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Tom BS pump has been conpetely assembled and test operated under pressure before being shipped to the field. Unless otherwise instructed, the lubrication is drained from the power end. Before putting the pomp into serTice, the following precautions and operations mast be performed or checked.
The skid under the BS pumps are suitable for most any type of installation. It should be noted, however, that the box type construction of the power frame has high resistance to bending but relatively le b b resistance against twist. Therefore, the support under the pump must be level and adequate to support the weight and operating forces exerted by the pump.
In land installations, a mat of 76md x 305nn boards laid side crosswise to the pump skids for the entire length, or at a minimum, at the points indicated in Fig. 2, is usually sufficient. The boards should be a few feet nider than the width of the pump skid runners. Wet or marshy locations may require a more stable foundation.
On permanent installations such as barge, platform,structural base, or concrete slab, "where pump skids arebolted dowm, it is essential tkat the skids be properlyshinned to prevent possiblity of twisting or distortingthe power frame. The pump Bkids mast sit solid on allshim points with bolts loose.
On barge installations, tbe pump skids are generallybolted down to T-beams running parallel and in line withthe pump skids. Install shims at points shown in Fig, 2and 3 and observe caution of proper shinning to preventtwist or distortion. -
On installations where the power unit or electric motor is mounted integrally with the pump skids, the preferred installation wonld be to set the pump package on the T-beari skids and proTide retention blocks rather than bolts to hold it in place. This will allow the pinup to "float* and mininize the transfer of barge deck or platform distortion into the frame.
Adjust the belt tension by moving the sheares apart until all of the sag has just been eliminated from the tight aide of the belt and sane of the belta on the slack side. Then increase the centers approximately 13HJ (l/2 ") for each 254Gmm (100") center distance. Example: On 318Qnm (150*) center, move pump and additional 19. 5nm (3/4 *) .
The pump drive chain lubrication system on the majority of BS pomps is an independent system having I its own oil pomp, reservoir, and drive. Fill chain case to the indicated level with a non-detergent oil as follows: Ambient temperature abore 32° F (0*0) SAE-30 Ambient temperature aboTe 32° F (O"C) SAE-20
1. 06 kg. cm2) - Volume of oil being applied to chain. - Condition of nozzles in spray tube. - Condition of oil pump driTe (V- belts or chain)
NOTE: Oil pressure may be adjusted with the pressure relief adjusting screw on the rear of the pump housing. Pressure drops may also indicate suction and discharge filter screens need cleaning. t"
IndiTidual installation conditions will dictate the design of the suction system. The suction of the BS F- series pumps must hare a poeitire head ( pressure) for satisfactory performance. The optimum suction manifold pressure is 20- 30 psi (0.14 - 0. 2lMpa) for maximum Tolmnetric efficiency and expendable parts life. This head pressure is. best supplied by a 5 z 6 centrifugal pump with 40h. p 1150 rpm electric motor. This type of drite requires a derice to automatically start and stop the centrifugal pump motor simultaneously with the triplex pump. On DC electric powered rigs a signal can usually be supplied from the DC control panel to energize a magnetic starter when the mud pump clutch air line will proride a set of contacts for energizing the magnetic a- a
Under sane conditions the BS F- Series pumps may be operated without a charging pump, prorided the fluid level in mad pits is higher than the top of the liners, L fluid being pumped is low Tiscosity and suction line must be short, straight and of at least the same diameter as j suction manifold inlet.
The suction lines should be piped with Talve arrangementsso the charging pump can be by-passed bo operation can becontinued in eYent of charging pump failure or formaintenance. Operation without a charging pump can beimproTed by replacing the auction valve springs with aweaker spring. — ÿ
Do not pipe the return line from the shear relief valve Iback into the suction system as a relief TalTe operationwill cause a sudden pressure rise in the system vastly Igreater than the system pressure ratings, resulting indamage to manifold, suction desurger and centrifugal pump.
PREPARATION OF POWER ENDI Toox BS pump has been completely assembled and test operated before being shipped to the field. Unless otherwise instructed, the lubrication is drained from the r
power end, and the expendables are remored from the fluid end for storage protection. Before operating the pump, the following mast be performed or cheeked.nID 1. Power End Lubricat ion " J I
flush by remoring the pipe plugs on each side of the pump. Refer Item 2. Pig. .7.[I Add the proper type and quantity of lubrication in the power end. Refer to lubrication plate on pomp frame for type and quantity required.
Recheck oil lerel after pump has operated for a period of 15 minutes. Shut pump down and allow approximately fire minutes for the oil lerel to equalize. Check atH" oil leiel gauge, Item 1, Pig. 7. It is usuallyV necessary for a few more gallons of oil to be added due to a certain amount being retained in the croeshead area and frame caYitiea.
: } With reference to Figure 4A, remoTe the diaphragm stuffing box and plate (1) and rotate pump so that cr os ahead is at the front of the Btroke, Thoroughly clean the front of the crosshead and the face of the crosshead extension rod. Insert alignment boss on
Stationary spray type haie been used on BS F-series pumps Ref. Fig 5. It consists of a fixture (I), a pipe (2) and a spray nozzle (3), irhich applies cooling fluid in the form of a spray to the piston and liner area. Adjust cooling irater supply to the manifold so that a spray approximately 305nn long is being discharged from -each spray nozzle. Inspect spray nozzle operation rery often. making sure the nozzle is pointed directly at the piston.
