Reciprocating pump project report part 1

1. PROJECT REPORT
On
Design, Installation and Fabrication of Reciprocating pump
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted By
NAME UNIVERSITY ROLL NUMBER
Under the guidance of
xxxxxxxx
Associate Professor
DEPARTMENT OF MECHANICAL ENGINEERING
FUTURE INSTITUTE OF ENGINEERING & MANAGEMENT,
KOLKATA-700150, INDIA

2. Contents
Sl. No. Article Page
No.
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
7
8
9
10
Reciprocating Pump performance 13
Selection of pumps 17
Design and Calculations 27
Applications 33
References 36

3. ACKNOWLEDGEMENT
We are highly grateful to the authorities of FUTURE INSTITUTE OF
ENGINEERING & MANAGEMENT, KOLKATA for providing this opportunity
to carry out the project work.
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..
We are also thankful to other faculty members of Mechanical department, FIEM,
Kolkata for their intellectual support. Our special thanks are due to our family
members & friends who constantly encouraged us to complete this study.
We are especially thankful to our classmates for their support.
SOURAV JANA
JAMES BABY
KRISHNENDU PRAMANIK
MD SHABBIR
SUPRIYA GHOSAL
ANIRBAN BISWAS
KUNAL ADHIKARI
ARNAB DEB
SANJU KUMAR SANJAY
PRAMOD SINGH
SANDEEP KUMAR
RAHUL KUMAR
PURUSHOTTAM DUTTA
ARNAB MAITRA

4. LIST OF FIGURES, GRAPH AND TABLES
1. SINGLE ACTING PUMP (PAGE 5)
2. DOUBLE ACTING PUMP (PAGE 5)
3. DIAPHRAGM PUMP (PAGE 8)
4. PLUNGER PUMP WITH SPLASH LUBRICATION (PAGE 10)
5. COMPONENTS OF RECIPROCATING PUMP (PAGE 11)
6. CENTRIFUGAL PUMPS (PAGE 17)
7. GRAPH OF FLOW RATE VS PRESSURE (PAGE 20)
8. TABLE USED TO ESTIMATE THE POWER REQUIREMENT FOR
PUMPING WATER (PAGE 28)
9. TABLE OF WATER - SUCTION FLOW VELOCITIES (PAGE 29)
10. GRAPH OF SYSTEM CURVE (PAGE 30)
11. GRAPH OF PUMP PERFORMANCE CURVE (PAGE 32)
12. PICTURE OF APPLICATIONS
I. AXIAL PISTON PUMP (PAGE 34)
II. RADIAL PISTON PUMP (PAGE 34)
III. HAND PUMP (PAGE 35)

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AIM OF THE PROJECT
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
Other Objectives are:
a) To facilitate the local people by providing water for various purposes.
b) To socialize the technology.
c) To apply the theoretical knowledge into practical application.
d) To optimize the resources.

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PROJECT PLAN
Work carried out so far....
 To design the various components of reciprocating pump.
 Selection of raw materials.
.
Future Scope....
 To model the reciprocating pump and analyse it.
 To select pump size based on design calculations..
 To analyse the model as a whole

