CAVITATION AND PIPE FRICTION Cavitation is a hydraulic condition which can exist in any type of pump. It is primarily a situation in which the pump is discharging less liquid than its rated capacity due to a reduction or lack of liquid supply to the pump intake. “Excessive suction lift, insufficient Npsh, or operation at too high a speed are common causes of cavitation. Pitting, vibration, and noise are common troubles stemming from cav- itation. While severe cavitation is usually accompa- nied by excessive noise and damage to the pump, mild cavitation may produce nothing more than a small reduction in pump efficiency and moderate wear of pump parts.”* Diaphragm pumps, like other pumps, “do not suck in liquids; they reduce pressure in the suction chamber, and external pressure, usually atmospher- ic, pushes the liquid into the pump. For any pump with a given size suction line, capacity or maximum speed is fixed by the existing net positive su head (Npsh)."? A diaphragm pump can be particu- larly vulnerable to a “starved suction” condition because generally pumping a viscous, solid- laden slurry. In fact, most cases of low flow rates can be traced to starved suction conditions due to either too high a static lit, too long a suction line, or a com- bination of both. It is likewise possible to experience cavitation even though the pump may have a “flooded suc- tion.” In this case it is due to trying to discharge more than can be pulled in through a suction line that is too long and/or too small in diameter. If a slurry is quite “thick’ it will only be possible to pump a much smaller amount than the pump’s full capacity. Cavitation is harmful to diaphragm life because on the suction stroke the diaphragm is being pulled mechanically by the shaft connected to the pressur- ized diaphragm. There is an “unbalanced” pressure on the diaphragm equal to the amount of suction produced. Cavitation makes the “unbalanced” pres- sure on the suction stroke higher. The lower the suc- tion lift condition imposed on the diaphragm, the less the unbalanced mechanical load, and the longer the diaphragm life. Every diaphragm has a given number of flexes before failure. If the pump is cavitating, less liquid is being pumped per flex; therefore, diaphragm cost per gallon is increased Cavitation can be eliminated in the Wilden air- operated double-diaphragm pump easier than with any other type of pump. Start the pump slowly by controlling the volume of compressed air to the pump by the use of a gate or globe vaive. After the unit starts pumping, the throttling valve can be ‘opened to increase capacity. The point at which fur- ther opening of the valve increases cycling rate without an increase in discharge rate will be the cavitation point, and the valve should be closed slightly. Further attempts to increase capacity should be oriented around a larger suction intake line, larger pump, reduced lift condition and/or a combination of these conditions. Under conditions of limited flow due to cavita- tion, damage to the Wilden