Armfield Instruction Manual Average Flow Rate V Theoretical Flow Rate Ni Volumetric Efficiency E Introduction to Fluid Pumps Description of a Plunger Pump min min % «flow volume through the flow wy ea acond, Calculated senso Vaotsl jinder, ie. the rept volume of the oy/ ; swetume of fluid delivered by the are no losses. Calculated. The total theoretical pump iter Ven = ALS Volumetric efficiency ‘of the pump. Vave 100% Videat | calculated ‘A plunger pump (or piston pump) is a reciprocating positive displacement pump. At its most basic, a plunger pump consists of a piston inside a chamber which is fitted with an inlet valve and an outlet valve. The piston moves in one direction to expand the volume within the cylinder, as the inlet valve opens and fluid is drawn into the chamber. The piston then returns, as the inlet v reducing volume in the chamber force falve closes and the outlet valve o| pens. The es the fluid back out through the outlet Plunger pumps may fall into a number of basic categories. 28Laboratory Teaching Exercises Direct and indirect action Direct acting pumps are connected directly to the driving force, for example to another piston driven by steam. indirect action pumps are connected via a beam or other indirect linkage (such as the nodding donkey’ pump) Simplex or duplex Simplex pumps have a single plunger and chamber. Duplex pumps have two pistons and chambers, and are arranged so that when one piston is at the top of its stroke, the other is at the bottom, This doubles the capacity of the pump and ensures a more constant flow (although flow still pulses). A two-cylinder petrol engine is one example. of a duplex pump. Additional chambers can be added, arranged so that the pistons act in an even, regular sequence Single or double action A single action pump has the fluid on one side of the piston. In a double action pump the piston moves along the chamber with fluids on both sides, so that the volume of ‘one end of the chamber increases as the other decreases and vice versa. The result is similar to that of a duplex pump, increasing pump capacity and reducing (alth not eliminating) the pulsing of the flow. Sigg: 29‘Armfield Instruction Manual ‘The plunger pump provided on the FMS3 isa direct, simplex, single action pump. Characteristics of a plunger pump A plunger pump is a positive displacement positive displacement pumps pressure. Because the pumps deliver a set q Pressure, very high pressures can develop, ‘ensure that the pressure does not increase Pump. For a given speed of operation, ill produce a fixed flow rate regardless of outlet, uantity of fluid regardless of system and a relief valve should be installed to above the design pressure of the system Flunger pumps are selt-priming, and can draw fuid up from a submerged inlet into ig piston cylinder. Many plunger pumps use the working fle te lubricant for the Piston, however, and so they should not be run dry for estensied Periods. 30 0 ES_ Objective To obtain graphs itustrating the o Perating characteristics of a plunger pump Method By using the Fmsg aera EMMA aieitacs a ana erformance measurements over a re ot press '2nge of pump speeds and outlet pressures Equipment Required ‘Armfield FMS3 Plunger Pump Armfield IFD7 PC running Armfield FM63 sontware Theory time Piston position, cylinder pressure and outlet pressure are both monitored over tres Possible to determine the relationship between cylinder displacement and Ihe pressures produced, The general pattern expected is that ofa sine wave It the pressures and the piston displacement are plotted on the same graph, it can be Seen whether they are in phase (e.g. maximum cylinder pressure and piston displacement occur at the same time), or out of phase (e.g, maximum outlet pressure Occurs at some time interval after the maximum cylinder pressure). V v Vv v v Vv v Measured parameters in phase 31Armfield Instruction Manual Measured parameters out of phase in many situations, the pulsing nature of piston pump flow is undesirable. The pulsation may be smoothed using a damping system of some kind, The FMBG includes a simple damper pot, which can be included in the flow circuit by opening the valve connecting itt the main pipework. The upper portion of the pot is filed with air, which is compressible. A pulse of flow entering the outlet pipework will divide, with part entering the damper pot and part continuing towards the outlet until the ait in the pot is compressed sufficiently to equal the pressure in the pipework. At the end of the pulse, when the outlet valve from the cylinder