allows by tightening correction of the wear and redtion of sip. Figure 2. Panp Stators. (a) (b) adjustable stator (4) (e) stator with uniform wail thickness (6): add) special inner contour of the stator with three helices instead of to (4). ‘The stator with uniform wall thickness (Figure 2 (c)) has less elastomer volume subject to filling and, therefore, yields lower losses due t0 friction, ‘At the same time, the stability of the shape is better than in solid stators. The admissible pressure per stage can be doubled (12 bar). Additionally the lower thickness of the wall permits higher manufacturing precision and, therefore, more precise adjustment of the amount of overlapping (i.e. clearance). As a result, the startup momentum and the wear are reduced. Rotors are manufactured ina solid and hollow designs. Hol- ow rotors exhibit lower centrifugal forces. They are particulaely used in large size pumps and cause a favorable substantial increase in the service life ofthe transport elements. “Multiple thread geometries (Figure 2 (d)) feature larger trans port chambers. The rotational speed can be lowered and highet pressure differences per stage are feasible thanks tothe higher Sffness of the elastomer stator. Cardan Couplings ‘The original pinjoint is still used as a simple, inexpensive variety, The dominating design actually is the cardan geared coupling with curved teeth, For special applications, a multitude fof customized designs are available (e.g., for quick cleaning, ‘with special seals), Tinrate eases, elastic drive shafts without joins are seen, This design requires a larger distance between motor and rotor and ‘exerts additional transverse forces, PUMP CHARACTERISTICS Following an introductory review of the basie principles of the pump, the pump performance with espect tothe discharge UNDERSTAND PROGRESSING CAVITY PUMPS CHARACTERISTICS AND AVOID ABRASIVE WEAR ° flow, the power consumption, efficiencies and the parameters ‘ofluencing these characteristics will be explained, Discharge Principle and Energy Balance ‘The displacement is based on the interaction of the eccen- trically rotating rotor and the fixed stator, which are character- cei peerage ed a , ee eer one ae Deva X Figure 3. Geomerry of the Displacement Elements we a Clearance (w < 0) deseribes combinations of the displacing, clements with inner gaps between the elements along the sealing lines, positive overlapping (w > 0) results in clamping between the tansport elements along the sealing lines. ‘The displacement geometry is defined by the shape of the stator and the rotor. The rotor constitutes some Kind of a screw ‘with rounded threads, extremely steep pitch and a small core jameter. The stafor serves asa “nut” forthe serew with the pitch as the rotor, 'By this configuration, transport volumes, moving towards the discharge side of the pump during rotation of the rotor, are ‘maintained berween the rotor and the stator. ‘At any arbitrary cross section of the transport elements, the rotor and the stator contact each other at two opposite points. ‘Two longitudinal sealing Ties delimitating the transport eham- bers along the pump form the connection between all these sealing points in the axial direction, Delimiating ofthe Faces ofthe transport chambers takes place bby semicircular sealing lines at the top dead position ofthe rotor, ice, in the places where the rotor is Tush withthe semicircular ‘contour ofthe stator crass section, ‘The course ofthe longitudinal sealing lines and the position of the facial sealing lines changes continuously with the progress ‘of the rotational angle, g, ofthe rotor, Projections are shown in Figure 4 for an arbitrarily picked angular postion ofthe longj- tudinal sealing lines on the cross sections of the transport clements. The length ofthe sealing lines can be computed from the geometrical data of the pump. For zero clearance between the transport elements, the geo- metrically defermined volume flow, Q,, can be expressed as. Figure 4. Sealing Lines. Qy=D ine 4-dyeeehy on @ Usually the transport elements are designed with overlapping. (> 0) the diameter of the roter is then slightly larger than the diameter ofthe width of the stator (typically dy/d,, = 1.01) ‘The geometrically determined transport flow Q, for pumps with internal clearances, where the rotor diameter is slightly smaller than the width of the stator (w < 0), shows the following relation to the clearance w: One [ee dy Be wee we wT) hm For pumps with overlapping betwees the displacement e ments, the transport flow can be described by the following expression [6]: | Gaur aresin 2 ar), EN « ‘This characteristic shows the decrease of the geometccally determined volume flow asthe overlapping increases, The flow ‘of energy and fluid in the pump can generally be illustrated by means of Figure 5 Figure 5. Flow and Power Consumption of the Positive Dis- placement Pump. 0 PROCEEDINGS OF THE TWELFTH INTERNATIONAL PUMP USERS SYMPOSIUM ‘The pump delivers not ihe entire geometrically determined volume flow, Qy sie part of it flows back tothe suction side ‘s interal slip, §. The power, P, entered into the pump i party delivered as effective power, Ps the remaining pats ate the tosses du to Frition, Fy and slip, (P). Discharge