double-diaphragm pump most likely will be limited only to the diaphragms, in comparison to numerous expensive parts in other types of pumps. “Tier G. Hicks and Theodore W. Edwards, Pump Application Engineering, page 87 “Tyler G. Hicks and Theodore W. Edwards, Pump Application Engineering, page 81, ILDEN Ain OPERATED DOUSLE DIAPHRAGM PUMPS 4 RESOURCES COMPANYHIGH VISCOSITY PIPE FRICTION Viscosity is that property of a liquid which resists free flow. The most common method of expressing viscosity is in SSU (Saybolt Seconds Universal) Water has a SSU viscosity of 81.5. Centrifugal pumps can handle viscosities up to 500 SSU. Beyond 500 SSU, a positive displacement pump must be used to move a liquid. Most pipe friction tables are based on water or at most go to liquids of up to 500 SSU. The Wilden air-operated double-diaphragm pump is capable of pumping viscous slurries. On page 3 and 4 is a Pipe Friction Chart showing line loses at viscosities up to 500,000 SSU. NOTE: These friction tables give the loss in Pounds per Square Inch. The losses at the very high viscosities (100,000 SSU and up) are great. Note also that all friction loses in these tables must be multiplied by the specific gravity of the slurry being pumped. With the high friction losses observed at these high viscosities, suction conditions become ultra critical. At best there will only be a maximum of 144 available at sea level to push liquid into the pump. For example, the friction loss in 100' of 2" pipe of a 100,000 SSU liquid at a flow rate of 7 gpm is 280#. (See chart.) Through 10' of 2" pipe the loss would be 234, well above the 14# available. It would only be possible to pull approximately 3. gpm through 10' of 2" pipe due to friction alone. No static lift would be possible. The fact is that no pump can exert force on a lig- id until it is in the pump. The only force able to act on the suction side is the earth atmospheric pressure of 14.7 psi at sea level. Once the liquid is, in the pump, the Wilden pump can push with as much pressure as the air supply pressure available. Typical “in plant” air supply pressures are sel- dom over 100 psi. Therefore, any calculated friction loss approaching this figure calls for either a shorter pipe, a larger pipe size, or a reduction in the amount of elbows. This will reduce the amount of friction loss. CONSIDERATIONS FOR SPECIFYING A WILDEN AIR-OPERATED DOUBLE-DIAPHRAGM PUMP. + Gallons per minute (GPM): or output. * Specific Gravity: The ratio of a tluid’s density to that of water. Water equals 1.0. * Viscosity: A measure of a fiuid’s tendency to resist a shearing force. Viscosity is not a con- stant, fixed property of a fluid, it varies with the conditions of the fluid and the system. fequired flow rate * Temperature: The temperature of a fluid at the pump inlet is usually of greatest concern, * Vapor Pressure: The absolute pressure (at a given temperature) at which a liquid will change to vapor. * Static Suction Lift: The vertical distance from the center line of the pump down to the free level