closes, pressure in the outlet pipework will no longer be increased due to the action ofthe piston. The pressure in the pot will then be greater than in the pipe and the air will expand, expelling water info the outlet unl the pressures are again equal. The reutis a smoothing of the outlet flow. 22Exercise A Equipment Setup Puecheaee eek FMB3 reservoir is fully closed, and fil the Fe8 easrar sae Beneath he FMBS reservoirs uly Close the needle valve and open the loading valve Check that the FMS3 has been connected to the IFD7, and the IFD7 is connected to a PC and to a suitable electrical supply. Check that the red and green indicator lights ‘on the front of the IFD7 are illuminated Switch on the IFD7. Run the FMS3 software and select Exercise A Select the ‘Power On’ switch on the mimic diagram and check that the ‘Watchdog Enabled’ indicator illuminates Prime the system as described in the Operation section. Procedure Gradually increase the motor speed using the arrow keys beside box on the mimic diagram. Check that water is drawn through the system an the outlet tube back into the reservoir. the motor control 1d out of ick on the ‘Reset' button for cylinder and With the motor at its maximum setting, cli t maximum values. outlet pressure, to ensure that the readings are for the current ; Then select the ~”icon to start recording the sensor readings and equipment settings to the results table, The software will ecord the results of high-speed dat logging over a short fixed period. Create a new results sheet using the & icon Close the load valve to raise the maximum outlet pressure by approximately 50 kPa Select the icon again Repeat at intervals of maximum outlet pressure up to a value of approximately 400 kPa (4 bar), creating a new results sheet and recording the data each time. Open the loading valve fully Repeat at a motor setting of 50% Greate Set the motor to 100% Fully open the pulsation damper valve. Repeat with the pulsation damper in use If time permits, use @ bicycle pump or similar to increase the pressure within the damper pot, and repeat the logging of results at low (loading valve open) and high (loading valve partly closed) outlet pressures. Fully open the loading valve and set the motor speed to 0%. Select ‘Save As...’ from the ‘File’ menu to save the results sheet, using a suitable name (such as the equipment code, experiment letter and date), 33Armfield Instruction Manual Results, The software tabulates the results under the followin ae —oalet | cylinder _7_—_Motor Water] Pump] _ Plunger] Sate austica Torgue g headings: Speed | Speed | Displacement | Pre5Pt aa | fee (iin) (Pa) (kPa) (Nm) Print 2 graph of piston displacement against time. On the second y-axis, plot the outlet pressure. Print a graph of outlet pressure against time. On the second y-axis, plot the cylinder pressure. For 100% motor speed, on the same axes, plot a graph of the damped and undamped flow with the loading valve fully open. On a second graph, do the same for '50% motor speed. Produce two further graphs at 100% motor speed and 50% motor speed for maximum outlet pressure (loading valve partly closed). Also print graphs of the effects of raised pot pressure if this part of the experiment was performed Conclusion Examine the graph of piston displacement and outlet pressure against time. Describe the shapes of the plots. Describe and explain the relationship between the plots. Are the plots in phase? Examine the graph of outlet pressure and cylinder pressure against time. Compare the shapes of the plots. Describe and explain the relationship between the plots. ‘Compare the graphs of damped and undamped flow, and describe the effect of damping, Explain the difference in the effect at low and high maximum pressures, and the result of increasing the pressure in the damping pot. 34Exercise B- The p. y Dligram Objective To construct a Pressure '® = Volume diagram for a plunger pump. Method ase he FES Bunge pump apparatus fo Gal LTD Ie measurements over ar 'S over a range of pump speeds and outlet pressures Equipment Required Armfield FMS3 Plunger Pump Armfield IF PC running Armfield FMS3 software Theory ‘The work processes occurring within the plunger pump may be deseribed by Considering each stage of a single complete cycle: 1 As the piston is drawn out, the volume enclosed within the cylinder increases. Fluid enters the cylinder from the higher pressure inlet pipework. UW V increases —— 2. As the piston reaches the end of its outward travel, there is no further volume Increase. The pressures equalise between the cylinder and the inlet. [Li P= minimum V = maximum ——S Pintet = Peyiinder 35‘Armfield Instruction Manual osed within the cylinder dof its inward travel, there is no further volume i the 4. As the piston reaches the en era able decrease. Pressures equalise between Peylinder = Pout | ee P= maximum V= minimum The cycle may be described in graphical format by plotting the cylinder pressure against the cylinder volume. As a Vv The work done by the pump in a cycle may then be calculated from the area ‘enclosed by the graph § =[fpav+ (fp av+ ‘nav + [tpav pd 36Exercise B The working fh incompressible Musee tree FMS3 is water, which may be considered an cylinder at iow presex t!