Positive Disp Pumps

Category:
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IPCL
NC: Training Module
Module No.
IPCLDSMEC006
Training Module
On
Positive Displacement Pumps
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NC: Training Module
Module No.
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Training Module Objectives

This Training module is intended to help Engineers to understand the
fundamentals and applications of Positive Displacement (PD) Pumps in
Process industries .In this module , an effort has been made to provide ,much
needed source of information in the field of PD Pumps.
In this module user will learn about:
The Function of PD Pumps

Fundamentals & Operating Principles
Application
Selection criteria
Basic measures to Improve PD PumpS Efficiency.
Identify PD Pump Types
Identify Operating Characteristics of PD Pumps
Calculating PD Pump Power.
Evaluate Pump Performance
Controlling PD Pumps
Problem trouble shooting of PD Pumps
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Confidentiality Statement
This training manual is prepared exclusively for the technical knowledge
enhancement of the personnel of Reliance Group of Industries.
No part of this document may be reproduced in any form , in an electronic

retrieval system or otherwise. The document must be returned when the
recipient has no further use of the same .The document or any part of the
document is not allowed to be taken out of the respective site or to be shared
with any person outside the Reliance Group.
Reliance Group of industries reserves the right to refuse access to the above
document on the grounds of Confidentiality.
Authorization for information disclosure is allowed with the written permission

of the respective site Engineering head.
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NC: Training Module
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Module Implementation Plan

Topic: Positive Displacement Pump
For:
Rev:00
Sn Contents
Author
1
2
3
4
5
6
Introduction
Terminology & Definitions
Positive displacement
Pumps Classification
Fundamentals & Operating
Principles
Performance
Characteristics
Controlling Positive
Displacement Pump
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Resources
Available
( Y/N)
JP
Internet
JP
Internet/
API 676
JP
Internet
JP
Internet
JP
Internet
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Internet.
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Code No: IPCLDSMEC006

Date :12.10.2004
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hr
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hr
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3 hrs
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Total
hrs
Category:
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Sn
7
8
IPCL
NC: Training Module
Contents
Author
Selection Guide Of Positive

Displacement Pump
Field Problems & Trouble
shooting
Tips to Improve PD Pump
Efficiency
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Resources
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Displacement NC: Training Module
Module No.
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Table of Contents
1.0
2.0
3.0
4.0
Introduction
Definitions & Terminology
Positive displacement Pumps Classification
4.1 Rotary Pump
4.1.1 Multiple Rotor
4.1.1.1
4.1.1.2
4.1.1.3
4.1.1.4
Gear
Lobe
Circumferential Piston
Screw
4.1.2 Single Rotor

4.1.2.1
4.1.2.2
4.1.2.3
4.1.2.4
4.1.2.5
Vane
Piston
Progressive Cavity
Screw
Peristaltic
4.2 Reciprocating Pump

4.2.1 Diaphragm
4.2.2 Piston Plunger
4.3 Function of Relief Valves in PD Pump
4.4 Calculating Friction Losses
4.4.1 Laminar Flow
4.4.2 Turbulent Flow
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8-11
12-18
19-21
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4.4.3 Reynolds Number

4.5 Slip
4.6 Volumetric Efficiency
4.7 Calculating Horsepower
4.8 Calculating Torque
4.9 Net Positive Inlet Pressure (NPIP)
4.10 Cavitation
4.11 Affinity Laws
5.0
Performance Characteristics
6.0
Controlling Positive Displacement Pump

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
7.0
8.0
9.0
10.0
11.0
12.0
62-71
72-82
Discharge Throttling
Suction Throttling
Recycle Control
Speed Control
Other Means Of Control
Machine Protection
Parallel Pump Installations
Series Pump Installations
Selection Guide Of PD Pumps

Field Problems & Trouble shooting
Tips to Improve PD Pumps Efficiency
Summary
References
Frequently Asked Questions (FAQs)
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83-85
86-91
92
93
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Chapter 1.0
Introduction to Positive Displacement Pumps
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1.0 Introduction
Pumping devices have been an important way of moving fluids for thousands of
years. The Ancient Egyptians invented water wheels with buckets mounted on
them to move water for irrigation. In the 200's B.C. Ctesibius, a Greek inventor,
made a reciprocating pump for pumping water. At about the same time,
Archimedes, a Greek mathematician, invented a screw pump made of a screw
rotating in a cylinder (now known as an Archimedes screw). This type of pump
was used to drain and irrigate the Nile Valley. Times may have changed but
pumps still operate in the same basic way.
A Positive Displacement Pump has an expanding cavity on the suction side of

the pump and a decreasing cavity on the discharge side. Liquid is allowed to flow
into the pump as the cavity on the suction side expands and the liquid is forced
out of the discharge as the cavity collapses. This principle applies to all types of
Positive Displacement Pumps whether the pump is a rotary lobe, gear within a
gear, piston, diaphragm, screw, progressing cavity etc.
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A Positive Displacement Pump, unlike a Centrifugal Pump, will produce the same
flow at a given RPM no matter what the discharge pressure is. A Positive
Displacement Pump cannot be operated against a closed valve on the discharge
side of the pump, i.e. it does not have a shut-off head like a Centrifugal Pump
does. If a Positive Displacement Pump is allowed to operate against a closed
discharge valve it will continue to produce flow which will increase the pressure in
the discharge line until either the line bursts or the pump is severely damaged or
both.
In contrast Centrifugal Pumps rely on kinetic energy rather than mechanical

means to move liquid. Liquid enters the pump at the center of a rotating impeller
and gains energy as it moves to the outer diameter of the impeller. Liquid is
forced out of the pump by the energy it obtains from the rotating impeller.
Centrifugal pumps can transfer large volumes of liquid but efficiency and flow
decrease rapidly as pressure and/or viscosity increases. PD pumps allow a wider
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range of liquids, slurries and foams to be transported without product

degradation. Understanding where PD pumps can be used may lead to
opportunities to improve processes.
Comparisons Between Rotary and Centrifugal Pumps

Parameters
Rotary
Centrifugal
Max Viscosity , cSt
1,320,000
550
Max. Capacity ,M3/Hr
750
27,250
Pumping Efficiency
Energy Costs
Self-Priming
Yes
No
Flow Control
Life-Cycle Cost
Initial Cost
E = Excellent, G = Good, A = Average, P = Poor
*****End of Chapter 1.0****
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Chapter 2.0
Definitions & Terminology
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2.0 Definitions & Terminology

2.1 Fluids and liquids
The term "fluid" covers liquids, gases, vapors and mixtures thereof. The word
"liquid" is used only to describe true liquids that are free of vapors and solids.
The word "fluid" is more general and is used to describe liquids that may contain,
or be mixed with, matter in other than the liquid phase.
2.2 Pumping chamber

The pumping chamber is the space formed by the body and end plate(s), into
which fluid is drawn and from which fluid is discharged by the action of the
rotor(s).
2.3 Inlet or suction port

One or more openings in the pump through which the pumped fluid may enter
the pumping chamber.
2.4 Outlet or discharge port

One or more openings in the pump through which the pumped fluid may leave
the pumping chamber.
2.5 Body
The body is an external part which surrounds the periphery of the pumping
chamber and which also may form one end plate. It is sometimes called a casing
or a housing .
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2.6 End plate

An end plate is a part which closes an end of the body to form the pumping
chamber. One or more are used, depending on the construction of the pump. It is
sometimes called a head or cover .
2.7 Stator
The stationary parts of the pump which surround the pumping chamber.
2.8 Rotor
A rotor is a part which rotates in the pumping chamber. One or more are used
per pump. It is sometimes referred to by a specific name such as gear , screw ,
impeller , etc.
2.9 Bearing
A bearing is a part which supports or positions the shafts on which a rotor is
mounted. A bearing may be internal (wetted by the liquid being pumped) or
external and may be either a rolling element bearing (ball or roller) or fluid film
type (sleeve and journal).
2.10 Timing gear

A timing gear is a part used to transmit torque from one rotor shaft to another and
to maintain the proper angular relationship of the rotors. It may be outside the
pumping chamber and is sometimes called a pilot gear .
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2.11 Rotating assembly

The rotating assembly generally consists of all rotating parts essential to the
pumping action but also may include other parts specified by the manufacturer.
2.12 Relief valve

A relief valve is a mechanism designed to control or to limit pressure by the
opening of an auxiliary passage at a predetermined pressure.
A relief valve may be either integral with the body or end plate or attachable. It
may be adjustable through a predetermined range of pressures or have a fixed
setting. It may be designed to bypass the liquid internally from the pump outlet to
the pump inlet or externally through an auxiliary port. Bypass of liquid internally is
not recommended for continuous operation.
Terms commonly used in specifying performance are:
2.13 Cracking pressure

Sometimes called set pressure , start-to-discharge pressure , or popping
pressure --the pressure at which the valve just starts to open. This pressure
cannot be determined readily in a valve which bypasses the liquid within the
pump.
2.14 Full-flow bypass pressure

The pressure at which the full output of the pump flows through the valve and the
auxiliary passage.
2.15 Reseating pressure
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The pressure at which the valve is closed completely. This pressure is usually
below the cracking pressure and is difficult to measure accurately when the liquid
is bypassed within the pump.
2.16 Percent overpressure

