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Design, Installation and Fabrication of Reciprocating Pump
Design, Installation and Fabrication of Reciprocating Pump
Design, Installation and Fabrication of Reciprocating Pump
On
Design, Installation and Fabrication of Reciprocating pump
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted By
NAME UNIVERSITY ROLL NUMBER
Acknowledgement
Aim of the project
1 Project plan 01
2 Reciprocating Pumps 04
3 Classification of Reciprocating Pump 04
4 Components of Reciprocating Pump 11
5 Advantages and Disadvantages of Reciprocating Pump 12
6 Reciprocating Pump performance 13
7 Selection of pumps 17
8 Design and Calculations 27
9 Applications 33
10 References 36
ACKNOWLEDGEMENT
We would like to express a deep sense of gratitude & thank profusely to our thesis
guide Dr. Manoj kumar Barai for his sincere & invaluable guidance, suggestions &
attitude which inspired us to submit project report in the present form..
Objectives
The overall objective of the project is to demonstrate a functional reciprocating pump
so that students can learn the manufacturing and installation of the technology.
Specific objectives are:
a) To identify the potential site for reciprocating pump installations
b) To design reciprocating pump per site and manufacture the same
c) To construct a demonstration/testing facility consisting reciprocating pump
d) To install the reciprocating pump
e) To test the performance of reciprocating pump
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PROJECT PLAN
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INTRODUCTION
Mechanical pumps serve in a wide range of applications such as pumping water from
wells, aquarium filtering, pond filtering and aeration, in the car industry for water-
cooling and fuel injection, in the energy industry for pumping oil and natural gas or
for operating cooling towers. In the medical industry, pumps are used for biochemical
processes in developing and manufacturing medicine, and as artificial replacements
for body parts
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Reciprocating Pumps
With only one cylinder the fluid flow varies between maximum flow when the
plunger moves through the middle positions, and zero flow when the plunger is in the
end positions. A lot of energy is wasted when the fluid is accelerated in the piping
system. Vibration and "water hammers" may be a serious problem. In general the
problems are compensated by using two or more cylinders not working in phase with
each other.
In a diaphragm pump the plunger pressurizes hydraulic oil which is used to flex a
diaphragm in the pumping cylinder. Diaphragm pumps are used to pump hazardous
and toxic fluids.
Follow are the three fields in which the reciprocating are classified
A single acting pump is one which has one suction valve, delivery valve and one
suction and delivery pipe. It suck up the fluid only in one direction and in single
stroke called suction stroke and deliver it in a single stroke called delivery stroke.
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SINGLE ACTING PUMP
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When the pump has three cylinders attached to a single shaft then the pump is called
triple cylinder pump. Crank is set at an angle of 120
A Positive Displacement Pump has an expanding cavity on the suction side and a
decreasing cavity on the discharge side. Liquid flows into the pumps as the cavity on
the suction side expands and the liquid flows out of the discharge as the cavity
collapses. The volume is a constant given each cycle of operation.
The positive displacement pumps can be divided in two main classes
reciprocating
rotary
The positive displacement principle applies whether the pump is a
rotary lobe pump
progressing cavity pump
rotary gear pump
piston pump
diaphragm pump
screw pump
gear pump
vane pump
regenerative (peripheral) pump
peristaltic
A Positive Displacement Pump, unlike a Centrifugal or Roto-dynamic Pump, will
produce the same flow at a given speed (RPM) no matter the discharge pressure.
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A Positive Displacement Pumps is a "constant flow machine"
A Positive Displacement Pump must never operate against closed valves on the
discharge side of the pump - it has no shut-off head like Centrifugal Pumps. A
Positive Displacement Pump operating against closed discharge valves continues to
produce flow until the pressure in the discharge line is increased until the line bursts
or the pump is severely damaged - or both.
A relief or safety valve on the discharge side of the Positive Displacement Pump is
absolute necessary. The relief valve can be internal or external the pump. An internal
valve should in general only be used as a safety precaution. An external relief valve
installed in the discharge line with a return line back to the suction line or supply tank
is highly recommended.
DIAPHRAGM PUMPS
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unlike pistons and plungers, diaphragms do not require a
sealing system and therefore operate leak free. This feature does,
however, preclude the possibility of a double acting design. If nearly
continuous flow is required, a double-diaphragm or duplex pump is usually
employed. The figure below is a cross section of an air operated, double
diaphragm pump.
