ENGINEERING HONOURS THESIS · Pump PU01 or PU02 will be used separately to pump the water into Tank...

ENGINEERING HONOURS THESIS

BACHELOR OF ENGINEERING

INSTRUMENTATION AND CONTROL AND INDUSTRIAL COMPUTER

SYSTEMS

PUMPS AND FLOW CONTROL VALVES FOR UNIVERSAL

WATER SYSTEM

Student Name : Muhammad Hafriz Mohd Tahir

Supervisor : Associate Prof. Graeme R. Cole

JANUARY 2018

1

Declaration

I, Muhammad Hafriz Mohd Tahir, certify that this work contains no material which has been

accepted for the award of any other degree or diploma in my name, in any university or institute

and to the best of my knowledge, contains no material previously published or written by other

individual, except where due reference has been made in the text.

I give consent to this copy of my thesis being made available for loan and photocopying and also

give permission for digital version of my thesis via the University’s digital research repository,

Library Search and through web search engines, unless permission has been granted by

University.

Singed : .………………………………..

Name : Muhammad Hafriz Mohd Tahir

Date : ………………………………...

2

Contents

Declaration ...................................................................................................................................... 0

Terms and abbreviations ................................................................................................................. 7

Abstract ........................................................................................................................................... 8

Acknowledgement .......................................................................................................................... 9

1.0 Introduction ........................................................................................................................ 10

1.1 Universal Water System (UWS) ......................................................................................... 10

1.2 Project Objectives ............................................................................................................... 13

2.0 Literature review ................................................................................................................ 14

2.1 Test specimen...................................................................................................................... 14

2.1.1 Pumps ........................................................................................................................... 14

2.1.2 Flow Control Valves .................................................................................................... 18

2.2 Fundamental ........................................................................................................................ 20

2.2.1Pumps ............................................................................................................................ 20

2.2.2 Flow Control Valve...................................................................................................... 34

2.2.3 Performance criteria of flow control valve ............................................................. 38

3.0 TECHNICAL APPROACHES .......................................................................................... 41

3.1 Methodology .................................................................................................................. 44

3.1.1 Pump ....................................................................................................................... 44

3.1.2Experimental ................................................................................................................. 57

3.1.2 Flow control valve .................................................................................................. 69

4.0 Result ................................................................................................................................. 72

4.1 Pump ................................................................................................................................... 72

3

4.1.1 Centrifugal pumps ........................................................................................................ 72

4.1.2 Progressive cavity pump ......................................................................................... 83

4.1.3 Air Operated Double diaphragm Pump. ............................................................... 100

4.2 Flow Control Valve ...................................................................................................... 107

4.2.1 Hysteresis test ....................................................................................................... 107

4.2.2 Response Time test. .............................................................................................. 110

5.0 Conclusion ....................................................................................................................... 116

6.0 Future works .................................................................................................................... 117

7.0 References ........................................................................................................................ 118

8.0 Appendices ....................................................................................................................... 123

Appendix A ............................................................................................................................. 123

Appendix B ............................................................................................................................. 125

Appendix C ............................................................................................................................. 127

Appendix D ............................................................................................................................. 128

Table of figures

Figure 1: overview of UWS [3]. ................................................................................................... 10

Figure 2: P&ID of UWS [4].......................................................................................................... 12

Figure 3: JSP60 Villamate centrifugal pump. ............................................................................... 15

Figure 4: CP25 pump. ................................................................................................................... 16

Figure 5: CP800 pump. ................................................................................................................. 16

Figure 6: A1T air operated double diaphragm pump.................................................................... 17

Figure 7: 755 Badger Research Control Valve (FV01) [4]........................................................... 18

4

Figure 8: Baumann 24000s (FV02). ............................................................................................. 19

Figure 9: Baumann 24000s with electric motor actuator (FV03). ................................................ 19

Figure 10: Classification of pump [22]. ........................................................................................ 20

Figure 11: Illustration of Centrifugal pimp [6]. ............................................................................ 21

Figure 12: Typical Characteristic curves of centrifugal pump [21]. ............................................. 22

Figure 13: illustration of head [25]. .............................................................................................. 23

Figure 14: Pumping system [32]. .................................................................................................. 24

Figure 15: Head vs. flow curve [36]. ............................................................................................ 24

Figure 16: Typical power curve of a pump [45]. .......................................................................... 25

Figure 17: categories of positive displacement pump [42]. .......................................................... 27

Figure 18: cross sectional of progressive cavity pump [45]. ........................................................ 29

Figure 19: pump slip [50]. ............................................................................................................ 30

Figure 20: cross sectional diagram of the air operated diaphragm valve [7]. ............................... 32

Figure 21: Typical characteristic curves of AODD pump [7]. ..................................................... 33

Figure 22: inherent characteristic curve [13]. ............................................................................... 35

Figure 23: path dependent characteristic for hysteresis [10]. ....................................................... 38

Figure 24: Response time, dead time and time constant of a control valve [10]. ......................... 40

Figure 25: overview of test rig. ..................................................................................................... 41

Figure 26: self-construct SCFM meter. ........................................................................................ 43

Figure 27: hole for pump speed measurement. ............................................................................. 43

Figure 28: reading measured by Fluke 435................................................................................... 53

Figure 29: P&ID of centrifugal pump test rig. .............................................................................. 57

Figure 30: P&ID of progressive cavity pump test setup. .............................................................. 61

Figure 31 ........................................................................................ Error! Bookmark not defined.

5

Figure 32 ........................................................................................ Error! Bookmark not defined.

Figure 33: Head and efficiency curves of PU02. .......................................................................... 75

Figure 34: power curves of PU02. ................................................................................................ 76

Figure 35: characteristic curves of PU04. ..................................................................................... 78


Figure 37: PU06 collected data. ..................................................... Error! Bookmark not defined.

Figure 38: characteristic curves of PU06. ..................................................................................... 81


Figure 40: flow curve for PU01 at 800rpm. .................................................................................. 86

Figure 41: efficiency curve of PU01 at 800rpm. .......................................................................... 86

Figure 42: flow curves for PU01 at 1100 rpm. ............................................................................. 87

Figure 43: efficiency curves for PU01 at 1100rpm. ..................................................................... 87

Figure 44: flow curves of PU01 at 1500 rpm. .............................................................................. 88

Figure 45: efficiency curve for PU01 at 1500 rpm. ...................................................................... 88

Figure 46: flow curve of PU03 at 800 rpm. .................................................................................. 92

Figure 47: efficiency curve at 800 rpm. ........................................................................................ 92


Figure 49: efficiency curve of PU03 at 1100 rpm. ....................................................................... 93

Figure 50: flow curves of PU03 at 1500rpm. ............................................................................... 94


Figure 52: flow curves of PU05 at 800 rpm. ................................................................................ 96

Figure 53: efficiency curve of PU05 at 800 rpm. ......................................................................... 96



6

Figure 56: head curve of PU07 at 4bar air supply pressure. ....................................................... 103



Figure 59: air consumption at 4 bar air supply pressure. ............................................................ 105



Figure 62: Hysteresis test result for FV01. ................................................................................. 108



Figure 65: 20% valve opening interval for FV01. ...................................................................... 110

Figure 66: 40% valve opening interval for FV0l. ....................................................................... 110




Figure 70: 80% interval for FV02. .............................................................................................. 113




Figure 74: datasheet of CP800 .................................................................................................... 123

Figure 75: CP25 datasheet. ......................................................................................................... 124

Figure 76:Kv test rig [51]. .......................................................................................................... 125

Figure 77: Moody chart. ............................................................................................................. 127

Figure 78: Kv value for Badger valve. ........................................................................................ 128

Figure 79: Kv value for Baumann 24000 valve. ......................................................................... 128

7

Terms and abbreviations

UWS Universal Water System

P&ID Piping and Instrument Diagram

PD Positive Displacement

VSD Variable Speed Drive

BEP Best Efficiency Point

AODD Air Operated Double Diaphragm

WP Hydraulic Power

BP Brake Power

Cv Flow coefficient

8

Abstract

The main purpose of this thesis is to investigate pump and flow control valve on Universal Water

System (UWS) located in Murdoch University by experiment to obtain their performance

characteristics and other behaviours.

Overall, USW equipped with 9 pumps with various types that can be categorised into 3 main

types which are centrifugal, positive displacement and air operated diaphragm pumps. Besides

that, UWS is installed with 35 valves. However, this project only focuses on 7 pumps and 3 flow

control valves.

To obtain the best result, experiment held in this project consists 3 main phases, experimental

setup, data collecting and data evaluation. Every detail regarding the setup, method and

calculation applied in this project are explained in this report.

9

Acknowledgement

Firstly, I would like to express my biggest gratitude and most sincere thanks to my supervisor

Associate Professor Graeme Cole for his time and effort spent in assisting the progression of this

thesis project and for supporting me in every way without losing faith.

My special thanks to Technical Officer Mr. Mark Burt, Mr. Graham Malzer, Mr. Lafeta “Jeff”

Laava and Mr. Will Stirling. Without their help on technical and software related issues, this

would not have been done.

Additional thanks to Mrs. Warunthon Poonlua, other fellow friends and to every individual

involved directly or indirectly in the completion of my thesis.

Not to forget my thanks to my family especially my parent for your moral support and for

everything you have done.

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1.0 Introduction

Pump and control valve are 2 most important instruments in a control system especially water

system. Pump has the important role in producing energy to transfer fluid from one location to

another. While the valve is used to control the variables in a system as flow, level, temperature

and others.

1.1 Universal Water System (UWS)

UWS is a process control plant that one of Murdoch University’s facility provided for the

student. Many students and individuals contribute to the construction of the UWS from the

beginning. As a facility built for students especially in Process Instrumentation and Control

engineering students, UWS is equipped with a variety of instrument equipment from a different

range of types,models and manufacturers. UWS is a system to control the water level in its tanks.

From the overview, UWS is a whole process system that can be divided into 3 subsystems which

are area A or System 1, B or System 2 and C or System 3 as shown in Figure 1 below by

controlling appropriate valves, it can be configured as one whole system, 3 individual

subsystems or 2 in 1 combination [3].

Figure 1: an overview of UWS [3].

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Referring to Figure 2 below, System 1, to control the water level in Tank 01 and Tank 03, it

involves the application of pumps PU01, PU02 and PU09 beside the flow control valves FV01.

Pump PU01 or PU02 will be used separately to pump the water into Tank 01 and Tank 03 from

Tank 06 (reservoir). FV 01 used to control the flowrate of water discharge from PU02. PU09

used either to pump water from Tank 03 to Tank 01 or can be used to drive water in recycle

system of Tank03. The speed of both PU01 and PU09 controlled by VSD01 and VSD04

respectively [3,4].

Similarly to System 1, System 2 consists 2 pumps which are PU03 and PU04 to push water from

Tank06 into Tank 02 and Tank 04 while PU08 is used to drive water from Tank04 into Tank02.

PU08 also be used in Tank04’s recycling system. This area also has 1 flow control valves which

FV02 is used to control flowrate of water from PU04 into Tank02. VSD02 and VSD05 are used

in this area to control the speed of PU03 and PU08 respectively [4].

System 3 only has a single tank with tag name Tank05. Tank05 has obviously different

dimension compare the other 4 tanks. This area was installed with 3 different type of pumps,

PU05, PU06 and PU07 where their purpose is to pump the water from Tank06 into Tank03. Only

PU05 used VSD03 to vary its speed. FV03 is used to regulate the flowrate of water discharge

from PU06 into Tank05 while FV04 is located at discharge pipeline from Tank05 to Tank06 [4].

12

Figure 2: P&ID of UWS [4].

13

1.2 Project Objectives

There are 3 objectives of this thesis which are:

1. To investigate the performance and characteristic of 7 pumps in UWS experiment.

UWS is equipped with 3 type of pumps. Each of this type has their own performance and

characteristic.From the experiments that will be done in this project, some performance

and characteristic of all the pump involved might be obtained such as head, flow,

pressure difference curve, power consumption, air consumption and the efficiency of the

pump[1].

2. To investigate the performance and characteristic of 3 flow control valves in UWS by

experiment.

This project focus on 3 flow control valves which will be inspected through several types

of testing experiment and outcomes such as flow coefficient, response time, hysteresis

and some others are expected [2].

3. To identify the possible procedures and equipment to test the pumps and flow control

valves involved[2].

Some of the testing methods are not possible to be done according to some limitation in

term of equipment availability, the step of the procedure, costing and et cetera. Before

deciding any of the experiment to be done, every aspect needs to be identified and

considered through series of discussions with some expert and individual involved.

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2.0 Literature review

2.1 Test specimen 2.1.1 Pumps

Overall, UWS installed with 9 pumps as listed in Table 1 and can be divided into 2 main types,

centrifugal and positive displacement (PD) pump.

Table 1: List of pumps.

P&ID Ref. Instrument Model Location Type

PU01 Mono pump CP25 System 1 PD

PU02 Villamate pump JSP60 System 1 centrifugal





PU07 Wilden pump A1T System 3 PD (air operated)



Out of the 9 pumps, 3 of them are centrifugal pumps manufactured by Pump master, model

JSP60 and tagged as PU02, PU04 and PU05. All the centrifugal pumps in UWS are involved in

this project [5].

15

Figure 3: JSP60 Villamate centrifugal pump.

JSP60 is operated using 3 phase induced motor at 50Hz of frequency. This 2 poles ac motor with

240V electric supply have full load speed of 2800 rpm and can produce 0.37 kW of output

power. From the pump nameplate, JSP60 can deliver water at a maximum flowrate of 52L/min

[5].

The second type of pump that has been analyzed in this project is positive displacement pump. In

term of working principle, PD pumps in UWS are divided into two type, progressive cavity and

air operated diaphragm pump. UWS consist 5 progressive cavity pumps in total where 4 of them

are a CP25 model and only 1 pump from model CP800. Due to the limited time of this thesis

period, only 2 CP25 pumps (PU01 and PU03) and a CP800 pump (PU05) are tested in this

project [5].

16

Figure 4: CP25 pump.

Figure 5: CP800 pump.