Sometimes called percent accumulation or percent regulation --the difference
between full bypass pressure and cracking pressure, expressed as a percent of
cracking pressure.
2.17 Stuffing-box
A stuffing-box is a cylindrical cavity through which a shaft extends and in which
leakage at the shaft is controlled by means of packing and a gland or a
mechanical seal.
2.18 Gland
A gland is a part which may be adjusted to compress packing in a stuffing-box. It
is sometimes called a gland follower . A gland is also used to hold the stationary
element of a mechanical seal.
2.19 Packing
A pliable lubricated material used to provide a seal around that portion of the
shaft located in the stuffing-box (see Figure 3.28).
2.20 Lantern ring

A lantern ring is an annular ring located in a stuffing-box to provide space
between or adjacent to packing rings for the introduction of a lubricant or a
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barrier fluid, the circulation of a cooling medium, or the relief of pressure against
the packing. It is sometimes called a seal cage .
2.21 Seal chamber
A seal chamber is a cavity through which a shaft extends and in which leakage at
the shaft is controlled by means of a mechanical seal or a radial seal.
2.22 Mechanical seal

A mechanical seal is a device located in a seal chamber or stuffing-box and
consists of rotating and stationary elements with opposed seal faces. A rotating
element is fastened and sealed to the shaft. A stationary element is mounted and
sealed to the gland or body. At least one element is loaded in an axial direction,
so that the seal faces of the elements are maintained in close proximity to each
other at all times. Usually, the seal faces are flat, highly lapped surfaces on
materials selected for low friction and for resistance to corrosion by the fluids to
be pumped. Mechanical seals are sometimes called face type seals .
2.23 Radial seal

A radial seal is a device located in a seal chamber which seals on its outside
diameter through an interference fit with its mating bore and on the rotating shaft
with a flexible, radially loaded surface. Radial seals include: lip type seals, O
rings, V cups, U cups, etc., and may or may not be spring-loaded.
2.24 Direction of rotation

Drive shaft rotation is designated as "clockwise" (CW) or "counterclockwise"
(CCW) as determined when viewing the pump from the driver end.
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2.25 Jacketed pump

A jacketed pump is one in which the body and/or end plates incorporate
passageways through which steam, oil, water, or other fluid can be circulated to
control the temperature of the pump or the fluid in the pump.
****End of Chapter 2.0****
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Chapter 3.0
Positive displacement Pumps Classification
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3.0 Classification of Positive displacement Pumps

The Hydraulic Institute Standards book differentiates PD pumps into rotary and
reciprocating pumps. Rotary pumps are defined as being: vane, piston, flexible
member, lobe, gear circumferential piston, or screw pumps. In all of the rotary
designs, the chamber is created progressively through rotation of the drive shaft.
There may be one or more chambers opened per revolution depending on the
design. The chambers are sealed off from suction by close clearance between
the rotor and the housing, or by close clearance between intermeshing rotors.
Rotation of the shaft moves the chamber along the bore or housing towards
discharge. The chamber is displaced to discharge by rotation. The release to
discharge progresses with rotation as the volume is expelled so that the flow is
typically pulsation free.
Reciprocating pumps are defined as being; steam, power, or controlled volume

pumps. In all reciprocating pumps, there are check valves on the suction and
discharge. Fluid flows through the suction valve and into the chamber as the
plunger, piston, or diaphragm recedes. At the end of the stroke, the chamber is at
its maximum size. The suction valve closes, the plunger moves forward into the
chamber, forcing the fluid out the discharge valve. The flow from each chamber
is a pulse flow. If the pump has several chambers, they are timed to have
sequential pulses to minimize the overall pulsation.
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Chapter 4.0
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4.0 Fundamentals & Operating Principles

PD pumps come in many designs and operating ranges, but they all work on the
same principle. An increasing volume is opened to suction, filled, closed, moved
to discharge, and displaced. The delivered capacity is nearly constant throughout
the discharge pressure range. This constant capacity will intersect a system
curve at a defined point, allowing a high degree of system control.
4.1 Rotary Pump

By definition ,Rotary Positive Displacement (PD) pumps displace a known
quantity of liquid with each revolution of the pumping elements (i.e., gears,
lobes, screws, vanes). PD pumps displace liquid by creating a space between
the pumping elements and trapping liquid in the space. The rotation of the
pumping elements then reduces the size of the space and moves the liquid out of
the pump. Rotary PD pumps have very tight internal clearances which minimize
the amount of liquid that slips back from discharge to suction side of the pump.
Because of this, they are very efficient. PD pumps can handle fluids of all
viscosities up to 1,320,000 cSt capacities up to 1,150 M3/Hr , and pressures up
to 700 bar. Rotary pumps are self-priming and deliver a constant, smooth flow,
regardless of pressure variations(Differential pressure).
4.1.1 Multiple Rotor
4.1.1.1
Gear Pump
Internal Gear
Internal gear pumps carry fluid between the gear teeth from the inlet to outlet
ports. The outer gear (rotor) drives the inner or idler gear on a stationary pin.
The gears create voids as they come out of mesh and liquid flows into the
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cavities. As the gears come back into mesh, the volume is reduced and the
liquid is forced out of the discharge port. The crescent prevents liquid from
flowing backwards from the outlet to the inlet port.
Internal Gear Pump

1. Liquid enters the suction port between the rotor (large exterior gear) and idler
(small interior gear) teeth. The arrows indicate the direction of the pump and
liquid.
2. Liquid travels through the pump between the teeth of the "gear-within-a-gear"
principle. The crescent shape divides the liquid and acts as a seal between the
suction and discharge ports.
3. The pump head is now nearly flooded, just prior to forcing the liquid out of the
discharge port. Intermeshing gears of the idler and rotor form locked pockets for
the liquid which assures volume control.
4. Rotor and idler teeth mesh completely to form a seal equidistant from the
discharge and suction ports. This seal forces the liquid out of the discharge port.
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Advantages
Only two moving parts.
Only one stuffing box.
Positive suction, nonpulsating discharge.
Ideal for high-viscosity liquids.
Constant and even discharge regardless of pressure conditions.
Operates well in either direction.
Can be made to operate with one direction of flow with either rotation.
Low NPSH required.
Single adjustable end clearance.
Easy to maintain.
Flexible design offers application customization.
Disadvantages
Usually requires moderate speeds.
Medium pressure limitations.
One bearing runs in the product pumped.
Overhung load on shaft bearing.
The rotor gear is driven by a shaft supported by journal or antifriction bearings.

The idler gear contains a journal bearing rotating on a stationary pin in the
pumped liquid. Depending on shaft sealing arrangements, the rotor shaft support
bearings may run in pumped liquid. This is an important consideration when
handling an abrasive liquid and can wear out a support bearing.
The speed of internal gear pumps is considered relatively slow compared to
centrifugal types. Speeds up to 1,150 rpm are considered common, although
some small designs operate up to 3,450 rpm. Because of their ability to operate
at low speeds, internal gear pumps are well suited for high-viscosity applications
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and where suction conditions call for a pump with minimal inlet pressure
requirements.
For each revolution of an internal gear pump, the gears have a fairly long time to
come out of mesh allowing the spaces between gear teeth to completely fill and
not cavitate. Internal gear pumps have successfully pumped liquids with
viscosities above 1,320,000 cSt / 6,000,000 SSU and very low viscosity liquids,
such as liquid propane and ammonia.
Internal gear pumps are made to close tolerances and are damaged when
pumping large solids. These pumps can handle small suspended particulate in
abrasive applications, but gradually wear and lose performance. Some
performance loss is restored by adjusting the pump end clearance. End
clearance is the closeness of the rotor gear to the head of the pump.
External Gear. External gear pumps also use gears which come in and out of
mesh. As the teeth come out of mesh, liquid flows into the pump and is carried
between the teeth and the casing to
the discharge side of the pump. The teeth come back into mesh and the liquid is
forced out the discharge port. External gear pumps rotate two identical gears
against each other. Both gears are on a shaft with bearings on either side of the
gears.
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External Gear Pump