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air operated, double diaphragm pump
The double diaphragm pump utilizes a common suction and discharge manifold
teamed with two diaphragms rigidly connected by a shaft. The pumped liquid resides
in the outside chamber of each while compressed air is routed to and from their inner
chambers. In the figure, the right hand chamber has just completed its suction stroke
and, simultaneously, the left chamber completed its discharge stroke. As would be
expected, the suction check is open so that liquid can flow into the right chamber and
the discharge check of the left chamber is open so that liquid can flow out. Except for
the double chamber configuration, its operation is just like the double acting piston
pump seen earlier. The difference, of course, resides within the inner chambers and
the method in which the reciprocating motion is maintained. This is
accomplished by an air distribution valve that introduces compressed air to
one diaphragm chamber while exhausting it from the other. Upon completion
of the stroke the valve rotates 90 degrees and reciprocation occurs.
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During the suction stroke (right to left) the single acting pump’s discharge valve
closes and allows fluid to enter the cylinder via the suction valve. When the piston
changes direction (reciprocates) the suction valve closes and water is discharged
through the discharge valve. In the double acting pump, the same sequence occurs
during both strokes and almost twice as much fluid is discharged per unit time.
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Components of Reciprocating Pump
Crank
Crank is a circular disk attached to the motor and used to transfer the rotation motion
of the motor to the piston
Connecting rod
Connecting rod is the long solid rod. It provide connection between crank and the
piston. It also convert the rotation motion of crank into the linear motion of the piston.
Piston
Piston is the solid cylinder like part of the pump which moves linearly in the hollow
cylinder of the pump. It motion is main reason behind suction and deliverance of the
liquid
Cylinder
It is a hollow cylinder in which piston moves. Suction and deliverance take place with
in it. Suction and delivery pipe and valves are attached to its one end piston come and
go back from other end.
Suction pipe
Pipe which take liquid from the source and provide it to the cylinder of the pump is
called suction pump
Suction valve
It is one way valve place between suction pipe and cylinder of the pump. It is open
when suction take place and close when delivery of the water is taking
Delivery pipe
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Pipe which take water from the cylinder of the pump and provide it to the tank is
called delivery pipe.
Delivery valve
It is one away vale and placed at the point of attachment of delivery pipe with
cylinder. It is open when delivery of water is taking place and closed when suction of
water in taking place
Strainer
It is a filter like parts provided at the end of suction pipe. Its main function is to stop is
solid particles from entering into the pipe
Air vessel
Installed at the suction and delivery pipe and its main function is to give a steady flow
by reducing the frictional head
High efficiency
No priming needed
Can deliver water at high pressure
Can work in wide pressure range
Continuous rate of discharge
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Reciprocating Pump Performance
The following data will outline the main terms involved in determining the
performance of a reciprocating pump.
MAIN TERMS:
a) Brake Horsepower (BHP) : Brake horsepower is the actual power
required at the pump input shaft in order to achieve the desired pressure and flow.
It is defined as the following formula:
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pressure.
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s = stroke of pump, (in.) (half the linear distance the plunger or piston moves linearly
in one revolution)
MINOR TERMS:
g) Valve Loss (VL) : Valve loss is the flow of liquid going back through the valve
while it is closing and/or seated. This is a 2% to 10% loss depending on the valve
design or condition.
h) Speed (n) : Design speed of a power pump is usually between 300 to 800 rpm
depending on the capacity, size, and horsepower. To maintain good packing life,
speed is limited to a plunger velocity of 140 to 150 ft/minute. Pump speed is also
limited by valve life and allowable suction conditions.
i) Pulsations: The pulsating characteristics of the output of a power pump are
extremely important in pump application. The magnitude of the discharge pulsation
is mostly affected by the number of plungers or pistons on the crankshaft.
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SELECTION
The centrifugal or roto-dynamic pump produce a head and a flow by increasing the
velocity of the liquid through the machine with the help of the rotating vane
impeller. Centrifugal pumps include radial, axial and mixed flow units.