of the liquid source. * Static Suction Head: The vertical distance from the center line of the pump up to the free level of the liquid source. * Static Discharge Head: The vertical elevation from the center line of the pump to the point of free discharge. * Dynamic Discharge Head: Static discharge head plus friction head * Pipe Diameter, Pipe Length and the number of Elbows are needed to calculate friction head.ENGINEERING DATA: PIPE FRICTION — VISCOUS LIQUIDS LOSS IN POUNDS PER SQUARE INCH PER 100 FEET OF NEW STEEL PIPE BASED ON SPECIFIC GRAVITY 1.0 wo a _ a = VISCOSITY — SAYBOLT SECONDS UNIVERSAL cpm FIPE | 100 | 200 | 300 | 400 | s00_| 1000 | 1500 | 2000 | 2500 | s000 | 4000 | 5000 | 6000 | 7000 | 8000 | 9000 | 10,000 | 15,000, % [11.0] 23 | 35 | 48 | 60 | 120 | 122 | 240 | 300 | 265 | 475 | 600 720 | s40 | o60 | - | - 5 3| x |37| 77 |i] 158 | 105 78 | 96 | 117 | 160 | 195| 237 | 273 | st2 | 351 585 i {44 | 30 | 45 | 60 | 74 | 375 | 45 | 60 | 75 | 90 | 106 | 120 | 195 228 x Te2 | 13 | 20 [25s | a3 65 | 196 | 266 | 300 [596 | 462 | 526 | coe 320 s|1]23| 5 | 74 | 100/125 625 | 74 | 100 | 125} 150 | 175 | 200 | 205 375 1x fova| 17 | 25 | 33 | a2 at | 25 | 34 | a2 | 50 | 58 | 66 | 75 25 % | 87 | 8 275] 37 | 46 ‘2s | Bao | 370 | 460] S52 | Gad | 7a6 | a2 = 7] 4] 33 | a9 |105| 44 [175 [a5 | 59 ‘a9 | 106 | 142 | 178 | 213 | 249 | 284 | 320 538 ac | 41 | 23 [35 | 47 [58 |it5 | 175 zo | 35 | a7 ‘at | 93 | 108 173 1150] 10] 15 | 20 | 2 | ot | 76 eB | 155 | 208 a7 | 408 | 459 765 to | | 16 |s3 | 50] 67) 8s | 167 | 25 42 | 50 | 66 117 | 134 | 150 250 1% [oaa| 18 |27| 36 | 45 | 90 | 135 23 | 27 | 36 63 | 72 | at 435, 1 [110] 15 | 22 | 90 |a75| 76 | 114 90" | 228 | 308 5x2 | 60s | o0e | | 27 | 49 | 76 |100] 125 | 25 | 75 es | 75 | 100 175 | 200 | 225 375 as | 42 | 27 | 40 | 54 | 68 | 135 | “20 3a_| at | 54 95 | 108 | 122 203 + [20 | 20 | 30 | 40 | 50 | 100 | 150 "250 | 300 | 400 700" | 800" | 900 z 20 | 1% | 23 | 38 |54|72 | 90 | 18 | 275 46 | 5 | 72 426 | 144 | 162 270 2 |oss| 13 | 20 | 27 | 33 | 67 | 10 |135| 17 | 20 | 27 47 | 55 | 60 400 aw} as [4s 67 [eo |irs| 23 | 34 [46 | sr | es | 90 Ter | tea | 207 | 230° | 345 as | 2 |10| 17 |25| 33 |42 | aa [125 | 185 | 215 | 25 | 39 so | ea | 76 | a4 | 126 | 2% |ow2| oa |12 | 46 | 20 | 0 [60 | a0 | 10 | 12 | 16 28 | 32 | 36 | 40 | 60 ie }so]sa [80 iio /ias | 27 | 41 | 54 | 69 | @1 | 108 | 195| te2 | 19 | 216 | eas | 270 | 405 a0 | 2 | 14| 20} 30] 40] 50 | 10 | 15 | 20 | 25 | 20 | 40 | 50| 60 | 70 | 80 | 90 | 100 | 150 2% |osoloss|15 | 19 | 24 | 4a | 72 | 8 | 12 |145| 10 | 24 | 20 | 34 | 33 | a3 | as | ve Tt [a0 | 90 [tots] 18 | s7 | s5 | 73 | a2 | 111 | 148 | tas | 220 | a50 | 206 | aa [G70 | ses 40 | 2 |26|27|39|53 | 67 |135| 20 | 27 | 34 | a0 | 54 | 68| a2 | 95 | 108 | 122 | 135 | 209 au | 41 | 13 | 20 | 26 | 33 | 65 | 97 | 13 | 165 | 19 |255| a2 | as | 45 | 2 | so | 65 | 08 tz [140 [140 [140] 180] 23 | 48 | 8 | 90 | 115 | 138 | tea | 230] 76 | Goo | aew | 4a | 260 | G00 so | 2 |38|40|50|67 | 84 | 17 |255| a4 | 43 | 51 | 08 | a5 | 102 | 119 | 196 | 153 | 170 | 