Both CP25 and CP800 are operated using 4 poles single phase induction motor with a supply

voltage of 450V at 50Hz that will produce a maximum head of 28 meters at maximum full load

speed of 1450 rpm. The speed for both models of the pump can be varied using Variable Speed

Drive (VSD) at a range between 1100 rpm to 15000 rpm. CP800 can deliver maximum flowrate

of 60 𝑙 𝑚𝑖𝑛⁄ while 25 𝑙 𝑚𝑖𝑛⁄ for CP25. Full specification provided by manufacturer are attached

in Appendix A.

17

The last pump that been analyzed in this project is air operated double diaphragm pump (PU07)

which fall under PD pump. This A1T model pump manufactured by Wilden operate using

compressed air as a power source at a recommended pressure of 6 to 8.6 bar. The pump’s output

flowrate is controlled by varying the frequency supplied to the 24V DC coil of the pump.

Figure 6: A1T air operated double diaphragm pump.

18

2.1.2 Flow Control Valves

Besides the pump, this thesis also purposed to investigate the behaviour of flow control valve in

UWS. UWS equipped with 4 flow control valves in total as listed in Table 2. However, upon the

time limitation, only 3 out of the 4 flow control valves are investigated in this project which is

tagged as FV01, FV02 and FV03. Both FV02 and FV04 are same by means of valve body and

model of positioner used.

P&ID Ref. Valve body Actuator

Actuating power Accessory Location

FV01 Badger 755 research control valve Diaphragm Pneumatic

Type1000 Bellfram transducer System 1

FV02 Baumann 24000s Diaphragm Pneumatic Fisher 3660 positioner System2

FV03 Baumann 24000s Motor Electrical Belimo NFV24 System3

FV04 Baumann 24000s Diaphragm Pneumatic Fisher 3660 positioner System3

Table 2: List of flow control valve.

Flow control valve installed in System is the only research control valve (model 754)

manufactured by Badger Meter in the whole UWS and installed in System 1. FV01 is an air to

open control valve mounted with type 1000 electro-pneumatic transducer from Bellfram with

supply pressure from 0.2 bar to 7 bar. Type 1000 needs 4-20 mA input signal to control the

Badger 755 valve at flow coefficient (Cv) in range of 0.1 to 6 [4].

Figure 7: 755 Badger Research Control Valve (FV01) [4].

19

FV02 located in System 2 is a Baumann 24000 series control valve which the operation of the

valve controlled by single acting 3600 pneumatic valve positioner by Fisher. 3600 positioner

needs 0.2 to 1.0 bar of air input and 4 to 20Ma of electric input supply to vary the valve opening

from 0% to 100%. Baumann 24000s valve body has maximum Cv of 9.5.

Figure 8: Baumann 24000s (FV02).

The last analyzed flow control valve in this project is FV03 which located at the suction pipeline

to Tank5 in System 3. The valve body used is exactly the same with FV02. However, FV03 used

Belimo NFV24-MFT-E50 electrical motor as an actuator. This actuator requires either 24V AC

or 24V DC electrical supply to operate [4].

Figure 9: Baumann 24000s with an electric motor actuator (FV03).

20

2.2 Fundamental 2.2.1Pumps

The pump is one of the most parts in controlling the flow of fluid in a system. Two main

purposes of a pump in a system are to transfer the fluid form one point to another and to circulate

the fluid around the system [31].

The pump can be classified according to its application, material, handling fluid. However, the

most common pump classification is based on their principle on how the energy transfer to the

fluid. Regarding this classification, the pump can be categorized into 2 main classes, dynamic

pressure and positive displacement as shown in Figure 10 below [30,31].

Figure 10: Classification of pump [22].

21

Centrifugal pump is the only dynamic pressure pump type used in UWS. Dynamic pressure

pump operates by creating a force in term of pressure to transfer the water. Commonly the force

created by rotation of the impeller [31].

Positive displacement pump designed to transfer a fixed amount of fluid per cycle of operation

which depends pump’s driving device such as motor. Focusing on UWS, diaphragm and

progressive cavity are the type of pump used that categorized under positive displacement pump

category [31].

2.2.1.1Centrifugal Pumps

Working principle of centrifugal pump

Basically, centrifugal pump has rotating part known as impeller as illustrated in Figure 11 that

used to create a force to pump out of the fluid. Impeller connected to a motor by a shaft and

immersed in the fluid. The impeller will rotate as the motor shaft rotate, it will drive the fluid

outwards from the impeller at high velocity. As the moving fluid hit the volute casing, sudden

drop in velocity of the fluid will create high pressure at the discharge side of the pump and will

force the fluid out through the discharge nozzle. At the same time, fluid will displaced at

impeller eye and will result in pressure drop or known as negative pressure and will cause the

pressure at the suction site is lower than atmospheric pressure which will lead to the suction

water from a supply tank. This continuous process will constantly suck fluid into the suction site

and remove it through the discharge nozzle [6, 38].

Figure 11: Illustration of Centrifugal pimp [6].

22

Performance criteria for centrifugal pump

Centrifugal pump has wide range of characteristic and behaviour regarding its impeller types

such as size, design and some other aspect. The characteristic of a pump is important in order to

choose the most suitable pump for a system. In this project, characteristic curves or behaviours

of a pump are tested in the scope of:

1. Head produced at different flowrate.

2. Power consumed and power created in the pump and it’s motor.

3. The efficiency of motor and pump.

4. Best efficiency point (BEP).

Figure 12: Typical Characteristic curves of centrifugal pump [21].

Head and flow relationship

Head plays an important role in pump selection as it defines the ability of a pump to create

energy to deliver fluid. Head is the maximum height of fluid can be raised from discharge point

of a pump in the vertical direction as illustrated in Figure 13. Head commonly measured in feet

or meters [32, 34].

23

Figure 13: illustration of head [25].

As the pump creates higher pressure at the discharge point, the higher head will produce. Even

head is related to pressure, the head is commonly used instead of pressure in pump

manufacturing industries because of several reasons. The main reason is pressure is affected by

the viscosity of the fluid to be pumped. So manufacturer needs to know the viscosity of the fluid

need to be pump by the user if pressure is used to determine the pump capacity instead of the

head. Bu using head instead of pressure, it will be more universal between manufacturer and user

[32, 33, 34, 37].

In a practical fluid pumping system as shown in Figure 14 below, discharge static head and

suction head express the amount of pressure energy at the discharge point and suction point of

the pump respectively. Suction head depends on the water level in the suction tank while the

water level in discharge tank varies according to the pressure energy at the discharge point. To

know the net total pressure energy provided by the pump or total head, the amount of suction

head that helps the pump must be subtracted from the total discharge static head. Total head or

also known as the static head is the difference in height between discharge static head and

suction head with respect to the suction flange elevation. Total head indicates the ability of a

pump to deliver fluid. Besides that, the value of pressure loss in the whole system due to pipe

diameter, pipe length, connectors and other instruments attached must be taken into calculation

[32, 34, 37].

24

Figure 14: Pumping system [32].

At the beginning of a pumping process, the pumped water will flow at the highest flowrate. At

this point, the head produced is at the lowest level. As the head increasing, the flow will decrease

proportionally until it reaches some point where the flow will stop flowing even the pump still

operate. This situation considered as the maximum head of a pump or known shut-off head and

can be identified from Head versus Flow curves as shown in Figure 15 [32, 37].

Figure 15: Head vs. flow curve [36].

25

Power

Power is the amount of energy used to do a work per unit time and commonly measured in Watt

(W). In a pumping system, horsepower (Hp) is used instead of Watt. However, to standardize the

unit system used in this thesis, power will be measured in kilowatts (kW). There are 3 terms of

power involve, motor input power, brake or shaft power and hydraulic or water power [43, 44,

45].

Motor input power (EP) is power input to the motor to run the pump and provide the particular

brake power. However, due to friction losses, bearing losses and other losses in the system, not

all the motor input power provided will convert into the mechanical or brake power (BP). Brake

power which also known as shaft power is the actual power produced by a motor in the system

and deliver water leaving the pump at specific flow and capacity. Hydraulic power (WP) or also

known as water power is the pump output power which representing minimum power of the fluid

from the pump needed to pump the water at specific flow and capacity. Figure 16 below

illustrates the common brake and water power plotted in centrifugal pump characteristic curve

[43, 44, 45].

Figure 16: Typical power curve of a pump [45].

26

Efficiencies

The efficiency that involves in a pump can be categorized into 3 which motor efficiency, pump

efficiency and total efficiency. Motor efficiency is the ration between the mechanical power

pump shaft to the power input of the motor. Pump efficiency is the ratio between the energy

delivered by the pump or water horsepower to the energy delivered to the pump shaft or brake

horsepower. While total efficiency is the ratio of energy delivered by the pump to the energy

supply at the motor input [43].

Best efficiency point (BEP)

Best efficiency point (BEP) indicate the flow through the pump where it operates at its optimum

performance and reliability. For most of the centrifugal pumps, the BEP is about 85% of the

shutoff head (SOH) as shown in Figure 17 below. In this thesis, BEP is located according to the

pump efficiency curve obtained from efficiencies test. The flow at the highest point of pump

efficiency considered as BEP of the pump [43].

Ideally, a pump should not be operated too far from its BEP for a sustained period of time to

prevent the pump from damage caused by cavitation and excessive vibration and to maximum

the pump life span. Due to friction in the system, pump design, impeller design and other

aspects, it is almost impossible to ensure a pump will be operated at the BEP in reality. Based on

the America Petroleum Institute (API) 610 11th edition guidelines, there is an operating region

where a pump allows to operate is indicated by vibration measurement. API 610 states that the

vibration levels must be less than 3mm/s for horizontal pumps and less than 5mm/s for vertical

pumps and allowable operating limits must be within 30% above this levels [46, 47, 48].

27

2.2.1.2 Positive Displacement Pump

Positive displacement pump can be categorized into 3 main types which are reciprocating, blow

case and rotary pump as shown in Figure 17 below. Out of total 9 pumps used in UWS, 6 of

them are positive displacement pump that falls under the air operated diaphragm and progressive

cavity pump.

Figure 17: categories of positive displacement pump [42].

Compare to the centrifugal pump, the pressure produced by positive displacement pump is nearly

constant due to almost constant volumetric flowrate change at specific pump speed, especially

for the reciprocating pump. Depending on this characteristic, this type of pump must not operate

against a closed valve on discharge side because it has infinite shut off the head. Therefore,

pressure relief or safety valve on the discharge side is necessary. Besides that, positive

displacement pump also can produce higher efficiency, suction capability and repeatability [42,

43].

28

Generally, positive displacement pump works base on 2 basic principles. Some of the pumps will

transfer a fixed amount of fluid by trapping it then displace the volume to the discharge side.

This principle used in screw pump, gear pump, flexible vane pump and much more [44].

While another pump such as diaphragm pump will pumping fluid by expanding cavity on the

suction side and reducing the cavity on the discharge side. As the cavity on suction side increase,

fluid will flow into it and the fluid will flow out of the pump as the cavity collapses [44].

29

Progressive cavity pump

Working principle of progressive cavity pump

Progressive cavity pump has helical shaped rotor and metal tube with internally moulded cavities

of rubber called stator as 2 main parts. Then the surface of the rotor and the stator make a

contact, it will forming a very tightly sealed cavities. As the rotor rotates, the cavities will move

forward, carrying the fluid to the discharge port [45, 46, 47].

Figure 18: cross-sectional of progressive cavity pump [45].

Performance criteria for progressive cavity pump.

To obtain the best result in describing the performance of a progressive cavity pump, each

progressive cavity pump in UWS are tested with 3 different speed and the

1. Theoretical flow versus differential pressure curve.

2. Actual flow versus differential pressure curve.

3. Volumetric efficiency curve.

4. Power.

Theoretical flow

Progressive cavity pump is known as a pump that can deliver fix amount fluid at a constant

speed. The value of the flowrate delivered by this type of pump can be estimated by some set of

30

calculation based on the stator and rotor design. Besides that, it also can be described as the

flowrate deliver when the differential pressure between suction and the discharge port is 0.

Actual flow

As explained in the previous section, progressive cavity pump is known by its advantage to

deliver fluid at fix flowrate. However, due to several factors, some amount of the pumped liquid

may recirculate into the pump while operating. This phenomenon are known as internal leakage

or pump slip as illustrated in Figure 19 below. Theoretically, at a fixed speed of a progressive

cavity pump, almost vertical flow as output will produce on pressure versus flow curve.

However, the real output is slipping away from the ideal output expected at some point

especially when the head or differential pressure is increase [49].

Figure 19: pump slip [50].

Slip can be either negative or positive. If the real output reading exceeds the ideal output reading,

it considered as positive slip while it considered as negative if the real output below the ideal

output [51].

Slip can happen upon several factors such as differential pressure, fluid viscosity, clearance and

condition of the pump. As the pump running, the differential pressure will keep rising to some

point where the recirculation will happen. Besides the increasing in differential pressure,

clearance of the pump design also affects the slip of a pump. Clearance is the space between

rotor and housing that kept in order to allow the mechanical to run. Clearance will provide the

31

space for the pumped liquid to flow back into the pump. The amount the slip also varies

inversely to the viscosity of the pumped liquid because the thicker the liquid the less slip will

occur. Viscosity is the resistance of a fluid to flow caused by shear stress or tensile stress and

usually measured as centipoise (cP). Liquid with higher viscosity is more difficult to flow caused

by its “thickness” [52].

Volumetric efficiency

Volumetric efficiency is the variable that describes the pump efficiency of a progressive cavity

pump. This efficiency is directly related to the amount of slip between the actual flowrate and

theoretical flowrate of the pump. The decreasing in pump efficiency will arise the difference

between theoretical and actual flow [52].

Power

The only power that matters in progressive cavity pump is motor input power and brake power.

Both of these power share the exactly same concept and fundamental as the power discussed in

power of centrifugal pump in previous section [52].

32

Air Operated Double Diaphragm (AODD) Pump.

Working Principle of AODD Pump.

This type of pump is controlled by pulsing a digital frequency input that determines the flowrate.