® @8sumption is correct then volume of fluid entering the ae “Sure should equal the volume of fluid exiting the eylinder at high Equipment Setup Ch EMSS nat the cain Vaive beneath the FM5S resarolrTs fully closed, and fil the FMSS reservoir if required Close the needle vaive nd open the oading valve one ie ‘he FMB3 has been connected to the IFD7, and the IFD7 is connected to to a Suitable electrical supply. Check that the red and green indicator lights on the front of the IFD7 are itummerey, Switch on the IFO7. Run the FM53 software and select Exercise B Select the ‘Power On’ switch on the mimic diagram and check that the "Watchdog Enabled’ indicator illuminates Prime the system as described in the Operation section Procedure Gradually increase the motor speed using the arrow keys beside the motor control box on the mimic diagram. Check that water is drawn through the system and out of the outlet tube back into the reservoir With the motor at its maximum setting, click on the ‘Reset’ button for cylinder and Outlet pressure, to ensure that the readings are for the current maximum values. Then select the ~ icon to start recording the sensor readings and equipment Settings to the results table. The software will record the results of high-speed data logging over a short fixed period. It has completed logging when the new results sheet icon (i) becomes available (not greyed oul) Create a new results sheet using the & icon Close the load valve to raise the maximum outlet pressure by approximately 100 kPa. Select the icon again. Repeat maximum outlet pressures of approximately 300 kPa (3 bar) and 400 kPa (4 bar), creating a new results sheet and recording the data each time. Open the loading vaive fully. Repeat at a motor setting of 50%, Fully open the loading valve and set the motor speed to 0%. Select ‘Save As...’ from the ‘File’ menu to save the results sheet, using a suitable name (such as the equipment code, experiment letter and date), 37Ar Results, The software tabulates t Motor | Pump | Plunger syinder | Cylinder | Outlet Speed | Speed (%) | (pm) Jd Instruction Manual Displacement s (mom) Pressure Pe (KPa) he results under the following headings: Volume | Pressure v Po (em) | (KPa) Motor Torque T (Nm) Work For each set of results, print a graph of cylinder pressure against volume and print out the result From the graph, calculate the area enclosed by the P-V values plotted. From the result, calculate the work done by the pump. Remember to allow for the units in which the pressure and volume were plotted. Conclusion Compare the graph obtained to the example given in the theory. Note any differences. and discuss possible reasons for those differences, The software calculates the ideal work done based on the maximum and minimum. cylinder pressures and volumes obtained. Compare the computer calculated values with the value obtained from the graphs. How significant is the difference between. the values? 38Exercise ¢ _ Volumetr Objective ic Efficiency To deter termine the volumetnc efficiency of a plunger pump Method By usi 5 measttere ne PUN up appara Meee 288 of pump speeds and outlet pressures. By using the volume tar re@Surement acy of he FMS3d04 sofware to deteniee te rue volume flow rate of the FMS3 plunger pump Equipment Required Armfield FMS3 Plunger Pump Armfield IFD7 PC running Armfield FMS3 software Theory The volumetric efficiency is defined as the ratio of actual volume of fluid delivered per cycle to the swept volume of the cylinder (ie. the volume traversed by the piston), where the swept volume would be the theoretical volume of fluid delivered each cycle if there were no losses, The swept volume is calculated from the cylinder area and the piston displacement Vesos = A(Snas~ Sp) Where Ais the cross-sectional area of the cylinder, and Sis the displacement of the piston, and Soar Sin = 15mm for the FMS3. A=nr where }émm, ‘The FMS3 is fitted with a flow meter and integrating circuit. This allows the total flow volume measured by the flow meter to be averaged over time. Accuracy is improved as the measurement is average over several cycles Veg, = Mota wa where View i$ the total flow volume measured by the flow meter, and nis the number of pump cycles over which flow is measured. 