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1.11 Pump Performance Curve: Hydraulic Pumps (Continued)
1.11 Pump Performance Curve: Hydraulic Pumps (Continued)
Pump performance characteristics are first analyzed independently of the rest of hydraulic
system and then as a part of the system. Both sets of data are valuable to the designer.
Analyzing the pump by itself gives an indication of its capabilities and performance based on
the speed of rotation, internal geometry, cost factors, etc., whereas analyzing pump
performance in system essentially determines pump system compatibility. In the first case,
the system designer may observe performance curves to see if a specific pump has the
pressure and volume flow rate to operate a given set of actuators. In a second instance, the
system designer may be computing the noise, vibration, cavitation and flow characteristics of
a specific pump before or after installation to determine if the pump and existing system are
compatible. Where the two are necessarily complimentary, in practice much of hands-on
work is completed independently. Pump performance characteristics are interpreted from data
in tabular form and then graphed.
Figure 1.20 shows a graphical representation of a typical positive displacement pump. Figure
1.20(a) represents the relationship between input power and pump output flow of a variable
displacement piston pump as a function of pump speed.Observe the linear relationship
between the discharge flow and pump speed. Figure 1.20(b) gives curves of overall and
volumetric efficiencies as a function of speed. Performance curves of radial piston pump are
given in Fig.1.20(c). Discharge flow of these pumps is nearly constant over a broad pressure
range.Discharge flow can be varied infinitely between the point of inflection on the constant
discharge portion of the curve and zero flow.
Flow
Power
(a)
(b)
(c)
Figure 1.20Pump performance curves
1.12Pump Noise
Pump noise is an important parameter used to determine the performance. Any increase in
noise indicates increased wear and eventually pump failure. Pumps are good generators but
poor radiators of noise. Noise is not just the sound coming directly from the pump, but also
from the vibration and fluid pulsation produced by the pump. Pumps are small in size and
hence, they are poor radiators of noise. Reservoirs, electric motors and piping being largerin
size are better radiators. Hence,a pump-induced vibration can cause audible noise greater than
that coming from the pump. Fixed displacement pumps are less noisy than variable
displacement pumps because of their rigid construction.
Figure 1.21 Pumpnoise characteristics
As can be seen from Fig.1.21, the pump speed has a strong effect on noise compared to
displacement and pressure. To reduce the noise levels, electric motors are used and the most
advantageous combination of size and pressure is selected to produce the needed power.
1.13Pump Cavitation
During the working of a positive displacement pump, vacuum is created at the inlet of the
pump. This allows atmospheric pressure to push the fluid in. In some situations, the vacuum
may become excessive, and a phenomenon known as cavitation occurs. When the pressure of
the liquid reaches a low enough level, it vaporizes or boils. Cavitation is the formation of oil
vapor bubbles due to a very low pressure (high vacuum) on the inside of the pump. The low
pressure also causes air, which is dissolved in the oil to come out of the solution and form
bubbles. These air and oil vapor bubbles collapse when they reach the outlet side of the
pump, which is under a high pressure. The collapsing of these vapor bubbles causes
extremely high localized pressure and fluid velocity. These pressures are so high that they
cause pitting of metal and consequently decrease the life and efficiency of the pump.
1. Undersized plumbing.
2. Clogged lines or suction filters.
3. High fluid viscosity.
4. Too much elevation head between the reservoir and the pump inlet.
4
D = 0.0266 m
Minimum bore suction pipe = 26.6 mm.
Note: in all calculations great care must be taken to ensure that units are correct.
Alternatively, if a flow velocity of 1m/s is used then suction pipe bore can be of diameter 29
mm. The required diameter of the pressure line can be calculated in a similar manner taking
the flow velocity as 3.5 m/s. Here the minimum bore of pressure pipe is equal to 15.6 mm.
