Module No.

5 : Pumps

Unit No. 3 - Reciprocating pumps

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UNITS IN THIS COURSE

UNIT 1 UNIT 2 UNIT 3 UNIT 4 UNIT 5 PUMP TERMINOLOGY. PUMP CLASSIFICATION. RECIPROCATING PUMPS. ROTARY PUMPS. CENTRIFUGAL PUMPS.

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Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

TABLE OF CONTENTS

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Para 3.0 3.1 3.2 COURSE OBJECTIVES TYPES OF RECIPROCATING PUMPS PISTON PUMPS 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.3 3.4 3.5 3.6 3.7 3.8 3.9 Casing Cylinder Piston and Piston Rings Stuffing Box and Packing Suction and Discharge Valves

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SINGLE AND DOUBLE ACTING PISTON PUMPS HOW PISTON PUMPS WORK ADVANTAGES AND DISADVANTAGES OF PISTON PUMPS PLUNGER PUMPS COMPARISON OF PLUNGER PUMPS TO PISTON PUMPS ADVANTAGES AND DISADVANTAGES OF PLUNGER PUMPS DIAPHRAGM PUMPS 3.9.1 3.9.2 3.9.3 3.9.4 Casing Diaphragm Suction and Discharge Valves Driving Mechanism

3.10 3.11 3.12

HOW A DIAPHRAGM PUMP WORKS ADVANTAGES AND DISADVANTAGES OF DIAPHRAGM PUMPS THE END USES OF RECIPROCATING PUMPS

3.13 PULSATION DAMPENERS

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Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

3.0

COURSE OBJECTIVES

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This course describes the different types of pumps commonly found in process plants. The course has five Units. These Units describe the basic terminology of pumps and pumping, the types of reciprocating, rotary and centrifugal pumps, start up of centrifugal pumps, pump problems, and pump control systems. When he has finished the course, the student will be able to: Explain the basic terminology of pumps. Identify different kinds of pumps and explain their functions. Identify the differences between the main types of reciprocating pumps and explain the end uses of these pumps in process plants. Explain the function of pulsation dampeners. Identify the differences between the main types of rotary pumps and explain the end uses of rotary pumps in process plants. Explain how centrifugal pumps increase pressure. Explain how pump shafts are sealed and how axial and radial thrust are balanced in single stage centrifugal pumps. Explain the reasons for, and the advantages of, multi-stage centrifugal pumps. Explain how axial thrust is balanced in a multi-stage centrifugal pump. Explain how cavitation and vapour lock occur in a centrifugal pump and explain how these problems are overcome. Explain why centrifugal pumps are connected in parallel or series. Explain the pre-start checks and start-up procedure for centrifugal pumps with electric motor and steam turbine prime movers. Explain the procedure for centrifugal pump changeover. Use pump readings to identify pump problems. Identify and explain pump control systems.

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Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

3.1

TYPES OF RECIPROCATING PUMPS

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In this Unit different types of reciprocating pumps will be explained. The types are: Piston pumps, both single acting and double acting, Plunger pumps, including simplex, duplex and triplex arrangements. Diaphragm pumps.

All of these pumps operate in the same way. The part of the pump that does the actual pumping moves in a straight line (reciprocates) either upwards and downwards, or from side to side. The different types of reciprocating pumps work in different ways, but they all have common components. There is the reciprocating part that moves the liquid. There is the device to enclose the reciprocating part, called either the housing or the casing. There is one or more suction and discharge valves. Finally, there is a device to make the reciprocating part move. This is called the prime mover. It may be a separate component such as an electric motor, or it may be part of the pump, such as a motor driven by steam or compressed air. 3.2 PISTON PUMPS

Figure 3-1 shows a typical single acting piston pump.

