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1
Theory Of Positive Displacement
Pumps
• Reciprocating and rotary positive displacement pumps are
common in the chemical and process industries.
• The characteristic features and operating principles of the most
common positive displacement pumps are discussed
previously.
• In this chapter the relation between their geometry and
performance is discussed.
2
4.1 Theory Of Reciprocating Pumps
3
4.1.1 Capacity of Reciprocating Pumps
4
• A single acting-reciprocating pump is a pump with only one
side of the piston acting on the liquid.
• When the two sides act we call it double acting.
R
R
Figure 4.1a Single acting piston pump Figure 4.1b Double acting piston pump
5
a. Single acting pumps
The capacity of a single acting reciprocating pump is the
product of the displaced volume, the number of double strokes
(rpm), and the volumetric efficiency as it is given
2
Q D Sn vol
4
Where:-
n= number of piston double strokes
D=Inner diameter of the cylinder (bore diameter)
S= piston stroke, S 2 R
vol= Volumetric efficiency
Q= Capacity (Volume flow rate)
6
The volumetric efficiency takes into account leakage through
clearances and suction and discharge valves during the suction
stroke and vice versa. It is determined, in the course of pump
tests, by measuring the actual volume of liquid delivered by
the pump per unit time.
Q
vol '
Q
7
For a reciprocating pump it is common to give the slip of the
pump instead of the volumetric efficiency.
The slip of the pump is the measure of the total volumetric loss
of the pump given as a fraction of the theoretical capacity.
The slip is given by:-
Slip 1
vol
' 2
Q D Sn
4
8
b. Double acting pumps
The capacity of a double acting pump is twice the capacity of
the single acting minus the reduction in capacity due to the
volume displaced by the connecting rod. Hence,
Q ( 2 D 2 d 2) Sn vol
4
Where:- d is the diameter of the rod
c. Multiple Cylinders
If a pump has several cylinders of same size with their
pistons actuated by a common crankshaft (multiplex pump),
the pump capacity is calculated as the capacity developed
by one times the number of pistons.
9
4.1.2 Suction and Discharge Pulsations in
Reciprocating Pumps
10
The Velocity and Acceleration of the Flow
Medium in Reciprocating Pumps
L
R
x
L+ R
11
x L2 R 2 sin 2 R cos L R
2
x R(1 cos ) L(1 1 R2 sin 2 )
L
vp
dx
dt
R sin
d 1 2 2 2
L R sin
dt 2
1 / 2
2 R 2 sin cos
d
dt
sin sin 2
dx R
2
(2 sin cos ) d vp R
v p R sin 2
2 L sin 2
dt 2 L2 R2 sin 2 dt 2
R
12
The ratio L/R is commonly in the range of 4:1 to 6:1.
Lower L/R ratio causes high pulsation and larger L/R ratio
results in large uneconomical power frame.
2
L 2 sin 2
Since sin v p R sin
R 2 L / R
2
For simple harmonic i.e., LR a p R cos
13
The Acceleration Head of the Flow Medium in
the Suction and Discharge Pipes
Because of the acceleration of liquid in the cylinder the liquid
in the suction and discharge pipes also accelerate.
From the continuity equation,
vp Ap
A p v p As v s vs
As
Where:-
Ap= Cross -sectional Area of the piston head
vp=velocity of the piston head
As= Flow area of the suction pipe
vs= velocity of the liquid in the suction pipe
14
Therefore the acceleration of the liquid in the suction pipe is
given by
dvs v p Ap
as
dt As
A p dv p Ap
as ap
As dt As
Ap cos 2
as R cos 2
As L/ R
15
Similarly for the liquid in the discharge pipe
Ap cos 2 2
ad R cos
Ad L/R
Ad= Flow area of the discharge pipe
16
ma s Ls ma d L d
Y a , s FL s a s Ls Y a , d FL d a d Ld
m m
17
Ap
Hence, Ya , s a p Ls
Ya ,d
Ap
a p Ls
As
Ad
18
4.1.3 The Minimum Pressure
for the Piston to Move in the Cylinder
19
2
Ls
hs
The relationship between the total mechanical energy of the flow medium at
point 1 and 2 , is given by:-
P1 P
z1 2 z 2 ha h fs
g g
Where
ha= acceleration head in the suction pipe
hfs= friction head in the suction pipe 20
Therefore the pressure inside the cylinder, P2 can be calculated
by:- P P
2 1
( z 2 z1 ) ha h fs
g g
Since most commonly P1=Patm
P2 P
atm hs ha h fs
g g
Similarly for the discharge stroke
P2 Pd
hd ha h fd
g g
21
4.1.4. The Minimum Pressure to Open the Suction
Valve
P2 P
atm h s h a h fs
g g
P2,min Patm
hs ha , max
g g
22
For simple harmonic motion , with =00.