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INTRODUCTION
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by
mechanical action. Pumps can be classified into three major groups according to the
method they use to move the fluid: direct lift, displacement, and gravity pumps.
Pumps operate by some mechanism (typically reciprocating or rotary), and consume
energy to perform mechanical work by moving the fluid. Pumps operate via many
energy sources, including manual operation, electricity, engines, or wind power, come
in many sizes, from microscopic for use in medical applications to large industrial
pumps.
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
Typical reciprocating pumps are
 plunger pumps
 diaphragm pumps
Plunger pumps consists of a cylinder with a reciprocating plunger in it. In the head of
the cylinder the suction and discharge valves are mounted. In the suction stroke the
plunger retracts and the suction valves opens causing suction of fluid into the
cylinder. In the forward stroke the plunger push the liquid out the discharge valve.
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.
Classification of Reciprocating Pump
Follow are the three fields in which the reciprocating are classified
1. According to the contact between water and plunger
2. According to the number of cylinders
3. According to the air vessel
According to the contactbetweenwater and plunger:-
Single acting pump
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
Double acting pump
A double acting pump is one which has two suction valves, delivery valves and two
suction and delivery pipes. If we suppose that piston is in the center of the cylinder
then one suction and delivery pipe is on one side and one delivery and suction pipe is
on other side of the piston.
According to the number of cylinders
1. Single cylinder pump
Single cylinder pump is one in which their is only cylinder connected to a single shaft.
It could be a single acting or double acting pump.
2. Double cylinder pump
Double cylinder pump is one which have two cylinder attached to a single
shaft.Separate suction and delivery valve is provided to each cylinder.Crank of the
pump is set at an angle of 180
3. Triple cylinder 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
According to the air vessel
1. With air vessel
Some reciprocating pump are provided with a separate air vessel attach to the
suction and delivery valve. Its main function is to accumulate excess quantity
of water by compressing the air in the vessel
2. Without Air vessel
Some pump lack the air vessel because of the nature of their work. for example
the reciprocating boiler feed pumps does not have air vessel because they may
introduce air into the deaerated water
POSITIVE DISPLACEMENT PUMP
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
Diaphragm pumps are reciprocating positive displacement pumps that employ a
flexible membrane instead of a piston or plunger to displace the pumped fluid. They
are truly self priming (can prime dry) and can run dry without damage. They operate
via the same volumetric displacement principle described earlier. The figure shows
the operational cycle of a basic, hand operated single diaphragm pump. Where its
operation any simpler, it would compete with gravity. The upper portion of the figure
shows the suction stroke. The handle lifts the diaphragm creating a partial vacuum
which closes the discharge valve while allowing liquid to enter the pump chamber via
the suction valve.
During the discharge stroke the diaphragm is pushed downward and the process is
reversed. Hand operated pumps are designed to deliver up to 30 gpm at up to 15 feet
but actual capacity is extremely dependent upon the physical condition of the driver.
Air, engine, and motor drive units are also available and offer capacities to 130 gpm.
Both suction and discharge head vary from 15 to 25 feet.

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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.
PISTON PUMP VS PLUNGER PUMP
The piston pump is one of the most common reciprocating pumps and, prior to the
development of high speed drivers which enhanced the popularity of centrifugals, it
was the pump of choice for a broad range of applications. Today , they are most often
seen in lower flow, moderate (to 2000 PSI) pressure applications. Its close cousin, the
plunger pump, is designed for higher pressures up to 30,000 PSI.
The major difference between the two is the method of sealing the cylinders. In a
piston pump the sealing system (rings, packing etc) is attached to the piston and
moves with it during its stroke. The sealing system for the plunger pump is stationary
and the plunger moves through it during its stroke.
Reciprocating pumps operate on the principle that a solid will displace a volume of
liquid equal to its own volume. The figure to the right is that of a generic double
acting piston pump. If we were to remove the two valves at the left hand side of the
figure and replace them with an extension of the cylinder, we would have a single
acting pump. The single acting pump discharges water only on its forward stroke
while the double acting pump discharges on its return stroke as well.

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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.
Plunger pump with splash lubrication

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Components of Reciprocating Pump
Components of reciprocating pump with their details are as follow
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
Advantages and Disadvantages of Reciprocating
Pump
Advantages of reciprocating pump
 High efficiency
 No priming needed
 Can deliver water at high pressure
 Can work in wide pressure range
 Continuous rate of discharge
Disadvantagesofreciprocating pump
 More parts mean high initial cost
 High maintenance cost
 No uniform torque
 Low discharging capacity
 Pulsating flow

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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:
BHP = (Q ¥ Pd) / (1714 ¥ Em) 102
Pumps Reference Guide where:
BHP = brake horsepower
Q = delivered capacity (gpm US)
Pd = developed pressure (psi)
Em = mechanical efficiency (% as a decimal)
b) Capacity (Q): The capacity is the total volume of liquid delivered per unit
of time. This liquid includes entrained gases and solids at specified conditions.
c) Pressure (Pd): The pressure used to determine brake horsepower is the
differential developed pressure. Because the suction pressure is usually small
relative to the discharge pressure, discharge pressure is used in lieu of differential