External gear pumps are similar in pumping action to internal gear pumps in that
two gears come into and out of mesh to produce flow. However, the external
gear pump uses two identical gears rotating against each other -- one gear is
driven by a motor and it in turn drives the other gear. Each gear is supported by a
shaft with bearings on both sides of the gear.
1. As the gears come out of mesh, they create expanding volume on the inlet
side of the pump. Liquid flows into the cavity and is trapped by the gear teeth as
they rotate.
2. Liquid travels around the interior of the casing in the pockets between the
teeth and the casing -- it does not pass between the gears.
3. Finally, the meshing of the gears forces liquid through the outlet port under
pressure.
Because the gears are supported on both sides, external gear pumps are quietrunning and are routinely used for high-pressure applications such as hydraulic
applications. With no overhung bearing loads, the rotor shaft can't deflect and
cause premature wear.
Advantages
High speed.
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Medium pressure.
No overhung bearing loads.
Relatively quiet operation.
Design accommodates wide variety of materials.
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Disadvantages
Four bushings in liquid area.
No solids allowed.
Fixed End Clearances
Because the gears are supported on both sides, external gear pumps are used
for high pressure applications such as hydraulics. Usually, small external gear
pumps operate at 1,750 or 3,450 rpm and larger versions operate at speeds up
to 640 rpm.
The design of external gear pumps allows them to be made to closer tolerances
than internal gear pumps. The pump is not very forgiving of particulate in the
pumped liquid. Since there are clearances at both ends of the gears, there is no
end clearance adjustment for wear. When an external gear pump wears, it must
be rebuilt or replaced.
External gear pumps handle viscous and watery-type liquids, but speed must be
properly set for thick liquids. Gear teeth come out of mesh a short time, and
viscous liquids need time to fill the spaces between gear teeth. As a result, pump
speed must be slowed down considerably when pumping viscous liquids.
The pump does not perform well under critical suction conditions. Volatile liquids
tend to vaporize locally as gear teeth spaces expand rapidly. When the viscosity
of pumped liquids rises, torque requirements also rise, and pump shaft strength
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may not be adequate. Pump manufacturers supply torque limit information when
it is a factor.
Reversing Gear Pump
This type of rotary gear pump moves liquid in the same direction regardless of
the direction the gears turn.
The valves (shown in yellow in this drawing) are forced open and closed by the
difference in pressure on the input and output sides.
In this drawing, fluid in the higher-pressure output side is shown in light blue
while fluid in the lower-pressure input side is dark blue.
Notice that when the green gear starts moving clockwise, the fluid in the outer
circular tubes changes pressure but stops flowing, and fluid flows more or less
straight up.
When the red gear is moving clockwise, fluid travels in a sideways 'S' shape
through the outer circular tubes.
The pump in above drawing reverses direction about every 8 seconds.
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4.1.1.2
Lobe Pump
Module No.
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Fluid is carried between the rotor teeth and the pumping chamber. The rotor
surfaces create continuous sealing. Both gears are driven and are synchronized
by timing gears. Rotors include bi-wing, tri-lobe, and multi-lobe configurations.
How Lobe Pumps Work
Lobe pumps are similar to external gear pumps in operation in that fluid flows
around the interior of the casing. Unlike external gear pumps, however, the
lobes do not make contact. Lobe contact is prevented by external timing gears
located in the gearbox. Pump shaft support bearings are located in the gearbox,
and since the bearings are out of the pumped liquid, pressure is limited by
bearing location and shaft deflection.
1. As the lobes come out of mesh, they create expanding volume on the inlet
side of the pump. Liquid flows into the cavity and is trapped by the lobes as they
rotate.
2. Liquid travels around the interior of the casing in the pockets between the
lobes and the casing -- it does not pass between the lobes.
3. Finally, the meshing of the lobes forces liquid through the outlet port under
pressure.
Lobe pumps are frequently used in food applications because they handle solids
without damaging the product. Particle size pumped can be much larger in lobe
pumps than in other PD types. Since the lobes do not make contact, and
clearances are not as close as in other PD pumps, this design handles low
viscosity liquids with diminished performance. Loading characteristics are not as
good as other designs, and suction ability is low. High-viscosity liquids require
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reduced speeds to achieve satisfactory performance. Reductions of 25% of

rated speed and lower are common with high-viscosity liquids.
Lobe Pump
Lobe pumps are frequently used in food applications, because they handle solids
without damaging the pump. Particle size pumped can be much larger in lobe
pumps than in other PD types. Since the lobes do not make contact, and
clearances are not as close as in other PD pumps, this design handles low
viscosity liquids with diminished performance. Loading characterisics are not as
good as other designs, and suction ability is low. High-viscosity liquids require
considerably reduced speeds to achieve satisfactory performance. Reductions of
25% of rated speed and lower are common with high-viscosity liquids.
Lobe pumps are cleaned by circulating a fluid through them. Cleaning is
important when the product cannot remain in the pumps for sanitary reasons or
when products of different colors or properties are batched.
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Advantages
Pass medium solids.
No metal-to-metal contact.
Superior CIP/SIP capabilities.
Positive suction, nonpulsating discharge.
Disadvantages
Requires timing gears.
Requires two seals.
Reduced lift with thin liquids.
4.1.1.3
Circumferential Piston
Fluid is carried from inlet to outlet in spaces between piston surfaces. Rotors
must be timed by separate means, and each rotor may have one or more piston
elements.
4.1.1.4
Screw Pump
Several different types of screw pumps exist as shown in following figures.. The
differences between the various types are the number of intermeshing screws
and the pitch of the screws. Screw pumps are used aboard ship to pump fuel and
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lube oil and to supply pressure to the hydraulic system. In the double-screw
pump, one rotor is driven by the drive shaft and the other by a set of timing
gears. In the triple-screw pump, a central rotor meshes with two idler rotors
In the screw pump, liquid is trapped and forced through the pump by the action of
rotating screws. As the rotor turns, the liquid flows in between the threads at the
outer end of each pair of screws. The threads carry the liquid along within the
housing to the center of the pump where it is discharged.
One of the disadvantages of screw-type positive displacement rotary pumps is
that they have performance characteristics sensitive to viscosity change.
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Most screw pumps are now equipped with mechanical seals. If the mechanical
seal fails, the stuffing box has the capability of accepting two rings of
conventional packing for emergency use.
Single screw pumps are commonly called progressive cavity pumps. They have
a rotor with external threads and a stator with internal threads. The rotor threads
are eccentric to the axis of rotation. Multiple screw pumps have multiple external
screw threads. These pumps may be timed or untimed.
Single Screw
The single screw pump is more commonly known as the Archimedean screw. It
is quite large; typical dimensions include a diameter of 12 inches or greater, and
a length up to about 50 feet. It is normally used as a water-raising pump with the
screw arranged at an angle of 30 degrees.
It can also be used for handling liquids containing solids in suspension with either
vertical lift or horizontal transport. The design of single screw pumps allows very
little fracturing of particles and little abrasion damage to the pump. One
disadvantage is the considerable bulk necessary to achieve high capacities since
rotational speeds are of the order of 30-60 rpm .
Intermeshing Screw Pump

The intermeshing screw pump is commonly called a rigid-screw pump. This type
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of pump is suitable for a wide range of sizes, and can be run at high speeds. The
larger screw pumps are used for bulk handling of oils and similar fluids. The
basic type is suitable for handling most clean fluids with low flow velocities and at
low heads.
Eccentric screw pump

The eccentric screw pump is versatile. It is capable of handling a variety of
liquids and products with high efficiency. It comprises of a rigid screw form rotor
rolling in a resilient internal helical stator of hard or soft rubber with a moderately
eccentric motion. It can handle viscous liquids, slurries, pastes, solids in
suspension, and delicate products. This is because of the low flow velocities
through the pump .
Capacity
The delivered capacity of any screw pump is the theoretical capacity minus the
internal leakage. In order to find the capacity of a screw pump the speed of the
pump must be known. The delivered capacity of any rotary screw pump can be
increased several different ways. The capacity can be increased by simply
increasing the speed, increasing the viscosity, or decreasing the differential
pressure. The capacity of the pump depends on several factors
Diameter of the screw
Speed of the screw
Number of flights mounted on the screw shaft
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Flights: Single, double, and triple flights are often used. Flights are also known
as helixes. With each increase in flights, there is a 20% increase in capacity.
Therefore, a single flight pump has a capacity that is 80% of a double flight
pump, which in turn has a capacity that is 80% of a triple flight capacity. The
three-flight pump can handle the most capacity in the least amount of space.
Advantages
Wide range of flows and pressures
Wide range of liquids and viscosities
Built-in variable capacity
High speed capability allowing freedom of driver selection
Low internal velocities
Self-priming with good suction characteristics
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High tolerance for entrained air and other gases

Minimum churning or foaming
Low mechanical vibration, pulsation-free flow, and quiet operation
Rugged, compact design -- easy to install and maintain
High tolerance to contamination in comparison with other rotary pumps
Disadvantages
Relatively high cost because of close tolerances and running clearances
Performance characteristics sensitive to viscosity change
High pressure capability requires long pumping elements (Fraser, et. al., 1986)
Applications
Utilities fuel oil service,
Industrial oil burners,
lubricating oil service,
Chemical processes,
Petroleum and crude oil industries
Power hydraulics
Listed below are some typical situations where a screw pump is used. Raw
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clogging, require little attention, are resistant to motor overloads, and are not
affected by running dry .
Sewage plant lift stations: Used for sewage lifts up to 40 feet and have selfregulating lift capacity (Normal lifts are 30 feet, while high lifts are 40 feet high.)
Return activated sludge: Little floc disintegration, non turbulent discharge into
effluent channel, low horsepower requirements, improved activated sludge
treatment.
Storm water pumping: Are ideal because of large capacity at low heads, no
prescreening necessary
Land Drainage: Used for flood control, can pump large volumes of water over
levees.
4.1.2 Single Rotor