Working principle of this pump will be explained based on Figure 20 below [7].

Figure 20: cross-sectional diagram of the air operated diaphragm valve [7].

Diaphragm valve can be separated into 2 chambers, A and B. each chamber has their own

diaphragm that linked each other by a shaft. Air supply is used as power source to move the shaft

back and forth [7].

As the shaft moves toward chamber B, it will reduce the pressure on chamber A. Hydraulic force

will lift the lower valve ball of chamber A from its seat to open the way for fluid to be filled into

chamber A. The hydraulic force also will draw the upper valve ball of chamber A to its seat and

close the upper valve. When the shaft moves toward Chamber A, the force created will open the

upper valve and close the lower valve of Chamber A. this action will discharge the fluid from the

pump. Both of chamber A and B will work in opposite condition that will result in the

continuous discharge of fluid from the pump[7].

33

Performance criteria of air operated double diaphragm pump

AODD pump has fewer factor to identify the pump performance compare to another 2 type of

tested pump in this thesis. Based on Figure 21 below, the common criteria involved in describing

the performance of an AODD pump is much similar to the centrifugal pump as explained before

[7,52].

Figure 21: Typical characteristic curves of AODD pump [7].

However, AODD pump have additional analysis need to be done which on the volumetric air

flow rate deliver to the pump or more specifically known as Standard Cubic Feet per Minute

(SCFM) in imperial unit which determine the weight of air to standard condition (pressure,

temperature and humidity) consumed by the pump the deliver the certain amount of water. As

the SI unit used in this whole experiment, the volumetric flowrate will be measured using cubic

meter per minute [52].

The AODD pump in this project will be analyzed in term of:

1. Head versus flow

2. Air consumption.

3. Minimum air supply pressure required by the pump to operate.

34

2.2.2 Flow Control Valve

In a control system, control valve plays a big role to ensure the system can deliver the output

accurately at and can operate at its best. By understanding the behaviour and performance of the

control valve as the final control element, controller tuning and process optimization can be done

much easier and their objective can be achieved easily.

To make the best decision in control valve sizing, several aspects need to be precisely considered

such as:

1. Flow coefficient (Kv)

2. Flow characteristic curve

3. Inherent gain

4. Rangeability

5. Hysteresis and deadband.

6. Response time.

2.2.2.1Flow coefficient (Kv)

Flow coefficient or Cv is the flowrate of fluid that flows through a valve in some specified

condition. Cv measured in US gallon per minute at temperature 60F of water that through a valve

in one pound per square inch pressure drop. This variable describes the ability of a valve to

deliver the amount of water where the pressure drop across the valve must be 1psi. Similar to Cv,

Kv is referring to the same variable but in the different measuring unit. Kv is the flowrate in

cubic meters per hour ( 𝑚3/h) of water that pass through a valve at a temperature of 15.5°

Celsius with 1 bar pressure drop across the valve. In this project, Kv is used instead of Cv to

standardize the unit system used. Equaivalence equation for both Cv and Kc of water shown as

Equation 1 below [1,20].

Kv = 0.865 × Cv (Equation 1)

35

2.2.2.2 Flow characteristic curve

Flow characteristic curve is a plotted graph that illustrates the relationship between flowrate and

percentage of opening valve flow fully closed to fully open. This characteristic curve can be

classified into 2, inherent and installed characteristic curve.

Inherent flow characteristic is a relationship between flow coefficient (Kv) and percentage of the

opening valve, from 0% to 100%. Based on the fixed pressure drop, the flow capacity or flow

coefficient only affected by the valve travel. To maintain the constant pressure drop across the

valve, piping system pressure drop must be concentrated at the valve and not distributes along

the pipe line. To achieve this condition, the system needs to install very short pipe line and

installation of equipment that will affect the piping system pressure drop such as fitting,

flowmeter and et cereta must be minimized. However, this situation infrequently exists in an

actual installation. Practically, the inherent characteristic curve is not the best dependent source

for process controller tuning. But, this data is very useful to compare the performance and ability

of a valve especially in valve sizing and selection and inherent flow is the characteristic flow that

focused on this thesis[1,13].

Typically, the inherent characteristic curve can be divided into 3 categories which are linear,

equal percentage and quick opening as shown in Figure 22 below. [13,15]

Figure 22: inherent characteristic curve [13].

36

2.2.2.3 Gain

Gain is the magnitude ratio of output that changes in a system or a device to the magnitude of the

input change. It can be classified into 2 main type, static gain and dynamic gain. Static gain is the

magnitude ratio if initial input change to the magnitude of output at steady state while the

dynamic gain is a relationship between input and output change when a system or process is in a

movement of flux. Focusing on control valve, the gain can be either inherent or installed valve

gain [1].

Inherent valve gain shows the ratio of magnitude change between the flow through a valve and

the valve travel at a constant pressure drop across the valve. Mathematically, the inherent gain is

the slope of the inherent characteristic curve [1].

Installed valve gain is defined as the magnitude ratio of changing the between valve travel and

the system flow under actual process without taking the constant pressure drop condition across

the valve into account. It also can be defined as the slope of installed characteristic curve [1].

To identify the one of the control valve performance, the inherent gain is the only gain that will

be considered.

37

2.2.2.4 Rangeability

Rangeability is the ability of a valve to control the flow through it or in simpler words,

rangeability is the ratio between highest controllable flow coefficient (Kv) to the lowest

controllable flow coefficient (Kv) of a control. Besides that, rangeability also can be defined as

the ratio of the maximum to the minimum controllable flowrate [1].

Rangeability defines the best controlling range of a control valve. Outside this best-controlling

range, the characteristic curve will drive away from its desired characteristic exceed its stated

tolerance [13].

However, to obtain the accurate data of Kv for the characteristic curve, inherent gain curve and

rangeability developing, a very precise test rig according to America Petroleum Institute (API)

610 standard must be followed, else, the data collected is the installed data instead of inherent.

Based on the API 610, the test on control valve must be held using separated test rig. This

requirement needs the control valve installed in UWS to be removed which involving a major

change in piping need to be done to the system. Due to limited time and this time-consuming

procedure is not be able to be done in this project. However, explanation of the method and

procedure will be attached in Appendix B.

38

2.2.3 Performance criteria for flow control valve

Instead of the tests as mention in the previous section, some other tests are still possible to be

done to investigate the characteristics of a control valve such as:

1. Hysteresis.

2. Time response.

2.2.3.1 Hysteresis

Hysteresis is one of the most important nonlinearities that affect the process performance.

Hysteresis is the difference stem position of a control valve in opening and closing path at same

input signal value. Figure 24 below shown the path dependent characteristic that illustrated the

phenomenon of hysteresis [9].

Figure 23: path dependent characteristic for hysteresis [10].

At the X input signal, the position of valve stem is different on its opening and closing path

which the stem position is at Y1 for opening and Y2 for closing. Friction from valve assembly is

the main contribution to valve hysteresis [9]. Hysteresis will also contribute to increasing of the

dead band [10].

39

Hysteresis can be caused by backlash and stiction. Backlash is a temporary phenomenon which

output of a device does not change as its input change in direction and commonly caused by

looseness of mechanical linkage in control valve assembly and one of the reasons contributing to

the dead band [1, 3].

The mechanical movement to operate a control valve need force and will produce friction.

Friction can be classified into two type, static and dynamic friction. Static friction or also known

as stiction is a force that must be overcome to initiate the movement of the control valve

assembly from its static state. Dynamic friction is a force that needs to be vanquished to maintain

the movement [1].

The backlash will rise the process variability. In open loop stable process, backlash only gives

effect in term of control performance but do not cause the limit cycle as it goes for integrated

closed-loop process. The phenomenon of backlash can be easily compensated using a method

introduced by Tore Hagglund (2007) without valve replacement compares to stiction. While for

stiction, it is cannot be totally remove and difficult to compensate [1,2].

40

2.2.3.2 Response time

Valve response indicates how fast a valve stem stroke from the time input signal (usually 1-5%)

initiate until the process reaches 63% of the overall time taken by the system to reach new steady

state. Parameter T63 or also known as Tee-63 used to measure the response time of a device or

the whole system process. Response time for a control valve is combined both dead time and

time constant [1].

Dead time is time consumed by a dead band which no corresponding action in respond when the

initial input signal applied on the system. Dead time should not more than one-third of overall

time response [1].

The time constant is a period where the process variable starts to respond until it reaches 63% of

overall time consumed to reach steady state. Figure 25 below illustrate the dead time and time

constant of a system [1].

Figure 24: Response time, dead time and the time constant of a control valve [10].

Basically, the time constant for a control valve depends on the time taken for the air supply to fill

the actuator. The sensitivity of positioner plays an important role for this [10].

41

3.0 TECHNICAL APPROACHES

To successfully complete the core part of this thesis, the tests undergo 3 stages:

1. Experimental setup.

2. Data collecting.

3. Data evaluation.

For experimental setup, both tests for pumps and flow control valves use the same test rig. The

test rig is prepared on the existing system piping with some modification done in the main

section of the UWS as shown n Figure 26. Gate valves, solenoid valve and bypass are used to

configure the individual test rig for every test specimen.

Figure 25: an overview of the test rig.

With guidance and help of pilot plant technicians, the test rig was successfully completed by

some piping have been done to install pressure taps and bypass to the system.

Pressure taps as shown in the yellow circle in the figure above are installed at 2 location, at the

bottom level of the supply tank and just after the discharge nozzle of each pump. The pressure

tap located at the bottom level of supply tank is purposed to measure the suction pressure that

42

will used in pressure drop of tested pump calculation which will explain later. It has supposedly

been installed just before the suction nozzle of the tested pump alongside with a flow transmitter

in order to collect the flowrate and pressure measurement for further pressure loss in suction side

calculation. However, due to no space along the suction side pipeline to install this instruments,

the only best option left is installing pressure tap at the bottom of supply tank and assume the

pressure at suction side according to its measurement without taking any other losses into the

calculation. As the matter of fact, the suction side has a very short pipeline which approximately

1 meter and contain few number of fitting which will cause a very minimum pressure loss and

considered as neglectable in this project.

A total number of 7 pressure taps are installed at discharge pipeline of the pumps to measure the

discharge pressure. In conjunction with respective flow transmitter, the pressure loss at this side

can be estimated and the total pressure can be calculated more accurate.

Besides pressure taps, bypass is installed to make connection within the pump in their system.

Gate valves used to control the opening and closing of the bypass. The main objective of this

bypass is to allow the output from PU01, PU03, and PU05 AND PU07 flow through respective

flow control valve and flow transmitter in each system so the required test variables can be

measured. As an example, during a test on PU01 take place, solenoid valve in System 1 will keep

closed and the bypass will opened. As the result, water pumped from PU01 will flow through

FV01 and FT01.

Other than that, some setup are done in order to measure the air consumption of AODD pump.

SCFM meter is an expensive meter used to measure the air consumption of an AODD pump. In

this project, the SCFM meter is self-construct by modifying one of facility in ICE lab as shown

in Figure 27 [54].

43

Figure 26: self-construct SCFM meter.

A simple electrical circuit powered with 9V battery is used to supply 4mA signal into the valve

to keep the valve open during the test. By knowing the metal tube area, air flowrate, air pressure

and some other variables, the air consumed by AODD pump can be calculated. The value

measured at the flow transmitter identify the actual air flowrate which needs to go through

several sets of calculation in order to get the standard air consumption of AODD pump [61].

Last test setup involved in this project is making a hole at the back side of every pump accept

AODD pump to measure the pump speed. The best method to measure the pump speed and

torque of a pump is by measure it at the motor shaft. But, upon the pump design where the shaft

is not exposed and cannot reached by any torque meter or tachometer directly, the best possible

way to measure it is by measuring the pump’s fan speed [58].

Figure 27: hole for pump speed measurement.

44

3.1 Methodology 3.1.1 Pump

3.1.1.1 Data collecting

To evaluate a performance of a pump in an experiment, several type of data must be collected

depending on the pump type such as:

1. Pump speed (rpm)

2. Suction pressure (bar)

3. Discharge pressure (bar)

4. Water flowrate (𝑚3 𝑚𝑖𝑛⁄ ).

5. Air flowrate (𝑚3 𝑚𝑖𝑛⁄ ).

6. Air pressure (bar).

7. Water temperature (°c).

8. Air temperature (°c).

While the Table 3 below summarizes the variables need to be measured depending to the type of

pump for further data analyzing.

Table 3: measuring variables according to the type of pump.

P&ID Ref.

pump speed

suction pressure

discharge pressure

water flowrate

air flowrate

air pressure

water temperature

air temperature

PU01 • • • • •

PU02 • • • • •

PU03 • • • • •

PU04 • • • • •

PU05 • • • • •

PU06 • • • • •

PU07 • • • • • • •

45

Pump speed is measured directly using tachometer. A hole is made at the back of tested pump to

allow a reflector to be attached at the pump’s fan.

Suction, discharge, air flowrate and air flowrate are directly measured from transmitter using

Fluke 744 Documenting Process Calibrator. The value measured in mA as the output from

transmitter need to go through some simple calculation to obtain the respective value in Bar for

pressure and 𝑚3 𝑚𝑖𝑛⁄ for flowrate.

Measurement of water flowrate is recorded directly from respective flow transmitter. Value

obtain is in𝑙 𝑚𝑖𝑛⁄ , however to standardize all the unit measurement used in this project, it needs

to be converted to𝑚3 𝑚𝑖𝑛⁄ .

Water and air temperature are measured using Digitech Digital Thermometer and measured in

°C.

3.1.1.2 Data Analyzing

After all the required data are collected, the data need to be analyzed to obtain the performance

curves and other behaviours of test pump as the final result.

3.1.1.2.1 Pressure conversion

Equation 2 below used to convert from pressure to head.

Head = 𝑃 0.0981 𝑆𝐺⁄ (Equation 2)

Where

P= pressure measured by pressure transmitter (Bar)

SG= specified gravity of fluid.

As the fresh water used as the fluid in this whole experiment, the fluid specific gravity is 1.