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pressure.
d) Mechanical Efficiency (Em):The mechanical efficiency of a power pump
at full load pressure and speed is 90 to 95% depending on the size, speed,
and construction.
e) Displacement (D): Displacement (gpm) is the calculated capacity of the
pump with no slip losses. For single acting plunger or piston pumps, it is
defined as the following: Where:
D = displacement, (gpm US)
A = cross-sectional area of plunger or piston, (in2)
M = number of plungers or pistons
n = speed of pump, (rpm)

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s = stroke of pump, (in.) (half the linear distance the plunger or piston moves linearly
in one revolution)
f) Slip(s) • Slip is the capacity loss as a fraction or percentage of the suction
capacity. It consists of stuffing box loss BL plus valve loss VL. However, stuffing
box loss is usually considered.
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.
j) Net Positive Suction Head Required (NPSHR): The NPSHR is the
head of clean clear liquid required at the suction centerline to ensure proper
pump suction operating conditions. For any given plunger size, rotating speed,

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pumping capacity, and pressure, there is a specific value of NPSHR. A change in one
or more of these variables changes the NPSHR. • It is a good practice to have the
NPSHA (available) 3 to 5 psi greater than the NPSHR. This will prevent release of
vapor and entrained gases into the suction system, which will cause cavitations
damage in the internal passages.
k) Net Positive Suction Head Available (NPSHA): The NPSHA is the
static head plus the atmospheric head minus lift loss, frictional loss, vapor pressure,
velocity head, and acceleration loss in feet available at the suction center-line.

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SELECTION
Selecting between Centrifugal Pumps and Positive Displacement Pumps
Pumps are in general classified as Centrifugal Pumps (or Roto-dynamic pumps) and
Positive Displacement Pumps
Centrifugal Pumps (Roto-dynamic pumps)
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
Discharge of pump per second:
The discharge of a double acting reciprocating pump/second= Volume of water
discharge in one revolution * No of revolution per second
So it can be written as= [ Π/4*D^2+Π/4(D^2-d^2)]*L*N/60
If ‘d’ the diameter of the piston rod is very small as compared to the diameter of the
piston, then it can be neglected and discharge of pump/sec,
Q=2*Π/4*D^2*LN/60=(2ALN)/60 as Π/4*D^2= cross section area of the piston
of the cylinder.
N= r.p.m of crank & L= length of the stroke= 2*r
Work done by a double acting reciprocating pump:
Work done per second= Weight of water delivered* Total Height= ρg*
discharge/sec8total height
= ρg*(2ALN)/60*(hs+hd)
p
Power required to drive the double-acting pump in KW:
Power required to drive a double acting reciprocating is given by as below:
P=(work done per second)/1000
=2ρg*ALN*(hs+hd)/60000
Slip of Reciprocating pump:
Slip of a pump is defined as the difference between the theoretical and actual discharge
of the pump. The actual discharge of the pump is less than the theoretical discharge due
to leakage. The difference of theoretical and actual discharge of the pump is known as
SLIP of the pump. Hence the mathematical expression is-
Slip=Qth-Qact
But slip is mostly expressed as percentage slip which is given by,
(1-Qact/Qth)*100= (1-Cd)*100
Where Cd=Co-efficient of discharge
Negative slip of the reciprocating pump:
If the actual discharge is more than theoretical discharge, the slip of the pump become
negative. In that case slip of the pump is known as Negative Slip.