4.1.2.1
Vane Pump
Despite the different configurations, most vane pumps operate under the same
general principle described below.
A slotted rotor or impeller is eccentrically supported in a cycloidal cam. The rotor
is located close to the wall of the cam so a crescent-shaped cavity is formed. The
rotor is sealed into the cam by two sideplates. Vanes or blades fit within the slots
of the impeller. As the impeller rotates (yellow arrow) and fluid enters the pump,
centrifugal force, hydraulic pressure, and/or pushrods push the vanes to the walls
of the housing. The tight seal among the vanes, rotor, cam, and side plate is the
key to the good suction characteristics common to the Vane pumping principle.
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Vane
Pump
The housing and cam force fluid into the pumping chamber through holes
in the cam (small red arrow on the bottom of the pump). Fluid enters the
pockets created by the vanes, rotor, cam, and sideplate.
3. As the impeller continues around, the vanes sweep the fluid to the
opposite side of the crescent where it is squeezed through discharge
holes of the cam as the vane approaches the point of the crescent (small
red arrow on the side of the pump). Fluid then exits the discharge port.
Vanes are the main sealing element between the suction and discharge
ports and are usually made of a nonmetallic composite material. Rotor
bushings run in the pumped liquid or are isolated by seals.
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Vane pumps usually operate at 1,000 rpm, but also run at 1,750 rpm. The
pumps work well with low-viscosity liquids that easily fill the cavities and provide
good suction characteristics. Speeds must be reduced
dramatically for high-viscosity applications to load the area underneath the
vanes. These applications require stronger-than-normal vane material.
Because there is no metal-to-metal contact, these pumps are frequently used
with low-viscosity non lubricating liquids such as propane or solvent. This type of
pump has better dry priming capability than other PD pumps. Vane pumps can
run dry, but are subject to vane wear.
Abrasive applications require the proper selection of vane material and seals.
Vane pumps have fixed end clearances on both sides of the rotor and vanes
similar to external gear pumps. Once wear occurs, this clearance cannot be
adjusted, but some manufacturers supply replaceable or reversible end plates.
Casing liners are a low-cost way of restoring pump performance as wear occurs.
Unlike lobe pumps, vane pumps cannot handle solids.
4.1.2.2
Piston Pumps
The basic Piston Pump is very simple having just two valves and one stuffing
box. as shown in following figure.
In this example the reciprocating piston is driven back and forth by a rotating
mechanism.
This piston pump uses suction to raise water into the chamber. The lower valve
can be placed below water level.
The piston must be within about 25 feet of the water level, but the water can then
be raised quite high.
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Piston Pump
Radial Piston Pumps can produce a very smooth flow under extreme pressure.
Generally they are variable-displacement pumps.
In variable models, flow rate changes when the shaft holding the rotating pistons
is moved with relation to the casing (in different models either the shaft or the
casing moves.) Output can also be varied by changing the rotation speed.
Radial Piston Pump
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In this animation if the casing (shown in red) is moved to the left, the flow rate
would decrease to zero. If it is moved even further to the left the flow would
reverse.
Input in this animation is through the TOP two black holes near the center below
the "Pintle" (shown in yellow). Output is through the BOTTOM two black holes,
above the pintle. Higher pressure areas are indicated with a DARKER blue fluid
color.
The pistons are usually forced out by springs. They are forced back in, expelling
liquid, by the casing.
An odd number of pistons is always used to smooth the hydraulic balance. These
pumps revolve at speeds up to about 1200 RPM.
4.1.2.3 Progressive Cavity Pump

Progressive (or Progressing) Cavity pumps, a type of Single Screw pump, are
used for highly viscous liquids such as peanut butter or glue, and also for liquids
with significant amounts of solids such as cement or sand slurry.
Fuild proceeds from the entrance, at the top on the right side here, to the left.
The rotor revolves inside the stator.
The stator is a twisted cavity with an oval-shaped cross-section. It is usually
made of natural or synthetic rubber, steel, or plastic. The rotor is usually steel.
For a given diameter and shape of the rotor, doubling the number of stages (the
length) will double the output pressure.
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The area of the cross-section of the rotor determines the backpressure the pump
must withstand.
progressive cavity pump is a kind of pump which moves fluid by means of a
cavity which progresses along the body of the pump. As the cavity moves, fluid is
Progressive Cavity Pump
sucked in to fill the cavity, further rotation of the pump causes the fluid to flow
and be delivered from the pump.
The rotor of the pump is a steel helix which has been coated in a smooth hard
surface, normally chromium. The rotor fits inside a pump body or stator which
normally is a rubber lined steel tube. The rubber core of the stator has a helical
cavity, the wavelength of each helix in the rotor is exactly half that of the rotor.
Rotation of the rotor inside the stator causes the cavity to progress along the
pump thus inducing fluid flow. Compare to a Archimedes' screw.
Whilst progressive cavity pumps offer long life and reliable service, abrasive
fluids will significantly shorten the life of the stator. The interface between rotor
and stator is lubricated by the fluid being pumped, however if the pump is
allowed to 'run dry' rapid deteriotation of the stator results.
Applications
Small sewage pumping
Sewage sludge pumping
Slurry pumping
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4.1.2.3
Peristaltic Pump
Module No.
IPCLDSMEC007
A peristaltic pump is a type of positive displacement pump used for pumping a

variety of specialized fluids. The fluid is contained in a flexible hose fitted inside a
circular pump casing. A rotor with a number of cams (also called 'shoes' or
'wipers') attached to the external circumference compresses the flexible tube. As
the rotor turns, the part of tube under compression rotates thus forcing the fluid to
be pumped to move through the tube. This process is called peristalsis and is
used in many biological systems such as the gastrointestinal tract. The pump
casing is typically filled with lubricant to prevent abrasion of the exterior of the
pump tube.
Peristaltic
Pump
Since the only part of the pump in contact with the fluid being pumped is the
interior of the tube, it is easy to sterilise and clean the inside surfaces of the
pump. Furthermore, since there are no moving parts in contact with the fluid,
peristaltic pumps are inexpensive to manufacture.
Applications
Dialysis machines
Food manufacturing
Pharmaceutical production
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Sewage sludge
tabletop decorative fountains and waterwalls
4.2 Reciprocating Pump

The pumping action in any reciprocating pump is dependent upon the positive
displacement or the fluid pumped by a piston or plunger. The capacity of the
pump is, therefore, determined by the area of the piston and its rate of travel. In
order to obtain a practical machine, some method of reversing the direction of the
pistons is required. In the direct-acting steam pump, this is accomplished by the
steam valves and valve gear; in power pumps, this is accomplished by use of
crank and connecting rods.
The ability of the pump to produce pressure is dependent upon the ratio of total
steam force (steam pressure per unit area x area of Steam piston) to total liquid
force (pump head x area of liquid piston). In order that pumping may occur, it is
necessary that the steam force exceed the liquid force by an amount which
slightly exceeds the various mechanical and hydraulic losses encountered. The
basic principles for steam pump operation are shown below.
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Types Of Reciprocating Pumps

Direct-acting
.Horizontal or vertical.
.Single or duplex. A single pump has one liquid piston or its equivalent
single or double-acting plunger; a duplex pump has two liquid pistons or their
equivalent single or double-acting plungers.
.Single or double-acting. A single-acting unit pumps on one direction of
piston travel only whereas double-acting units pump on both strokes. Directacting steam pumps are usually double acting.
2. Direct-acting steam pumps are conventionally described by stating the steam
cylinder diameter, the liquid cylinder diameter, the length of stroke, horizontal or
vertical (H or V), single or duplex (S or D), and single or double-acting (SA or
DA). Thus a pump identified as 11 x 8 x 18
Usage In Maritime Service
Auxiliary feed.
Standby fuel oil service.
Fuel oil transfer.
Auxiliary circulating and condensate.
Fire and bilge.
Ballast.
High pressure evaporator.
Lubricating oil transfer.
Cargo stripping.
General service.
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Direct-acting steam reciprocating pumps are not obsolete. If the steam conditions
are not too severe in pressure, temperature, or superheat, they have many
features of simplicity, reliability, and economy of operation and maintenance that
still warrant serious consideration for many services.
Pumping Capacity
Simplex single acting pumps discharge the cylinder volume for each 2 strokes.
The forward stroke discharges the cylinder and the back stroke or reverse stroke
fills the cylinder.
Duplex double acting pumps use 2 double-acting cylinders in parallel, and pump
two cylinder volumes for each pump stroke.
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Duplex single acting pumps use 2 single-acting cylinders in parallel, and pump
one cylinder volume for each pump stroke.
Pump Capacity i= volume discharged in m3 per pump stroke multiplied by

strokes per minute.
To determine the volume of the cylinder, multiply the area of the circle by the
height of the cylinder.
Volume of a Cylinder is equal to:
= (area of the circle) * (height)
= (PI X r2) * (height)
4.2.1 Diaphragm-type reciprocating pump

The diaphragm pump is an offshoot of a plunger pump. Because of the risk that
contamination could travel between the plunger and the cylinder, the diaphragm
is safer for microbial processing .Type is indirect acting .This applet is crude but
shows how a reciprocating piston (plunger) pump works. The flywheel that
moves the plunger can attach the arm to the plunger at various points to change
the amplitude of the stroke and thus the pumping rate. The pumping rate can
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also be changed with a different rotational speed, but variable speed motors or
mechanical means of changing rpm are expensive.
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4.2.2 Plunger type Metering Pumps