46

3.1.1.3 Total head

Total head created by a pump cab be calculated using Equation 3:

H = 𝐻𝑑 - 𝐻𝑠 (Equation 3)

Where

H = total head in meters (m)

Hd = total discharge head in meters (m)

Hs = total suction head in meters (m)

To find the accurate total head, total friction in the pipeline system caused by fluid velocity,

fitting, valves and location of pressure transmitter must be taken into calculation. Equation 4

below shown the factor needs to be considered in total discharge head calculation.

𝐻𝑑 = ℎ𝑠𝑑 + ℎ𝑓𝑑 + 𝐶𝑑 (Equation 4)

Where

ℎ𝑠𝑑 = discharge static head in meters (m)

ℎ𝑓𝑑= discharge friction head in metes (m)

𝐶𝑑= discharge correction, distance between pressure transmitter to the pump center line (m).

Discharge static head is the value measured by pressure transmitter located at discharge pipeline

of a pump in bar which then converted using Equation 2. Calculation for discharge friction head

will be shown in next section (3.1.1.4).

For the suction static head calculation, the same steps are taken. But, as described before, no

flow transmitter installed at the suction pipeline. So pressure drop in pipeline are impossible to

estimate. Besides than that, suction pressure transmitter is located exactly at the same level of

47

pump centre lime which resulting suction correction equal to 0. Equation 5 used to calculate the

total suction head [57].

𝐻𝑠 = ℎ𝑠𝑠 (Equation 5)

Where

ℎ𝑠𝑠 = suction static head in meters (m)

3.1.1.4 Head loss

One of the most important variables involved in most of friction calculation is the flow velocity

which can be calculated using Equation 6 below.

v = 𝑄 𝐴⁄ (Equation 6)

Where

v = fluid velocity (m/min)

Q = fluid volumetric flowrate (𝑚3/min)

A= pipe area ( 𝑚2). Pipe area involve in this experiment is 0.0013𝑚2.

According to Hydraulic Institute Engineering Data Book (first edition), head loss by velocity of

fluid through a pipeline (ℎ𝑙𝑝) can be defined using the Darcy equation provided below [56].

ℎ𝑙𝑝 = f 𝐿

𝐷 𝑣2

2𝑔 (Equation 7)

Where

f = friction factor (dimensionless)

L = length of pipe (m)

D = inside pipe diameter of pipe (meters) where all the pipes involved have same

diameter of 0.04m.


g = gravitational acceleration (m/𝑚𝑖𝑛2 ) which will be constant of 35316 m/𝑚𝑖𝑛2

Friction factor can be obtained through several methods such as by using Swamee-Jain equation.

In 1944, LF Moody plotted a data using Colebrook equation and resulting in a chart known as

Moody chart which is used widely to obtain a reasonably accurate friction factor of fluid in a

48

pipe based on Reynolds number and Relative roughness of the pipe. Moody chart is attached in

Appendix C.

Reynolds number can be calculated using Equation 8 below [55,56].

𝑅𝑒= vρD/µ (Equation 8)

Where

𝑅𝑒= Reynolds number (dimensionless)


ρ = fluid density (kg/𝑚3). The density of fresh water at temperature of 25c is 997 kg/𝑚3

D = inside pipe diameter which is 0.04m for this experiment.

µ = dynamic viscosity of fluid. Dynamic viscosity of fresh water used at temperature of 25c is

0.89 centipoise (cP) or equivalent to 0.0536 kg/ m min.

Besides the Reynolds number, relative roughness of the pipe also needs to be calculated using

Equation 9 below [55].

Relative roughness = e / D (Equation 9)

Where

e = roughness of the pipe (meters) which depend on the pipe material. The roughness value of

pipe in this experiment is 0.0000015m which is for PVC pipe.

D = inside pipe diameter (meters) which will be 0.04m for this experiment.

49

Head loss in fitting and control valves considered as minor loss and there are various methods to

estimate the total head loss by fitting and control valve in a piping system. 3 main methods used

to determine minor head loss are equivalent length, resistance coefficient (K) and valve flow

coefficient (Kv). All these methods have their own advantages and disadvantages depending on

application and system condition [57].

Equivalent length method is the simplest method compare to other. This method used to

calculate the minor losses based on total value of major losses by multiplying the constant

(Le/D) of fitting to the total head loss in a piping. The fitting constants in this method are same

depending on the fitting type without taking the fitting size into the account which made it

impossible to calculate the losses caused by fitting that changes in diameter and orifices such as

expander. However, an experiment done by AioFlo Company prove the head loss caused by the

same type of fitting with different diameter using this method having a small error which still

within the acceptable tolerance [57].

Minor head loss calculation using K method is independent without influenced by piping length

and properties as the constant (K) multiplied by velocity head loss instead of major head loss. In

the early invention as in 3rd Edition of Perry’s Chemical Engineers’ Handbook 1950, this method

has similar disadvantage to the equivalent length method as the constant K is similar according

to the fitting type and applicable to all size. This issue was corrected by Hydraulic Institute in

1954 through the Pipe Friction Manual Handbook. Another disadvantage is this method only

applicable to turbulent flow. The more accurate K method was introduced by Crane Company is

known through Technical Paper No. 410 published in 1976 as Crane K method which provides a

method for adjusting the K value for different fitting size [57, 59].

A better K method was invented by William Hooper in 1981 known as 2-K Method or Hooper’s

2-K Method that included the influence of both fitting size and Reynolds number which make it

possible to calculate the head loss for laminar flow. This method was improvised by Ron Darby

in 1999 known as 3-K Method or Darby’s 3-K Method which used to calculate the minor head

loss by fittings in this whole experiment [57, 58, 59].

50

To calculate the minor head loss by a fitting using Equation 10, the value of fitting resistance

coefficient (𝐾𝑓) must be obtained from Equation 11 as below [58,59].

ℎ𝑙𝑓= 𝐾𝑓 (𝑣2

2𝑔) (Equation 10)

Where

ℎ𝑙𝑓= head loss by fitting (m)

𝐾𝑓 = fitting resistance coefficient (dimensionless)


g = gravitational acceleration (m/𝑚𝑖𝑛2) which will be the constant as 35316 m/𝑚𝑖𝑛2

𝐾𝑓= 𝐾1

𝑅𝑒 + 𝐾𝑖 (1 +

𝐾𝑑

𝐷0.3) (Equation 11)

Where

𝐾1 = K factor at Reynolds number of 1 (dimensionless)

𝑅𝑒= Reynolds number (dimensionless)

𝐾𝑖 = K factors at higher Reynolds number (dimensionless)

𝐾𝑑 = K factor for fitting inside diameter (dimensionless)

D = internal diameter of fitting (m)

Value of 𝐾1, 𝐾𝑖 and 𝐾𝑑 used in this experiment can be obtained from Table 4 below [59].

51

Table 4:K value for 3K Method [59].

type 𝐾1 Ki Kd

90° Elbow

threaded 800 0.14 4

flanged 800 0.071 4.2

mitered 1000 0.27 4

45° Elbow standard 500 0.071 4.2

Tees standard 500 0.274 4

run through 200 0.091 4

valves

gate valve 300 0.037 3.9

ball valve 300 0.017 3.5

butterfly valve 1000 0.69 4.9

Flow coefficient (Kv) method is the method to calculate the head loss in both fitting and control

valve when the flow coefficient of them are known. 2 types of the control valve are used in this

experiment which Badger’s Research Control valve (model number: 1004 GCN 36 SVCS

60L36) and Baumann’s 24000s control valve (model number: 24688s). By referring to the

datasheet provided by the manufacturer (Appendix D), rated Kv at different valve opening

percentage can be plotted [60].

Using the Kv value from control valve datasheet attached in Appendix D, the value of control

valve friction coefficient can be calculated by Equation 12 below [61].

𝐾𝑐𝑣 = 1.604 × 10−3 × (1000𝐷)4

𝐾𝑣2 (Equation 12)

Where

𝐾𝑐𝑣= control valve friction coefficient (dimensionless)

52

D = piping inside diameter which will be the constant 0.04m.

𝐾𝑣= control valve flow coefficient (𝑚3/ hr).

While the head loss by the control valve can be calculated using Equation 13 below.

ℎ𝑙𝑣 = 𝐾𝑐𝑣 (𝑣2

2𝑔) (Equation 13)

From all the head loss calculation above, total friction head loss , ℎ𝑓 is sum of all head loss as in

Equation 14.

ℎ𝑓 = ℎ𝑙𝑣 + ℎ𝑙𝑓 + ℎ𝑙𝑝 (Equation 14)

53

3.1.1.5 Power

Motor power input in this project is planned to directly measure using Fluke 435 Power Quality

and Energy Analyzer. However, there is some faulty on that device where the reading of current

measured is too small (3mA) for an AC motor and significantly unacceptable. Figure 29 below

shown the reading appears on the measuring device. After several attempts are taken to solve this

problem with other technicians, the result still unchanged. Besides that, upon to the old motors

used with the pumps in UWS, limited resources about the motor such as power factor and others

cause it impossible to calculate the motor power input using the theoretical method.

Figure 28: reading measured by Fluke 435.

The most accurate way to calculate the brake power is using Equation 15 below where the

torque and shaft speed measured directly. However, as explained before, upon the pump design

the torque is impossible to measure directly. Another possible approach is taken to calculate the

brake power by depending on shaft slip. This method was published by United State Department

of Energy in a document “Determining Electric Motor Load and Efficiency” [59].

Brake power = torque * rpm/5252 (Equation 15)

54

Using this method, slip can be calculated using Equation 16 below. Then brake power can be

obtained from Equation 19 [59].

Slip =𝑠𝑦𝑛𝑐ℎ𝑟𝑜𝑛𝑜𝑢𝑠 𝑠𝑝𝑒𝑒𝑑 (𝑟𝑝𝑚)−𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑠𝑝𝑒𝑒𝑑(𝑟𝑝𝑚)

𝑠𝑦𝑛𝑐ℎ𝑟𝑜𝑛𝑜𝑢𝑠 𝑠𝑝𝑒𝑒𝑑 (𝑟𝑝𝑚)−𝑁𝑎𝑚𝑒𝑝𝑙𝑎𝑡𝑒 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 𝑠𝑝𝑒𝑒𝑑 (𝑟𝑝𝑚) (Equation 16)

While,

Synchronous speed can be calculated by this equation.

Synchronous speed =120 𝑋 𝑓

𝑛 (Equation 17)

Where,

f = motor frequency (Hz)

n = number of the pole of motor

Brake power = slip x nameplate full-load rated power (kW) (Equation 18)

The equation used Hydraulic power as below:

Wp =𝑔𝑄H

216000 (Equation 19)

Where,

Wp = hydraulic power (kW)

Q = flowrate (m3/min)

H = head (m)

55

3.1.1.6 Efficiency

Without knowing the motor input power, motor and overall efficiencies cannot be calculated.

The only efficiency can be obtained through this experiment is pump efficiency and volumetric

efficiency which shown in Equation 20 and Equation 21 respectively.

Pump efficiency = 𝑊𝑝

𝐵𝑝 x100% (Equation 20)

Where,

𝑊𝑝 = hydraulic power (kW)

𝐵𝑝 = brake power (kW)

Volumetric efficiency = 𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑓𝑙𝑜𝑤−𝑎𝑐𝑡𝑢𝑎𝑙 𝑓𝑙𝑜𝑤

𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑓𝑙𝑜𝑤 x 100% (Equation 21)

56

3.1.1.7 Air consumption

For AODD pump, air consumption can be calculated by Equation 22 below.

𝑄𝑠 = 35.336 (35.71 𝑄𝐴 x 0.9864P x ( 519

1.8 𝑇+32) (Equation 22)

Where,

𝑄𝑠 = specific air consumed (𝑚3 min )⁄

𝑄𝐴 = actual air consumed (𝑚3 min )⁄

P =air pressure (bar)

T =air temperature (°C)

57

3.1.2Experimental

3.1.2.1 Centrifugal pump

This test is held on PU02, PU04 and PU06 to investigate the pump’s characteristic in term of:

1. The relationship between head and flow.

2. The relationship between brake power and flow.

3. The relationship between hydraulic power and flow.

4. The relationship between pump efficiency and flow.

5. Location of BEP.

3.1.2.1.1 Test setup.

Setup for this test can be shown in Figure 30. Water is pumped from supply tank to discharge

tank during the test. Flow control valve is used to vary the flow and create additional pressure

drop in discharge pipeline. Control valve is fully open (100%) at the beginning of the test and the

reading (water temperature, suction pressure, discharge pressure, water flowrate and motor

speed) are taken. The valve opening then reduced the reducing span of 10% until it reaches 5.01

%, the lowest percentage of valve opening allow by the interlock in UWS system to ensure the

safety of pump. The variation consists of 11 steps in total and reading of the variables are taken

at every valve opening steps for evaluation.

Figure 29: P&ID of centrifugal pump test rig.

58

TT1: thermometer used to measure the water temperature during the test.

PT1: pressure transmitter with output range of 1 to 1.6bar installed at the bottom of supply tank

which used to measure the pressure at suction side of tested pump.

PT2: pressure transmitter with output range of 1 to 10bar installed just after the pump discharge

port which used to measure the static pressure at discharge side of tested pump.

FV: flow control valve used to vary the flow and create additional pressure drop in discharge

pipeline by step down the valve opening from 100% to 5.01%.

FT: flow transmitter used to measure the water flowrate from the tested pump.

3.2.1.2 Test procedure.

1. Setup the test rig as shown in Figure 29 above.

2. Open the control valve to 100% and run the pump.

3. Measure and record the motor speed, water temperature, suction pressure, discharge

pressure and water flowrate.

4. Repeat steps 2 and 3 at valve opening of 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%,

10% and 5.01%.

Same test setup and procedure applied for all centrifugal pumps’ test.

3.2.1.3 Data evaluation.

1. Using Equation 2, convert both static suction and static discharge pressure into static

suction and discharge head respectively at every percentage of valve opening.

2. To calculate the total head loss caused by water velocity in discharge pipeline, Equation 8

and Equation 9 in Section 3.1.1.4 are used to obtain the friction factor. Then, Equation 6

and 7 in the same section are used to calculate the head loss at every percentage of valve

opening.