Cooling fluid be thanfuaed from pump (Item 3. Fig. 6) and Water tank (Item 5 Fig 6) to the manifold on the frame. Adjust regulating TalTe (item 4 Fig. 6) to apply as much water as possible to the liners without splashing back on A-lfi nthe croaahead extension rods and diaphragm staffing" boxplate. 40L (lO-gallons) per minute per liner is thepreferred f low rate. If water is allowed to splash onthe croashead extension rods, some of the water will workback into the power end to contaminate the lubricationoil.
Vahea and Seats iRemoTe all three discharge Talre pot corers (1), and thethree cylinder heads (2) and plugs (10) , and thoroughly Iclean all machined surfaces in the fluid end with a goodcleaning solrent. iMake sure all Talre seat bores are VERY CLEAN AND DRY (free of dirt, grease, anti-rust compound,remote all burrs or nicks with a fine emery etc. ) and cloth, using lcircular motion around seat surfaces.THOROUGHLY CLEAN AND MY the ralre seats and install Isuction and discharge TaWe seats into the raWe potbores. Drire seats firmlj into place with a bar* and Ihanmer. In stall Talres and springs and the other parts.
Install fluid baffle (11), fig. 8. 8A on end of crosshead lextension rod. BS F-500, BS F-800, BS F-1000 ASSEMBLY OF FLUID END. PARTS
A cross-aection through the fluid end for BS F-500, BS F-800, and BS F-1000 is shown in Pig. 8. With reference to Fig. 8, clean and assemble the fluid end parts in the following manner:
Install rear liner seal (5) and push into position against liner shoulder. Ref. Fig. 8. Slide liner cage (8) into fluid end, align one hole in the cage with lower valve pot bore. Set lower ralve guide (8) over ralve stem through lower hole in cage with the wings on the guide turned crosswise to the pump. Press downi0 A-20
on the" guide, compressing the valve spring (7) until the guide can be rotated l/4 tnrn and seat into place underneath the cage. Insert the lover Talve guide locking clip (9) through" the pad eyes on the lover valve guide and rotate dip to the right to lock the valve guide tight against the OD of the liner cage. It may sometimes be necessary to put more or less bend in the center of the clip to make it retain the guide tightly while the clip handle snaps into position on the right hand side. Cylinder Head & Insert the outer seal (5) in the fluid end bore against the liner cage. Slide the cylinder head plug (10) into fluid end. Apply a liberal coat of grease to both mating thread surfaces of the cylinder head (2) Screw- cylinder head in and tighten with wrench furnished with pump and sledge banner. Fluid leakage through the weep hole will indicate a defective seal or loose cylinder head. DO NOT plug weep holes as this can result in severe damage to sylinder head threads, thread rings, etc., in eTent of a liner seal failure.
With reference to Fig. 8A A cross- section through the fluid end for BS F -1300/1600 is shown in Fig &A. clean and assemble the fluid end parts in the following manner.
Note: All of the parts in this fluid end assembly are designed with metal to metal seating to alleiiate friction wear from breathing action encountered in modern high pressure pump operation. For this reason it iB essential that all parts be clean and free of rust, nicks and burrs before being assembled.Liner Install wear plate seal (l) in counterbore of fluid end. Slide wear plate (2) oTer studs until it seats BS F-1300. BS F-160Q ASSEMBLY OF FLUID END PARIS @
The shear relief valve ( 3) is installed on the ! > discharge manifold for the purpose of protecting the ! pump from excessively high pressure overloads. The relief valve must be installed so that it will be directly exposed to the mud DO NOT POT ANY TYPE OP . SHOT OFF VALVE between, the relief ralre and the J manifold. Pipe the discharge side of the relief valve* directly into the mad pit with as few. turns in the line as possible. IT IS NOT RECOAENDED for the discharge Bide of the valve to be piped into the sue t ion line of the pump.
O Precharge dampener before .a tar ting up pump. Precharge pressure should not be more than 2/3 of the pomp discharge pressure, or a maximum of 4. fiMpa.
Proper lubrication of the moving parts in any piece ofmachinery is tie moat important single factor affectingits ultimate life. To obtain maximum trouble -freeservice life from the poorer end of the BS pranp, it isnecessary to perform routine maintenance care andinspections to insure the proper amount of CLEANlubricant is being provided.The F-Series pumps utilize the controlled flow oil bath splash and pressure system to lubricate the entire powerend. The type of pressure system prorided in each individual pump will govern the minimum SHI at which thepump can be operated, i. e. pumps which haTe pressure lubrication only to the main and pinion bearingst hare aminimum rated speed of 40 SPM Pumps in which pressurelubrication is provided to the main. pinion, andctosshead bearings and crosshead compartments may beoperated at a minimum Epeed of 25 SM proTided there isa* minimum of 0. 035Mpa (5PSI) oil pressure. .
CAUTION: The pressure lubricating system can be provided with an externally mounted oil pomp driren through V- belts or an internally mounted oil pump driven from the main gear. When an internally mounted oil pump is used, the direction of rotation of the pinion shaft must be as shown in Fig. 10. B-2 rfcf r
haiing to gbe attention to hole alignment. This permits the installation of croashead pins fraa either direction. For BS P-600 pump. Oil passage from the top of the crosshead guid compartment to the crosshead bearing is shown in Pig. 11A. Oil accumulates in the compartment over the crossheads. The oil runs through the oil passage, (1) ( 2) and crosshead pins oil passage (3), and on to the crosshead pin bearing. As noted, the duplicate set of passageways (3) in the crosshead pin permits the crosshead pins to be rotated without hating to gire attention to hole alignment. This permits the installation of crosshead pins from either direction.
The total pressure lubrication system, incorporating the oil pump for the BS F-series pumps, is shown in Figure 12 B-4 p
A pressure relief raWe (6) is mounted, to the manifold block (2) to keep excess pressure from damaging oil pump and drive. The relief ralre is preset at 0. 2.7I4pa (40 PSI) and mnst not be tampered with.