Metering pumps provide precision control of very low flow rates. Flow rates are
generally less than 1/2 gallon per minute. They are usually used to control
additives to the main flow stream. They are also called proportioning or
controlled-volume pumps. Metering pumps are available in either a diaphragm or
packed plunger style, and are designed for clean service and dirty liquid can
easily clog the valves and nozzle connections.
This is a picture of a plunger-type metering pump:
4.2
Function of Relief Valves in PD Pump
A relief valve on the discharge side of a Positive Displacement Pump is an

absolute must - no ifs, and / or buts about it!
Internal Relief Valves
Pump manufacturers normally have an option to supply an internal relief valve.
These relief valves will temporarily relieve the pressure on the discharge side of
a pump operating against a closed valve. They are normally not full ported, i.e.
cannot by pass all the flow produced by the pump. These internal relief valves
should be used for pump protection against a temporary closing of a valve.
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External Relief Valve

An external relief valve (RV) installed in the discharge line with a return line back
to the supply
tank is highly recommended to provide complete protection
against an unexpected over pressure situation.
4.3 Calculating Friction Losses

Frictional losses are directly proportional to
Length of pipe
Pipe Diameter
Flow rate
Frictional losses due to flow in pipes occur in two principle modes:
Laminar & Turbulent
4.3.1 Laminar Flow

The fluid moves through the pipe in concentric layers with maximum velocity in
the center of the pipe, decreasing towards the walls where the fluid particles are
essentially standing still. A cross section of the velocity would appear as shown
below. There is very little mixing of the fluid across the pipe cross section.
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4.4.2 Turbulent Flow

In turbulent flow considerable mixing takes place and the velocity is nearly
the same across the pipe cross section as shown below. Turbulent flow is
more likely to occur in thinner liquids and is often characterized by higher
friction losses than would be expected.
4.4.3 Reynolds Number

A convenient number, called the Reynolds number, can be used for estimating
the transition between laminar and turbulent flow. The Reynolds number, a ratio
of flow rate to viscosity, can be computed by the relation:
R = Q (/) d (x) u (/) SG
Where
R = Reynolds Number
Q = Flow in GPM
d = Pipe Diameter in inches
u = Viscosity in poises
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SG = Specific Gravity
Laminar Flow exists if
R > 63
Turbulent Flow exists if R > 63
Whether flow is under Laminar or Turbulent conditions becomes extremely

important when computing frictional losses in valves and fittings.
4.5 Slip
A major effect on positive displacement pump performance is the loss in flow due
to slip. The expanding cavity on the inlet side of a positive displacement pump
creates a low pressure area that asks to be filled with fluid. This cavity can be
filled with fluid from the inlet line in normal performance. However, if slip occurs,
the cavity will also be partly filled with fluid flowing back through the pump
clearances from the outlet side.
Pump performance is dependent on the slip which occurs in a pump.
Slip Increases:
Directly with Pressure
Directly with Clearance
Inversely with Viscosity
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4.6 Volumetric Efficiency

When a positive displacement pump is operating under a slip condition the pump
looses the ability to deliver the volume of fluid it is theoretically capable of
pumping.
Volumetric Efficiency = Actual Flow / Theoretical Flow
For a given pump and fluid ,the slip is proportional to the pressure differential
from outlet to inlet. If the pump had no slip the volume pumped would be directly
proportional to speed (RPM).
When slip occurs the Actual Flow is reduced.
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If a certain flow is required at a given pressure the speed (RPM) must be

increased.
At a given speed (RPM) and viscosity if the pressure is increased the slip will
increase and the actual flow will decrease.
For a given pressure differential if the viscosity increases the slip will decrease.
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4.7 Calculating Horsepower

The Horsepower required to operate a Positive Displacement Pump has
two factors
The Work Horsepower (WHP) - the actual work done:
WHP = Flow(GPM) (X) Pressure(PSI) (/) 1714
The Viscous Horsepower(VHP) - the power required to turn the rotors,
gears, etc. inside the viscous fluid. The Viscous Horsepower required is
determined by the pump design and speed and is supplied by the pump
manufacturer
HP = WHP + VHP
4.8 Calculating Torque

Torque(T) is a function of Horsepower(HP) and Speed(RPM)
T = HP (X) 5250 (/) RPM
The Torque required by a pump application must not exceed the Torque
limit of the pump shaft.
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4.9 Net Positive Inlet Pressure
The Net positive inlet pressure (NPIP) available is the absolute pressure above
fluid vapour pressure at the pump inlet and is determined as follows.
NPIP available = Pa + Pz Pf - Pvp
Where:
Pa = Pressure at surface of liquid in kg/cm2(a)
Pz = Static head (+) or Static Lift (-) in kg/cm2(a)
Pf = Inlet line , valve & fitting friction losses at maximum viscosity in kg/cm2(a).
Pvp = Fluid vapor pressure or gas dissolution pressure in kg/cm2(a)
NPIP required is a function of pump type , speed and viscosity of fluid pumped.
NPIP available must always be greater than NPIP required to prevent occurrence
of cavitation.
4.10 Cavitation
Cavitation occurs when the pump suction is under a low pressure/high vacuum
condition where the liquid turns into a vapor at the inlet of the pump. This vapor is
carried over to the discharge side of the pump where it no longer sees vacuum
and is compressed back into a liquid by the discharge pressure. This imploding
action occurs violently and attacks the pump rotors, gears etc. Rotors, screws,
gears, etc. that have been operating under a suction cavitation condition have
large chunks of material removed from their faces causing premature failure of
the pump.
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4.11 Affinity Laws for Positive Displacement pump

The affinity laws accurately predict the affect of changing the speed of a
centrifugal or rotary pump, and they also do a fairly good job of predicting the
affect of changing the diameter of a centrifugal pump.
Rotary pumps are very different from centrifugal pumps:
They do not have a best efficiency point (BEP).
There is no impeller shape (specific speed) to consider.
There is no system curve to match.
Their capacity is a constant even if the head changes.
Take a look at the following two curves. The one on the left describes a
centrifugal pump curve with the curve shape determined by the specific speed
number of the impeller. The curve
on the right describes the curve we get with a typical rotary pump.
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H = Head in meters ,
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Q = Capacity in M3/hr
Capacity varies directly with the speed

There is no direct change in head with a change in speed. The pump generates
whatever head or pressure necessary to pump the capacity.
The Power varies directly with the speed.
The NPIP required varies by the square of the speed
Rotary pumps are often used with high viscosity fluids. There is a set of affinity
laws for changes in viscosity, but unlike changes in speed the change in viscosity
does not give you a direct change in capacity, net positive suction head required
(NPSHR), or horsepower.
As an example: an increase in viscosity will increase the capacity because of
less slippage, but twice the viscosity does not give you twice the capacity.
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Since there are a variety of rotary pump designs operating over a wide range of
viscosities, simple statements about changes in operating performance are hard
to make, but the following relationships are generally true.
Here are the viscosity affinity laws for rotary pumps:
Viscosity1>Viscosity2 = Q1 > Q2
Viscosity1>Viscosity2 = Power1 > Power2
Viscosity1>Viscosity2 = NPIPR1 > NPIPR2
Viscosity1>Viscosity2 = No direct affect on differential pressure.
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Chapter 5.0
Performance Characteristics
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5.0 Characteristic Curves

PD pumps create flow, centrifugal pumps create pressure. In a PD pump, flow is
created by enclosing a volume at suction, moving it to discharge, and releasing it.
Pressure is created by the system's response to flow. If there was no connection
at the discharge flange, the flow would exit the pump at atmospheric pressure.
Centrifugal pumps create pressure by first imparting velocity to the fluid with the
impeller, then converting the velocity to pressure with the volute. If there was no
discharge flange connection, the flow would exit the pump with that developed
pressure.
The system requirements will determine the type of pump required in most, but
not all, cases. If a system calls for a pressurized network of piping with a
constant pressure at various flow rates, a centrifugal pump is the best option.
An example of this type of system is municipal water. In this system, a PD
pump would be less efficient.
Oil pipelines normally require a constant flow at various pressures. At a constant
flow rate, pipeline pressure will vary with changes in viscosity. Pipelines transport
different products with different viscosities and pressures. Product cooling will
increase viscosity and pressure. This is of concern if a pipeline is temporarily
shut down then restarted. A centrifugal may not be able to produce a high
enough pressure to clear the line. A PD pump will overcome the pressure and
restart flow.
Fuel delivery systems require a constant fuel flow to control turbines or boilers.
Pressure may vary as nozzles become clogged or erode open, but flow
requirement remains constant. PD pumps supply a steady source of power.
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The quality and quantity of information on suction conditions will determine the
ultimate success or failure of any pump installation. The majority of pump
problems, both centrifugal and PD, start at the suction. There must be a
minimum amount of absolute pressure available to supply fluid to the pump
suction. PD pumps generally require less absolute pressure at Suction than
centrifugal pumps.
Net Positive Inlet Pressure Required (NPIPR), at the pump suction flange, is
the rating of total inlet losses within that pump at rated conditions.
These losses include the fluid friction loss along the internal suction path, the
change in elevation from the suction flange to the enclosed volume, the fluid
friction loss of entering the enclosed volume, and the acceleration to the velocity
of the enclosed volume.
For any given size, NPIPR will increase with increased viscosity or flow
(increased flow = increased speed).
Centrifugal pumps are usually not applied above viscosities of 4000 SSU, due to
the rapid loss of efficiency as viscosity increases. PD pumps maintain high
efficiencies throughout the viscosity range. Entrained gasses can be handled in
large quantities by most PD pump designs.
System Response
The point at which the system curve and the pump performance curve intersect
is the condition of operation. Typically, a system curve will require higher
pressures for higher flow rates. Centrifugal pump performance has reduced flow
with increased pressure. The slopes are of the two curves are opposite. If the
slopes are both gradual, the angle of intersection will be small. Minor variations
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of resistance to flow (partially clogged strainer, valves, etc.) will shift the point of
intersection over a range of operation.
By looking at the performance curve you can see just how different they are. The
centrifugal Pump has varying flow depending on pressure or head, whereas the
PD pump has more or less constant flow regardless of pressure.
Another major difference between the pump types is the effect viscosity has
on the capacity of the pump. You will notice in the flow rate chart how the
centrifugal pump losses flow as the viscosity goes up but the PD pump actually
increases flow. This is because the higher viscosity liquids fill in the clearances of
the pump causing a higher volumetric efficiency. This chart shows only the effect
of viscosity on the pump flow. Remember, when there is a viscosity change there
is also greater line loss in the system. This means you will also have to calculate
the change in pump flow from the first chart for pressure changes.
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The pumps behave very differently when considering mechanical efficiency as