It is unlikely that a pipe having the exact bore is available, in which case select a standard
pipe having a larger bore. Alternatively, a smaller bore pipe may be chosen but it will be
necessary to recheck the calculation to ensure that the flow velocity falls within the
recommended range. That is, a standard pipe with an outside diameter of 20 mm and a wall
thickness of 2.5 mm is available. This gives an internal diameter of 15 mm.
Flow through pipe
Flow velocity =
Area of pipe bore
Now
π
Area of pipe bore = 152 mm2 177 mm2 177 106 m2
4
So
60 103
Flow velocity = 3.77 m / s
60 177 106
This is satisfactory. It is also important to ensure that the wall thickness of pipe is sufficient
to withstand the working pressure of the fluid.
1.14Pump Selection
The main parameters affecting the selection of a particular type of pump are as follows:
In general, the higher the operating pressure, the higher the component cost and the lower the
choice of components. The main advantage of higher working pressures is the reduction in
fluid flow rates for a given system power, resulting in smaller pumps, smaller bore pipes and
smaller components. The disadvantage is that at higher working pressures, the
compressibility of the fluid used can have considerable adverse effects where precision
control is required over a wide range of loads.
The general tendency is toward increased operating pressures. Typical maximum pressures
for fewapplications are given in Table 1.3. The operating pressures of pumps depend to some
extent on the fluid used. A fire-resistant fluid is generally not as good lubricant as a mineral
oil. So to give a reasonable pump life expectancy when using a fire-resistant fluid, the
maximum operating pressure must be reduced and it is advisable to consult the pump
manufacturer.
The maximum operating pressure and range of flow rates for different types of currently
available hydraulic pumps are shown in Table 1.4.The figures given cover a range of sizes
and makes; maximum valuesof delivery and pressure are not applicable to one pump.
Various types of pump controls are available such as manual servo control, pressure
compensated control, constant power control and constant flow control. The choice of control
is dependent upon the circuit requirement such as complexity, accuracy of control, cost, type
of machining operation,etc.The designer has to choose carefully the type of control after a
detailed study of system characteristics.
1.14.5Types of Fluid
Pumps are designed to operate within a particular range of fluid viscosity. Mineral oils of the
correct viscosity work satisfactory with most pumps provided the oil is clean. Operating with
synthetic or water-based fluids reduces the working life of a pump that relies on the hydraulic
fluid to lubricate the bearings and moving parts. When any fluid other than a mineral oil is to
be used, it is advisable to seek the pump manufacturer’s advice.
1.14.6Fluid Contamination
Any fluid contamination causes pump damage. Precision pumps with very fine clearances are
more susceptible to damage. If a contaminated fluid has to be pumped, such as in a cleanup
loop, particular attention must be paid to pump selection. Non-precision gear pumps, lobe
pumps and gerotor pumps are the most dirt tolerant.Whichever type is used, a strainer must
be fitted in the suction line. In the case of precision pumps, the manufacturer’s
recommendation on filtration must be followed; otherwise the life of pump will be drastically
reduced and the maker’s warranty voided.
1.14.7Pump Noise
Noise has become increasingly important environmentally. Operating levels vary
considerably between the pumps of the same type but of different makes.The manufacturers
are working on those aspects which most affect the emission of noise– port plate design,
bearings, flow passages, pressure controls, materials and methods of mounting. Generally, the
sound generated increases with speed and pressure. Certain kinds do, however, propagate
lower noise levels, in particular, those with internal gears. A multi-stage internal gear pump is
marketed by one manufacturer under the name Q pump, with Q signifying quiet.
Example 1.15
The intensity (in units of W/m2) of the noise of a pump increases by a factor of 10 due to
cavitation. What is the corresponding increase in noise level in decibels?
Solution:
I (final)
dB increase 10 log 10 log10 10 dB
I (initial)
1.14.9Efficiency
Reciprocating pumps tend to have higher efficiencies than rotary pumps. The actual
efficiency depends on design, operating pressure, speed and fluid viscosity.Table1.5gives an
indication of the range of efficiencies of various types of pumps.