3. Equation 10 is used to calculate the head loss by fitting at every percentage of valve

opening. To obtain the coefficient value in Equation 10, Equation 11 is used. Besides

that, the number and nominal diameter of the fitting involved in the system and the K

values must be known and shown in Table 5 below. In this step, head loss coefficient for

every fitting should be calculated individually.

59

Pump fitting nominal diameter no. of fitting K1 Ki Kd

PU02

Tee 2 4 500 0.274 4

90° elbow 2 4 800 0.14 4

45° elbow 2 1 500 0.071 4.2

gate valve 2 1 300 0.037 3.9

PU04

Tee 2 5 500 0.274 4

90° elbow 2 7 800 0.14 4

45° elbow 2 2 500 0.071 4.2

Pu06

Tee 2 5 500 0.274 4

90° elbow 2 8 800 0.14 4

45° elbow 2 2 500 0.071 4.2

Table 5: fitting information for centrifugal pumps.

4. To calculate the head loss caused by percentage of valve opening, Equation 12 and 13 are

applied. Appendix D provided the value of Kv depends on the percentage of valve

opening which is required in Equation 12.

5. Calculate the total head loss in discharge using Equation 14 and total discharge head can

be calculated using Equation 4.

6. By using Equation 3, total head at every percentage of valve opening can be obtained and

the head versus flowrate curve can be potted.

7. After the head and corresponded flowrate are acquired, hydraulic power is calculated

using Equation 29 in Section 3.1.1.5.

8. To calculate brake power, Equation 16, 17 and 18 are applied.

9. From the value of the hydraulic and brake power, pump efficiency is calculated using

Equation 20 and the highest efficient through all flowrate is defined as BEP.

All these steps must be applied individually to every percentage of valve opening and the

same steps repeated on all centrifugal pump test.

60

3.1.2.2 Progressive cavity pump

This test is held on PU01, PU03 and PU05 to investigate the pump’s characteristics as below at 3

different pump speed (800rpm, 1100rpm and 1500rpm.

1. The relationship between theoretical flow, actual flow and differential pressure.

2. The relationship between brake power and differential pressure.

3. The relationship between volumetric efficiency and flow.

Test setup

Setup for this test can be shown in Figure 31. Water is pumped from the supply tank to discharge

tank during the test. Flow control valve is used to vary the flow and create additional pressure

drop in discharge pipeline. The control valve is fully open (100%) at the beginning of the test

and the reading (water temperature, suction pressure, discharge pressure, water flowrate and

motor speed) are taken. The valve opening then reduced the reducing span of 10% until it

reaches 5%, the lowest percentage of valve opening set by the interlock in UWS system to

ensure the safety of pump. The variation consists of 11 steps in total and reading of the variables

are taken at every valve opening steps for evaluation. Each pump is tested at 3 different speed

(800rpm, 1100rpm and 1500rpm) controlled directly from VSD. 800 rpm is the minimum speed

while 1500rpm is the maximum speed allowed by the VSD.

61

Figure 30: P&ID of progressive cavity pump test setup.



which used to measure the pressure at suction side of the tested pump.

PT2: pressure transmitter with an output range of 1 to 10bar installed just after the pump

discharge port which used to measure the static pressure at the discharge side of the tested pump.

FV: flow control valve used to vary the flow and create an additional pressure drop in discharge



Test procedure


2. Open the control valve to 100% and run the pump at 800rpm.

3. Measure and record the motor speed, water temperature, suction pressure, discharge

pressure and water flowrate.

62

4. Repeat steps 2 and 3 at valve opening of 90%, 80%, 70%, 60%, 50%, 40%, 30%,

20%, 10% and 5.01%.

5. Repeat step 2 to 4 at 1100 rpm and 1500rpm.

Same test setup and procedure applied for all centrifugal pumps’ test.

Data evaluation

1. As mention previously in this report, theoretical flow is obtained through the pump’s

manufacturer datasheet which attached in Appendix A.



3. To calculate the total head loss caused by water velocity in discharge pipeline, Equation 8

and Equation 9 in Section 3.1.1.4 are used to obtain the friction factor. Then, Equation 6

and 7 in the same section are used to calculate the head loss at every percentage of valve

opening.




values must be known and shown in Table 6 below. In this step, head loss coefficient for

every fitting should be calculated individually.

Table 6: fitting information for progressive cavity pump test.

Pump fitting nominal diameter no. of fitting K1 Ki Kd

PU01

Tee 2 4 500 0.274 4

90° elbow 2 4 800 0.14 4

45° elbow 2 1 500 0.071 4.2

gate valve 2 1 300 0.037 3.9

PU03

Tee 2 5 500 0.274 4

90° elbow 2 7 800 0.14 4

45° elbow 2 2 500 0.071 4.2

PU05

Tee 2 5 500 0.274 4

90° elbow 2 8 800 0.14 4

45° elbow 2 2 500 0.071 4.2

63

5. To calculate the head loss caused by percentage of valve opening, Equation 12 and 13 are

applied. Appendix D provided the value of Kv depends on percentage of valve opening

which is required in Equation 12.

6. Calculate the total head loss in discharge using Equation 14 and total discharge head can

be calculated using Equation 4.

7. By using Equation 3, total head at every percentage of valve opening can be obtained

then converted into pressure using Equation 2. The theoretical flow and actual flow

versus differential pressure curves can be potted.

8. To calculate brake power, Equation 16, 17 and 18 are applied.

9. Equation 21 is used to plot volumetric efficiency versus differential pressure curve.

All these steps must be applied individually to every percentage of valve opening and the

same steps repeated on all progressive cavity pump test.

64

3.1.2.2 Air operated double diaphragm pump

PU07 is the only AODD pump in UWS and this pump is tested to investigate its:

1. Minimum required air supply pressure to operate.

2. Relationship between head and flowrate

3. Air consumption of the pump during operation.

This pump went through 2 different test procedures which one to test the minimum required air

supply pressure and the second test is for the head versus flow relationship and air consumption.

For the second test, the pump is tested at three different pressure of air supply, 4bar, 6 bar and 8

bar. 4 bar is just above the minimum operating air supply and 8 bar is the maximum. Both value

obtained from minimum operating air supply pressure (Test 1) and maximum air supply pressure

recommended by manufacturer respectively.

65

Test setup

Setup for this test can be shown in Figure 32. Water is pumped from the supply tank to discharge

tank during the test. Flow control valve is used to vary the flow and create an additional pressure

drop in discharge pipeline. Control valve is fully open (100%) at the beginning of the test and the

reading (water temperature, suction pressure, discharge pressure, water flowrate, air supply

pressure, air supply temperature and air supply flowrate) is taken. The valve opening then

reduced with the reducing span of 10% until it reaches 5.01 %, the lowest percentage of valve

opening allow by the interlock in UWS system to ensure the safety of pump. The variation

consists of 11 steps in total and reading of the variables are taken at every valve opening steps

for evaluation.

Figure 31: test setup.

66


TT2: thermometer used to measure the air supply temperature during the test.


which used to measure the pressure at suction side of tested pump.

PT2: pressure transmitter with output range of 1 to 10bar installed just after the pump discharge

port which used to measure the static pressure at discharge side of tested pump.

PT3: pressure transmitter used to measure the air supply pressure.

FV: flow control valve used to vary the flow and create additional pressure drop in discharge



FT2: flow transmitter used to measure air supply flowrate

Air regulator: used to vary the air supply pressure.

Compressor: used to supply air to pump.

67

Test procedure

Test 1

1. Run the pump.

2. Slowly reduce the air supply pressure at the air supply regulator until the pump stop

operate. Record the data.

3. Repeat stem 1 and 2 for another 2 times.

4. Calculate the mean of recorded value.

Test 2


2. Open the control valve to 100% and run the pump at 4 bar.

3. Measure and record the water temperature, suction pressure, discharge pressure,

water flowrate, air supply pressure, air supply temperature and air supply flowrate.

4. Repeat steps 2 and 3 at valve opening of 90%, 80%, 70%, 60%, 50%, 40%, 30%,

20%, 10% and 5.01%.

5. Repeat step 2 to 4 at 6bar and 8bar air supply pressure.

68

Data evaluation



2. To calculate the total head loss caused by water velocity in discharge pipeline,

Equation 8 and Equation 9 in Section 3.1.1.4 are used to obtain the friction factor.

Then, Equation 6 and 7 in the same section are used to calculate the head loss at every

percentage of valve opening.




values must be known and shown in Table 7 below. In this step, head loss coefficient

for every fitting should be calculated individually.

Table 7: fitting information for PU07 test.

fitting nominal diameter no. of fitting K1 Ki Kd

Tee 2 5 500 0.274 4

90° elbow 2 8 800 0.14 4

45° elbow 2 2 500 0.071 4.2

4. To calculate the head loss caused by percentage of valve opening, Equation 12 and 13

are applied. Appendix D provided the value of Kv depends on percentage of valve

opening which is required in Equation 12.

5. Calculate the total head loss in discharge using Equation 14 and total discharge head

can be calculated using Equation 4.

6. By using Equation 3, total head at every percentage of valve opening can be obtained

and the head versus flowrate curve can be potted.

7. Lastly, air consumption by the pump can be calculated using Equation 2 and the

result is plotted against flow.

69

3.1.2 Flow control valve

Flow control valves that involved in this test are FV01, FV02 and FV03 which located in System

1, System 2 and System 3 respectively. All the flow control valve are tested in the field of:

1. Hysteresis

2. Time response

The same test rig setup is applied to all tested control valves as shown below.

Figure 32: test setup.

3.1.2.1 Hysteresis test

Hysteresis test should be done by having 29 points of input steps with 0.25% interval. Figure 34

shows the input signal for the test that commonly is run at nominal of 50%. However, due to

limited resource, interval of 0.25% of step input is too small to detect. Instead, this test is ran

depending on percentage of opening valve from fully closed to fully open with interval of 20%

control using Labview. A piece of paper is stuck on the valve position indicator as shown in

Figure 35 below and position of stem is marked at every step input. The marking process is done

after the flowrate monitored from LabView reaches steady state which indicates the valve stem

already at its position. It then measured using vernier calliper for data evaluation purpose.

70

Figure 34: hysteresis test step input.

Figure 35: hysteresis marking method.

71

3.1.2.1.1 Test procedure

1. Set up the test rig as in Figure 34 and Figure 35 above.

2. Mark the position when valve is fully closed.

3. Increase the valve opening percentage by to 10% and wait until the water flowrate

reaches steady state then mark the position of valve stem.

4. Repeat step 3 until valve opening reaches 100%.

5. Reduce the valve opening percentage by to 90% and wait until the water flowrate reaches

steady state then mark the position of valve stem.

6. Repeat step 5 until valve opening percentage reaches 0%.

This test procedure applied to all tested valve.

3.1.2.2 Response time test

Response time test is a test held on flow control valve to study its dead time, time constant and

overall time taken for the process to reach 63% of the steady-state output. In this test, tested

valve will be stepped up with 3 different step input interval, which 20% to 40%, 20% to 60% and

20% to 100%. The valve will be stepped up after the monitored output flow reaches steady state

at 20% of valve opening.

72

4.0 Result

4.1 Pump 4.1.1 Centrifugal pumps

4.1.1.1 PU02

Table 8 shows the collected data at 11 different valve opening percentage.

Table 8:PU02 collected data.

valve opening (%)

temperature (°c)

motor speed (rpm)

flowrate (𝑚3/min)

suction pressure (bar)

discharge pressure (bar)

100 24.9 2722 0.053 1.179 2.465

90 24.9 2681 0.052 1.178 2.496

80 24.9 2675 0.052 1.179 2.556

70 25.0 2657 0.050 1.179 2.709

60 25.0 2644 0.048 1.179 2.906

50 24.8 2632 0.043 1.179 3.029

40 24.9 2632 0.037 1.179 3.146

30 25.0 2626 0.031 1.179 3.305

20 24.9 2637 0.024 1.179 3.525

10 24.9 2639 0.016 1.179 4.036

5.01 24.9 2639 0.012 1.178 3.845

73

From the collected data. Total head loss in the system was calculated and value of total discharge

head, total suction head and total head create by PU02 shown in Table 9 and Table 10 shows the

hydraulic power, brake power and efficiency while Figure 34 shows the head and pump

efficiency against flowrate curves. Figure 35 illustrates the power curves of PU02.

Table 9: total head of PU02.

valve opening (%)

flowrate (m3/min)

total discharge head (m)

total suction head (m)

total head (m)

100 0.053 26.210 12.022 14.188

90 0.052 26.639 12.016 14.623

80 0.052 27.415 12.019 15.397

70 0.050 29.154 12.014 17.140

60 0.048 31.407 12.019 19.389

50 0.043 32.831 12.013 20.818

40 0.037 34.202 12.018 22.184

30 0.031 36.184 12.013 24.171

20 0.024 39.132 12.018 27.114

10 0.016 46.851 12.015 34.835

5.01 0.012 51.454 12.011 39.442

74

Table 10: power and efficiency of PU02.

valve opening (%)

flowrate (m3/min)

brake power (kW)

hydraulic power (kW)

pump efficiency (%)

100 0.053 0.266 0.122 45.795

90 0.052 0.232 0.125 53.728

80 0.052 0.228 0.131 57.358

70 0.050 0.216 0.141 65.360

60 0.048 0.208 0.153 73.641

50 0.043 0.201 0.147 73.158

40 0.037 0.201 0.134 66.689

30 0.031 0.198 0.122 61.427

20 0.024 0.204 0.106 51.880

10 0.016 0.205 0.094 45.815

5.01 0.012 0.205 0.080 38.874

75

Figure 33: Head and efficiency curves of PU02.

Blue line shows the head of PU02 aver flow where the maximum head is 39.442m at the flow of

0.012 𝑚3/min. the head decreasing as the flow increasing. Pump efficiency can be observe from

orange line which shows the highest efficiency at flowrate of 0.48 𝑚3/min. From this

experiment, PU02 indicated the best performance at the head of 31.407m as in Table 15.