well. By looking at the efficiency chart you can see the impact of pressure
changes on the pumps efficiency. Changes in pressure have little effect on the
PD pump but a dramatic one on the centrifugal.
The most obvious reason to use a PD pump is when you have a high
viscosity application. It is common knowledge that a centrifugal pump
becomes very inefficient at even modest viscosity. However, there are
many other reasons to select a PD pump over a centrifugal other than
high viscosity. In fact PD pumps are very commonly used on thin liquids
like ammonia and solvents.
A simple rule of thumb for selecting a PD pump is: whenever you might be
operating a centrifugal pump at other than at the BEP. Of course the further away
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from the BEP, PD pump will be a better choice. This can typically happen at low
flow conditions, modest to high head conditions, or any type of elevated viscosity.
As you can see from the efficiency curve it takes more horsepower to operate a
centrifugal pump outside of its BEP.
This horsepower has a cost, the initial cost of the larger motor plus a higher life
cycle cost in energy consumed. Many times the PD pump will have a lower initial
cost as well as a lower operating cost.
Another reason to use a PD pump would be if the application has variable

pressure conditions. A centrifugal pump will "walk" up and down the curve
which can cause process problems. A PD pump will give near constant
flow that makes it possible to match the flow to the process requirements.
The desire to have constant flow is the reason that a PD pump is the
pump of choice for metering applications.
Obviously, if there is changing viscosity in the application the PD pump is

the best choice. As can be seen from the charts, viscosity has a major
impact on the centrifugals performance. Even a small change in viscosity,
like 200-400 SSU, has a large impact on the centrifugal.
PD pumps generally can produce more pressure than centrifugals. This

will depend on the design of each pump but pressures of 250 psi (580
feet) are not unusual for a PD pump with some models going to over 1000
psi (2,300 feet). This is a significant difference between the two principles.
The capability for a PD pump to produce pressure is so great that some
type of system overpressure protection is required.
Generally speaking pumps tend to shear liquids more as speed is

increased and the centrifugal is a high speed pump. This makes the PD
pump better able to handle shear sensitive liquids. Shear rates in PD
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pumps vary by design but they are generally low shear devices, especially
at low speeds. Internal gear pumps, for example, have been used to pump
very shear sensitive liquids. It is important to contact the manufacturer for
specific information on shear rates and application recommendations.
By their nature, PD pumps create a vacuum on the suction side so they

are capable of creating a suction lift. The standard ANSI centrifugal does
not create a vacuum so it can not lift liquid into the suction port. There are
self-priming centrifugal designs that can lift liquid an average of 15 feet.
This corresponds to a vacuum of 13" hg. Wetted PD pumps (a pump that
is not full of liquid but with some liquid in it) can often reach vacuums of 25
to 28" hg. So a PD pump is the logical choice when there is a suction lift
required.
As mentioned earlier, PD pumps tend to run at lower speeds than

centrifugals. This will have an impact on seal life, so PD seals tend to last
longer than seals in centrifugal pumps. In addition, to assure adequate
seal life a centrifugal will typically require one of the seal flush plans. A PD
pump, because of its lower shaft speed typically does not need an
external flush plan. Also, generally speaking, low speed mechanical
devices tend to operate longer than high speed mechanical devices.
At certain combinations of flow and pressure centrifugals are inherently

inefficient, due to the design of the impeller and the short radius turn the
flow must make. These applications are generally under 100 GPM but
particularly under 50 GPM. A PD pump, by contrast, is very well suited for
low flow conditions. Centrifugals, by contrast, tend to do very well in high
flow conditions.
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Worked Example (Positive Displacement Pump)

A positive displacement type pump is used to transfer oil fuel from an
underground storage tank to the oil burners on a boiler plant system. At
maximum fire, the burners require a total of 700 L/h of oil at a minimum pressure
of 40 kPa (gauge). A pressure relief valve, set at the minimum required burner
pressure, allows the unused part of the oil to return to the storage tank when the
boiler operates at less than full-fire capacity. The burner is located 1 metre higher
than the pump and the oil level in the vented storage tank is 2 metres lower than
the pump. Measurements indicate a pump speed of 280 rpm, 700 L/h flow, 90
kPa total differential pressure, and 37.0 W power draw. The friction head for the
piping system is proportional to the square of the flow. The specific gravity of oil
is 0.9.
What is the overall efficiency of the existing pump operation? As part of an

energy conservation retrofit, new burners are being installed which at full-fire
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conditions, require only 600 L/h at a minimum pressure of 30 kPa. At what speed
should the existing pump now operate to suit these new conditions and what is
the new power requirement?
First, the problem should be simplified by converting all parameters to standard

units (i.e. m /h flow and equivalent metres water head). The existing flow is 0.7 3
m /h [700 /1,000] and the new flow will be 0.6 m /h. The elevation difference 3 3
between the oil source and destination is 3 metres [2 + 1]. With oil at * = 0.9, the
equivalent water column is 2.7 metres [3 x 0.9]. The 2.7 m elevation head across
the pump will not change with the new operation. The oil in the tank is at zero
gauge pressure (vented to atmosphere) and at the destination (burner), the
pressure is 4.1 metres head [40 / 9.81]. With the new burner, the relief valve
setting can be reduced to 30 kPa or 3.1 metres head [30 / 9.81]. Thus the
existing and new system pressure differential across the pump is 4.1 m and 3.1
m, respectively. The total pump head is currently at 9.2 metres head [90 / 9.81].
Existing Pump Efficiency
Existing pump efficiency is a ratio of theoretical power to actual power. The
theoretical power is:
The overall pump efficiency, based on a measured power of 37.0 W, is:
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New Pump Speed

New pump speed (previously 280 rpm) is proportional to the change in flow
from 700 L/h to 600 L/h.
New Power Requirement

The new power requirement depends on the new total head across the pump.
Total head (P ) is the sum of elevation head (P ), system pressure (P ) head t e s
and friction head (P ). The friction head is not known for the existing 70 L/h flow f
but can be determined as the difference between the other heads.
The new friction head (proportional to square of flow) at 600 L/h is:
The new total head across the pump will be:
The new power is proportional to the flow and the total head. Thus:

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Chapter 6.0
Controlling Positive Displacement Pump
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6.0 Controlling Positive Displacement Pump

The positive displacement pump is in some ways an even simpler device to
control than the centrifugal pump. It has the same function, namely to provide the
pressure necessary to move a liquid at the desired rate from point A to point B
of the process. Below mentioned figure shows a 'generic' process with a positive
displacement pump connected to deliver liquid from A to B.
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There is a great variety of positive displacement pumps. They are divided into
two broad categories: Rotary and reciprocating. From the controls point of view,
however, they are all similar. Their characteristic curve is so simple that it is
rarely drawn. It is essentially a straight vertical line, as shown in previous Figure.
All are constant flow machines whose pressure rises to whatever value is
necessary to put out the flow appropriate to the pump speed. If the discharge is
blocked, the pressure will rise until something yields -- preferably a relief valve.
Close examination of the curve shows a slight counter clockwise rotation. This is
due to internal leakage.
For PD pumps the major cause of leakage is the small amount of reverse flow
that occurs before a check valve closes and possibly past the check valve after it
is closed. Leakage past the piston is negligible. Diaphragm operated PD pumps
have no cylinder to leak past. Rotary PD pumps, such as gear pumps or
progressing cavity pumps have internal clearances which permit a small reverse
flow, called "slip" or "blow by". There is another reason why the curve may rotate
to slightly lower flows at higher discharge pressures: The driver may slow down
as the load increases. None of these have a significant effect in curving the slope
of the characteristic enough that this slope can be used for control. For most
practical purposes the slope is vertical. The system curve of the process is also
shown in above Figure. Its intersection with the pump characteristic defines the
operating point.
As always, the process control engineer has the responsibility of matching the
capacity of a specific piece of equipment to the demands of the process at every
instant of time. Rarely does the actual system curve fall exactly on the one used
for design and selection. As with any two port device, there are three locations in
which a control valve can be placed: On the discharge, on the suction, and as a
recycle valve.
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6.1
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Discharge Throttling
Discharge throttling does not work! Looking at the process from the point of view
of the pump, discharge throttling rotates the system curve counter clockwise so
that the modified system curve intersects the pump curve higher up. The
additional pressure is dropped through the valve so that the pressure and flow to
the process is (almost) exactly the same as before. The "almost" is due to small
increase in internal leakage that results in an equally small reduction in flow. An
increased wear rate and a shortening of the life of the machine are the only
results of this approach. If the pump is seen from the point of view of the process
so that the valve is considered part of the pump, the same result is obtained. To
obtain a modified pump characteristic curve, the pump curve must be rotated
clockwise around the intersection with the pressure axis. The problem is that this
hypothetical intersection is far off the top of the operating range. It is the point
where the pressure is so high that 100% internal leakage occurs.
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The machine would self-destruct from excess pressure if one were stubborn
enough to attempt to find this point. To cut a long story short, you can't control
a PD pump with discharge throttling.
6.2 Suction Throttling