Table 1.5Efficiency ranges of pumps
Pump Type Volumetric Efficiency Overall Efficiency
Piston
Plunger in line 99 95
Radial 95 90
Axial 95 90
Precision gear pumps 95 90
Vane pump 90 80
1.14.10Cost
The initial cost of a pump is usually of secondary importance to running and maintenance
costs.Gear pumps are cheaper, vane and piston pumps are expensive.
Example 1.16
A pump has a displacement volume of 120 cm3. It delivers 0.0015 m3/s at 1440 RPM and 60
bar. If the prime mover input torque is 130 Nm. What is the overall efficiency of the pump?
What is the theoretical torque required to operate the pump. The pump is driven by an electric
motor having an overall efficiency of 88%. The hydraulic system operates 12 h/d for 250
days per year. The cost of electricity is Rs 8 per kWh. Determine the yearly cost of electricity
to operate the hydraulic system. The amount of the yearly cost of electricity that is due to the
inefficiencies of the electric motor and pump.
Solution: Given volumetric displacement, VD = 120 cm3 , QA 0.0015 m3 /s, N 1440 rpm ,
P 60 bar , input torque TA 130 N m .
rev 100 cm
Theoretical dischargecan be calculated as
1440
QT VD N 0.000120 rev/s 0.00288 m3 /s
60
First we calculate the mechanical input power the electric motor delivers to the pump.
Example 1.17
For the fluid power system of Fig. 1.22, the following data are given:
(i)The total pressure drop in the line from the pump discharge port to the blank end of the
cylinder is 517000 Pa.
(ii) The total pressure drop in the return line from the rod end of the cylinder = 345000 Pa.
Determine the
(a) Volumetric displacement of the pump.
(b) Input power required to drive the pump.
(c) Input torque required to drive the pump.
(d) Percentage of pump input power delivered to the load.
Motor
Reservoir
Directional control Valve
Solution:
(a) Volumetric displacement of pump.
Qpump-actual Apiston Vpiston ext
0.2032 0.0762 0.00247 m3 /s
4
= 2.47 LPS
Qpump-actual 0.00247 m3
Qpump-theoretical 0.00268
Vol 0.92 s
Now
Qpump-theoretical VD N
1800
0.00268 VD
60
VD 0.0000893 m 0.0893 L
3
Example 1.19
The system of in Example 1.17 contains a fixed displacement pump with a pressure relief
valve set at 6871 kPa. The system operates 20 h/d for 250 days in a year. The cylinder is
stalled in its fully extended position 70% of the time. When the cylinder is fully extended,
0.0633 LPS leaks past its piston.
(a) If the electric motor driving the pump has an efficiency of 85% and the cost of electricity
is Rs 10 per kWh, find the annual cost of electricity for powering the system
(b) It is being considered to replace fixed displacement pump with a pressure-
compensated pump (compensator set at 6871 kPa) that cost Rs 250000
more. How long will it take for the pressure-compensated pump to pay for
itself if its overall efficiency is same as fixed displacement pump?
Solution
(a)Annual cost of electricity for powering the system
pblank-end 5758000 Pa 5758 kPa
The total pressure drop in the line from the pump discharge port to the blank end of the
cylinder is 517000 Pa.
Pump inlet pressure = −27600 Pa
Pump discharge pressure = 5758000 Pa 517000 Pa 27600 Pa 6247.4 kPa
Pump input power = 18.8 kW
Electric motor input power = 18.8/0.85 = 22.1 kW
Thus with the cylinder fully extended (pressure relief valve set at 6871 kPa) we have
6871
Electric motor input power = 22.1 24.3 kW
6247.4
Thus, the yearly cost of electricity is
Yearly cost = Power rate × Time per year × Unit cost of electricity
= 0.30 × 22.1 (kW) 20 h/d 250 d/yr 10/kWh + 0.70 24.3 20 250 10
= Rs 1182000/year
(b) The fixed displacement pump produces 2.47 LPS at 6871 kPa when the cylinder is fully
extended. Leakis 0.0633 LPS through the cylinder plus 2.407 LPS through the relief valve.