When installing the internally mounted oil pomp ( 9 Fig. 12), position pump so that the back face of the drive gear is flash and parallel with the edge of the main gear, and gear teeth haTe 0. 60~ 0. 9 tern backlash.
m Fig. 13 B-fi r fRef. Pig. 13, Adjust tit 7- be It drire (2) to a point where tie two halves of the belt can almost be "pinched* together between the thumb and fingers at the center of the driTe. Orertightening can cause premature failure of the pump.
Adequate lubrication of the moving parts is, as stated, the most important single factor affecting the ultimate service life of the pump, CARE AND MAINTENANCE of the system is the sole responsibility of the operator or cren to which it has been assigned, and the extent to which „ ~ this is applied will determine the amount of ,trouble-free - j service life that will be obtained. : !ÿ The lubricant recommendations shown below, on the name plate on the side of the pump, are the result of extensive field tests. Substitutions b hou Id be made only ill extreme emergencies.
ONCE EACH SIX MQtflUb, or more often if oil becomescontaminated with abrasive particles or corrosiTecompounds, drain and flash the oil reservoir ew lubricant.Oil drains are located on either aide of the pump frame.
During the flushing procedure, thoroughly clean the oiltroughs and the compartment in top of the crosshead guide.Also clean or replace the filter element in the airbreather cap and clean suction screen. Remove coyer s fronsettling chamber and purge out contaminants before addingnew oil.Routine inspection on condition of oil should be made ascondensation of moisture in the air, intrusion of mud,water or dirt, can necessitate a more frequent oil change.
A settling chamber is located in the forward area of thepower end f loor, Contamination in the oil splashed intothis area is allowed to settle out and should be drainedout of the pump through the clean out covers located onthe frame wall underneath the crosBhead inspection doors.
Once each month, remove clean out covers on both sides ofpump to drain contaminated oil from settling chamber.Approximately 15-gallons of oil will be lost; replenishthe main reservoir to compensate for the amount drainedout. I
2. Safety wires - Check safety wires on all bolts including the main bearing hold-down bolts and eccentric bearing retainer bolts, Replace any broken wires after retightening the bolts. Refer to crankshaft assembly section for bolt torque requirements. 3. Oil lines - Check all oil lines to insure they are intact and free of obstructions. Check oil pump suction hose for damage or flat areas.
6. Main gear and pinion teeth - Inspect the condition of the main gear teeth and pinion gear teeth for any indications of abnormal wear. During the initial break-in period, there will be some ; pitting on the face of the gear teeth. This isn referred to as "initial pitting* and is not harmful to the life of the gear. However, if routine inspection indicates the degree of pitting continues to increase,m immediately contact the pump manufacturer for a more thorough inspection of the gear.
Although the basic construction of the rarious sizes ofBSF pumps raries somewhat, they all haie one reryimportant detail in common roller bearings. A rollerbearing is a precisely built machine within itself;therefore, careful handling is required in order toobtain the long service life and high load carryingcharacteristics associated with anti-fr ication bearings.
It is always necessary to completely replace any roller bearing that fails, even though only one part of the bearing shows damage. Since the running clearances of these bearings are extremely small, excessive clearances, worn or grooTed raceways, and any pitting or flaking of the parts is indicative of failure and the entire bearing should, be changed as soon as possible.
The suction, flange has a standard thread connection (8" NPT for BS F-500, 10* NPT for BS F-800, 12* NPT for BS F-1000/l300/ 1600) and is custom made to match the companion flange on the pump suction manifold. The connection is sealed off by an 0-ring seal.
crankshaft is mounted in the pump frame, the running clearance in main bearings will require that a simultaneous Bet of dial indicator readings be taken at the end of the shaft and the face of the gear; the actual face runout at any point being I the difference between these readings.
b. Install the outer races of the eccentric bearingB (13) I and the outer race retainer ring ( 3) in the three eccentric straps. Outer race retainer ring must be positioned so that oil scoop ij at tie bottom when I pump ib at mid-stroke. frighten retainer bolts (4) to the following torque; safety wire heads.
In order to obtain a more precise fit between tie mainbearing housing and the frame bore on BS P-Series pumps,the installation procedures outlined below are to befollowed (Refer to Pig. 16)
NOTE: For BS F-800, BS F- 1000, BS F- 1300, BS F-1600 upper and lower croashead guides are NOT interchangeable. In these pumps, the guides are machined so that the lower guide places the
TkoroagEl"ÿferreah; tie frame" fforeani tie making surfaces: "CÿL ÿ£.of tie*"",frame wall- and1 erogsSeadT guide (Position A1 — r-SSgfr .ÿTÿ"Tieaeÿscrface£" ~ABS0II7rEIir "FEES OF "DIET iiSjV." FOREIGK MATERIAL- in order -..for crossiead- guide ta gire .~z==k- Tresis-.- proper "alignment between tie power end and fluid end- ÿ•H-" . parts. * "*• "ÿ. "T?V -"r:ÿ ÿ "• ÿ rt ÿ— ÿ . x -* -v ÿ" *»• ."»* #V*p,i * i* ** t ÿ
5. Check mating surfaces (position A} for metal-to-metal make-up by Attempting to insert a 0. 025mu - 0. 050nn feeler gauge between tie two parts.