Centrifugal pumps can be classified further as
end suction pumps
in-line pumps
double suction pumps
vertical multistage pumps
horizontal multistage pumps
submersible pumps
self-priming pumps
axial-flow pumps
regenerative pumps
Positive Displacement Pumps
A positive displacement pump operates by alternating filling a cavity and then
displacing a given volume of liquid. A positive displacement pump delivers a constant
volume of liquid for each cycle independent of discharge pressure or head.
Reciprocating pumps - piston, plunger and diaphragm
The positive displacement pump can be classified as:
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Power pumps
Steam pumps
Rotary pumps - gear, lobe, screw, vane, regenerative (peripheral) and
progressive cavity
Selecting between Centrifugal or Positive Displacement Pumps
Selecting between a Centrifugal Pump or a Positive Displacement Pump is not always
straight forward.
Flow Rate and Pressure Head
The two types of pumps behave very differently regarding pressure head and flow
rate:
The Centrifugal Pump has varying flow depending on the system pressure or
head
The Positive Displacement Pump has more or less a constant flow regardless
of the system pressure or head. Positive Displacement pumps generally makes
more pressure than Centrifugal Pump's.
Capacity and Viscosity
Another major difference between the pump types is the effect of viscosity on
capacity:
In a Centrifugal Pump the flow is reduced when the viscosity is increased
In a Positive Displacement Pump the flow is increased when viscosity is
increased
Liquids with high viscosity fills the clearances of Positive Displacement Pumps
causing higher volumetric efficiencies and Positive Displacement Pumps are better
suited for higher viscosity applications. A Centrifugal Pump becomes very inefficient
at even modest viscosity.
Mechanical Efficiency
The pumps behaves different considering mechanical efficiency as well.
Changing the system pressure or head has little or no effect on the flow rate in
a Positive Displacement Pump
Changing the system pressure or head may have a dramatic effect on the flow
rate in a Centrifugal Pump
Net Positive Suction Head - NPSH
Another consideration is the Net Positive Suction Head NPSH.
In a Centrifugal Pump, NPSH varies as a function of flow determined by
pressure
In a Positive Displacement Pump, NPSH varies as a function of flow
determined by speed. Reducing the speed of the Positive Displacement Pump
pump, reduces the NPSH
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CHARACTERISTICS OF RECIPROCATING PUMP
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Negative slip will occur when delivery pipe is short, suction pipe is long and
pump is running on high speed.
A positive displacement pump makes a fluid move by trapping a fixed amount and
forcing (displacing) that trapped volume into the discharge pipe. Some positive
displacement pumps use an expanding cavity on the suction side and a decreasing
cavity on the discharge side.
In this curve we see the flow rate is almost constant in spite of pressure differe nce,
but in centrifugal pump the flow rate is changing due to pressure difference. This is the
advantage of reciprocating pump over centrifugal pump.
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MATERIALS USED IN RECIPROCATING PUMP
The piston is a part which is constantly subjected to various stresses as a result of the
usage of the reciprocating pump. Since in most designs, the users are unable to see the
damage caused to the piston. The design and fabrication of the piston is of utmost
importance. We must use our knowledge of material sciences to the fullest for
preparing a piston which is capable to withstand the heat generated due to friction
between parts and corrosion due to the usage of water as the pumping fluid.
Before we go into the details of the materials used in the making of the pump, we
must highlight the typical problems faced in its usage. These include:
Pulsation Analysis
Features include:
Operating conditions. An operating condition analysis to assess the pump’s
operation across the entire operating envelope. The standard service evaluates up to
20 operating conditions.
Pulsation levels. An evaluation of the pulsation levels given varying performance of
the pump valves. Pulsation levels are drastically influenced by the behaviour of the
pump valves
Upset conditions. Reporting of the effect of upset conditions such as pulsation
levels when a pump valve fails, thus deactivating a plunger throw. Vibration and
pulsation characteristics are greatly influenced by the number of fluid ends active.
Pressure drop. As a standard feature BETA will assess static and total pressure
drop. Total pressure drop includes dynamic pressure drop losses.
Piping restraint or mechanical review. This includes an evaluation of pipe support
locations using charts, empirical calculations, and good engineering design practices.
Water Hammer Analysis, also known as a transient surge analysis for liquid
systems, is another optional study that is sometimes required when reciprocating
pump and piping systems are affected by transient events such as power outages,
valve swings, check valve slam, and other causes. Some operators require an
investigation of transients in the system to ensure integrity under upset conditions.