Suction throttling has the same effect on the characteristic curve as discharge
throttling and doesn't work either. PD pumps have a Net Positive Suction Head
required (NPSHR) just as centrifugal pumps do. In fact their requirements are
even more stringent. Therefore restrictions and pressure drops in the suction
lines must be similarly avoided.
6.3 Recycle Control

Recycle control is the only means of using a valve to control a PD pump. The
valve is installed in a line teeing off from the discharge and leading back to the
source of the liquid, possibly a surge tank. It must be full open , of course. Below
mentioned Figure shows its effect on the characteristic curves. Viewing the
process from the point of view of the pump, its effect is to rotate the system curve
clockwise around its intersection with the pressure axis. Note that the little "tail"
at the bottom left of the modified system curve is due to the flow through the
recycle valve before the discharge check valve has opened. The flow through the
pump is essentially as before but the pressure to the process has been reduced.
Process flow will, of course, also be reduced by the amount flowing through the
recycle line.
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Viewing the pump from the process point of view gives a different perspective on
the same phenomenon. This time it is the pump curve that is rotated counter
clockwise around its intersection with the flow axis. This modified pump curve
gives the effect of greatly increased internal leakage. From the point of view of
the process, this is exactly what is happening. Note that I have not used the
same operating points in Discharge throttling curve as I did in Recycle control
curve. It is simply impossible to show any significant reduction in flow on a curve
representing the effects of discharge throttling.
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Recycle control is an efficient method of control for PD pumps. Since the flow
rate is essentially constant, the power requirement is roughly proportional to
discharge pressure. Since the effect of recycle is to drop the discharge pressure,
it results in significant reductions in power requirement. Nevertheless there is still
wasted power in proportion to discharge pressure times recycle flow.
Recycle valves experience rather severe service if the pressure drop is high.
Cavitation will destroy them if they are not appropriately selected. Two
approaches exist to deal with this problem
-The first solution is to drop the pressure in many small stages through the use of
many twists and turns in the valve trim.
-The second is to tolerate the resulting cavitation by shooting the liquid as a jet
through a small hole in the middle of a disk. The jet then blasts directly into the
discharge piping. The line diameter is often increased immediately downstream
of the valve and the wall thickness is also increased. In this way the jet cavities
down the middle of the pipe. It makes a terrific racket.
In either case it may be necessary to put a fixed restriction downstream of the
valve. It should be sized so that the ratio of the high to intermediate pressure is
the same as the ratio of intermediate to low pressure. Keep in mind that the
restriction will reduce the range of the valve by making it act like a quick opening
valve. This is because the restriction becomes the dominant factor in the line
once the valve is about half way open. From that point on, the valve has little
control.
Recycle lines for PD pumps should be run back to the suction vessel. This allows
any entrained bubbles to escape. If they do not, they can build up to the point
Where Pump Capacity Is Impaired. It May Even Vapor Lock.
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6.4 Speed Control

Speed control is an obvious method of controlling the flow rate of PD pumps
since flow is essentially proportional to speed. Pressure can also be controlled by
sliding up and down the system curve. Any point on the system curve can, in
theory, be reached. Most drivers, however, have low speed limits which limit the
turn
down
of
the
system.
Variable speed electric motors are somewhat modified versions of normal

motors. They require special provision for cooling and lubrication at low speed. In
addition, they require specialized electronic power supplies called "invertors".
These units provide power of the appropriate frequency and voltage. They are,
unfortunately, still quite expensive and do not have the reliability of control
valves. There is another reason why large variable speed electric drives are
seldom used with reciprocating pumps. The large inertia of the system means
that speed changes cannot be made quickly. If it is possible for a valve in the
process side to close suddenly, a variable speed electric cannot reduce speed
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fast enough to prevent a severe pressure rise. A recycle valve will be required to
protect the pump, as detailed below in the section on machine protection. A more
simple type of electronic control is frequently used for small chemical injection
pumps.
7.5 Other Means Of Control

The great variety of types of PD pumps results in a variety of specialized means
of flow control. A pneumatic actuator may be used to vary the geometry of the
crank arrangement of a reciprocating pump so that each cycle displaces a
greater or lesser amount of cylinder volume. Direct acting diaphragm pumps
driven by compressed air or some other gas can be controlled by regulating the
gas supply. There is also a technique known as "lost motion" whereby the crank
arrangement first compresses a spring or volume pocket before it begins to work
on the piston or diaphragm. These specialized methods are usually integral parts
of the equipment and the controls engineer simply connects a pneumatic or
milliamp signal to the appropriate input port. None of these methods changes the
essentially constant flow nature of the pump curve. (The flow is still "constant"
but at a different value.)
"Stroke Counting" is a method used when fixed amounts of liquid must be
injected at specific intervals such as in batch processes. An electronic device is
used to count the number of revolutions of a PD pump. After a sufficient number
has been counted, the pump is shut off. When this method is used for pH control,
the correct number of strokes can be calculated from a titration curve.
7.6 Machine Protection. The greatest danger to positive displacement

pumps is overpressure. The rigid, unyielding nature of the pump characteristic
means that overpressure is certain if the discharge is blocked. Many smaller(non
API)
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pumps, such as the gear pumps used to supply lube oil for larger equipment,
have integral relief valves to release pressure from the discharge back to the
suction. In the majority of cases, an external relief valve must be supplied by the
user. It must be connected as closely to the pump discharge as possible and
must not have any means of blocking either its inlet or its outlet. It should
discharge back to the pump supply. If, for any reason, the discharge is blocked
and the relief valve is not capable of relieving, the pressure will rise very rapidly
until something busts. It may be connecting rods, the check valves or even the
cylinder head. Don't count on the motor stalling because events unfold very
rapidly and the inertia of the system is sufficient to cause major damage. The
most likely point of failure is the bolting on the discharge flanges.
It is often advisable to install a high discharge pressure shutdown switch or
transmitter in addition to the relief valve.
7.7 Parallel Pump Operation

PD pumps are quite suitable for parallel operation. Since the discharge pressure
of each pump rises as necessary, all pumps will discharge into the common
header. A common recycle valve is sufficient for flow or pressure control.
Starting up a pump that is discharging into a header that is already pressurized
by other pumps may overload its driver. To prevent this it is necessary to have an
individual recycle valve on each pump. This may be a slow acting ball valve.
Starting the pump then becomes a simple timed sequence in which the valve is
first opened, then the pump is started, and finally the valve is closed again. The
pump should also be shut down in the same sequence. Remember that the ball
valve will be opening against the full discharge head and may need a large
actuator. In water service it is extremely important that the appropriate water
resistant grease is used.
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If variable speed pumps are used, the majority should be placed on fixed speed.
One pump is then selected for process control to take the swings in demand.
7.8 Series Pump Operation

PD pumps are not generally installed in series. Since series pumps must both
discharge an identical flow and both are discharging a "constant" flow, it is
extremely unlikely that the two can be matched without complex controls. It is
common, however, to have one or more parallel centrifugal pumps servings as
boosters to one or more parallel PD pumps. The centrifugal pumps serve to
provide the NPSH that the PD pumps require. The PD pumps in turn can provide
a very high discharge pressure.
The centrifugal boosters should have sufficient flow capacity to supply the
pulsating requirements to the PD pumps. This means the full peak flow, not the
average. If they need controls they should be on pressure control by way of a
recycle valve since there should be no interference in the suction to the PD
pumps.
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Chapter 7.0
Selection Guide Of PD Pumps
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7.0 Selection Guide Of Positive Displacement PumpS

Before attempting to select a pump for a particular application, it is important to
understand the types of pumps available and how they operate. This course
covers the fundamentals of centrifugal and positive displacement pumps,
including the major components of a pump, the operating principle and the
different types of pumps available within each category. The course material
covers Module 3 - "Pumps" in the DOE Mechanical Science Fundamentals
Handbook, which is an excellent source of information in the Engineering
Sciences.
High-Viscosity Liquids.
Internal gear pumps are often a good
choice.
Sanitary Liquids.
Sanitary lobe pumps work well for most food,
beverage, pharmaceutical, and biotechnology applications