0

10

20

30

40

50

60

70

80

0

5

10

15

20

25

30

35

40

45

0 0.01 0.02 0.03 0.04 0.05 0.06

EFFI

CIE

NC

Y %

HEA

D (

m)

FLOWRATE (m3/min)

CHARACTERISTIC CURVES

HEAD

PUMPEFFICIENCY

76

Figure 34: power curves of PU02.

Power curves shows the PU02 the output power of the motor and the pump are nearly constant

until the pump delivers water at 0.05 𝑚3/min.

0

0.05

0.1

0.15

0.2

0.25

0.3

0 0.01 0.02 0.03 0.04 0.05 0.06

PO

WER

(kW

)

FLOWRATE (m3/min)

POWER CURVES

brake power (kW)


77

4.1.1.2 PU04

From the experiment on PU04, recorded data shown as in Table 11 and the calculated total head

as in Table 12 below.

Table 11: field collected data for PU04.

valve opening (%)

temperature (°c)

motor speed (rpm)

flowrate (m3/min)



100 25.1 2669 0.0521 1.1781 2.7690

90 25.1 2652 0.0519 1.1777 2.7680

80 25.1 2639 0.0515 1.1782 2.7740

70 25.1 2623 0.0514 1.1778 2.7855

60 25.1 2613 0.0511 1.1779 2.7835

50 25.1 2607 0.0508 1.1775 2.8535

40 25.1 2601 0.0491 1.1779 2.9205

30 25.1 2604 0.0447 1.1775 2.9895

20 25.1 2614 0.0385 1.1781 3.0975

10 25.1 2624 0.0279 1.1777 3.3865

5.01 25.1 2630 0.0204 1.1782 3.6555

Table 12: total head for PU04.

valve opening (%) flowrate (m3/min) total discharge head (m) total static head (m)

total head (m)

100 0.0521 29.1706 12.0099 17.1608

90 0.0519 29.2067 12.0049 17.2018

80 0.0515 29.3265 12.0098 17.3167

70 0.0514 29.5420 12.0041 17.5379

60 0.0511 29.6621 12.0073 17.6548

50 0.0509 30.6174 12.0032 18.6141

40 0.0491 31.8031 12.0073 19.7957

30 0.0447 32.8555 12.0033 20.8522

20 0.0385 35.0618 12.0090 23.0528

10 0.0279 41.0555 12.0049 29.0506

5.01 0.0204 50.6734 12.0106 38.6628

78


valve opening (%) flowrate (m3/min) brake power (kW) hydraulic power (kW) pump efficiency

100 0.0521 0.2235 0.1461 65.3503

90 0.0519 0.2126 0.1461 68.6855

80 0.0515 0.2050 0.1459 71.1513

70 0.0515 0.1963 0.1476 75.2193

60 0.0511 0.1912 0.1475 77.1629

50 0.0509 0.1883 0.1548 82.2356

40 0.0491 0.1855 0.1589 85.6898

30 0.0447 0.1869 0.1525 81.5824

20 0.0385 0.1917 0.1450 75.6501

10 0.0279 0.1968 0.1325 67.3000

5.01 0.0204 0.2000 0.1290 64.4842

From the Table 11 and 12, the data can be plotted as in Figure 36 and 37 below.

Figure 35: characteristic curves of PU04.

0

10

20

30

40

50

60

70

80

90

0

5

10

15

20

25

30

35

40

45

0 0.02 0.04 0.06

EFFI

CIE

NC

Y (%

)

HEA

D (

m)

FLOWRATE (m3/min)


head

PUMPEFFICIENCY

79


The head of PU04 keep decreasing start from 38.67m at flowrate of 0.03𝑚3/𝑚𝑖𝑛 until it reaches

17.16 at flowrate of 0.05𝑚3/𝑚𝑖𝑛. The BEP of this pump located at flowrate of 0.049 𝑚3/𝑚𝑖𝑛

with the highest efficiency, 85.69%. While the power curves show similar thread as PU02.

0

0.05

0.1

0.15

0.2

0.25

0 0.01 0.02 0.03 0.04 0.05 0.06

PO

WER

(kW

)

FLOWRATE (m3/min)

POWER CURVES

BRAKE POWER

HYDRAULIC POWER

80

4.1.1.3 PU06

Table 38 shows the collected data at 11 different valve opening percentage.

Table 14:PU06 collected data.

valve opening (%)

temperature (°c)

motor speed (rpm)

flowrate (m3/min)



100 25.1 2716 0.05626 1.17584 2.3255

90 25.1 2700 0.055265 1.1752 2.3625

80 25.1 2683 0.054256 1.1744 2.418

70 25.1 2672 0.053216 1.17456 2.455

60 25.1 2664 0.052844 1.17376 2.5115

50 25.1 2650 0.051661 1.17384 2.6165

40 25.1 2633 0.050456 1.17344 2.765

30 25.1 2622 0.046352 1.174 2.9665

20 25.1 2634 0.035333 1.17368 3.1865

10 25.1 2643 0.01488 1.17488 3.9025

5.01 25.1 2636 0.003499 1.17552 4.5355

From the collected data. Total head loss in the system were calculated and value of total

discharge head, total suction head and total head create by PU06 shown in Table 14 and Table 15

shows the hydraulic power, brake power and efficiency while Figure 39 shows the head and

pump efficiency against flowrate curves. Figure 40 illustrates the power curves of PU02.

Table 15: total head of PU06.

valve opening (%) flowrate (m3/min)


total static head (m)

total head (m)

100 0.0563 24.7539 11.9861 12.7677

90 0.0553 25.1568 11.9796 13.1772

80 0.0543 25.7728 11.9714 13.8013

70 0.0532 26.2273 11.9730 14.2542

60 0.0528 26.9540 11.9649 14.9890

50 0.0517 28.2385 11.9657 16.2727

40 0.0504 30.3119 11.9616 18.3503

30 0.0464 32.7723 11.9673 20.8050

20 0.0353 35.4778 11.9641 23.5137

10 0.0149 41.8932 11.9763 29.9169

5.01 0.0035 46.9675 11.9828 34.9846

81


valve opening (%)

flowrate (m3/min)

brake power (kW)


pump efficiency (%)

100 0.0563 0.2605 0.1174 45.073

90 0.0553 0.2466 0.1190 48.270

80 0.0543 0.2334 0.1224 52.446

70 0.0532 0.2256 0.1240 54.972

60 0.0528 0.2202 0.1295 58.806

50 0.0517 0.2114 0.1374 65.009

40 0.0504 0.2016 0.1513 75.077

30 0.0464 0.1957 0.1573 80.540

20 0.0353 0.2021 0.1358 67.184

10 0.0149 0.2072 0.0727 35.113

5.01 0.0035 0.2032 0.0200 9.8448

Figure 37: characteristic curves of PU06.

0

10

20

30

40

50

60

70

80

90

0

5

10

15

20

25

30

35

40

0 0.01 0.02 0.03 0.04 0.05 0.06

Axi

s Ti

tle

HEA

D (

m)

FLOWRATE (m3/min)


HEAD

PUMPEFFICIENCY

82


Blue line in Figure 39 shows the head of PU06 0ver flow where the maximum head is 34.98m at

the flow of 0.035 𝑚3/min. the head decreasing as the flow increasing. Pump efficiency can be

observe from orange line which shows the highest efficiency at flowrate of 0.05 𝑚3/min. From

this experiment, PU06 indicated the best performance at the head of 31.407m.

0

0.05

0.1

0.15

0.2

0.25

0.3

0 0.01 0.02 0.03 0.04 0.05 0.06

PO

WER

(kW

)

FLOWRATE (m3/min)

POWER CURVES

BRAKE POWER

HYDRAULIC POWER

83

4.1.2 Progressive cavity pump

4.1.2.1 PU01

Data shown Table 16, 17 and 18 below are the collected data of PU01 at pump speed of 800,

1100 and 1500 respectively.

Table 17: collected data for PU01 test at 800rpm.

valve opening

(%)

temperature (°c)

motor speed (rpm)

theoritical flow

(m3/min)

actual flowrate (m3/min)

suction static head (m)

discharge statichead

(m)

VSD measured

100 23.6 800 799.4 0.0158 0.01477 12.044 21.197

90 23.7 800 799.1 0.0158 0.01473 12.044 21.228

80 23.7 800 799.4 0.0158 0.0147 12.044 21.253

70 23.7 800 799.4 0.0158 0.01466 12.040 21.365

60 23.7 800 799.4 0.0158 0.01462 12.045 21.595

50 23.6 800 799.4 0.0158 0.01456 12.042 21.936

40 23.6 800 799.4 0.0158 0.01446 12.042 22.599

30 23.6 800 799.4 0.0158 0.01446 12.047 24.016

20 23.6 800 798.6 0.0158 0.01444 12.009 26.911

10 23.6 800 797.5 0.0158 0.01335 12.042 33.144

5.01 23.6 800 796.2 0.0158 0.01204 12.048 39.097

Table 18: collected data for PU01 at 1100rpm.

valve opening

(%)

temperature (°c)

motor speed (rpm)

theoretical flowrate (m3/min)


suction pressure

(bar)

discharge pressure

(bar)

VSD

measured

100 23.3 1100 1099 0.02183 0.021223 1.18208 2.1155

90 23.3 1100 1099 0.02183 0.02121 1.18168 2.118

80 23.3 1100 1099 0.02183 0.021207 1.18128 2.1285

70 23.3 1100 1099 0.02183 0.021168 1.18168 2.15

60 23.3 1100 1098 0.02183 0.021232 1.18128 2.203

50 23.3 1100 1099 0.02183 0.021428 1.18176 2.277

40 23.3 1100 1099 0.02183 0.021241 1.18128 2.408

30 23.3 1100 1098 0.02183 0.02068 1.18128 2.6285

20 23.3 1100 1097 0.02183 0.019478 1.18184 3.012

10 23.3 1100 1093 0.02183 0.017358 1.18128 3.709

5.01 23.3 1100 1089 0.02183 0.015692 1.1816 4.2505

84

Table 19: collected data of PU01 at 1500rpm.

valve opening

(%)

temperature (°c)

motor speed (rpm)



suction pressure

(bar)

discharge pressure

(bar)

VSD

measured

100 23.3 1500 1499 0.03 0.0298 1.18112 2.1805

90 23.3 1500 1499 0.03 0.029791 1.18168 2.185

80 23.3 1500 1498 0.03 0.029772 1.18128 2.2035

70 23.3 1500 1498 0.03 0.029751 1.18144 2.252

60 23.3 1500 1497 0.03 0.029501 1.1812 2.343

50 23.3 1500 1497 0.03 0.029226 1.18144 2.4535

40 23.3 1500 1495 0.03 0.028523 1.18112 2.642

30 23.3 1500 1493 0.03 0.027115 1.1816 2.9955

20 23.3 1500 1485 0.03 0.024727 1.18112 3.4525

10 23.3 1500 1457 0.03 0.021165 1.18144 4.234

5.01 23.3 1500 1426 0.03 0.01876 1.1808 4.6975

From the calculations on the collected data, final result evaluated as in Table 19, 20 and 21 for

pump speed at 800, 1100 and 1500 respectively.

Table 20: final result for PU01 at 800rpm.

valve opening

(%)

differential pressure (Bar)

theoritical flow (m3/min)


flowrate slip (%)

volumetric efficiency (%)

100 0.8979 0.0158 0.01477 6.5189 93.48

90 0.9009 0.0158 0.01473 6.7721 93.22

80 0.9034 0.0158 0.0147 6.9620 93.03

70 0.9148 0.0158 0.01466 7.2151 92.78

60 0.93682 0.0158 0.01462 7.4683 92.53

50 0.97064 0.0158 0.01456 7.8481 92.15

40 1.03564 0.0158 0.01446 8.4810 91.51

30 1.17416 0.0158 0.01446 8.4810 91.51

20 1.46184 0.0158 0.01444 8.6075 91.39

10 2.07014 0.0158 0.01335 15.5060 84.49

5.01 2.65358 0.0158 0.01204 23.7974 76.20

85

Table 21: final result of PU01 at rpm1100.

valve opening

(%)




flowrate slip (%)


100 0.967888664 0.02183 0.021223 2.7805 97.21

90 0.970808689 0.02183 0.02121 2.8401 97.15

80 0.981736842 0.02183 0.021207 2.8538 97.14

70 1.002877176 0.02183 0.021168 3.0325 96.96

60 1.05634198 0.02183 0.021232 2.7393 97.26

50 1.129974367 0.02183 0.021428 1.8415 98.15

40 1.261641696 0.02183 0.021241 2.6981 97.30

30 1.482509024 0.02183 0.02068 5.2679 94.73

20 1.866349713 0.02183 0.019478 10.774 89.22

10 2.567849602 0.02183 0.017358 20.485 79.51

5.01 3.12201871 0.02183 0.015692 28.117 71.88

Table 22: final result of PU01 at 1500rpm.

valve opening

(%)




flowrate slip (%)


100 1.033967303 0.03 0.0298 0.6666 99.33

90 1.037946966 0.03 0.029791 0.6966 99.30

80 1.056902175 0.03 0.029772 0.7600 99.24

70 1.105322636 0.03 0.029751 0.8300 99.17

60 1.196678321 0.03 0.029501 1.6633 98.33666667

50 1.307128062 0.03 0.029226 2.5800 97.42

40 1.496263794 0.03 0.028523 4.9233 95.07

30 1.849867281 0.03 0.027115 9.6166 90.38

20 2.308697846 0.03 0.024727 17.576 82.42

10 3.095505774 0.03 0.021165 29.450 70.55

5.01 3.577878257 0.03 0.01876 37.466 62.53

86

From evaluated data in Table 19 above, flow curves shown in Figure 40 below while Figure 41

shown the volumetric efficiency of PU01 at 800 rpm.

Figure 39: flow curve for PU01 at 800rpm.

Figure 40: efficiency curve of PU01 at 800rpm.