The croaaheada in the pumps can be installed through thefront (f laid end) or back end of the croaahead guide.Reference Fig. 18. ISA. When inatalling croaaheada, obaervethe following precantiona:
.Install the center croaahead first. Crosshead pin is installed through the top of the pomp by removing the inspection corer. Slide crosshead pin into bore bat do not seat taper until the crosshead pin retainer (2) Fig. ISA has been installed NOTE: If old crossheads are to be reused, inspect the sliding surfaces for *ear or scoring. If necessary, the crossheads may be Buitched to opposite sides of the pump and rotated 180° to proTide a smooth surface for the bottom of the crosshead The center crosshead can be rotated 180° and the crosshead pin installed from the opposite side of pomp.
4. If the center Line of the extension rod is more than 0. 381mn (0. 015 ") Io* in the diaphragm plate bore, shims should be inserted tinder the lower guide- to bring the extension rod back to center, provided there is ample clearance between the top of crosshead and upper crosshead guide. It is normal for the lower guide to wear more at the rear dne to heavier loading at this point because of the angle of the eccentric strap. It is permissable to shim the guides on a taper if it iB done accurately to proTide firm support for the guide. Do not shim guides to leas than 0. 50nrn (0.020*) clearance. Iiar.gft cmahead clearances ire acceptable due to characteristics of triplex pump operation, the crosshead pressure is always on the lower guide.
For many years, the fluid end of a pump iras considered anon-wearing part which did not cause any concern otherthan possible infrequent repairs or replacementsresulting from fluid cuts or washouts. However, thehigher pressures of the present-day drilling requirementshave resulted in higher stresses being imposed on thefluid end which, when combined with the corrosivecharacteristics of the drilling fluid, have resulted inthe demand that more and better maintenance be given tothe fluid end parts and pieces if a reasonable operatinglife is to be obtained.ÿ
b. Do not engage pump clutch when prime moTer is running at a high rate of speed To do so can cause undesirable shock loads against both power end and fluid end
d Do not operate the pump for an extended per.iod of time if a seTere fluid knock is present. e. Properly prepare fuHd end for storage. When pump is to be shut down or not operated for a period of ten days or more, it is reconmended that the fluid end parts such as liners, piBtons, rods, etc., be remoTed from the pump and the fluid end flushed out completely with fresh water. After a thorough flushing, apply grease or a rust preventative to all of the machined surfaces such as Talve pot cover threads, valve pot cover gasket surfaces, valve seats, liner bores, etc. the parts removed from the pump including liners, piston rods, etc., should of course be protected from the elements. This will not only extend the life of the fluid end through resistance to corrosion, bat will also protect the usable life still left in the expendable parts and maintain them in good condition C-2S
The fluid end assembly for these triplex pumps consists of three forged cylinder blocks, complete with valve pot covers and cylinder heads, a suction manifold, and a discharge manifold.
CiJW AH 8- - <3 fin OIY DESCRIPTION PART No. 1 ii. i 4 r b g c 1 1b p ( u - F B00 AH Jb003~U6. 01. 00 F-IOOO AHisnn.i-06. oi. 00 ] 1 2 1 Coppt* Tbf Aiiy 010 AH34001-06A. 03.00 AH33001 -06A. 01. 00 J 3 1 C o nn 4 c t o r AH36001-06A. 30 AH36001-06A. 30 ~1 4 Tb ( C 1 lap-Do u b 1 1 08 AH35003-06. 02. 00 (2) AH35003-06. 02. 00 (371 5 1 01 1 Pnmp M 1 g PUtt AH34007-06. 03 IH33009-06 01A. 00 1 6 Skin Si I AH33001-06. 06. 00 AH33I101-06. 06, 00 7 1 0 I! Pflap 2S 25 0 1 Co nn 4 c t o r NPT"/» AH36001-06A. 29 AH36001-06A. 29 1 9 1 PreiiTtrl Gln
For best results, dampener precharge pressure should be not more than 2/3 of pump discharge pressure. Maximum precharge 650 PSI.
ITEM >0. QTY DESCRIPTION PART NO. 1 1 | .A d » p t e r B a < i1 a ( AH33003-01 2 1 Flkls Tuber AH33003-02 3 1 Pliaftr S e » 1 AH33003-03. 00 4 - 1 Bo dr AH33003-04 5 1 I Planter Stca AH33003-05 6 1 -| Buaper AH33003-06 7 1 Ro 1 1 Pin AH33003-07 8 1 Carer Spr lit AH33003-08 9 1 Cerer AH33003-09 10 1 Shear Bar AH33003-10 11 1 Shear P Ia AH33003-11 12 1 ItralK Plate AH33003-1HB 13 1 Shear Bar Ptn AH33003-13 14 Retainer Rlnf AH33003-14 15 1 Nine P 1 (-1 e AH33003— 15A 16 1 Cutter Pitt 4X26 GB 9 1-8 6 17 Not M4 GB4-1-B6 18 C ip g cr ew M4X15 GB6-7-B5 1S 1 Belt "A-16UNCX47, T50-10 16 20 1 Nut V.-16UNC T51-1005 21 ! 1 C.pecre* M3XB GB67-B 6J I I PACXING LIST U foil bsf-iooo triplex: PUMPS I i l i I
Emsco、Gardner-Denver, National oilwell, Ideco, Brewster, Drillmec, Wirth, Ellis, Williams, OPI, Mud King, LEWCO, Halliburton, SPM, Schlumberger, Weatherford
Triplex: This mud pump is used for drilling applications needing high pump pressure. This model works by decreasing the working fluid volume being discharged to generate pressure for producing the flow. There are three pistons in the triplex pump, with the middle piston generating more pressure on the crankshaft. High piston load can lead to excessive pressure and crankshaft failure if the components are not properly sourced.