A p R 2 Ls
has ,max
As
P2,min Patm A p R 2 Ls
hs
g g As
23
4.1.5 The Minimum Pressure to Open the Discharge
Valve
P2,minPd A p R 2 Ld
hd
g g Ad
24
4.1.6 The Indicator Diagram
25
Theoretical Indicator Diagram
As the piston moves to the right the pressure inside the
cylinder is reduced and the suction valve is opened while the
discharge valve is closed. The enclosed space of the cylinder is
increased and is filled with liquid coming from the intake pipe
through suction valve.
3 2
Patm
4 1
1
S (Vpist)
27
The Indicator Power
The indicator power is the theoretical power of a reciprocating
pump that can be calculated from the theoretical indicator
diagram.
It can also be noted that Q’=Apist S n, hence the indicator power is
equal to the product of the indicator pressure and the theoretical
volume flow rate.
N i Pi A pist Sn N i Pi Q'
29
Brake Power and Useful Power
The break power that should be delivered from the motor to
the pump hence is,
N brake N i
m
Where:- m is the mechanical efficiency
m = 0.9 to 0.95
Pi A pist Sn
N brake
m
Q'
N brake Pi
m
30
The useful power N N N i i
N brake
P A
i pist
Sn
P i A pist Sn vol h m P i Q h m Pi h
H
m Qg m Qg g
H
Pi h
g
32
The Actual Indicator Diagram
33
2
3 1
P Patm
A(Vpist)
As soon as the valve opens, the pressure in the valve chest falls off
abruptly and the valve bobs rapidly up and down several times in
the liquid flow, thus throttling the flow and causing the pressure in
the valve chest to fluctuate, which accordingly affects the
discharge line of the indicator diagram. The actual indicator
diagrams are drawn using readings of indicators connected to
pumps.
34
Cavitations in Reciprocating Pumps
for =0 PA PT A p R 2 Ls
es 0
g g As
AS L s PA P
2 es T
RLsA p g g
AS L s PA P
e s T
RLsA p g g
1 AS L s PA P
2n n es T
2 RLsA p g g
37
In a process where uniform discharge is required, either
the discharge pulsation should be reduced or eliminated
somehow or other type of pumps should be used.
The other major problem related to discharge pulsation is
mechanical instability. Due to the non-uniformity of
velocity of the liquid in the cylinder and the discharge
pipe the liquid will decelerate.
This deceleration causes pressure pulsation, which in
some cases cause serious mechanical instability. The
following section discusses the methods for reducing
pulsation in reciprocating pumps.
38
a. Using multiplex pumps
39
40
35
30
25
20
15
10
5
0
-5 0 60 120 180 240 300 360
40
Table 5.2 Effect of number of piston/cylinder on variation in capacity
Triplex 3 6 17 1200
Quadraplex 4 11 22 900
Quintaplex 5 1 5 720
Sextplex 6 5 9 600
Septuplex 7 1 3 51.50
% above mean v max v mean 100% % below mean v min v mean 100%
v mean v mean
41
b. Air Chambers in the suction and Discharge
lines
Air vessels are closed cylindrical vessels for storing excess
flow. Towards the middle of the stroke, when the velocity of
the flow is greater than the average, the excess flow gets into
the air vessel and compresses the air in the cylinder, building
up a pressure higher than the atmospheric pressure.
Air chambers
Air
Liquid
42
• Towards the end and the beginning of the next stroke, when
the velocity is low, the liquid under pressure in the air vessel is
pushed back to the delivery or suction line depending on
whether the stroke is delivery or suction stroke, thus increasing
the velocity there to the average value. The only liquid which
is accelerated is that between the air vessel and the cylinder.
43
The Average Volume of Air in The Chamber
44
Air
Vmin
Top level
Vmax
Middle level
Bottom level
Q A p R sin
46
• The average capacity does not depend on the crank angle and
is given by Equation 5.1 for a single acting single cylinder
reciprocating pumps. Figure 5.10 is a typical representation of
the actual and average volume flow rates as function of time
for one complete rotation, i.e. between 00and 3600. The area
under each of the curves represents the total volume to be
delivered by the pump in one complete rotation of the crank
(one suction and one discharge stroke). The two areas should
be equal, since whether the flow is uniform or not the same
amount of liquid is drawn into the pump and is discharged out
in every rotation.