0

0.002

0.004

0.006

0.008

0.01

0.012

0.014

0.016

0.018

0.5 1 1.5 2 2.5 3

flo

wra

te (

m3

/min

)


FLOW CURVES

theoriticalflow(m3/min)

actualflowrate(m3/min)

0

10

20

30

40

50

60

70

80

90

100

0.5 1 1.5 2 2.5 3

volu

me

tric

eff

icie

ncy

(%

)


volumetric efficiency

volumetric efficiency(%)

87

Graph plotted based on final result of PU01 at 1100 rpm and 1500 rpm are shown below.

Figure 41: flow curves for PU01 at 1100 rpm.

Figure 42: efficiency curves for PU01 at 1100rpm.

0

0.005

0.01

0.015

0.02

0.025

0 1 2 3 4

flo

wra

te (

m3

/min

)

differential pressure (bar)

flow curves

theoreticalflow

actual flow

0

20

40

60

80

100

120

0 1 2 3 4

effi

cien

cy (

%)


efficiency curve

volumetricefficiency(%)

88

Figure 43: flow curves of PU01 at 1500 rpm.

Figure 44: efficiency curve for PU01 at 1500 rpm.

Overall, this test shows that the efficiency of PU01 decrease as the motor speed increase. From

the result the minimum efficiency at speed of 800rpm, 1100rpm and 1500rpm is 76%, 71% and

62% respectively.

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

1 1.5 2 2.5 3 3.5 4

FLO

WR

ATE

(m

3/m

in)

DIFFERENTIALPRESSURE( bar)

FLOW CURVES

theoreticalflow

actual flow

0

20

40

60

80

100

120

1 1.5 2 2.5 3 3.5 4

effi

cien

cy (

%)

flowrate (m3/min)

efficiency curve


89

4.1.2.2 PU03

Data shown Table 22, 23 and 24 below are the collected data of PU03 at pump speed of 800,

1100 and 1500 respectively.

Table 23: collected data for PU03 at 800 rpm.

valve opening

(%)

temperature (°c)

motor speed (rpm)



suction pressure

(bar)

discharge pressure

(bar) VSD

measured

100 23.3 800 779.2 0.0158 0.01431 1.1812 2.3255

90 23.3 800 799.1 0.0158 0.014289 1.18096 2.3255

80 23.3 800 799.1 0.0158 0.014276 1.18144 2.326

70 23.3 800 799.1 0.0158 0.01427 1.18096 2.329

60 23.3 800 798.9 0.0158 0.014265 1.18136 2.33

50 23.3 800 798.9 0.0158 0.014259 1.18096 2.3375

40 23.3 800 798.6 0.0158 0.014322 1.18152 2.3425

30 23.3 800 798.6 0.0158 0.014353 1.18088 2.36

20 23.3 800 789.6 0.0158 0.014292 1.18144 2.3935

10 23.3 800 798.3 0.0158 0.014202 1.18096 2.543

5.01 23.3 800 797.8 0.0158 0.013798 1.18136 2.7855


valve opening

(%)

temperature (°c)

motor speed (rpm)



suction pressure

(bar)

discharge pressure

(bar) VSD

measured

100 23.3 800 779.2 0.02183 0.020734 1.18072 2.352

90 23.3 800 799.1 0.02183 0.020735 1.18088 2.3525

80 23.3 800 799.1 0.02183 0.020694 1.18136 2.3535

70 23.3 800 799.1 0.02183 0.020681 1.1808 2.3555

60 23.3 800 798.9 0.02183 0.020662 1.18112 2.3595

50 23.3 800 798.9 0.02183 0.020659 1.1808 2.37

40 23.3 800 798.6 0.02183 0.020655 1.18096 2.383

30 23.3 800 798.6 0.02183 0.020653 1.18088 2.4165

20 23.3 800 789.6 0.02183 0.020501 1.1812 2.4845

10 23.3 800 798.3 0.02183 0.019868 1.1808 2.7505

5.01 23.3 800 797.8 0.02183 0.018491 1.18136 3.135

90


valve opening

(%)

temperature (°c)

motor speed (rpm)



suction pressure

(bar)

discharge pressure

(bar)

VSD

measured

100 23.4 1500 1500 0.03 0.029449 1.18064 2.397

90 23.4 1500 1500 0.03 0.029169 1.18032 2.3965

80 23.4 1500 1500 0.03 0.028987 1.18008 2.395

70 23.4 1500 1500 0.03 0.02877 1.18 2.4005

60 23.4 1500 1500 0.03 0.028515 1.18016 2.417

50 23.4 1500 1500 0.03 0.028419 1.17976 2.428

40 23.4 1500 1500 0.03 0.028293 1.18008 2.454

30 23.4 1500 1499 0.03 0.027917 1.18024 2.508

20 23.4 1500 1498 0.03 0.02773 1.17992 2.6295

10 23.4 1500 1494 0.03 0.026318 1.1804 3.028

5.01 23.4 1500 1484 0.03 0.023574 1.18016 3.5805

From the calculations on the collected data, final result evaluated as in Table 25, 26 and 27 for

pump speed at 800, 1100 and 1500 respectively.

Table 26: final result for PU03 at 800 rpm.

valve opening

(%)




flowrate slip (%)


100 1.181637707 0.0158 0.01431 9.4303797 90.56962025

90 1.181881243 0.0158 0.014289 9.5632911 90.43670886

80 1.181906317 0.0158 0.014276 9.6455692 90.35443038

70 1.185393757 0.0158 0.01427 9.6835443 90.3164557

60 1.186005323 0.0158 0.014265 9.7151898 90.28481013

50 1.193924537 0.0158 0.014259 9.7531645 90.24683544

40 1.198414003 0.0158 0.014322 9.3544303 90.64556962

30 1.216618828 0.0158 0.014353 9.1582278 90.84177215

20 1.249777804 0.0158 0.014292 9.5443037 90.4556962

10 1.400906411 0.0158 0.014202 10.113924 89.88607595

5.01 1.64729233 0.0158 0.013798 12.670886 87.32911392

91

Table 27: final result of PU03 at 1100 rpm.

valve opening

(%)




flowrate slip (%)


100 1.208689143 0.02183 0.020734 5.0206138 94.97938617

90 1.209036887 0.02183 0.020735 5.0160329 94.98396702

80 1.20956728 0.02183 0.020694 5.2038479 94.79615208

70 1.212142772 0.02183 0.020681 5.2633989 94.73660101

60 1.21584686 0.02183 0.020662 5.3504351 94.64956482

50 1.226707298 0.02183 0.020659 5.3641777 94.63582226

40 1.239648332 0.02183 0.020655 5.3825011 94.61749885

30 1.273361142 0.02183 0.020653 5.391662 94.60833715

20 1.341488531 0.02183 0.020501 6.0879523 93.91204764

10 1.610093224 0.02183 0.019868 8.9876316 91.0123683

5.01 2.001475624 0.02183 0.018491 15.295464 84.70453504

Table 28: final result of PU03 at 1500 rpm.

valve opening

(%)




flowrate slip (%)


100 1.25386244 0.03 0.029449 1.8366666

67 98.16333333

90 1.253695386 0.03 0.029169 2.77 97.23

80 1.252454018 0.03 0.028987 3.3766666

67 96.62333333

70 1.258060761 0.03 0.02877 4.1 95.9

60 1.274443979 0.03 0.028515 4.95 95.05

50 1.285918517 0.03 0.028419 5.27 94.73

40 1.311784847 0.03 0.028293 5.69 94.31

30 1.365852555 0.03 0.027917 6.9433333

33 93.05666667

20 1.488493953 0.03 0.02773 7.5666666

67 92.43333333

10 1.890317555 0.03 0.026318 12.273333

33 87.72666667

5.01 2.454756821 0.03 0.023574 21.42 78.58

92

From evaluated data in Table 25 above, flow curves shown in Figure 47 below while Figure 48

shown the volumetric efficiency of PU01 at 800 rpm.

Figure 45: flow curve of PU03 at 800 rpm.

Figure 46: efficiency curve at 800 rpm.

0.013

0.0135

0.014

0.0145

0.015

0.0155

0.016

1 1.2 1.4 1.6 1.8

flo

wra

te (

m3

/min

)


FLOW CURVES



87

87.5

88

88.5

89

89.5

90

90.5

91

91.5

1 1.2 1.4 1.6 1.8

effi

cien

cy (

%)


efficiency curve


93

Graph plotted based on final result of PU01 at 1100 rpm and 1500 rpm are shown below.


Figure 48: efficiency curve of PU03 at 1100 rpm.

0.018

0.0185

0.019

0.0195

0.02

0.0205

0.021

0.0215

0.022

1 1.2 1.4 1.6 1.8 2 2.2

flo

wra

te (

m3

/min

)


flow curves



84

86

88

90

92

94

96

1 1.2 1.4 1.6 1.8 2 2.2

effi

cien

cy (

%)


efficiency curve


94

Figure 49: flow curves of PU03 at 1500rpm.


Overall, this test shows that the efficiency of PU03 decrease as the motor speed increase. From

the result the minimum efficiency at speed of 800rpm, 1100rpm and 1500rpm is 87%, 84% and

78% respectively.

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

1 1.5 2 2.5 3

flo

wra

te (

m3

/min

)


flow curves

theoritical flow(m3/min)

actual flowrate(m3/min)

0

20

40

60

80

100

120

1 1.5 2 2.5 3

effi

cien

cy (

%)


Efficiency curve


95

4.1.2.3 PU05

Data shown Table 28 and 29 below are the collected data and final result of PU03 at pump speed

of 800 rpm.


valve opening

(%)

temperature (°c)

motor speed (rpm)



suction pressure

(bar)

discharge pressure

(bar)

VSD measured

100 23.4 800 777.5 0.036 0.035009 1.1788 2.22

90 23.4 800 777.2 0.036 0.034949 1.1784 2.222

80 23.4 800 777.2 0.036 0.034737 1.17864 2.236

70 23.4 800 777.7 0.036 0.034713 1.1784 2.2515

60 23.4 800 777.8 0.036 0.034493 1.17896 2.272

50 23.4 800 779 0.036 0.034181 1.17848 2.3265

40 23.4 800 780.9 0.036 0.033956 1.1788 2.407

30 23.4 800 785.8 0.036 0.03371 1.17832 2.587

20 23.4 800 800 0.036 0.033323 1.17888 3.1295

Table 30: final result for PU05 at 800 rpm.

valve opening

(%)




flowrate slip (%)


100 1.07876109 0.036 0.035009 2.7527777 97.24722222

90 1.081182141 0.036 0.034949 2.9194444 97.08055556

80 1.094969351 0.036 0.034737 3.5083333 96.49166667

70 1.110753044 0.036 0.034713 3.575 96.425

60 1.130756416 0.036 0.034493 4.1861111 95.81388889

50 1.185841797 0.036 0.034181 5.0527777 94.94722222

40 1.266288143 0.036 0.033956 5.6777777 94.32222222

30 1.447110651 0.036 0.03371 6.3611111 93.63888889

20 1.99022418 0.036 0.033323 7.4361111

11 92.56388889

96

Through data evaluation process, the final result of PU05 at 800 rpm are illustrated as Figure 53

and Figure 54 below.



0.033

0.0335

0.034

0.0345

0.035

0.0355

0.036

0.0365

1 1.5 2 2.5

flo

wra

te (

m3

/min

)


flow curves

theoriticalflow (m3/min)


92

93

94

95

96

97

98

1 1.2 1.4 1.6 1.8 2 2.2

effi

cien

cy (

%)


Efficiency curve


97

However, data collected from PU05 at 1100 cannot be evaluated because the flow regime in this

test is a transitional flow which the flow is in the exchange condition from laminar flow to

turbulent flow. This type of flow have the Reynolds number value between 2300 and 4000.

Transitional flow known as very unstable flow in term of flowrate and its particles movement

which make it almost impossible to analyze. Besides no solution to find the friction factor for

this type of flow. Value of Reynolds number in this test at every percentage of valve opening

show in Table 30 below.

Table 31: Reynolds number of PU05 at 1100 rpm.

valve opening (%)

temperature (°c)

velocity (m/min)

density (kg/m3)

dynamic viscosity (kg/m min)

relative roughness Reynolds no

friction factor

100 23.3 3.877461

538 997 0.0497688 0.00375 3107.03023

1 NA

90 23.3 3.875538

462 997 0.0497688 0.00375 3105.48925

9 NA

80 23.3 3.865230

769 997 0.0497688 0.00375 3097.22965

1 NA

70 23.3 3.862692

308 997 0.0497688 0.00375 3095.19556

9 NA

60 23.3 3.870076

923 997 0.0497688 0.00375 3101.1129 NA

50 23.3 3.861769

231 997 0.0497688 0.00375 3094.45590

3 NA

40 23.3 3.899846

154 997 0.0497688 0.00375 3124.96714 NA

30 23.3 3.884 997 0.0497688 0.00375 3112.26953

4 NA

20 23.3 3.987153

846 997 0.0497688 0.00375 3194.92725

1 NA

While the result from PU05 test at 1500 rpm, transitional flow occurs when the valve opening is

below 40%. So, in this test, only collected data start from 40% of valve opening and above will

be evaluate. However, the flow regime just only changing from the transitional phase and this

condition caused the actual flowrate is not too stable and the result is not as much as expected.

Table 32 below show the final result of PU03 at 1500 rpm while Figure 54 and Figure 55 show

the performance curves.

98

Table 32: final result of PU05 at 1500rpm.

valve opening

(%)




flowrate slip (%)


100 1.478447591 0.072 0.06955 3.4027777

78 96.59722222

90 1.549328594 0.072 0.06938 3.6388888

89 96.36111111

80 1.715251061 0.072 0.06938 3.6388888

89 96.36111111

70 1.751258324 0.072 0.07029 2.375 97.625

60 1.856540349 0.072 0.07029 2.375 97.625

50 2.132869681 0.072 0.07121 1.0972222

22 98.90277778

40 2.338910428 0.072 0.06949 3.4861111

11 96.51388889


0.069

0.0695

0.07

0.0705

0.071

0.0715

0.072

0.0725

1 1.5 2 2.5

flo

wra

te (

m3

/min

)

differential flow (bar)

flow curves



99


96

96.5

97

97.5

98

98.5

99

99.5

1 1.5 2 2.5

effi

cien

cy (

%)

differential flow (bar)

Efficiency curve


100

4.1.3 Air Operated Double diaphragm Pump.

Test 1

Table 32 below shows the result for Test 1 on PU07. The mean of all 3 trials indicate the

minimum required air supply pressure by PU07 to operate which approximately 4bar.