Figure 3-1 Typical Single Acting Piston Pump

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Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

Figure 3-1 shows the main parts of a single acting piston pump which are; the Page 9/17

casing, the cylinder, the piston, the piston rings, the stuffing box and packing, the suction valve, and the discharge valve. Each of these parts is now explained in more detail. 3.2.1 Casing The casing contains all the parts of a piston pump. The casing may be a single casting (in small or simple piston pumps), or be several parts joined together (in large pumps). The casing can be made from several different materials depending on the liquid which will be pumped. Cast iron is a common material. The casing is machined (cut, drilled and shaped) where necessary to take other parts of the pump, such as the suction and discharge valves, and to make the cylinder.
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3.2.2 Cylinder The function of the cylinder is to contain: 3.2.3 The liquid to be pumped. * The piston, piston rod and piston rings. The suction and discharge valves. The inside wall of the cylinder must be very smooth.

Piston and Piston Rings The piston is built to fit inside the cylinder. The diameter of the piston is slightly smaller than the diameter of the cylinder. The function of the piston is: To pull the liquid into the cylinder on the suction stroke. * Force the liquid out of the cylinder on the discharge stroke.

The piston is connected to the prime mover by a piston rod. The piston rings fit in slots cut into the piston.

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Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

The function of the piston rings is:

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To stop liquid from passing by the sides of the piston on each stroke.

3.2.4 Stuffing Box and Packing The stuffing box is found where the piston rod passes through the cylinder. The stuffing box is filled with packing. Packing is a soft material which is compressed around the piston rod. The packing lets the piston rod move but stops liquid leaking out. The function of the stuffing box and packing is: To stop liquid from leaking out of the cylinder. Give smooth movement of the rod.

3.2.5 Suction and Discharge Valves The suction and discharge valves are in a chamber at the open end of the cylinder (see Figure 3-1). Both valves are usually spring-loaded, non-return valves. The suction valve lets liquid enter the cylinder, and then closes. The discharge valve lets the liquid leave the cylinder under pressure, and then closes. Complete valve and pump operation is described later in this Unit.

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Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

3.3

SINGLE AND DOUBLE ACTING PISTON PUMPS

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Figure 3-2 shows a single acting pump and a double acting pump. Compare the two arrangements.

Figure 3-2 Single and Double Acting Pumps A single acting pump has one suction and one discharge valve at one end of the cylinder. A single acting pump only discharges liquid every second stroke. A double acting pump has two suction valves and two discharge valves. There is one set of valves at each end of the cylinder. A double acting pump discharges liquid during each stroke.

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Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

On the back stroke, that is from left to right in Figure 3-2 (upper drawing), the piston

is pushing the liquids through the discharge valve on the 'A' side of the piston. At the same time, the piston is drawing in liquid through the suction valve on the 'B' side of the piston. When the piston is on the forward stroke (moving from right to left on Figure 3 -2, lower drawing) the opposite happens. Liquid is drawn in to the cylinder on the 'A' side of the piston, and pushed out through the discharge valve on the 'B' side of the piston. 3.4 HOW PISTON PUMPS WORK Look at the single acting piston pump shown in Figure 3-3. The piston moves from one end of the cylinder to the other end. This movement is called a stroke.

Figure 3-3 How Piston Pumps Work

Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

When the piston is not moving both the suction valve and the discharge valve are

closed. This is shown in the top picture of Figure 3-3. As the piston starts to move on the back stroke liquid is drawn into the cylinder. At the end of the backstroke the cylinder is full of liquid. As the piston begins its forward stroke the liquid is forced out of the cylinder through the discharge valve. This 'cycle' of events is repeated for every stroke the piston makes. In a double acting pump the same things happen as in a single acting pump. However, they happen on each side of the piston but opposite to each other. This means that when there is a back stroke on one side of the piston, there is a forward stroke on the other side of the piston Piston pumps can be arranged to operate in duplex, triplex, and quadruplex arrangements. 1. 1. 1. Duplex means there is one -prime mover with two pumps connected to it. Triplex means there is one prime mover with three pumps connected to it. Quadruplex means there is one prime mover-with four pumps connected to it.

Multiplex pumps are connected to the prime mover to give: Steady discharge flows. Balanced forces on the pump parts.

Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

3.5

ADVANTAGES AND DISADVANTAGES OF PISTON PUMPS

Advantages Strong. Versatile. Simple design and construction. Wide range of pressures. Higher discharge consumption. pressures than centrifugal pumps for less power

Better suction lift than centrifugal pumps. to 20% more efficient than centrifugal pumps. Self-priming. Accurate volume control. Disadvantages More expensive to buy than centrifugal pumps. More moving parts requiring more maintenance. Expensive to repair. Not good for abrasive liquids. The liquid in the discharge line has pulses of pressure. Too many moving parts to operate well at high speeds. Need to have Pressure Relief Valves (PRV) fitted.

Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

3.6

PLUNGER PUMPS

Figure 3-4 shows a simplified version of a typical plunger pump. Comparing this to Figure 3-1 (a typical single acting piston pump) shows that the two pumps look very similar. Plunger pumps are single acting, but can be operated in duplex and triplex arrangements just as piston pumps can. There are some differences between piston pumps and plunger pumps. The most important difference is that the plunger of a plunger pump does not touch the walls of the cylinder. In fact, the cylinder is more like a chamber, although cylinder is still the correct word to use.

Figure 3-4 Typical Plunger Pump 3.7 COMPARISON OF PLUNGER PUMPS TO PISTON PUMPS Similarities Main parts. Pumping action. Design (can be duplex, triplex).

Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

Differences

Plunger moves the liquid. Plunger does not touch the cylinder wall. No piston rings in a plunger pump. Pump discharge volume is equal to the volume of the multiplied by the stroke of the plunger. Plunger pump is only single acting. 3.8 ADVANTAGES AND DISADVANTAGES OF PLUNGER PUMPS Advantages Strong. Versatile. High discharge pressures possible. Better suction lift than centrifugal pumps. Self priming. Can pump liquids with a high solids content. Can pump abrasive liquids. Adjustable stroke pumps can handle very small quantities of liquids, for example, as required in a chemical injection system. Disadvantages Pulsation (changing discharge volume and pressure). Does not operate well at high speeds.

Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

3.9

DIAPHRAGM PUMPS

The diaphragm pump has a flexible diaphragm which is used to pump the liquid. The main advantage of this is that the driving mechanism of the pump is separated from the liquid. Diaphragm pumps can be used to pump very corrosive liquids.

Figure 3-5 Diaphragm Pump As shown on Figure 3-5, the main parts of a diaphragm pump are the casing, the diaphragm, the suction and discharge valves, and the driving mechanism. 3.9.1 Casing The casing of a diaphragm pump is usually made in at least two parts. The split line is across the cylinder at the widest part of the cylinder so it can be opened to check and repair the diaphragm. More splits may be provided so the suction and discharge valves can be maintained. 3.9.2 Diaphragm The diaphragm is made of a flexible material and is usually made stronger by a thin metal plate in the centre of the diaphragm where the connecting rod is attached to the diaphragm. This prevents wear on the diaphragm.

Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

Various materials may be used to make the diaphragm depending on the liquid

which will be pumped. The diaphragm is securely fixed across the largest part of the cylinder, completely sealing one half of the cylinder from the other. 3.9.3 Suction and Discharge Valves, . Suction and discharge valve arrangements are the same as the piston pump s and plunger pumps.
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3.9.4

Driving Mechanism The diaphragm is connected to the driving mechanism through a connecting rod. Stuffing boxes and packing are not required because the liquid does not enter that part of the pump. If the prime mover delivers a rotary movement this is converted to a reciprocating movement by a crank and crankshaft.

3.10

HOW A DIAPHRAGM PUMP WORKS Like piston pumps and plunger pumps, a diaphragm pump is a positive displacement pump. It works by the reciprocating motion of one part within_ another. Displacement has been described as the introduction of a solid object in to a liquid. Looking at a picture of a diaphragm pump it may be difficult to see where this solid object is. In this case, the solid object is the diaphragm. The shape of the diaphragm is changed by the movement of the connecting rod. Figure 3-6 shows the suction stroke and discharge stroke of a diaphragm pump. The starting point is the right-hand picture in Figure 3-6. The pump has just reached the end of its discharge stroke. The pressure in the cylinder has become equal to the pressure in the discharge pipeline so both the suction valve and the discharge valve are closed. As the crankshaft turns, the connecting-rod is pulled out of the cylinder area, pulling the diaphragm with it. The pressure below the diaphragm gets less, until it is lower than the suction pressure. The suction valve opens and liquid enters the pump. As the diaphragm reaches the end of the suction stroke the pressure in the cylinder below the diaphragm increases until it is the same as the suction pressure. At this point the suction valve closes.

Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

Figure 3-6 How Diaphragm Pumps Work The pump begins its discharge stroke, pressing down on the diaphragm. The pressure in the cylinder increases until it is equal to the pressure in the discharge pipeline. The discharge valve opens and liquid flows into the discharge pipeline. As the diaphragm continues towards the end of the discharge stroke, the pressure in the cylinder becomes less and less until it equals the pressure in the discharge pipeline. The discharge valve closes. Both the suction valve and the discharge valve are closed, and the pump has completed one cycle. The process is repeated as long as the prime mover is running. 3.11 ADVANTAGES AND DISADVANTAGES OF DIAPHRAGM PUMPS Advantages * Simple design and construction.
1.
e Can

pump abrasive or corrosive liquids.

Disadvantages Diaphragm can be easily damaged The liquid in the discharge line has pulses of pressure.

Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

3.12

THE END USES OF RECIPROCATING PUMPS

At one time reciprocating pumps were very common in process plants. In modern process plants centrifugal pumps have taken over most of the duties of reciprocating pumps. However, reciprocating pumps can still be found in process plants. Piston pumps work best with liquids that have lubricating properties, although they are not restricted to this work. The pumped liquid must not contain solid materials otherwise the internal parts of a piston pump will be damaged. Piston pumps can handle a wide range of capacities. They may be used for chemical injection purposes with a capacity as low as 1 litre per hour (I/h), or as crude oil pipeline pumps with a capacity of thousands of barrels of oil per day. A very common application is as a mud pump in oil well drilling operations. Plunger pumps have similar applications to piston pumps, but they have lower discharge capacities than piston pumps. Plunger pumps can be used in place of piston pumps for liquids which may cause the piston of a piston pump to stick or to damage the cylinder of the pump. Diaphragm pumps have small capacities compared to piston pumps. Because the main moving parts of the pump do not come into contact with the liquid, diaphragm pumps can pump liquids with a high solids content, or liquids which are very thick (viscous) or very corrosive. 3.13 PULSATION DAMPENERS All reciprocating pumps create pulses of pressure in the pump discharge pipeline, which can cause problems. One way to reduce the pulsation is to use pumps in a duplex or triplex arrangement, but this will not remove the problem entirely. Another way to smooth out the pressure pulsations is to use a pulsation dampener fitted to the discharge pipeline of the pump. Figure 3-7 shows a typical pulsation dampener, and its position in relation to the pump. The pulsation dampener is a pressurised chamber partly filled with gas. With some pulsation dampeners the gas is contained in a bag, or bladder. This keeps the gas out of contact with the liquid. It also prevents the gas from escaping into the discharge pipeline if there is no liquid in the pulsation dampener or in the discharge pipeline.

Module No. 5 : Pumps

Unit No. 3 - Reciprocating pumps

Figure 3-7 Pulsation Dampener

During the discharge stroke of the pump, the discharge valve opens when pressure in the cylinder of the pump is higher than the pressure in the discharge pipeline. As the piston continues its discharge stroke the speed of the piston inside the cylinder increases until the mid-point of the stroke is reached. The increase in speed causes an increase in pressure in the discharge pipeline. This causes pressure pulsations in the discharge pipeline. hen a pulsation dampener is fitted, the increase in pressure from the pump compresses the gas in the pulsation dampener so that the pressure in the discharge pipeline remains constant. When the pump completes its discharge stroke and starts on its suction stroke, no liquid is being discharged to the discharge pipeline. The compressed gas now forces the liquid out of the pulsation dampener and into the discharge pipeline. In this way, the pressure in the discharge pipeline remains the same during the suction stroke of the pump. Pulsation dampeners must be the correct size for the pump they are used with. Also the gas pressure in the pulsation dampener must be correctly set for the discharge pressure of the pump.