Flow The effective discharge Mow, Q. represents the difference between the geometica discharge flow, Q,y and the internal slips. Q-Q,-S nen= Quen o ‘The theoretical volume flow is determined by the entire geometry of the pump and by the operational speed of the drive y= Fld yy wm) © ‘The volumetric efficiency'a, is influenced by the internal slip of the pump, Cone a a ° ‘The slip inturndependson the pressure difference across the ‘pump, the geometry of the clearances and the viscosity of the ‘id: S-fp.n.9) ® Forlamingr and turbulent flow through theclearanees, the slip flow can be roughly expressed as: laminar: §, turbulent 8,,- Ep" ‘These Equations (9) yield the basic characteristes for the volume flow for pamps with overlapping (w > 0) or clearance Power Consumption ‘The power input ofthe pump is deerme by the fective yale power Bethe lea, Pe de mera sad the Tse eased he tol of ton PaPyt Pen P+ Py* Pe =Q,:Ap+P,-Qeap+s-dper, — (10 ‘The theoretical hydraulic power P.,, ofthe pump is defined by the geometry of the pump, the rotational speed and the pressure ifference: Pay = (dys € By sm, BP) an ‘The losses Py due to friction are determined by the coefficient ‘of friction ofthe rotor/stator materials and by the lubricating properties of the fluid: P,= f(y, lubrication) «ay ‘The pump efficiency results from the energy balance of the pump as the ratio of effective power o total power consumption of the pump: PLL _Q-ap oF” Qe apt, any, a3) This expression yields the besie power performance both for ‘pumps with clearances (w < 0) and with overlapping (w > 0) Pumps with elesrance (Figure 7 (a) and (¢)) demonstrate ‘significant internal slip, S: the effective power, P,, is noticeably lower than the theoretical power, P.,. The losses, P,, due to friction, result mainly from fluid rictfon and ate distinctly lower than those eaused by mechanical friction of the displacement elements. en Thrace of pumps wih cles (gr and veo woo (c)) are influenced by the internal slip, S, which, according to a. rC Equation (9), depends on the pressure difference. c Bee ee anda) ae eum a Fae ea pc rmentncsenemas | ine Pe aia taunt one — ewe 7. Power Chances | pangs hovering ue 7 (0) ad ere neg q Approximation determined by the theoretical power, P_. The Figure 6. Flow Characteristics. total power consumption, P, is additionally determined’ by the comparatively high losses, P,, caused by frietion between the displacing elements, UNDERSTAND PROGRESSING CAVITY PUMPS CHARACTERISTICS AND AVOID ABRASIVE WEAR, st Operational Performance Tests ‘The characteristics Qcermimed experimentally and presented below ate the result of exhaustive tests mainly performed with 2 standard pump permitting operation at high speed (Table 1). Table 1. Data of the Pump Tested. Trail Pomp NEE) BNO ose CAs 1001 wae Sinai! et Ser yen erpyesentr Share A = 70 Caigaion Volume Flow Since water was used in all tests, the intersl stip losses are pasiculatly ecogaizable. The volume flow, Q,shovs an slmost linear dependency on the speed n. AS the transport pressure difference, Ap, increases, the flow deviates more and more from ‘the geomettically determined volume flow, Q, The influence of the pressure differential on flow is much mofe pronounced in & pump with clearance (Figure § (a), w = 0.15 mat) than in pump ‘ith overlapping (Figure 8 b. w = 0.1 mm). For a pump configuration with clearance and under he oper sional conditions selected, the influence ofthe pressure on the leakage flow is digressive, a remarkable observation, This re sponse indicates a transition from Tasines to turbulent flow through the clearance, where the leakage flow is correlated with the pressure differential via a square root relation. Itelearly ca ‘be shown that undes the respective conditions, the low through the gaps is turbulent ‘In pumps with positive overlapping, the dependency of the ‘small iatereal slip due to the pressure differential is superim- posed by the widening of the stator geometry by effects due 19 fulling of the stator related fo the rotational speed of the pump. The clearance, i.c., overlapping, w, clearly influences the hydraulic vatiabies. Figure 9). The volume flow, fer examt= ple, shows fora cestain operating point (speed: 1000 min", Ap: 5.0 bar) distinct maximum (w = 0,1 mm). The decrease ofthe volume flow for growing w can be atsibured te Equatiaa 3). OF course, the slip, , decreases as the clearance gets smaller. Ifthe overlapping grows the slip stays approximately constant though fulling effects nthe elastomer stator show certain ifluence. Important remark: The slip flow statically measured at the blocked pump correlates well with the valnes determined as the ‘pump operates, Apparently for pumps with internal clearances, onelusians are admissible concerning the behavior during ep eration based on simple measurements of the leakage flow through the clearance while the transport clements are at rest. ‘This elation is important and valuable, since in practice, 8ye © she manufacturing tolerances present at the transport, elements the theoretical flow through the clearances cannot he evaluated with adequate accuracy, Power ‘The required power, P, is increasing with speed and peessure

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