College of Engineering

Department of Mechanical Engineering

Design of Triplex Plunger Pump

Abdullah Al-Jubran
Ali Al-Qahtani
Haitam Al-Mubarak

Project Advisor: Dr. Emad Tanbour

A Design Project Submitted in Partial Fulfillment

of the Requirements for the Course

Assessment III: Graduation Project

 College of Engineering
Department of Mechanical Engineering

Statement of Purpose

To design a triplex plunger pump that can be

manufactured using locally available
resources and manufacturing techniques

To practice the application of computer-aided

design program in the design of machines
 College of Engineering
Department of Mechanical Engineering

Table of Contents

 Introduction
 Scope of Project
 Pumps Classification
 Triplex Pump Basics/Concept
 Calculations
 Crankshaft Diameter
 Bearings
 Triplex Pump Prototype
 College of Engineering
Department of Mechanical Engineering

Introduction

Triplex Plunger Pump

Positive Displacement Pump

Three Plungers in parallel

High-Pressure Low-Capacity Application

hydrostatic testing

water blasting

surface preparation

car washing

pipe and tube cleaning

oil drilling
 College of Engineering
Department of Mechanical Engineering

Scope of Project

Designing of Triplex Plunger Pump

Discharge Pressure: 350 bar (5,076 psi)
Flow Rate: 24 li/min (6.3 gpm)

Crankshaft

Bearings

Material Selection

Fasteners

Making of Digital Prototype

 College of Engineering
Department of Mechanical Engineering

Design Approach

Group Brainstorming

Gather Literatures from the web

Design Conceptualization

Identification of Critical Components

Sizing and Strength Calculations

Prototyping by CAD Solidworks
 College of Engineering
Department of Mechanical Engineering

Triplex Pump Design GANTT Chart

Positive Displacement Pump versus Centrifugal Pump
Classification Diagram of Displacement Pumps
Classification Diagram of Displacement Pumps
 Reciprocating Positive Displacement Pumps

1. Piston Pump 2. Plunger Pump 3. Diaphragm Pump

Good packing life
Higher Pressure
Suitable for Chemicals

Good for slurries
Easier to maintain
Expensive
 Ways to Achieve Reciprocating Motion

1. Crankshaft with crank pin

2. Crankshaft with eccentric sheave or strap

 Slider Crank Mechanism

The offset between the shaft center and eccentric

sheave center determines the pump stroke
Plunger Pump with Eccentric Sheave
 Critical Components
a. Crankshaft
b. Eccentric Sheave
c. Crankshaft Support Bearing
d. Eccentric Sheave Bearing
e. Wrist Pin
f. Wrist Pin Bearing
g. Fluid End Plunger
 Design Calculations
Criteria: Displacement: 24 li/min
Discharge Pressure: 350 bar
# of Plungers: 3

Computation to determine required power

kW = Q × Ptd / 36 × ME
Where Q = delivered capacity, m3/h
Ptd = differential pressure (discharge – suction), bar
ME = mechanical efficiency, %

At 24 liters/minute, 350 bar and typical efficiency of 88%,

(24 liters/min)(60min/hr)(1m3/1000liters)(350bar)
kW =
(36×0.88)

kW = 15.91 kilowatts, or 21.33 Hp

Computation to determine Pump Speed and Plunger Speed
From Pump Handbook, 3rd edition, pages 3.4, 3.6

Q = A × m × n × s × 6× 10-8
Sp = s × n / 30,000
Where Q = displacement, m3/h
Sp = plunger speed, m/s
A= cross-sectional area of plunger, mm2
M= number of plungers
n= rpm of pump
s= stroke of pump, mm