Thus, when the cylinder is fully extended, we have power lost with a fixed displacement
pump
pQ = 6871 0.00247 = 16.97 kW
Hence, the electric motor input power is
16.97
24.1
0.828 0.85
The overall efficiency of the pump 82%.The pressure-compensated pump would produce
only 0.0633 LPS at 6871 kPa when the cylinder is fully extended. For this case we have the
power lost with pressure-compensated pump is
pQ = 6871 × 0.0000633 = 0.44 kW
Hence, the electric motor input power is
0.44
0.63 kW
0.828 0.85
Thus, the kW power saved while cylinder is fully extended = 24.1−0.63 = 23.47 kW
Savings per year = 23.47 0.70 20 250 10 = Rs 821450 per year
Time to pay for pump = Rs 250000/821450 = 0.3 years
Objective-Type Questions
Fill in the Blanks
1. The volumetric capacity of a positive displacement pump is less than that of a non-positive
displacement pump.
2. Too low elevation head between the reservoir and the pump inlet causes cavitation.
3. Efficiency is almost constant with the head in the case of non-positive displacement
pumps.
4. The sole purpose of pumps is to create pressure.
5. Mechanical efficiency indicates the amount of energy losses that occur for reasons other
than leakage.
Review Questions
1. What is a positive displacement pump? In what ways does it differ from a centrifugal
pump?
2. Define the source of hydraulic power (pump).
3. Explain the working principle of a pump.
4. Pumps do not pump pressure. Justify this statement.
5. What is the function of a pump in a hydraulic system?
6. How is the pumping action in positive displacement pumps accomplished?
7. How the volumetric efficiency of a positive displacement pump is determined?
8. List the advantages of hydrostatic pumps over hydrodynamic pumps.
9. Give the classification of hydrostatic pumps used in a fluid power system.
10. What is the difference between a fixed displacement pump and a variable displacement
pump?
11. What types of pumps are available in variable displacement designs?
12. How can the vane pump/piston pumps be made as variable displacement pumps?
13. Name three designs of external gear pumps.
14. Name two designs of internal gear pumps.
15. What are the advantages of screw pumps over other gear pumps?
16. Why is the operation of screw pump quiet?
17. How can the unbalanced vane pump be used as a variable displacement pump?
18. What is a pressure-compensated vane pump and how does it work?
19. What is meant by a balanced design vane pump?
20. Name the important considerations when selecting a pump for a particular application.
21. Why a gear pump cannot be used as a variable displacement pump?
22. How can the displacement of an axial piston pump be varied?
23. What is pump cavitation and what is its cause?
24. How is pressure developed in hydraulics systems?
25. Why centrifugal pumps are rarely used in fluid power systems?
26. Draw the graphical symbols for the fixed displacement and variable displacement pumps.
27. Which parameters affect the noise level of a positive displacement pump?
28. What is meant by the pressure rating of a positive displacement pump?
29. Name the four rules that control or eliminate cavitation of a pump.
30. Comment on the relative comparison in performance among gear, vane and piston pumps.
31. What are the two ways of expressing a pump size?
32. What are pump characteristic curves? Draw the same for the positive displacement
pumps.
33. How is the capability of a variable displacement pump affected by the addition of
pressure compensation?
34. Name the three principal ways in which noise reduction can be accomplished.
35. What are the most common things apart from pressure or speed that can cause a pump to
fail? Explain each.
36. Where are external gear pumps used?
Answers
Fill in the Blanks
1.Velocity, large
2.Not change, decreases
3.Greater pulsation,meshing
4.Higher;
5.Double, two
1.True
2.False
3.False
4.False
5.True