Quintuplex:Quintuplex mud pump is perfect for pumping fluid at the time of drilling operations. It works as a continuous duty return piston. This is used in terms of its external bearings to provide crankshaft support to ensure the proper functioning of the sheaves.
Duplex: These mud pumps ensure that the mud circulation reaches the well"s bottom from the mud cleaning system. Duplex pumps have binocular floating seals as well as safety valves.
Saigao offers high-quality OEM mud pump spares, consumables, expendables and spare parts. Our mud pump parts are made with the highest standards of quality, offering competitive pricing and exceptional durability.
A Mud Pump may have many changeable parts, such as liner, piston, extension rod, pulsation dampener, valve, clamp, etc. Lake Petro could provide 100% interchangeable parts of many common brands of pump. We offer Liners with Ceramic (Zirconia and Aluminium oxide) and Steel (Metal and Bi-metal) materials. Piston assembly is the important spare parts and expendable parts of oil drilling mud pumps. Mud pump valve assy include valve body, valve seat, valve insert (valve rubber ). Pulsation Dampener is usually installed on the discharge line to reduce the fluctuation of pressure and displacement of the drilling mud pump. Fluid End Module is an important component of the hydraulic pump end of the mud pump.
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 and other components of heating, ventilation and air conditioning systems. In the medical industry, pumps are used for biochemical processes in developing and manufacturing medicine, and as artificial replacements for body parts, in particular the artificial heart and penile prosthesis.
When a pump contains two or more pump mechanisms with fluid being directed to flow through them in series, it is called a multi-stage pump. Terms such as two-stage or double-stage may be used to specifically describe the number of stages. A pump that does not fit this description is simply a single-stage pump in contrast.
In biology, many different types of chemical and biomechanical pumps have evolved; biomimicry is sometimes used in developing new types of mechanical pumps.
Pumps can be classified by their method of displacement into positive-displacement pumps, impulse pumps, velocity pumps, gravity pumps, steam pumps and valveless pumps. There are three basic types of pumps: positive-displacement, centrifugal and axial-flow pumps. In centrifugal pumps the direction of flow of the fluid changes by ninety degrees as it flows over an impeller, while in axial flow pumps the direction of flow is unchanged.
Some positive-displacement pumps use an expanding cavity on the suction side and a decreasing cavity on the discharge side. Liquid flows into the pump as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses. The volume is constant through each cycle of operation.
Positive-displacement pumps, unlike centrifugal, can theoretically produce the same flow at a given speed (rpm) no matter what the discharge pressure. Thus, positive-displacement pumps are constant flow machines. However, a slight increase in internal leakage as the pressure increases prevents a truly constant flow rate.
A positive-displacement pump must not operate against a closed valve on the discharge side of the pump, because it has no shutoff head like centrifugal pumps. A positive-displacement pump operating against a closed discharge valve continues to produce flow and the pressure in the discharge line increases until the line bursts, the pump is severely damaged, or both.
A relief or safety valve on the discharge side of the positive-displacement pump is therefore necessary. The relief valve can be internal or external. The pump manufacturer normally has the option to supply internal relief or safety valves. The internal valve is usually used only as a safety precaution. An external relief valve in the discharge line, with a return line back to the suction line or supply tank provides increased safety.
Rotary-type positive displacement: internal or external gear pump, screw pump, lobe pump, shuttle block, flexible vane or sliding vane, circumferential piston, flexible impeller, helical twisted roots (e.g. the Wendelkolben pump) or liquid-ring pumps
Drawbacks: The nature of the pump requires very close clearances between the rotating pump and the outer edge, making it rotate at a slow, steady speed. If rotary pumps are operated at high speeds, the fluids cause erosion, which eventually causes enlarged clearances that liquid can pass through, which reduces efficiency.
Hollow disk pumps (also known as eccentric disc pumps or Hollow rotary disc pumps), similar to scroll compressors, these have a cylindrical rotor encased in a circular housing. As the rotor orbits and rotates to some degree, it traps fluid between the rotor and the casing, drawing the fluid through the pump. It is used for highly viscous fluids like petroleum-derived products, and it can also support high pressures of up to 290 psi.
Vibratory pumps or vibration pumps are similar to linear compressors, having the same operating principle. They work by using a spring-loaded piston with an electromagnet connected to AC current through a diode. The spring-loaded piston is the only moving part, and it is placed in the center of the electromagnet. During the positive cycle of the AC current, the diode allows energy to pass through the electromagnet, generating a magnetic field that moves the piston backwards, compressing the spring, and generating suction. During the negative cycle of the AC current, the diode blocks current flow to the electromagnet, letting the spring uncompress, moving the piston forward, and pumping the fluid and generating pressure, like a reciprocating pump. Due to its low cost, it is widely used in inexpensive espresso machines. However, vibratory pumps cannot be operated for more than one minute, as they generate large amounts of heat. Linear compressors do not have this problem, as they can be cooled by the working fluid (which is often a refrigerant).
Reciprocating pumps move the fluid using one or more oscillating pistons, plungers, or membranes (diaphragms), while valves restrict fluid motion to the desired direction. In order for suction to take place, the pump must first pull the plunger in an outward motion to decrease pressure in the chamber. Once the plunger pushes back, it will increase the chamber pressure and the inward pressure of the plunger will then open the discharge valve and release the fluid into the delivery pipe at constant flow rate and increased pressure.