Preselected Plunger Bore and Stroke

Plunger Bore Size : 18, 19, 20, 21 and 22 mm

Plunger Stroke : 21, 22, and 23 mm

 Table 1 Pump Speed at Different Plunger Bore and Stroke

Plunger Bore, mm Plunger Stroke, Pump Speed, rpm Plunger Speed,

mm m/s
21 1,497 1.05
18 22 1,429 1.05
23 1,367 1.05
21 1,344 0.94
19 22 1,283 0.94
23 1,227 0.94
21 1,213 0.85
20 22 1,158 0.85
23 1,107 0.85
21 1,100 0.77
21 22 1,050 0.77
23 1,004 0.77
21 1,002 0.70
22 22 957 0.70
23 915 0.70
The obtained plunger speeds above are in accordance with the industry
standard
Computation to determine Pump Required Torque
From Pump Handbook, 3rd edition, page 3.8
M = p × 9.549 / n
Where M = pump torque, N·m
n = speed, rpm
p = power, W
Plunger Bore, mm Plunger Stroke, Pump Speed, rpm Torque,
mm N·m
21 1,497 102
18 22 1,429 106
23 1,367 111
21 1,344 113
19 22 1,283 118
23 1,227 124
21 1,213 125
20 22 1,158 131
23 1,107 137
21 1,100 138
21 22 1,050 145
23 1,004 151
21 1,002 152
22 22 957 159
23 915 166
a. Calculation to Determine Crankshaft Diameter
a. Calculation to Determine Crankshaft Diameter

From Machine Design Data Book, 2nd edition, page 14.3

For rotating shafts with dynamic load, dynamic effect taken

indirectly into consideration

The diameter of shaft subjected to simple torsion

16 ⅓
D = Kt × Mt × 1000
πτyd

Where D = shaft diameter, mm

Kt = shock and endurance factor applied to computed twisting
moment
(Table 14-2 Machine Design Data Book, 2nd ed. page 14.18)
Mt = twisting moment or torque, N·m
τyd = design yield stress, Pa
From Machine Design Data Book, 2nd edition, page 14.18
 From Shigley's Mechanical Engineering Design, 8th Edition, page 212

τmax = Sy / 2n

Where τmax = maximum shear stress, Pa

Sy = yield stress, Pa
n = design factor

Using AISI 1020 steel which has a yield strength of about 206 MPa,
and using a design factor of 1.5,

τmax = 206 MPa × 10^6 Pa/MPa

(2 × 1.5)
τmax = 68,666,666 Pa

16 ⅓
D = 1.5 × Mt × 1000
3.1415 × 68,666,666
 Table 1: Computed Shaft Diameter at Different Plunger Bore and Stroke

Plunger Bore, Plunger Stroke, Pump Speed, Pump Torque, Computed

mm mm rpm Nm Shaft
Diameter, mm
21 1,497 102 22.4
18 22 1,429 106 22.8
23 1,367 111 23.1
21 1,344 113 23.3
19 22 1,283 118 23.6
23 1,227 124 24.0
21 1,213 125 24.1
20 22 1,158 131 24.4
23 1,107 137 24.8
21 1,100 138 24.9
21 22 1,050 145 25.3
23 1,004 151 25.6
21 1,002 152 25.6
22 22 957 159 26.0
23 915 166 26.4
 b. Calculation to Determine Eccentric Sheave Diameter

Sd
= (s/2) + (D/2) + sw
2
Where Sd = eccentric sheave diameter, mm
s = plunger stroke, mm
D = shaft diameter, mm
sw = minimum sheave width, mm
- pre-selected to be 4.7625 mm (3/16 inch) to facilitate easy
welding of the eccentric sheave to the shaft
 Table 2: Eccentric Sheave Diameter at Different Shaft Size

Plunger Bore, Plunger Stroke, Computed Shaft Ecc. Sheave

mm mm Diameter, mm Diameter, mm
21 22.4 53.0
18 22 22.8 54.3
23 23.1 55.7
21 23.3 53.8
19 22 23.6 55.1
23 24.0 56.5
21 24.1 54.6
20 22 24.4 56.0
23 24.8 57.3
21 24.9 55.4
21 22 25.3 56.8
23 25.6 58.2
21 25.6 56.2
22 22 26.0 57.6
23 26.4 59.0
 c. Calculation to Determine Strength of Eccentric Sheave Weldment

Stresses in welded joints in torsion

τ" = Mr / J

Where τ” = shear or torsional stress, Pa

M = torsional moment, N·m
r = distance from the centroid of the weld group to the point in the weld
of interest, m
J = second polar moment of area, m4
 J = 0.707hJu

For circular fillet welds

Ju = 2 × π × r3

The distance from the centroid of the weld group to the point in the weld of interest,
r, can be taken as the radius of the shaft.

The force exerted by the plunger

Fp = Pressure × Plunger Cross-Sectional Area

Example, 22mm plunger bore

Fp = (350 bar) × (100KPa/bar) × (1000Pa/Kpa) × (1N/m2/Pa) × π ×

(22mm/1000mm/m)2/4
Fp = 13,304 N
Maximum moment = Fp × (stroke/2). For 23mm stroke,

M = 13,304 N × (23mm/1000mm/m) ÷ 2

M = 153 N·m
By using the results above, the stress on the 3/16 inch fillet weld can be calculated.