The transient pressures can create serious risks for piping integrity including pipe
rupture, pipe collapse, cavitation, column separation, and check valve slam. The
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transient events created are known generally as water hammer, but as this
phenomenon can happen with any liquid, other terms are fluid hammer, or dynamic
pressure surge.
Water Hammer Transient Studies are recommended for:
Any liquid piping system in the design stage to evaluate pipe system integrity under
transient conditions
Predicting water hammer in pump systems for regular operating and upset scenarios
(e.g., Loss of power)
Predicting transients due to valve swings, sudden valve openings, new streams
coming online, or other operating changes
Pump system upgrades to flow and available head
Systems with high consequence of failure, such as hazardous fluids, safety,
environmental
Calculating resultant transient forces on pipes to determine stress levels
Any existing system where high vibration or shocks are occurring with valve
closures or pump shutdowns
ISOLATION VALVE
An isolation valve, or shutoff valve, should be installed in the discharge pipe. It
assists in the priming of the pump, starting the pump, and for isolation, as may be
required for pump maintenance. Except for axial and mixed flow pumps, the
isolation valve should be closed before stopping pump, especially if no check valve
is installed. An isolation valve should not be used for the throttling of the pump.
Throttling of the discharge isolation valve contributes to a substantial waste of
energy in the pump. Should an existing discharge valve be found to be throttling the
pump excessively, a correctly sized pump should be installed, or some other variable
speed drive should be considered.
CHECK VALVE
A check valve is utilized in a pump system to prevent back flow of the liquid when
the pump is stopped. This reverse flow could cause damage to the pump, from the
impeller becoming loose for example, or cause difficulty in re-priming the pump.
The check valve is located in the discharge line, between the pump and isolation, or
shutoff, valve, and on the far side of the expansion joint, away from the pump. It
should never be installed in the suction line. A check valve is a flow restrictor in the
piping, and will cause a pressure drop.
REDUCER
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A pipe reducer is a fitting that allows a change in the diameter of the pipe in the
system. The information in this section is also applicable to a pipe increaser. It is
important to properly size and install a reducer to insure that smooth flow through
the system is not disturbed, causing damage to the equipment or the system.
STRAINER
The function of a strainer in a pump’s suction piping is to keep solids out of the
pump and the pumping system. A strainer can be used in most all pumps, except in
large units. For the larger pumps, a temporary strainer can be installed for the start
up of a new installation. This temporary strainer can be left in place until the system
is clean and construction debris is removed. Strainers will cause a moderate pressure
drop in the system, until it begins to clog and accumulate solid materials. At this
point, the pressure drop across the strainer will increase, and may cause the pump to
starve. Ideally, the pipe on the up stream and down stream side of the strainer should
be tapped and used to monitor the pressure drop. After some experience, a set point
can be determined when the strainer requires cleaning. The cleaning of the strainer
can then be added to a routine maintenance schedule. The size of the strainer should
be chosen so that the open or “free” area of the strainer is three (3) times the suction
pipe area.
FOOT VALVES
Foot valves are used on the suction side of a pump to provide suction lift for pumps
that are not self-priming. They act as a check valve, maintaining liquid in a pump’s
suction line. A foot valve can fail the pumping system when it loses its sealing
capabilities and begins to leak. In addition, it may fail the system if solids or some
other type of foreign matter prevents it from closing properly. If a pump is utilizing a
foot valve for priming from a suction lift, the failure of the foot valve will cause the
pump to run dry because of the lack of liquid in the pump and suction line. Operating
with no liquid in the pump may possibly cause catastrophic damage to the unit.