Pumps in this category range from simplex, with one cylinder, to in some cases quad (four) cylinders, or more. Many reciprocating-type pumps are duplex (two) or triplex (three) cylinder. They can be either single-acting with suction during one direction of piston motion and discharge on the other, or double-acting with suction and discharge in both directions. The pumps can be powered manually, by air or steam, or by a belt driven by an engine. This type of pump was used extensively in the 19th century—in the early days of steam propulsion—as boiler feed water pumps. Now reciprocating pumps typically pump highly viscous fluids like concrete and heavy oils, and serve in special applications that demand low flow rates against high resistance. Reciprocating hand pumps were widely used to pump water from wells. Common bicycle pumps and foot pumps for inflation use reciprocating action.
These positive-displacement pumps have 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 constant given each cycle of operation and the pump"s volumetric efficiency can be achieved through routine maintenance and inspection of its valves.
This is the simplest form of rotary positive-displacement pumps. It consists of two meshed gears that rotate in a closely fitted casing. The tooth spaces trap fluid and force it around the outer periphery. The fluid does not travel back on the meshed part, because the teeth mesh closely in the center. Gear pumps see wide use in car engine oil pumps and in various hydraulic power packs.
A screw pump is a more complicated type of rotary pump that uses two or three screws with opposing thread — e.g., one screw turns clockwise and the other counterclockwise. The screws are mounted on parallel shafts that have gears that mesh so the shafts turn together and everything stays in place. The screws turn on the shafts and drive fluid through the pump. As with other forms of rotary pumps, the clearance between moving parts and the pump"s casing is minimal.
Widely used for pumping difficult materials, such as sewage sludge contaminated with large particles, a progressing cavity pump consists of a helical rotor, about ten times as long as its width. This can be visualized as a central core of diameter x with, typically, a curved spiral wound around of thickness half x, though in reality it is manufactured in a single casting. This shaft fits inside a heavy-duty rubber sleeve, of wall thickness also typically x. As the shaft rotates, the rotor gradually forces fluid up the rubber sleeve. Such pumps can develop very high pressure at low volumes.
Named after the Roots brothers who invented it, this lobe pump displaces the fluid trapped between two long helical rotors, each fitted into the other when perpendicular at 90°, rotating inside a triangular shaped sealing line configuration, both at the point of suction and at the point of discharge. This design produces a continuous flow with equal volume and no vortex. It can work at low pulsation rates, and offers gentle performance that some applications require.
A peristaltic pump is a type of positive-displacement pump. It contains fluid within a flexible tube fitted inside a circular pump casing (though linear peristaltic pumps have been made). A number of rollers, shoes, or wipers attached to a rotor compresses the flexible tube. As the rotor turns, the part of the tube under compression closes (or occludes), forcing the fluid through the tube. Additionally, when the tube opens to its natural state after the passing of the cam it draws (restitution) fluid into the pump. This process is called peristalsis and is used in many biological systems such as the gastrointestinal tract.
Efficiency and common problems: With only one cylinder in plunger pumps, the fluid flow varies between maximum flow when the plunger moves through the middle positions, and zero flow when the plunger is at the end positions. A lot of energy is wasted when the fluid is accelerated in the piping system. Vibration and
Triplex plunger pumps use three plungers, which reduces the pulsation of single reciprocating plunger pumps. Adding a pulsation dampener on the pump outlet can further smooth the pump ripple, or ripple graph of a pump transducer. The dynamic relationship of the high-pressure fluid and plunger generally requires high-quality plunger seals. Plunger pumps with a larger number of plungers have the benefit of increased flow, or smoother flow without a pulsation damper. The increase in moving parts and crankshaft load is one drawback.
Car washes often use these triplex-style plunger pumps (perhaps without pulsation dampers). In 1968, William Bruggeman reduced the size of the triplex pump and increased the lifespan so that car washes could use equipment with smaller footprints. Durable high-pressure seals, low-pressure seals and oil seals, hardened crankshafts, hardened connecting rods, thick ceramic plungers and heavier duty ball and roller bearings improve reliability in triplex pumps. Triplex pumps now are in a myriad of markets across the world.
Triplex pumps with shorter lifetimes are commonplace to the home user. A person who uses a home pressure washer for 10 hours a year may be satisfied with a pump that lasts 100 hours between rebuilds. Industrial-grade or continuous duty triplex pumps on the other end of the quality spectrum may run for as much as 2,080 hours a year.
The oil and gas drilling industry uses massive semi trailer-transported triplex pumps called mud pumps to pump drilling mud, which cools the drill bit and carries the cuttings back to the surface.
One modern application of positive-displacement pumps is compressed-air-powered double-diaphragm pumps. Run on compressed air, these pumps are intrinsically safe by design, although all manufacturers offer ATEX certified models to comply with industry regulation. These pumps are relatively inexpensive and can perform a wide variety of duties, from pumping water out of bunds to pumping hydrochloric acid from secure storage (dependent on how the pump is manufactured – elastomers / body construction). These double-diaphragm pumps can handle viscous fluids and abrasive materials with a gentle pumping process ideal for transporting shear-sensitive media.
Devised in China as chain pumps over 1000 years ago, these pumps can be made from very simple materials: A rope, a wheel and a pipe are sufficient to make a simple rope pump. Rope pump efficiency has been studied by grassroots organizations and the techniques for making and running them have been continuously improved.
Impulse pumps use pressure created by gas (usually air). In some impulse pumps the gas trapped in the liquid (usually water), is released and accumulated somewhere in the pump, creating a pressure that can push part of the liquid upwards.
Instead of a gas accumulation and releasing cycle, the pressure can be created by burning of hydrocarbons. Such combustion driven pumps directly transmit the impulse from a combustion event through the actuation membrane to the pump fluid. In order to allow this direct transmission, the pump needs to be almost entirely made of an elastomer (e.g. silicone rubber). Hence, the combustion causes the membrane to expand and thereby pumps the fluid out of the adjacent pumping chamber. The first combustion-driven soft pump was developed by ETH Zurich.
