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Triplex Pump Design PDF
Triplex Pump Design PDF
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
Table of Contents
Introduction Scope of Project Pumps Classification Triplex Pump Basics/Concept Calculations Crankshaft Diameter Bearings Triplex Pump Prototype
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
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
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
1. Piston Pump
Good packing life Good for slurries
2. Plunger Pump
Higher Pressure Easier to maintain
3. Diaphragm Pump
Suitable for Chemicals Expensive
The offset between the shaft center and eccentric sheave center determines the pump stroke
Critical Components
a. b. c. d. e. f. g.
Crankshaft Eccentric Sheave Crankshaft Support Bearing Eccentric Sheave Bearing Wrist Pin Wrist Pin Bearing 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%, kW = (24 liters/min)(60min/hr)(1m3/1000liters)(350bar) (360.88)
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 = Sp = A= M= n= s= displacement, m3/h plunger speed, m/s cross-sectional area of plunger, mm2 number of plungers rpm of pump stroke of pump, mm
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, mm 21 22 23 21 22 23 21 22 23 21 22 23 21 22 23 Pump Speed, rpm 1,497 1,429 1,367 1,344 1,283 1,227 1,213 1,158 1,107 1,100 1,050 1,004 1,002 957 915 Plunger Speed, m/s 1.05 1.05 1.05 0.94 0.94 0.94 0.85 0.85 0.85 0.77 0.77 0.77 0.70 0.70 0.70
18
19
20
21
22
The obtained plunger speeds above are in accordance with the industry standard
Plunger Bore, mm
18
19
20
21
22
Plunger Stroke, mm 21 22 23 21 22 23 21 22 23 21 22 23 21 22 23
Pump Speed, rpm 1,497 1,429 1,367 1,344 1,283 1,227 1,213 1,158 1,107 1,100 1,050 1,004 1,002 957 915
Torque, Nm 102 106 111 113 118 124 125 131 137 138 145 151 152 159 166
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 D =
Where
16 yd Kt Mt
1000
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, Nm yd = design yield stress, Pa
From Shigley's Mechanical Engineering Design, 8th Edition, page 212 max = Sy / 2n Where max = 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, max = 206 MPa 10^6 Pa/MPa (2 1.5) max = 68,666,666 Pa 16 D = 3.1415 68,666,666 1.5 Mt
1000
Table 1: Computed Shaft Diameter at Different Plunger Bore and Stroke Plunger Bore, Plunger Stroke, mm mm 21 22 23 21 22 23 21 22 23 21 22 23 21 22 23 Pump Speed, rpm 1,497 1,429 1,367 1,344 1,283 1,227 1,213 1,158 1,107 1,100 1,050 1,004 1,002 957 915 Pump Torque, Nm 102 106 111 113 118 124 125 131 137 138 145 151 152 159 166 Computed Shaft Diameter, mm 22.4 22.8 23.1 23.3 23.6 24.0 24.1 24.4 24.8 24.9 25.3 25.6 25.6 26.0 26.4
18
19
20
21
22
Sd 2 Where Sd s D sw
= (s/2) + (D/2) + sw = = = = eccentric sheave diameter, mm plunger stroke, mm shaft diameter, mm 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, mm 18 Plunger Stroke, mm 21 22 23 21 22 23 21 22 23 21 22 23 21 22 23 Computed Shaft Diameter, mm 22.4 22.8 23.1 23.3 23.6 24.0 24.1 24.4 24.8 24.9 25.3 25.6 25.6 26.0 26.4 Ecc. Sheave Diameter, mm 53.0 54.3 55.7 53.8 55.1 56.5 54.6 56.0 57.3 55.4 56.8 58.2 56.2 57.6 59.0
19
20
21
22
= 0.707hJu
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 Fp = (350 bar) (100KPa/bar) (1000Pa/Kpa) (1N/m2/Pa) (22mm/1000mm/m)2/4 = 13,304 N
By using the results above, the stress on the 3/16 inch fillet weld can be calculated. (153Nm)(27mm/1000mm/m)2 " " = (0.707)(3/16in.)(1m/39.37in.)(23.1415)((27mm/1000mm/m)2)3
C10 = FD
LDnD60 LRnR60
1/a
Where C10 = catalog load rating, kN FD LD nD LR nR a = = = = = = desired radial load, kN desired life, hours desired speed, rev/min rating life, hours rating speed, rev/min constant; a = 3 for ball bearings, a = 10/3 for roller bearings
C10 = FD
LDnD60 106
1/a