39Armfield Instruction Manual Equipment Setup Check that the drain valve beneath the FMS3 reservoir is fully closed, and fil the FMS3 reservoir if required Close the needle valve and open the loading valve z 7, and the IFD7 Check that the FMS3 has been connected to the IFD’ 's connected to 2 PC and to a suitable electrical supply. Check that the red and green indicator lights Cn the front of the IFD7 are illuminated ‘Switch on the IFD7. Run the FMS3 software and select Exercise B. Select the ‘Power On’ switch on the mimic diagram and check that the ‘Watchdog Enabled’ indicator illuminates Prime the system as described in the Operation section Procedure Gradually increase the motor speed using the arrow keys beside the motor control box on the mimic diagram. Check that water is drawn through the system and out of the outlet tube back into the reservoir. With the motor at 100%, click on the ‘Reset’ button for cylinder and outlet pressure, to ensure that the readings are for the current maximum Values, The software for this exercise is configured to take samples over a fixed number of cycles. Select the ‘Start’ button on the mimic diagram to begin sampling. The results may be observed in the Flow Rate display boxes on the mimic diagram as the software averages the sensor readings over the set number of cycles. The values will settle when the required number of cycles has been reached, and the ‘Start’ button will become available again. Select the © icon to record the sensor readings, equipment settings and calculations to the results table. Set the motor to 90%. Select the ‘Reset’ buttons for the cylinder and outlet pressures Select the ‘Start’ button and complete another measurement cycle. Record the results with the ® icon, Repeat for motor settings of 80%, 70% etc, down to 20%. Set the motor to 100%. Create a new results sheet using the icon. Partly close the loading valve to give an outlet Pressure of approximately 200 kPa. Repeat the measurements at a range of motor settings as before. Create further sets of results at approximately 300 kPa and 400 kPa maximum outlet pressure, Remember to create a new results sheet each time using the Fully open the loading valve and set the motor speed to 0% Select ‘Save As... from the ‘File’ menu to save the results sheet, using a suitable name (such as the equipment code, experiment letter and date) 40 eeExercise Results The softwar Mwave tabulates the resuits under the following headings [sae eae = | Speea] Soeea] og an] Caer] Care| NS -Voune erage | aes Vara | sostTem'|Prssr| ere Torue | Concea] “Ree | Best | Ease ©) | osm | as ed a! gas ame |opeme | ee Lal (rm caper | im | anes) | cam | dai Be For each outlet Speed These Pressure settin may be plotted 9, plot the volumetric efficiency against the pump on the same graph for comparison between results, Conclusion trow does the Volumetric effciency of the pump vary with increasing pump speed? Is tre gcesconstant trend, or does the efficiency reach a peak voleo? tine latter, note Ihe speed at which peak efficiency is achieved and the menenen efficiency value obtained for each outlet pressure Compare the graphs obtained What was the effect of increasing outlet pressure on the sae pence? Did the maximum efficiency (if any) increase, decrease, of stay the same? Did the speed at which it occurred differ? What are the implications of the results obtained when considering the choice of Pump type for practical applications? aTypical Results Exercise a Alot of essure an simi 3 Displacement against ime obtaineg at Should be similar to the graph shown belay Sane 8 & S snd Hanger Displacement sansa Sample Tine The sinusoidal motion of the plunger will on} ty vary with the speed of the motor but the shape of the pressure trace will a Is0 vary with the settings of the loading valve, the needle valve and damper. Note that tolerances in manufacture ofthe equipment will Fesult in variations in the ‘numerical values obtained, 42Typical Results Exercise B Sno ete Pronsure against Cylinder Volume binned wt resin Spee should be similar to the graph shown below Banc as ene © 7 i Prom Benga Cyr Volume v Note that tolerances in manufacture of the equipment will result in variations in the numerical values obtained 43