(153Nm)(27mm/1000mm/m)÷2
τ" =
(0.707)(3/16in.)(1m/39.37in.)(2×3.1415)((27mm/1000mm/m)÷2)3

τ" = 39,682,448 N/m2 or 39.7 MPa (5.473 ksi)

 c. Calculation to Determine Crankshaft Bearing

Bearing Catalog Load Rating

LDnD60 1/a
C10 = FD
LRnR60
Where C10 = catalog load rating, kN
FD = desired radial load, kN
LD = desired life, hours
nD = desired speed, rev/min
LR = rating life, hours
nR = rating speed, rev/min
a = constant; a = 3 for ball bearings, a = 10/3 for roller bearings

For most bearing manufacturers LRnR60 = 106

LDnD60 1/a
C10 = FD
106
 Forces acting on the crankshaft bearing

Total maximum force acting on the bearing

1 3F
Fb1 = Fp2 + p1
2 4
5 =F
Fb1 = F bmax
4 p
Where Fp = Pressure × Plunger Cross-Sectional Area

Fp = (350 bar) × (100KPa/bar) × (1000Pa/Kpa) × (1N/m2/Pa) × π ×

(bore in mm/1000mm/m)2/4
Table 3: Maximum Bearing Load at Different Plunger Bore Sizes

Plunger Bore, mm
18 19 20 21 22
FP, k·N 8.91 9.92 11.0 12.12 13.30
Fbmax 11.13 12.40 13.74 15.15 16.63
 Table 4: Shaft Bearing Load Rating
Plunger Bore, mm
18 19 20 21 22
FP, (kN) 8.91 9.92 11.0 12.12 13.30
Fbmax, (kN) 11.13 12.40 13.74 15.15 16.63
nD, (rpm) 1,497 1,344 1,213 1,100 1,002
LD, (hours) 5,000 5,000 5,000 5,000 5,000
C10, (kN)
(ball bearing) 85.25 91.64 98.12 104.71 111.40
C10, (kN)
(roller bearing) 69.55 75.03 80.61 86.31 92.11
Computed Shaft
Dia, (mm) 23.1 24.0 24.8 25.6 26.4
Std. Shaft
Dia., (mm) 25 25 25 30 30
Available
Bearing - - - - -
 Table 4: Shaft Bearing Load Rating
Plunger Bore, mm
18 19 20 21 22
FP, (kN) 8.91 9.92 11.0 12.12 13.30
Fbmax, (kN) 11.13 12.40 13.74 15.15 16.63
nD, (rpm) 1,497 1,344 1,213 1,100 1,002
LD, (hours) 5,000 5,000 5,000 5,000 5,000
C10, (kN)
(ball bearing) 85.25 91.64 98.12 104.71 111.40
C10, (kN)
(roller bearing) 69.55 75.03 80.61 86.31 92.11
Computed Shaft
Dia, (mm) 23.1 24.0 24.8 25.6 26.4
Initial Std. Shaft
Dia., (mm) 25 25 25 30 30
Adjusted Std.
Shaft Dia., (mm) 30 30 30 30 30
Available NU 2306 NU 2306 NU 2306
Bearing, SKF - -
NJ 2306 NJ 2306 NJ 2306
Available SKF Bearing for the crankshaft
 Table 5: Eccentric Sheave Bearing Load Rating

Plunger Bore, mm
18 19 20
FP, (kN) 8.91 9.92 11.0
nD, (rpm) 1,497 1,344 1,213
LD, (hours) 5,000 5,000 5,000
C10, (kN)
(ball bearing) 68.20 73.31 78.50
C10, (kN)
(roller bearing) 55.64 60.02 64.49
Eccentric Sheave
Internal Dia., (mm) 30 30 30
Eccentric Sheave
Outside Dia., (mm) 60 60 60
NKIS 60 NKIS 60 NKIS 60
Available Bearing,
NA 4912 NA 4912
SKF
NKI 60/35 NKI 60/35
e. Pump Driver Selection
e. Pump Driver Selection
 e. Pump Driver Selection