255 2 | ie | 47 |24 | 32 |40 | a0 | 12 | 16 | 20 | 24 | x2 | a0] a | 55 | os | v2 | 80 | 120 [2 [sa [se [se | 0 |100| 20 | 20 | a | s2 | 61 | 80 | t00| 120 | 140 | 160] 10 | 200 | 300 oo | «| 23 | 24/29/38 |48 | a6 | 145/195 | 24 | 20 | a8 | 49| se | 67 | 77 | 96 | 96 | 144 3 {oa jos |12| 17 |21 | 41 | 61 | as | 10 |125| 165 | 205|245| 23 | 33 | a7 | a1 | o2_| zi f2a fae faa faster |i | a7 | 23 | 26 | [ae | 55 | 66 | 77 | 8a | 99 | 110 | 165 w|s io] ia |ia} 19 foe |as | 71 faz | t2 |ias| 19 | 24| 29 | a4 | oo | ao | 48 | 72 4 [027 [032 {02a |oes |oao | 16 | 24 | 32 | 41 | 49 | 66 | at] to |r2| 13 | 144 | te | 24 Be] 87 [4s [43 | 52 ya [ies] 26 | a3 | 39 | s2 | 05 | 78 | 91 [tor] 117 | 130 | 195 eo | 3 [43 |44]47|22|20 | ss | a2 | 11 |135| 17 | 22 | 275] 33 |sas| a4 | so | 55 | a3 4 [036 [096 |os4|o74]oae| 18 | 27 | a7 | 47 | se] 75 | 93\115|126|144| 162 | 18 | 27 Be] 55 [67 |e7 |o7 | 80 | 165 | 245 |o25| 41 | 48 | e4 | 60 | OG | 112 | toa | 144 | 160 soo| ‘3 | 19] 22|22|28/as | ee | 10 | 14 | 17 | 21 |ors| 34 | a1 | aa | 54 | 61 | 68 4 |053|057|o03 [092/12 | 23 | 34 | 45 | 5a | 70 | 95 | 115| 14 | 164 | 185 | 207 | 23° MULTIPLY VALUES IN THIS TABLE BY SPECIFIC GRAVITY OF LIQUID Example —30GPM. Viscosity 1000 SSU. Speci Gravity 0.90 200 Feet of 2" pipe Loss = 10.x 0.80 x 2s 18 Lb/Sq. in. Caution — Since vscosiy increases greatly with a litte reduction in temperature, its wise to be liberal In estimating pipe ticton IF VISCOSITY IS GIVEN IN CENTIPOISES: CONVERT TO SSU BY MULTIPLYING BY 4.6. ILDEN' AIR OPERATED DOUBLE DIAPHRAGM PUMPSENGINEERING DATA: PIPE FRICTION — VISCOUS LIQUIDS LOSS IN POUNDS PER SQUARE INCH PER 100 FEET OF NEW STEEL PIPE BASED ON SPECIFIC GRAVITY 1.0 = 7 VISCOSITY — SAYBOLT SECONDS UNIVERSAL Pu GPM | PE | ano | | sna | s0an0| soso | sno | a000 | eoow | soa | ron00n | 12500 | ssoo% | v7son0 | 20n00 | sooo 2 | 20 | 2 | % | «0 | so | oo | 7 | eo | 2 | to | tas | ts | 175 | 200 | soo | 2x | a7 |121 | ie | 194 | 289 | 201 | s40 | sas | as | 485 | o07 | 728 | 48 | 70 | 249 3 | «|'s |e |’ | to | 12 | “Se | “te | “te | 20 | os | ao | os | a | 100 2 | w] a2} 50] S63] es [os | 16] iss | ia0 | 108) 08 [20s | a0 —aae [829 s | 2x | 82 | 209 | 243 | 524 | aos | aas | sor | ota | 729] s.r | tor | 22 | 142 | 162 | 05 3 | 68 | 6 | 02 | 1a6| t70 | 204 | 250 | 272 | 06 | a40 | as | sto | sos | oso | 170 2] 46] 86] 70 | 2 | tis | 108) 161 | 104 | 207 | 230 | 2a | a4 | 40a | 460] 7| 2% | 203 | ase | 905 | 406 | sos | as | 710 | ai2 | 913 | toe | ter | 152 | 178 | 209 | sor 3 | 95 | 119 | 43 | 190 | ana | 29s | ao2 | seo | 427 | a7s | soa | 712 | oor | 050 | ax7_| ar] we] | a) 6 | 00 | 96 | 112 | 126 | 148] 160 | 200 | 20 | 290 | 320 | a00 10} 3 | 136 | 170 | 204 | er2| a40 | aoe | 47s | sea | or2 | es | 2 | 109 | t19 | 196 | oo 4 | 45 | 87 | 70 | 92 | 15 | 138 | t61 | tas | 207 | 230 | zea | os | ao2 | ao | 115_| ar] a | 60 | 72 | 6 | 120 | 14a [tes] 102 [ate | 280 [300 | 360 420 490 | - 1s| 2 | 20 | 2 | 3 | «| 80 | 60 | 70 | e0 | 90 | 100 | 125 | 150 | 175 | 200 | 500 4 | &7 | a6 | 105 | 137| 170 | 