In addition to the considerations that must be made with the various system
components, the design and fabrication of the suction and discharge piping must
followed according to best practices of the industry. As with any project, it is
important that the piping design and fabrication is done right the first time. If it is not
done following recommended practices, it will be difficult and expensive to
correcting the future. DESIGN The first consideration in the design of a piping
system is the sizing of the pipe. The capacity must be established not only for the
entire process or system, but for the individual branches as well. The design flow
should not be oversized by a large margin to prevent throttling of valves and wasting
energy. The goal of selecting the pipe size of the system is maximize the pipe sizes
used, while minimizing the costs of the pipe. As pipe sizes are increased, the system
head loss, due to friction, is decreased. Additional consideration must be made for
pumping viscous materials. Viscous materials have a greater friction loss than water
in the same size pipe. Many of the references in this article have friction charts that
assist in pipe size selection for various flow rates. The size of the suction and
discharge piping should be at least the size of the pump connections. Suction pipe
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should be one (1) to two (2) sizes larger than the pump connection, never smaller. A
reducer can be used to in the suction line to allow for the suction pipe that is
oversized. The overall design of the piping system should be as straight and as short
as possible, with a minimal about of bends or turns in the system. Sudden changes in
pipe diameter will cause turbulence and head loss in a system, and, therefore, should
be avoided. A final design consideration for the piping system is for the ease of
pump removal for repair. As a pump will eventually require removal and
maintenance, the piping system should be designed to allow technicians to work on
the pump at the site, as well as remove it safely. Liberal spacing should be
maintained around the equipment.
during fabrication, a simple method to determine if pipe flange faces are parallel is to
see if you can visibly see a difference in the flange face planes. If the gap between
the faces is visible and is not even, then it will cause pipe strain. Other causes of pipe
strain, that may impose a force and torque on the pump, include thermal growth, an
inadequate piping design and support system, pressure surges, and water hammer.
The effects of pipe strain include:
• Coupling misalignment
• Cracking of the piping nozzles or pump casing
• Distortion of pump casing and bearing housing
• Excessive vibration
• False appearance of soft foot conditions during alignment
• Inconsistent alignment data
• Leakage at the pump flanges
• Shortened mechanical seal and bearing life
• Wear ring contact
Standard industry practices recommend that the pipe be run from the pump to a point
several feet away, where the final pipe connection can be made. During the
fabrication, temporary braces and supports should be used to maintain the piping and
fittings in place while the system is being completed. During fabrication of the pipe,
the piping should never be drawn into place by force, as with ratchet pullers or chain
hoists. This may cause strain, breakage, distortion, or misalignment, and may affect
the operation or damage the equipment. The pipe should not be connected to the
pump until grout has cured and pump/driver/base bolts have been tightened. After
the fabrication of the piping system is completed, the pump installation is complete,
and the connections are made to the pump, the shaft should be rotated to insure there
is no binding. The alignment should be checked to determine the absence of pipe
strain. The piping should be corrected if pipe strain is present and causing
misalignment.
SUPPORT
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suction and discharge piping must be anchored, supported, and restrained near the
pump to avoid the forces and movements of the system being applied to the pump.
The pipe should be anchored close to the pump flanges on suction and discharge to
prevent vibration and putting strain on the piping. A system of hangers and braces
should be used to support the piping system. The hangers and braces should be
installed in a manner such that they do not have to be removed during normal
maintenance on the equipment. Long pipe runs should be supported at unequal
distances to prevent resonant vibrations from occurring in the system. After the
piping has be installed and supported, the alignment should be rechecked. The piping
should then be adjusted if there is any significant change to the equipment’s last
alignment readings.
SUMMARY
Proper sizing of the piping system will result in the lowest overall pumping system
life cycle cost. This requires finding the optimum balance between pipe purchase and
installation costs and energy costs associated with the pipe frictional losses. It should
further be noted that the frictional losses created by piping systems can require larger
pumps, motors, and power supplies to overcome the losses than if larger pipe were
used. Pump discharge pressure will also be greater when frictional losses are
excessive. Proper design and fabrication will ensure that the equipment will be
reliable and will not fail due to the effects of the piping system.
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DESIGN CALCULATIONS
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Pumping Water - Horsepower Requirements
Energy imparted to the water by a pump is called water horsepower - and can be
calculated as
Pwhp = q h SG / (3960 μ) (1)
where
Pwhp = water horsepower (hp)
q = flow (gal/min)
h = head (ft)
SG = 1, water Specific Gravity
μ = pump efficiency (decimal value)
Horsepower can also be calculated as:
Pwhp = q dp / (1715 μ) (2)
where
Pwhp = water horsepower (hp)
dp = delivered pressure (psi)
The table below can be used to estimate the power requirement for pumping water.