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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 difference,
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:
 excessive piping vibration and piping failures;
 small bore attachment failures;
 pressure pulsation-induced cavitation;
 undesired opening of PSVs due to pulsations; and
 improper pump valve dynamics leading to poor valve life, and reduced flow
capacity.
The fabrication of different components of the reciprocating pump require a deep
insight into the world of design by usage of various softwares to get detailed analysis
on the possible stresses and the parts which will be affected by them. However these
are done depending on the risk factors associated with the operation. Two such
analysis which are performed primarily are the Pulsation and Mechanical analysis.
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
PIPING CONNECTION CONSIDERATIONS
Although the fabrication and installation of the piping system may appear trivial, it is
important that some basic piping considerations be observed. By following these
concepts, the life of the pumping equipment and its accessories will be extended. If
good piping practices on the suction and discharge sides of the pump are not
followed, it can be expected that the following problems may be experienced: •
Noisy pump and driver during operation
• Axial load fluctuations
• Excessive equipment vibration
• Premature bearing failure of the pump and driver
• Premature wear and failure of other pump parts, such as the mechanical seal and
wear rings
• Cavitation damage to the impeller and inlet of the casing, and possibly the
discharge
• Leakage at the flanges
• Cracking or breakage of the flanges or casing.
PIPING SYSTEM COMPONENTS
Before considering the overall system, an understanding of the components of the
piping system and their effect on the system should be reviewed. Pumps can be
connected to their piping systems through various means. The most basic connection
is a threaded connection, typically to National Pipe Thread (NPT) standards.
Threaded connections are commonly used on smaller pumps in water applications.
Other connections used in various industries include grooved or Victaulic, clamp, or
Tri-clamp. Probably the most common pump connection is a flange. Flanges are
typically cast or formed integrally with the volute. As with pipe flanges, cast iron
pump flanges are rated as 125# or 250# with flat faces.
If the system has no pressure or other limitations, cast iron flanges can be connected
to steel flanges. For most pump systems, it is preferred to utilize flat face (F.F.)
flanges on both the pump and the piping connection. This flat mating flange will

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help insure that an acceptable gasket surface is available to obtain a good seal, and
prevent breaking when the bolts are tightened. Occasionally, a system will require
increase pressure containment capabilities at connections. The use of raised face
(R.F.) flanges allows more pressure to be concentrated on a smaller gasket area.
However, care must be taken when tightening bolts on R.F. flanges. If not properly
tightened and torqued to the manufacturer’s recommendations, the flanges can pivot
along the edge of the raised face. This can cause distortion in the pump volute, as
well as possibly cracking or breaking a flange.
EXPANSION JOINTS
Expansion joints can be used when the piping system can expect axial movement
due to thermal expansion of the liquid. The expansion joints will assist in preventing
the pump from being shifted out of alignment. Typically, they are installed in low-
pressure systems. Important to the reliability of the pump and piping system is the
need for proper selection and installation. An expansion joint can be installed on the
suction and discharge side of a pump. The location should be on the opposite side of
the piping support, or anchor, away from the pump. If the expansion joint is placed
between the anchor and the pump, a force could be caused that would be more than
the pump or the system could handle. The force would be equal to the area of the
maximum expansion joint inside diameter multiplied by the pressure in the pipe. In
addition, according to HI1 , if the joint is not properly aligned with the pipe, the
shear force and torsion may be transmitted to the equipment. To insure that the
expansion joints are effective in the piping system, they must be sized properly and
the material of construction must correspond with the application. Although these
joints provide relief of axial pipe movement, they are not as flexible as many
perceive. The pump and system can also be subjected to excessive forces due to poor
expansion joint sizing.
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

28. Page | 24
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.
PIPING DESIGN CONSIDERATIONS
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

29. Page | 25
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
Besides proper fabrication of a piping system, it is important to properly support the
pipe as well. If no pipe support exists, the pipe strain will induce stress into the
equipment and support system. In determining the proper support of the piping
system, the forces and moments of the piping system must be calculated. The
calculations must include the weights of the pipe, the liquid in the pipe, and the pipe
insulation. Thermal expansion and contraction must also be taken into account. The

30. Page | 26
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.
OTHER PIPING CONSIDERATIONS
Pressure gauges should be mounted on the suction and discharge of the pump. The
gauges not only provide a means of monitoring the equipment, but also can be used
in troubleshooting problems. The gauges MUST be mounted before any valves or
fittings. If placed after valves or fittings, false pressure readings of the pump output
will be observed and will not provide accurate information. Simple vents and drains
should be used with pumping systems, unless handling a corrosive or toxic product.
Vents should be installed on the pump casing as well as system piping high points to
allow the pump and system to be completely filled. A drain will remove product out
of the pump and away from the site when repairing the equipment. When positive
displacement pumps are used in a system, a means of pressure relief must be
installed in the system. Without some type of pressure relief, the system pressure
will continue to build when the pump is operating against a closed discharge. The
weakest point in the system will eventually fail, causing damage or injury. The rules
for design of piping systems for pumping slurries may not necessarily apply as for
water-like liquid. Light slurries do act similar to water. However, heavy slurries
don’t act like water. Heavy slurries are considered as liquids with greater than
20%solids by volume. Typically, additional power and higher velocities are required
to move heavy slurries. These systems also see greater wear to the pipe, fittings and
equipment. The proper design of piping systems handling heavy slurries is very
detailed and is more than can be covered in this article.
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.