Solids. Pump selection depends on the particular application. For food-type
applications containing solids, begin searching sanitary lobe pumps. For slurries
and other industrial-type solids, start with internal gear pumps.
Corrosive Liquids.
Proper selection of the right materials of
construction will have the greatest impact on pump performance.
Composite
external gear and stainless steel internal gear pumps are good starting points.
Abrasive Liquids.
A number of factors can combine to minimize the
effects of abrasion. Begin with internal gear pumps manufactured with hardened
steel parts.
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Toxic, Hazardous, or Hard-To-Seal Liquids.
Preventing leaks is
critical for handling these fluids. Magnetically-driven or mechanically sealed

internal or external gear pumps offer a good starting point
Extreme Temperature Conditions.
Internal gear pumps with jacketing
features offer excellent temperature control.
PD Pumps Selection Summary

Pump
Internal
Abrasives
Thin
Liquids
Viscous
Solids Dry Prime
Diff.
Pressure
Lobe
Vane
Gear
External
Gear
E = Excellent, G = Good, A = Average, P = Poor
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Chapter 8.0
Field Problems & Trouble shooting
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8.0 Field Problems & Trouble shooting

No liquid discharge.
The pump is not primed. Prime it from the outlet side by keeping the outlet
air vent open until liquid comes out the vent.
The rotating unit is turning in the wrong direction.
Valves are closed or there is an obstruction in the inlet or outlet line.

Check that the flange gaskets have their center cut out.
The end of the inlet pipe is not submerged. You can either increase the
length of the inlet pipe into the liquid level or raise the level in the tank.
The foot valve is stuck.
A strainer or filter is clogged.
The net inlet pressure is too low.
A bypass valve is open.
There is an air leak some where in the inlet line. Air can come in through
gaskets or valves above the fluid line.
The stuffing box is under negative pressure. Packing is allowing air to get
into the system. You should convert the packing to a mechanical seal
The pump is worn. The critical clearances have increased.
Something is broken. Check the shaft, coupling, internal parts, etc.
There is no power to the pump.
The pump is putting out a low capacity.
The pump's internal clearances have increased. Set the clearances right /
replace worn out parts.
The net inlet pressure is too low; the pump is cavitating.
A strainer or filter is partially clogged.
The speed is too low. Check the voltage.
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The tank vent is partially frozen shut.
A bypass line is partially open.
A relief valve is stuck / partially open.
The inlet piping is damaged.
A corrosion resistant liner has collapsed in the inlet piping.
Air is leaking through the packing. Replace packing or go for Mechanical

seal.
The pump looses its prime after it has been running for a while.
The liquid supply is exhausted. Check the tank level; sometimes the float
is stuck, giving an incorrect level reading.
The liquid velocity has increased dramatically.
The liquid is vaporizing at the pump inlet.
A bypass line is heating the incoming fluid.
An air leak has developed in the suction piping.
The pump is taking too much power
The speed is too high.
The liquid viscosity is higher than the design.
The discharge pressure is higher than design.
The packing has been over tightened. Adjust gland tightness or go for
Mechanical seal.
A rotating element is binding. Misalignment could be the problem or

something is stuck in a close clearance and binding the rotating element.
Excessive noise and vibration.
Relief valve chatter.
Foundation or anchor bolts have come loose.

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The pump and driver are misaligned.
The piping is not supported properly.
The liquid viscosity is too high. The pump is starving. Check the
temperature of the incoming liquid. Check to see if the supply tank heater
has failed.
Excessive noise or a loss of capacity is frequently caused by cavitation. Here is

how the NPSH required was determined initially:
With the pump initially operating with a 0 psig. inlet pressure and constant
differential pressure, temperature, speed and viscosity; a valve in the inlet line is
gradually closed until cavitation noise is clearly audible, there is a sudden drop
off in capacity or there is a 5% overall reduction in output flow. Cavitation occurs
with:
A loss of suction pressure.
An increase in fluid velocity.
An increase in inlet temperature.
Cavitations problem
A foot valve or any valve in the suction piping is sticking.
Something is occasionally plugging up the suction piping. If the pump

suction is coming from a river, pond or the ocean, grass is a strong
possibility.
A loose rag is another common cause.
A collapsed pipe liner.
A filter or strainer is gradually clogging up.
The tank vent partially freezes in cold weather.
The sun is heating the suction piping, raising the product temperature
close to its vapor point.

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The level in the open suction tank decreases causing vortex problems that
allow air into the pump suction.
Several pumps in the same sump are running, decreasing the level too
much.
The suction tank float is stuck. It will sometimes show a higher level than
you really have.
A discharge recirculation line, piped to the pump suction, opens and heats
the incoming liquid.
Sometimes the suction lift is too high. The increase in pipe friction will
reduce the suction head.
The vapor pressure of the product is very close to atmospheric pressure.

The pump cavitates every time it rains because of a drop in atmospheric
pressure.
The tank is being heated to de-aerate the fluid. Sometimes it is being

heated too much.
The process fluid specific gravity is changing. This can happen with a
change in product operating temperature or if a cleaner or solvent is being
flushed through the lines.
The source tank is changing from a positive pressure to a vacuum due to

the process.
A packed valve in the suction piping is at a negative pressure and air is

leaking in through the packing.
The tank is being pumped dry.
The inlet piping has been moved or altered in some way. Has a foot valve,
strainer, elbow, or some other type of hardware been installed in the
suction piping?
Has a layer of hard water calcium or some other type of solid formed on
the inside of the suction piping reducing its inside diameter over some
period of time?
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Rapid pump wear
There are abrasives in the liquid you are pumping causing erosion
problems. You may have to go to a larger pump running at a slower
speed.
There is some corrosion in one or more of the pump elements.
There is a lack of lubrication.
You have a severe pipe strain problem. It could have been caused by
thermal growth of the hardware.
Too much misalignment.
The pump is running dry.
When all else fails the best way to reduce NPSH required is to select a
larger pump and run it at a slower speed.
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9.0 Tips to Improve Pump Efficiency

Shut down unnecessary pumps.
Restore internal clearances if performance has changed.
Control by Recycle or speed .
Replace oversized pumps.
Use multiple pumps instead of one large one.
Use a small booster pump.
Change the speed of a pump for the most efficient match of horsepower
requirements with output.
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10.0 Summary
In this module user have learned about:
Types of PD Pumps,
Pump Operating Principles
Pump Power Requirements
Multiple Pump Systems
Pump Cavitation
Trouble shooting
PD Pump Selection criteria
You should now be able to perform the following tasks
Identify Pump Types and Characteristics
Measure Operating Conditions
Calculate Power and Energy Consumption
Evaluate Pump Performance
Develop System Improvement Recommendations.
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11.0 References
1. Internet
2. API 676
3. Metering Pumps by James P. Poynton
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Training Module Objectives

The Function of PD Pumps

No part of this document may be reproduced in any form , in an electronic

Authorization for information disclosure is allowed with the written permission

Module Implementation Plan

Code No: IPCLDSMEC006

Selection Guide Of Positive

4.1.2 Single Rotor

4.2 Reciprocating Pump

4.4.3 Reynolds Number

Controlling Positive Displacement Pump

Selection Guide Of PD Pumps

Introduction to Positive Displacement Pumps

A Positive Displacement Pump has an expanding cavity on the suction side of

In contrast Centrifugal Pumps rely on kinetic energy rather than mechanical

range of liquids, slurries and foams to be transported without product

Comparisons Between Rotary and Centrifugal Pumps

Max Viscosity , cSt

Max. Capacity ,M3/Hr

E = Excellent, G = Good, A = Average, P = Poor

*****End of Chapter 1.0****

Definitions & Terminology

2.0 Definitions & Terminology

2.2 Pumping chamber

2.3 Inlet or suction port

2.4 Outlet or discharge port

2.6 End plate

2.10 Timing gear

2.11 Rotating assembly

2.12 Relief valve

2.13 Cracking pressure

2.14 Full-flow bypass pressure

2.15 Reseating pressure

2.16 Percent overpressure

2.20 Lantern ring

2.22 Mechanical seal

2.23 Radial seal

2.24 Direction of rotation

2.25 Jacketed pump

****End of Chapter 2.0****

Positive displacement Pumps Classification

3.0 Classification of Positive displacement Pumps

Reciprocating pumps are defined as being; steam, power, or controlled volume

****End of Chapter 2.0****

Fundamentals & Operating Principles

4.0 Fundamentals & Operating Principles

4.1 Rotary Pump

Internal Gear Pump

Only two moving parts.

Only one stuffing box.

Positive suction, nonpulsating discharge.

Ideal for high-viscosity liquids.

Constant and even discharge regardless of pressure conditions.

Operates well in either direction.

Low NPSH required.

Single adjustable end clearance.

Flexible design offers application customization.

Usually requires moderate speeds.

Medium pressure limitations.

One bearing runs in the product pumped.

Overhung load on shaft bearing.

The rotor gear is driven by a shaft supported by journal or antifriction bearings.

*End of Chapter 1.0

End of Chapter 2.0

End of Chapter 2.0

End of Chapter 4.0