47
Excess volume
Actual capacity (function
of the crank angle)
Q
Average capacity
48
• Hence the volume of the liquid to be stored in the chamber can
be computed by drawing the actual and average volume flow
rates on the same scale for a time of one complete rotation, and
determining graphically the area above the average volume
flow rate line (shaded area).
49
Calculating the Average Volume of Air in the
Chamber
Pmax Pmin
( Pmax Pmin ) / 2
PmaxVmin
Pmin
Vmax
Vmin V
Pmax Pmax 1 min
Vmax Vmax
V V
Pmax Pmax min 2 1 min 2
Vmax Vmax
51
• The average volume of air in the chamber can be
determined using (5.48) for a predetermined degree of
irregularity. Note it is earlier discussed how to determine
the excess volume graphically. This procedure is used
both for suction and discharge air chambers. The
commonly accepted degrees of irregularity are
• For Suction Air Chambers 0.02
• For Discharge Air Chambers 0.04 0.05
• A calculation based on the above procedure gives the
average volume of air in the chamber in terms of the area
of the piston and stroke length as given in the table
below.
52
Performance Characteristics of Reciprocating
Pumps
The performance characteristic of reciprocating pumps is quite
different from centrifugal pumps. As in the case of centrifugal
pumps, the performance characteristics is commonly described
as a graph. In such cases it is called characteristic curve
H
n1 n2 n3
Q ’1 Q ’2 Q ’3
Q’
55
Actual Performance Characteristics
The difference between the actual and theoretical performance
characteristic curves is caused by the dependence of the slip on
head.
The slip of a reciprocating pump increases with the head
against which it operates.
Actual
H Theoretical
Q’
57
4.2.1 Operating Principle of Rotary Pumps
• There are three distinct parts in the any rotary pump that is in
operation.
• These parts are defined by the rotating and stationary parts of
the pump and determine the amount of the displaced volume.
The first part is defined by the part that is open to the inlet and
is sealed from the outlet.
The second is the part that is sealed from both the inlet and
outlet.
The third is the part that is sealed from the inlet but open to the
outlet.
58
CTIO
OTO
OTI
59
Displacement of Common Rotary Pumps
60
Displacement of External Gear Pumps
R1
Suction Discharge
R2
D l ( R22 R12)
l=Total axial length of the rotor
R1=Minimum radial dimension of the rotor elements
R2=Maximum radial dimension of the rotor elements
62
1.Capacity of Rotary Pumps
In general the capacity of any rotary pump is the product of its
displacement (D), speed of rotation of the drive (n) and the
volumetric efficiency (v).
Q Dn v
63
1.Pressure (Head) of Rotary Pumps
Rotary pumps unlike centrifugal pumps can deliver
whatever head is required by the system.
The only limitations are the power of the drive and the
strength of the pump. If the drive can deliver sufficient
power, yet if the strength of the pump is low the pump will be
damaged. Hence all positive displacement pumps are
commonly, fit with relief valves that limits the maximum
pressure inside the pump. Another limiting factor for the
maximum pressure is the pump slip. The pump slip (leakage) in
rotary pumps generally increases with pressure hence running
at very high pressure may result in very low efficiency.
P
Note that the total head of the pump is given H t
g
by:-
Where Pt is the total pressure developed by the pump
64
1.Power of Rotary Pumps
The useful and brake power of a rotary pump are calculated
from the total pressure to be transferred to the flow medium,
the volume flow rate and overall efficiency of the pump.
Useful Power
The useful power of a rotary pump is the product of the flow
rate and total pressure of the pump (Useful), and is given by,
N QPt
Brake Power
The brake power is calculated from the useful power
and the overall efficiency using :- QPt
Nb
The overall efficiency of rotary pumps is determined by
test
65
4.2.6 Performance Characteristic of Rotary Pumps
The performance characteristics of all positive displacement
pumps are similar and can be applied to rotary pumps also.
For rotary it is also common to present the curves as
functions of the total pressure:-
Q f (P ) N b f (P ) f (P )
n[rpm]=constant
Viscosity= Constant
Q
P Plim
67