It takes in water at relatively low pressure and high flow-rate and outputs water at a higher hydraulic-head and lower flow-rate. The device uses the water hammer effect to develop pressure that lifts a portion of the input water that powers the pump to a point higher than where the water started.
The hydraulic ram is sometimes used in remote areas, where there is both a source of low-head hydropower, and a need for pumping water to a destination higher in elevation than the source. In this situation, the ram is often useful, since it requires no outside source of power other than the kinetic energy of flowing water.
Rotodynamic pumps (or dynamic pumps) are a type of velocity pump in which kinetic energy is added to the fluid by increasing the flow velocity. This increase in energy is converted to a gain in potential energy (pressure) when the velocity is reduced prior to or as the flow exits the pump into the discharge pipe. This conversion of kinetic energy to pressure is explained by the
A practical difference between dynamic and positive-displacement pumps is how they operate under closed valve conditions. Positive-displacement pumps physically displace fluid, so closing a valve downstream of a positive-displacement pump produces a continual pressure build up that can cause mechanical failure of pipeline or pump. Dynamic pumps differ in that they can be safely operated under closed valve conditions (for short periods of time).
Such a pump is also referred to as a centrifugal pump. The fluid enters along the axis or center, is accelerated by the impeller and exits at right angles to the shaft (radially); an example is the centrifugal fan, which is commonly used to implement a vacuum cleaner. Another type of radial-flow pump is a vortex pump. The liquid in them moves in tangential direction around the working wheel. The conversion from the mechanical energy of motor into the potential energy of flow comes by means of multiple whirls, which are excited by the impeller in the working channel of the pump. Generally, a radial-flow pump operates at higher pressures and lower flow rates than an axial- or a mixed-flow pump.
These are also referred to as All fluid pumps. The fluid is pushed outward or inward to move fluid axially. They operate at much lower pressures and higher flow rates than radial-flow (centrifugal) pumps. Axial-flow pumps cannot be run up to speed without special precaution. If at a low flow rate, the total head rise and high torque associated with this pipe would mean that the starting torque would have to become a function of acceleration for the whole mass of liquid in the pipe system. If there is a large amount of fluid in the system, accelerate the pump slowly.
Mixed-flow pumps function as a compromise between radial and axial-flow pumps. The fluid experiences both radial acceleration and lift and exits the impeller somewhere between 0 and 90 degrees from the axial direction. As a consequence mixed-flow pumps operate at higher pressures than axial-flow pumps while delivering higher discharges than radial-flow pumps. The exit angle of the flow dictates the pressure head-discharge characteristic in relation to radial and mixed-flow.
Regenerative turbine pump rotor and housing, 1⁄3 horsepower (0.25 kW). 85 millimetres (3.3 in) diameter impeller rotates counter-clockwise. Left: inlet, right: outlet. .4 millimetres (0.016 in) thick vanes on 4 millimetres (0.16 in) centers
Also known as drag, friction, peripheral, traction, turbulence, or vortex pumps, regenerative turbine pumps are class of rotodynamic pump that operates at high head pressures, typically 4–20 bars (4.1–20.4 kgf/cm2; 58–290 psi).
The pump has an impeller with a number of vanes or paddles which spins in a cavity. The suction port and pressure ports are located at the perimeter of the cavity and are isolated by a barrier called a stripper, which allows only the tip channel (fluid between the blades) to recirculate, and forces any fluid in the side channel (fluid in the cavity outside of the blades) through the pressure port. In a regenerative turbine pump, as fluid spirals repeatedly from a vane into the side channel and back to the next vane, kinetic energy is imparted to the periphery,
As regenerative turbine pumps cannot become vapor locked, they are commonly applied to volatile, hot, or cryogenic fluid transport. However, as tolerances are typically tight, they are vulnerable to solids or particles causing jamming or rapid wear. Efficiency is typically low, and pressure and power consumption typically decrease with flow. Additionally, pumping direction can be reversed by reversing direction of spin.
Steam pumps have been for a long time mainly of historical interest. They include any type of pump powered by a steam engine and also pistonless pumps such as Thomas Savery"s or the Pulsometer steam pump.
Recently there has been a resurgence of interest in low power solar steam pumps for use in smallholder irrigation in developing countries. Previously small steam engines have not been viable because of escalating inefficiencies as vapour engines decrease in size. However the use of modern engineering materials coupled with alternative engine configurations has meant that these types of system are now a cost-effective opportunity.
Valveless pumping assists in fluid transport in various biomedical and engineering systems. In a valveless pumping system, no valves (or physical occlusions) are present to regulate the flow direction. The fluid pumping efficiency of a valveless system, however, is not necessarily lower than that having valves. In fact, many fluid-dynamical systems in nature and engineering more or less rely upon valveless pumping to transport the working fluids therein. For instance, blood circulation in the cardiovascular system is maintained to some extent even when the heart"s valves fail. Meanwhile, the embryonic vertebrate heart begins pumping blood long before the development of discernible chambers and valves. Similar to blood circulation in one direction, bird respiratory systems pump air in one direction in rigid lungs, but without any physiological valve. In microfluidics, valveless impedance pumps have been fabricated, and are expected to be particularly suitable for handling sensitive biofluids. Ink jet printers operating on the piezoelectric transducer principle also use valveless pumping. The pump chamber is emptied through the printing jet due to reduced flow impedance in that direction and refilled by capillary action.