204 | 230 | 272 | soe | sso | 42s | sto | sos | os | 170 3 [aro sar | 405 [540 | 75] 810 | 945 | toa] 122) 105 | 169 | 202 | 296 | 270 | 675 zo] 4 | 90 | 118 | 140 | tea | 290 | 2re | s22 | o66 | aia | 450 | srs | eo | aos | ozo | 220 é | sa | 23 | 27 | se | 20 | ss | os | 75 | ‘a2 | or | t4 | to7 | 159 | 122 | a55 SM [es] st] a |e | 102 | 119 | te] 103 | 170 | 21s | 256 | zor [a4 | 050 as| a | sta |44s Jars | 23 | cae | as | 403 | 451 | sis| srs | 72 | asa | tor | 115 | 2a @ | 22 | 2a | 22 | 44 | ‘55 |e | 77 | ee | oa | 110 | 138 | ws | a | 22 | 5 =] 4] 80} 60 | 80 | 100 | 120 | ido] 160] iao™}200 | —as0 | ~00 | 880 ~a00 so} 4 |ias| i | 2 | 23 | cea] ata | 4a2 | ss1| 2 | ose | oe | 103 | tr | 198 | aia |" 6 | Ze aa | ao | 62 | es | Fe | or | tou | 7 | 130 | tes | 105 | 228 | 26 | os | Psy seers] et] ioe | tas | i02 [tes | 216 | 24s [270 [337 | 405 [are [sa w| 4 | te |e | 29 | ar | 46 | e52 | ots | 706 | 2a] ce | 155 | 190 | 101 | tee | 400 3 | 3s | 4s | 53 | 70 | ae | tos | v9 | 0 | 157 | 75 | 219 | 252 | soo | oso | ors aes] | | 4 [75] 6 | os] se) oe ms | v4 | 73 [a1 | 290 | 575 | —~ so| 6 | 4 |se | 6 | ae |s0| 192 | 154 | 176 | 198] 2 | ars | so | a5 | 44 | 110 8 | i549 | 29 | a0 | 97 | 45 | 53 | co | eo | 75 | oa | 113 | tas | 150 | vs | |-a| er | oe] ae | saa] 605 | e22 | oa | aio] 123 | as7_| 171 [208 | 240 274 | 685 co} 6 | 53 | 67 | 80 | ie | 193 | 160 | 186 | 213 | 239 | 266 | os2 | goo | aes | saz | 199 8 | ts | 23 | 2a | 36 | ts | 55 | oa | Za | as | oz | 115 | tas | 101 | toa | aso 2 |e] a | 4 | «| a | 96 | 112 | we | i4a] too | 200 [240 | 200 | —a20 | 600 wo | 6 | 61 | 78 | 93 | 124] 15 | se | 217 | 288 | 279 | sto | ses | 465 | saz | 62 | 155 8 | 21 | 27 | 32 | da | sa | oa | 7a | es | os | 06 | 199 | 159 | we | a2 | 50 6 | 70] 80 | 17 | uz] we pes] ee [wea] TO [aes | 4a | sas | e2t | 7 | 178 w| 8 | 24| 30 | 30 | 4a| eo |72 | es | o6| tos] 2 | ws | 1s | 1 | 2 | oo to [oa | i2 | 48 | 49 | 24 | a0 | a5 | so | a5 | so | 63 | 75 _| 88 | 10 | 25 6 | 79] 88 [Hs] 8] 07 | a7 | we] oe | as | sos | aoa | sos | oat | 700 | 197 oo | 8 | 27| 34] 41 | s4| 6a | e2 | ee | t10| 23 | 137 | t71 | 206 | 240 | 274 | cas to | t1 | ta | 47 | 22 | 27 | a5 | a0 | sa | 50 | 55 | ce | es | 96 | 110 | 275 Ie} aa fito [sz Fire} 220 | 264 | 208 | 52] aos | a4 | ss | 08 | 77 | 08 | 220 wo] 8 | 30| 32 | 45 | sa | 75 | 90 | 105 | 120| 135 | 150 | ws | 225 | 26a | soo | 75 to | 12 | 15 | 18 | 24 | 30 | a7 | 42 | ve | 54 | eo | 75 | eo | 105 | 120 | 90 MULTIPLY VALUES IN THIS TABLE BY SPECIFIC GRAVITY OF LIQUID Example—50.GPM. Viscosity 100,000 SSU, Specific Gravity 11.900 Feetof 6" pipe Loss = 22x 1.1 x9 = 726 Lb/Sq.in. ‘Caution — Since viscosty increases greatly with a litle reduction in temperature, itis wise to be liberal in estimating pipe riction. IF VISCOSITY IS GIVEN IN CENTIPOISES: CONVERT TO SSU BY MULTIPLYING BY 4.6. ILDEN . AIR OPERATED DOUBLE DIAPHRAGM PUMPS 22069 Van Buren Street, Grand Terrace, CA 92313-5607 * Telephone (909) 422-1730 * FAX (909) 783-3440 www. wildenpump.com A SDOVER) nesounces company