Total maximum force acting on the bearing Fb1 = Fb1 = 3F 1 Fp2 + p1 4 2 5 =F F bmax 4 p
Where Fp = Pressure Plunger Cross-Sectional Area Fp = (350 bar) (100KPa/bar) (1000Pa/Kpa) (1N/m2/Pa) (bore in mm/1000mm/m)2/4
Table 3: Maximum Bearing Load at Different Plunger Bore Sizes Plunger Bore, mm 18 FP, kN Fbmax 8.91 11.13 19 9.92 12.40 20 11.0 13.74 21 12.12 15.15 22 13.30 16.63
Table 4: Shaft Bearing Load Rating 18 8.91 11.13 1,497 5,000 85.25 69.55 23.1 25 Plunger Bore, mm 19 20 9.92 11.0 12.40 13.74 1,344 1,213 5,000 5,000 91.64 75.03 24.0 25 98.12 80.61 24.8 25 21 12.12 15.15 1,100 5,000 104.71 86.31 25.6 30 22 13.30 16.63 1,002 5,000 111.40 92.11 26.4 30 -
FP, (kN) Fbmax, (kN) nD, (rpm) LD, (hours) C10, (kN) (ball bearing) C10, (kN) (roller bearing) Computed Shaft Dia, (mm) Std. Shaft Dia., (mm) Available Bearing
Table 4: Shaft Bearing Load Rating 18 8.91 11.13 1,497 5,000 85.25 69.55 23.1 25 30 NU 2306 NJ 2306 Plunger Bore, mm 19 20 9.92 11.0 12.40 13.74 1,344 1,213 5,000 5,000 91.64 75.03 24.0 25 30 NU 2306 NJ 2306 98.12 80.61 24.8 25 30 NU 2306 NJ 2306 21 12.12 15.15 1,100 5,000 104.71 86.31 25.6 30 30 22 13.30 16.63 1,002 5,000 111.40 92.11 26.4 30 30 -
FP, (kN) Fbmax, (kN) nD, (rpm) LD, (hours) C10, (kN) (ball bearing) C10, (kN) (roller bearing) Computed Shaft Dia, (mm) Initial Std. Shaft Dia., (mm) Adjusted Std. Shaft Dia., (mm) Available Bearing, SKF
Table 5: Eccentric Sheave Bearing Load Rating Plunger Bore, mm 19 9.92 1,344 5,000 73.31 60.02 30 60 NKIS 60 NA 4912 NKI 60/35
FP, (kN) nD, (rpm) LD, (hours) C10, (kN) (ball bearing) C10, (kN) (roller bearing) Eccentric Sheave Internal Dia., (mm) Eccentric Sheave Outside Dia., (mm) Available Bearing, SKF
e. Pump Driver Selection Table 6: List of Applicable Drive Motors Efficiency, % 91.7 93.0 93.0 91.7 91.7 93.0 93.0
Manufacturer
Hp 25
Cat. No. S279 M7549 ECP4111T 1LE29313A C116AA3 N0256 EP0256 HH0256
e. Pump Driver Selection Table 6: List of Applicable Drive Motors Efficiency, % 91.7 93.0 93.0 91.7 91.7 93.0 93.0
Manufacturer
Hp 25
Cat. No. S279 M7549 ECP4111T 1LE29313A C116AA3 N0256 EP0256 HH0256
Selected Plunger Bore and Stroke Plunger Bore,mm 18 Plunger Stroke, mm 21 22 23 21 22 23 21 22 23 21 22 23 21 22 23 Speed, rpm 1,497 1,429 1,367 1,344 1,283 1,227 1,213 1,158 1,107 Remarks Disregarded. Motor speed is only 1,200 rpm. Disregarded. Motor speed is only 1,200 rpm.
Disregarded. Motor speed is only 1,200 rpm
19
20
21
22
Since the standard shaft diameter chosen is 30mm, and the eccentric sheave diameter is 60mm, the minimum sheave thickness, sw, is recalculated.
sw = sw =
= 4 mm
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,
max = Sy / 2n
Where the yield strength, Sy, for 1030 steel is equal to 260 Mpa. Using a design factor of 1.5,
max = 260 / (21.5) = 86.7 Mpa
f. Calculation to determine wrist pin size (contd) Wrist pin will fail by shearing on sections a and b.
max = 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, max = Fp / 2A = Fp 2(dw2/4) ; dw = wrist pin diameter By transposing the equation above dw = (4Fp/2 max)1/2 dw =
411kN1000N/kN 23.141586.7Mpa106Pa/Mpa
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, kN P0 = equivalent static bearing load, kN S0 = static safety factor Based on SKF guideline, for non-rotating roller bearing with normal operations, S0=1. Since P0=11kN, then C0 = 111kN C0 = 11kN From SKF catalogue, a drawn cup needle roller bearing with C0=11.4kN is available. The bearing designation is HN1010.
h. Bill of Materials Item Description 1 Crankshaft Crankshaft Suppport 2 Bearing 3 Eccentric Sheave 4 Eccentric Sheave Bearing 5 Wrist Pin 6 Wrist Pin Bearing 7 Motor Specifications 30 mm O.D., AISI 1020 steel SKF NU 2306 or NJ 2306 60 mm I.D., AISI 1030 steel SKF NKIS 60 10 mm O.D., AISI 1030 SKF HN 1010 GE M7549 Quantity 1 2 3 3 1 1 1