Table 6: List of Applicable Drive Motors

Efficiency,
Manufacturer Hp Speed, rpm Cost, $ Cat. No.
%

25 1,200 91.7 2,312 S279

GE
25 1,200 93.0 2,800 M7549

Baldor 25 1,200 93.0 5,090 ECP4111T

1LE29313A
Siemens 25 1,200 91.7 2,480
C116AA3

25 1,200 91.7 3,438 N0256

TECO
25 1,200 93.0 4,456 EP0256
Westinghouse
25 1,200 93.0 4,635 HH0256
 e. Pump Driver Selection

Table 6: List of Applicable Drive Motors

Efficiency,
Manufacturer Hp Speed, rpm Cost, $ Cat. No.
%

25 1,200 91.7 2,312 S279

GE
25 1,200 93.0 2,800 M7549

Baldor 25 1,200 93.0 5,090 ECP4111T

1LE29313A
Siemens 25 1,200 91.7 2,480
C116AA3

25 1,200 91.7 3,438 N0256

TECO
25 1,200 93.0 4,456 EP0256
Westinghouse
25 1,200 93.0 4,635 HH0256
 Selected Plunger Bore and Stroke

Plunger Plunger
Speed, rpm Remarks
Bore,mm Stroke, mm
21 1,497
Disregarded. Motor speed is only
18 22 1,429
1,200 rpm.
23 1,367
21 1,344
Disregarded. Motor speed is only
19 22 1,283
1,200 rpm.
23 1,227
21 1,213 Disregarded. Motor speed is only 1,200 rpm
20 22 1,158 Selected Plunger Bore & Stroke
23 1,107 Disregarded. Not optimal.
21
21 22 Disregarded. No crankshaft bearing available.
23
21
22 22 Disregarded. No crankshaft bearing available.
23
 Since the standard shaft diameter chosen is 30mm, and the eccentric
sheave diameter is 60mm, the minimum sheave thickness, sw, is
recalculated.

From
Sd
= (s/2) + (D/2) + sw
2

Sd - s - D
sw =
2
60 - 22 - 30
sw = = 4 mm
2
 f. Calculation to determine wrist pin size
AISI 1030 steel is chosen because of higher yield strength than AISI
1020 steel.
Based on maximum shear stress theory, the maximum allowable shear
stress,
τmax = Sy / 2n

Where the yield strength, Sy, for 1030 steel is equal to 260 Mpa. Using a
design factor of 1.5,
τmax = 260 / (2×1.5) = 86.7 Mpa
 f. Calculation to determine wrist pin size (cont’d)

Wrist pin will fail by shearing on sections a and b.

τmax = Fp / (Aa + Ab)

Where A = cross-sectional area of wrist pin.

But since the cross-sectional area of the wrist pin is the same, therefore
Aa=Ab, then,
τmax = Fp / 2A = Fp ÷ 2(πdw2/4) ; dw = wrist pin diameter

By transposing the equation above

dw = (4Fp/2π τmax)1/2

4×11kN×1000N/kN
dw =
2×3.1415×86.7Mpa×106Pa/Mpa

dw = 0.00899m or 8.99mm

The next preferred size is chosen which is 10 mm.

 g. Computation to determine the wrist pin bearing

The bearing size is selected based on the static load rating, C0, because
the wrist pin

a. makes a slow oscillating or alignment movements under load

b. rotates under load at very low speed
Basic static load rating C0

C0 = S0 P0
Where C0 = basic static load rating, k·N
P0 = equivalent static bearing load, k·N
S0 = static safety factor

Based on SKF guideline, for non-rotating roller bearing with normal

operations, S0=1. Since P0=11kN, then
C0 = 1×11k·N
C0 = 11k·N

From SKF catalogue, a drawn cup needle roller bearing with C0=11.4k·N is
available. The bearing designation is HN1010.
 h. Bill of Materials

Item Description Specifications Quantity

1 Crankshaft 30 mm O.D., AISI 1020 steel 1
Crankshaft Suppport
2 SKF NU 2306 or NJ 2306 2
Bearing
3 Eccentric Sheave 60 mm I.D., AISI 1030 steel 3
4 Eccentric Sheave Bearing SKF NKIS 60 3
5 Wrist Pin 10 mm O.D., AISI 1030 1
6 Wrist Pin Bearing SKF HN 1010 1
7 Motor GE M7549 1
j. Triplex Pump Solidworks Digital Prototype
j. Triplex Pump Solidworks Digital Prototype
j. Triplex Pump Solidworks Digital Prototype
j. Triplex Pump Solidworks Digital Prototype
i. Triplex Pump Solidworks Digital Prototype
j. Triplex Pump Solidworks Digital Prototype