31. Page | 27
DESIGN CALCULATIONS
 Speed of the motor= 1800 rpm
 Dia of motor’s pinion= 5cm
 Dia of gear= 18cm
 Now, the reduced speed of gear= 500 rpm
 Crank’s dia =30cm
 Connecting rod’s length= 30cm
 Cylinder’s length= 40cm
 Inner Dia of cylinder=15cm
 Outer dia of cylinder=17cm
 Length of piston rod= 50cm
 Dia of piston= 15cm
 Thickness of piston= 5 cm
We know that,
 velocity of the crank = velocity of piston
 Reciprocating speed of piston= 2*l* n=80ncm/s
 Velocity of crank=3.14*30*500/60=785.4cm/s
So, 80n=785.4
=)n = 9.82=10
 Flowrate =3.14*(15^2)/4*2*40*10 = 0.1413cum/s
 Net flow velocity = 20 m/s
 c.s area of valves=q/v=3.14*d^2/4
=)d =.095m=95mm
By this way we can,
get the value of dia of one way directional valve.
No. of one way directioinal valve =4

32. Page | 28
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.

33. Page | 29
Water Pumping Costs
The costs of pumping water can be calculated as
C = 0.746 Q h c / (3960 μp μm)
where
C = cost per hour
Q = volume flow (gpm)
h = head (ft)
c = cost rate per kWh
μp = pump efficiency
μm= motor efficiency
Water - Suction Flow Velocities
Recommended water flow velocities on suction sides of pumps. Capacity problems,
cavitation and high power consumption in pumps, are often results of the conditions on the
suction side.
In general - as a rule of thumb - keep the suction fluid flow speed below the following values:

34. Page | 30
System Curve and Pump Performance Curve
To select a proper pump for a particular application it is necessary to utilize the
system curve and the pump performance curve.
The System Curve
A fluid flow system can in general be characterized with the System Curve - a
graphical presentation of the Energy Equation.
The MechanicalEnergyEquation in Terms of Energy per Unit Mass
The mechanical energy equation for a pump or a fan can be written in terms of energy per unit
mass:
pin / ρ + vin
2
/ 2 + g hin + wshaft = pout / ρ + vout
2
/ 2 + g hout + wloss (1)
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
wloss = loss due to friction

35. Page | 31
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
A generic expression of head loss is:
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.
Pump Performance Curve
The pump characteristic is normally described graphically by the manufacturer as a pump
performance curve. The pump curve describes the relation between flowrate and head for the
actual pump. Other important information for proper pump selection is also included
- efficiency curves, NPSHr,curve,pump curves for severalimpeller diameters and different
speeds,and power consumption.

36. Page | 32
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.
BestEfficiencyPoint - BEP
The best operating conditions will in general be close to the best efficiency point - BEP.
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.

37. Page | 33
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:
For Hydrotesting of Pressure Vessels, Pipe Lines, Valves, Heater Treater
etc
2. Petrochemicals and Refineries are two core industries that have applications of
reciprocating pumps
 To meter additives for bacteria control of water for well flooding
 To dose chemicals for desalting of crude
 To dose sludge inhibitors for fuel oils
 To dose metal antioxidants to eliminate gum formation
 To dose caustics to adjust pH of sour gas or crude oil and prevent corrosion
 To dose anti icing additives to jet fuels.
 For rationing antifoam and E.P. additives to lubricants
 To dose anti knocking additives to lubricants
 To dose gasoline coloring additives To dose acids for polymerization

38. Page | 34
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.
3. Radial piston pump:
inside impinged radial piston pump
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)

39. Page | 35
 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
Cross section and details of a hand pump

40. Page | 36
REFERENCES
 http://www.engineeringtoolbox.com/pumps-t_34.html pumps
 http://www.engineeringtoolbox.com/positive-displacement-
pumps-d_414.html positive displacementpump
 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%3APlungerpump with
splash lubrication
 http://www.green-mechanic.com/2014/07/classification-of-
reciprocating-pump.html classificationofreciprocating 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