Examining pump repair records and mean time between failures (MTBF) is of great importance to responsible and conscientious pump users. In view of that fact, the preface to the 2006 Pump User"s Handbook alludes to "pump failure" statistics. For the sake of convenience, these failure statistics often are translated into MTBF (in this case, installed life before failure).
In early 2005, Gordon Buck, John Crane Inc.’s chief engineer for field operations in Baton Rouge, Louisiana, examined the repair records for a number of refinery and chemical plants to obtain meaningful reliability data for centrifugal pumps. A total of 15 operating plants having nearly 15,000 pumps were included in the survey. The smallest of these plants had about 100 pumps; several plants had over 2000. All facilities were located in the United States. In addition, considered as "new", others as "renewed" and still others as "established". Many of these plants—but not all—had an alliance arrangement with John Crane. In some cases, the alliance contract included having a John Crane Inc. technician or engineer on-site to coordinate various aspects of the program.
Not all plants are refineries, however, and different results occur elsewhere. In chemical plants, pumps have historically been "throw-away" items as chemical attack limits life. Things have improved in recent years, but the somewhat restricted space available in "old" DIN and ASME-standardized stuffing boxes places limits on the type of seal that fits. Unless the pump user upgrades the seal chamber, the pump only accommodates more compact and simple versions. Without this upgrading, lifetimes in chemical installations are generally around 50 to 60 percent of the refinery values.
Unscheduled maintenance is often one of the most significant costs of ownership, and failures of mechanical seals and bearings are among the major causes. Keep in mind the potential value of selecting pumps that cost more initially, but last much longer between repairs. The MTBF of a better pump may be one to four years longer than that of its non-upgraded counterpart. Consider that published average values of avoided pump failures range from US$2600 to US$12,000. This does not include lost opportunity costs. One pump fire occurs per 1000 failures. Having fewer pump failures means having fewer destructive pump fires.
As has been noted, a typical pump failure, based on actual year 2002 reports, costs US$5,000 on average. This includes costs for material, parts, labor and overhead. Extending a pump"s MTBF from 12 to 18 months would save US$1,667 per year — which might be greater than the cost to upgrade the centrifugal pump"s reliability.
Pumps are used throughout society for a variety of purposes. Early applications includes the use of the windmill or watermill to pump water. Today, the pump is used for irrigation, water supply, gasoline supply, air conditioning systems, refrigeration (usually called a compressor), chemical movement, sewage movement, flood control, marine services, etc.
Because of the wide variety of applications, pumps have a plethora of shapes and sizes: from very large to very small, from handling gas to handling liquid, from high pressure to low pressure, and from high volume to low volume.
Typically, a liquid pump can"t simply draw air. The feed line of the pump and the internal body surrounding the pumping mechanism must first be filled with the liquid that requires pumping: An operator must introduce liquid into the system to initiate the pumping. This is called priming the pump. Loss of prime is usually due to ingestion of air into the pump. The clearances and displacement ratios in pumps for liquids, whether thin or more viscous, usually cannot displace air due to its compressibility. This is the case with most velocity (rotodynamic) pumps — for example, centrifugal pumps. For such pumps, the position of the pump should always be lower than the suction point, if not the pump should be manually filled with liquid or a secondary pump should be used until all air is removed from the suction line and the pump casing.
Positive–displacement pumps, however, tend to have sufficiently tight sealing between the moving parts and the casing or housing of the pump that they can be described as self-priming. Such pumps can also serve as priming pumps, so-called when they are used to fulfill that need for other pumps in lieu of action taken by a human operator.
One sort of pump once common worldwide was a hand-powered water pump, or "pitcher pump". It was commonly installed over community water wells in the days before piped water supplies.
In parts of the British Isles, it was often called the parish pump. Though such community pumps are no longer common, people still used the expression parish pump to describe a place or forum where matters of local interest are discussed.
Because water from pitcher pumps is drawn directly from the soil, it is more prone to contamination. If such water is not filtered and purified, consumption of it might lead to gastrointestinal or other water-borne diseases. A notorious case is the 1854 Broad Street cholera outbreak. At the time it was not known how cholera was transmitted, but physician John Snow suspected contaminated water and had the handle of the public pump he suspected removed; the outbreak then subsided.
Modern hand-operated community pumps are considered the most sustainable low-cost option for safe water supply in resource-poor settings, often in rural areas in developing countries. A hand pump opens access to deeper groundwater that is often not polluted and also improves the safety of a well by protecting the water source from contaminated buckets. Pumps such as the Afridev pump are designed to be cheap to build and install, and easy to maintain with simple parts. However, scarcity of spare parts for these type of pumps in some regions of Africa has diminished their utility for these areas.
Multiphase pumping applications, also referred to as tri-phase, have grown due to increased oil drilling activity. In addition, the economics of multiphase production is attractive to upstream operations as it leads to simpler, smaller in-field installations, reduced equipment costs and improved production rates. In essence, the multiphase pump can accommodate all fluid stream properties with one piece of equipment, which has a smaller footprint. Often, two smaller multiphase pumps are installed in series rather than having just one massive pump.
A rotodynamic pump with one single shaft that requires two mechanical seals, this pump uses an open-type axial impeller. It is often called a Poseidon pump, and can be described as a cross between an axial compressor and a centrifugal pump.
The twin-screw pump is constructed of two inter-meshing screws that move the pumped fluid. Twin screw pumps are often used when pumping conditions contain high gas volume fractions and fluctuating inlet conditions. Four mechanical seals are required to seal the two shafts.
These pumps are basically multistage centrifugal pumps and are widely used in oil well applications as a method for artificial lift. These pumps are usually specified when the pumped fluid is mainly liquid.
A buffer tank is often insta
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