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Water Pumping Costs
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System Curve and Pump Performance Curve
where
p = static pressure
ρ = density
v = flow velocity
g = acceleration of gravity
h = elevation height
wshaft = net shaft energy per unit mass for a pump, fan or similar
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The system head visualized in the System Curve is a function of the elevation - the static head
in the system, and the major and minor losses and can be expressed as:
h = dh + hl (1)
where
h = system head
dh = h2 - h1 = elevation (static) head - difference between inlet and outlet of the system
hl = head loss
hl = k q2 (2)
where
q = flow rate
k = constant describing the total system characteristics - including all major and minor losses
Increasing the constant - k - by closing some valves, reducing the pipe size or similar - will
increase the head loss and move the system curve upwards. The starting point for the curve -
at no flow, will be the same.
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Increasing the impeller diameter or speed increases the head and flow rate capacity - and the
pump curve moves upwards.
The head capacity can be increased by connecting two or more pumps in series, or the flow
rate capacity can be increased by connecting two or more pumps in parallel.
Selection of Pump
A pump can be selected by combining the System Curve and the Pump Curve:
The operating point is where the system curve and the actual pump curve intersect.
Special consideration should be taken for applications where the system conditions change
frequently during operation. This is often the situation for heating and air conditioning system
or water supply systems with variable consumption and modulating valves.
Carry Out
When a pumps operates in the far right of its curve with poor efficiency - the pumps carry out.
Shutoff Head
Shutoff head is the head produced when the pump operates with fluid but with no flow rate.
Churn
A pump is in churn when it operates at shutoff head or no flow.
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Applications of reciprocating pumps :
The applications of reciprocating pumps include:
1. Reciprocating pump has a wide range of applications in the Oil and Gas
Industries Form Production to Drilling to Operations:
2. Petrochemicals and Refineries are two core industries that have applications of
reciprocating pumps
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Axial piston pumps :
Axial piston pumps are used to power the hydraulic systems of jet aircraft, being gear-
driven off of the turbine engine's main shaft, The system used on the F-14 used a 9-
piston pump that produced a standard system operating pressure of 3000 psi and a
maximum flow of 84 gallons per minute.
They are also used in some pressure washers. For example Kärcher has several
models powered by axial piston pumps with three pistons.
Due to the hydrostatically balanced parts it is possible to use the pump with
various hydraulic fluids like mineral oil, biodegradable oil, HFA (oil in water), HFC
(water-glycol), HFD (synthetic ester) or cutting emulsion. That implies the following
main applications for a radial piston pump:
machine tools (e.g., displace of cutting emulsion, supply for hydraulic equipment
like cylinders)
high pressure units (HPU) (e.g., for overload protection of presses)
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test rigs
automotive sector (e.g., automatic transmission, hydraulic suspension control in
upper-class cars)
plastic- and powder injection moulding
wind energy
4. Hand pump
Hand pumps are manually operated pumps; they use human power and
mechanical advantage to move fluids or air from one place to another. They
are widely used in every country in the world for a variety of industrial,
marine, irrigation and leisure activities. There are many different types of hand
pump available, mainly operating on a piston, diaphragm or rotary vane
principle with a check valve on the entry and exit ports to the chamber
operating in opposing directions. Most hand pumps have plungers or
reciprocating pistons, and are positive displacement
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REFERENCES
http://www.engineeringtoolbox.com/pumps-t_34.html pumps
http://www.engineeringtoolbox.com/positive-displacement-
pumps-d_414.html positive displacement pump
https://www.google.co.in/search?q=PLUNGER+PUMPS&safe
=off&espv=2&source=lnms&tbm=isch&sa=X&ved=0ahUKEw
jGroSRpbLJAhUCTI4KHdahAFEQ_AUIBygB&biw=1366&b
ih=623#imgrc=bCSya4TlU3cI3M%3A Plunger pump with
splash lubrication
http://www.green-mechanic.com/2014/07/classification-of-
reciprocating-pump.html classification of reciprocating pump
www.google.com
www.scribd.com
Engineering_Design_Guideline__Pump_Rev3.pdf
Energy Conservation in Pumps.ppt
PUMPS - TYPES & OPERATION
Fluid mechanics & machinery Laboratory
Positive Displacement Pumps (Part One) Reciprocating Pumps
Reciprocating Pump files
Fluid mechanics and hydraulic machines-by R K BANSAL
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