Table 33: minimum air supply pressure required by PU07.

trial air supply pressure (bar)

1 3.61

2 3.58

3 3.59

minimum air supply (bar) 3.59

Test 2

Table 34: collected data for PU07 at air supply of 4 bar.

valve opening (%)

water temperature (°C)

air temperature (°C)

water flowrate (m3/min)

air flowrate (m3/min)

air pressure (bar)

static suction pressure (bar)

static discharge pressure (bar)

standard air flowrate (m3/min)

100 25.2 22 0.0086 17.5267 4.417 1.17944 2.54 698470.252

90 25.2 22 0.00839 17.4268 4.422 1.1792 2.565 695275.067

80 25.2 22 0.008119 17.2543 4.427 1.17928 2.635 689167.951

70 25.2 22 0.00784 17.1891 4.392 1.1792 2.645 681147.453

60 25.2 22 0.00754 17.1455 4.451 1.17904 2.66 688685.670

50 25.2 22 0.0074 17.1673 4.442 1.1792 2.73 688015.203

40 25.2 22 0.00678 17.2181 4.442 1.17928 2.755 690049.465

30 25.2 22 0.00623 17.3120 4.432 1.176 2.745 692252.431

20 25.2 22 0.00589 17.1310 4.357 1.17912 2.76 673444.429

10 25.2 22 0.00529 17.0142 4.42 1.1792 2.905 678811.391

5.01 25.2 22 0 16.4023 4.432 1.17928 3.805 655877.870

101

Table 35: collected data for PU07 at 6bar air supply pressure.

valve opening (%)





air pressure (bar)




100 25.2 22 0.00888 17.6401 6.638 1.17928 2.55 1056472.56

90 25.2 22 0.0088 17.4554 6.658 1.17928 2.66 1048553.81

80 25.2 22 0.00866 17.4483 6.682 1.17912 2.72 1052053.19

70 25.2 22 0.00863 17.3910 6.658 1.17912 2.755 1044685.38

60 25.2 22 0.00855 17.3479 6.682 1.1792 2.835 1046004.37

50 25.2 22 0.0083 17.3408 6.583 1.1792 2.845 1029953.78

40 25.2 22 0.00802 17.2615 6.583 1.1788 2.875 1025245.89

30 25.2 22 0.00798 17.2976 6.658 1.17912 2.885 1039072.24

20 25.2 22 0.00696 17.2905 6.717 1.17912 2.89 1047982.28

10 25.2 22 0.00618 17.3048 6.677 1.17912 3.38 1042622.05

5.01 25.2 22 0.00407 17.2831 6.687 1.17912 5.64 1042875.57

Table 36: collected data for PU07 at 8bar supply pressure.

valve opening (%)





air pressure (bar)




100 25.2 22 0.01041 18.9814 7.621 1.17928 2.47 1305185.5

90 25.2 22 0.00985 18.3196 7.581 1.17928 2.715 1253082.2

80 25.2 22 0.00947 18.8165 7.501 1.17912 2.735 1273510.2

70 25.2 22 0.00942 18.1487 7.546 1.17912 2.745 1235669.9

60 25.2 22 0.00938 18.5025 7.546 1.1792 2.785 1259755.7

50 25.2 22 0.00867 18.3196 7.226 1.1792 2.815 1194511.6

40 25.2 22 0.00845 18.1830 7.491 1.1788 2.825 1228999.6

30 25.2 22 0.00792 18.5832 7.451 1.17912 2.835 1249349.6

20 25.2 22 0.00712 18.1075 7.815 1.17912 2.845 1276891.2

10 25.2 22 0.00631 18.0661 7.815 1.17912 3.495 1273974.8

5.01 25.2 22 0.00418 19.6336 7.182 1.17912 5.99 1272227.6

102

After the evaluation of collected data, final result of PU07 test at all those 3 different air supply

pressure are shown in Table 36, 37 and 38 below. While the evaluated data can be plotted into a

graph as in Figure 57, 58 and 59 show the head curves of PU07 at 4 bar, 6 bar and 8 bar air

supply pressure respectively.

Table 37: evaluated data for PU07 at 4 bar air supply pressure.

valve opening (%)

flowrate (m3/min)



total head (m)

100 0.0086 26.24229814 12.02283384 14.21946429

90 0.00839 26.49716987 12.02038736 14.47678251

80 0.008119 27.2107279 12.02120285 15.18952505

70 0.00784 27.31267034 12.02038736 15.29228298

60 0.00754 27.46558884 12.01875637 15.44683247

50 0.0074 28.17918911 12.02038736 16.15880175

40 0.00678 28.43408879 12.02120285 16.41288593

30 0.00623 28.33221253 11.98776758 16.34444494

20 0.00589 28.48545052 12.01957187 16.46587865

10 0.00529 29.96491706 12.02038736 17.9445297

5.01 0 39.13695209 12.02120285 27.11574924


valve opening (%) flowrate (m3/min) total discharge head (m)


total head (m)

100 0.00888 26.344279 12.02120285 14.32307615

90 0.0088 27.4655946 12.02120285 15.44439175

80 0.00866 28.07722621 12.01957187 16.05765435

70 0.00863 28.43403022 12.01957187 16.41445836

60 0.00855 29.24956116 12.02038736 17.2291738

50 0.0083 29.35154458 12.02038736 17.33115722

40 0.00802 29.65748427 12.01630989 17.64117438

30 0.00798 29.75961836 12.01957187 17.74004649

20 0.00696 29.81094336 12.01957187 17.79137149

10 0.00618 34.80783969 12.01957187 22.78826782

5.01 0.00407 57.84766571 12.01957187 45.82809385

103


valve opening (%)

flowrate (m3/min)


total static suction head (m)

total head (m)

100 0.01041 25.52887809 12.02120285 13.5076752

90 0.00985 28.02631249 12.02120285 16.0051096

80 0.00947 28.23018572 12.01957187 16.2106138

70 0.00942 28.33215117 12.01957187 16.3125793

60 0.00938 28.73994738 12.02038736 16.7195600

50 0.00867 29.04577116 12.02038736 17.0253838

40 0.00845 29.14785845 12.01630989 17.1315485

30 0.00792 29.24992337 12.01957187 17.2303515

20 0.00712 29.35227948 12.01957187 17.3327076

10 0.00631 35.98024468 12.01957187 23.9606728

5.01 0.00418 61.41574122 12.01957187 49.3961693

.

Figure 55: head curve of PU07 at 4bar air supply pressure.

0

5

10

15

20

25

30

0 0.002 0.004 0.006 0.008 0.01

HEA

D (

m)

flowrate (m3/min

HEAD CURVE)

104



From the overview, this test proves that the higher the air pressure supply, the bigger the total

head range produced. At 8 bar air supply, PU07 produce highest head at almost 50 meters and

lowest head is approximately 11 meters.

0

10

20

30

40

50

0.004 0.005 0.006 0.007 0.008 0.009 0.01

hea

d (

m)

flowrate(m3/min)

HEAD CURVE

0

10

20

30

40

50

60

0.004 0.005 0.006 0.007 0.008 0.009 0.01 0.011

hea

d (

m)

flowrate (m3/min)

HEAD CURVE

105

Figure 60, 61 and 63 below show the air consumption by the PU07 at 4 bar, 6 bar and 8 bar

respectively.

Figure 58: air consumption at 4 bar air supply pressure.


650000

660000

670000

680000

690000

700000

710000

0 0.002 0.004 0.006 0.008 0.01

air

con

sum

pti

on

(m

3/m

in)

flowrate (m3/min)

air consumption (m3/min)

1020000

1025000

1030000

1035000

1040000

1045000

1050000

1055000

1060000

0.004 0.005 0.006 0.007 0.008 0.009air

con

sum

pti

on

(m

3/m

in)

flowrate (m3/min)

air consumption

106


Measuring air consumption by AODD pump is the most critical phase because it need very

precise value of some variables such as air temperature, pressure, humidity and some others. The

best way to measure air consumption is by using SCFM meter. However, due to equipment

limitation, resulting the collected data are not accurate to obtain satisfying outcome.

1180000

1200000

1220000

1240000

1260000

1280000

1300000

1320000

0.004 0.005 0.006 0.007 0.008 0.009 0.01 0.011

air

con

sum

pti

on

(m

3/m

in)

flowrate (m3/min)

AIR CONSUMPTION

107

4.2 Flow Control Valve 4.2.1 Hysteresis test

Table 39 shows the valve input percentage and actual valve stem travel for both opening and

closing direction for FV01, FV02 and FV03.

Table 40: valve hysteresis test collected data.

valve input (%)

actual valve stem travel

opening (cm)

closing (cm) opening (%) closing(%)

FV01

0 0 0 0 0

20 0.28 0.29 23.33 24.17

40 0.49 0.5 40.83 41.67

60 0.71 0.71 59.17 59.17

80 1 0.98 83.33 81.67

100 1.2 1.2 100 100

FV02

0 0 0 0 0

20 0.29 0.3 26.36 27.27

40 0.55 0.58 50 52.73

60 0.78 0.79 70.91 71.82

80 1.04 1.04 94.55 94.55

100 1.1 1.1 100 100

FV03

0 0 0 0 0

20 0.17 0.24 13.6 19.2

40 0.49 0.56 39.2 44.8

60 0.74 0.77 59.2 61.6

80 1 1.07 80 85.6

100 1.25 1.25 100 100

From the data in Table 39 above, Figure 63, 64 and 65 show the relationship between the valve

input and actual valve position for FV01, FV02 and FV03 respectively. Blue line indicate the

valve position on opening path while red line for closing path.

108

Figure 61: Hysteresis test result for FV01.


0

20

40

60

80

100

120

0 20 40 60 80 100 120

valv

e o

pe

nin

g(%

)

input signal (%)

FV01

opening

closing

0

20

40

60

80

100

120

0 20 40 60 80 100 120

valv

e o

pe

nin

g (%

)

input signal (%)

FV02

opening

closing

109


As the test summary, FV01 shows the lowest hysteresis while FV03 which operated using

electrical motor have the highest hysteresis as expected. Mechanical design such as gear will

create bigger friction which lead to higher hysteresis.

0

20

40

60

80

100

120

0 20 40 60 80 100 120

ste

m p

osi

tio

n (

%)

input signal (%)

FV03

opening

closing

110

4.2.2 Response Time test.

4.2.2.1 FV01

Figure 66, 67 and 68 below show the respond of water flow over time at valve opening interval

of 20%, 40% and 80% respectively.

Figure 64: 20% valve opening interval for FV01.

Figure 65: 40% valve opening interval for FV0l.

20

25

30

35

40

20

25

30

35

40

45

0 50 100 150 200 250 300

flo

wra

te (

l/m

in)

valv

e in

pu

t(%

)

time (s)

FV01

valveop…

0

10

20

30

40

50

60

20

30

40

50

60

70

0 20 40 60 80 100 120

flo

wra

te (

l/m

in)

valv

e in

pu

t (%

)

time (s)

FV01 valveinput

flowrate

111


The comparison of response time for FV01 at different valve opening interval shown in Table

40.

Table 41: FV01 response test summary.

Valve opening interval (%) dead time (s) time constant (s) response time (s)

20 4 10 14

40 3 4 7

80 3 4 7

FV01 have the longer response time of 14 seconds at lower valve opening interval of 20%.

0

10

20

30

40

50

60

20

40

60

80

100

120

0 10 20 30 40 50 60

flo

wta

re (

l/m

in)

valv

e in

pu

t (%

)

time (s)

FV01

valveinput

flowrate

112

4.2.2.1 FV02





0

5

10

15

20

25

30

0

5

10

15

20

25

30

35

40

45

0 10 20 30 40 50 60 70

flo

wra

te (

l/m

in)

valv

e in

pu

t (%

)

time (s)

FV02

valve input

flowrate

0

5

10

15

20

25

30

0

10

20

30

40

50

60

70

0 5 10 15 20 25 30 35 40

flo

wra

te (

l/m

in)

valv

e in

pu

t (%

)

time (s)

FV02

flowrate

valveinput

113

Figure 69: 80% interval for FV02.


41.

Table 42: FV02 response test summary.


20 5 8 13

40 5 9 14

80 5 9 14

Response time for FV02 is almost constant at any valve opening interval.

0

5

10

15

20

25

30

0

20

40

60

80

100

120

50 60 70 80 90 100 110

flo

wra

te (

l/m

in)

valv

e in

pu

t (%

)

time (s)

FV02

valveinput

flowrate

114

4.2.2.2 FV03





0

10

20

30

40

50

60

0

5

10

15

20

25

30

35

40

45

0 20 40 60 80 100 120

flo

wra

te (

l/m

in)

Axi

s va

lve

inp

ut

(%)

time (s)

FV03

valv…

0

10

20

30

40

50

60

0

10

20

30

40

50

60

70

0 50 100 150 200

flo

wra

te (

l/m

in)

valv

e in

pu

t (%

)

time (s)

FV03

valveinput

flowrate

115



42.

Table 43: result summary for response test of FV03.


20 4 10 14

40 8 30 38

80 12 38 50

Summary from Table 42 shows the time response of FV3 is greatly increase as the valve opening

interval increasing.

0

10

20

30

40

50

60

0

20

40

60

80

100

120

0 50 100 150 200 250 300 350

flo

wra

te (

l/m

in)

valv

e in

pu

t (%

)

time (s)

FV03

valveinput

116

5.0 Conclusion

Overall, all the experiments considered as successes where almost all the outcomes obtained as

expected except several characteristic such us air consumption by AODD pump test result.in

order to obtain accurate result, several factors need to fulfill in the scope of test setup, method

and device used for collecting data and method applied for data evaluation.

Every test should have individual isolated test rig with minimum fitting or other factor that can

caused disturbance in the system. Right and suitable equation used for data evaluation also one

of the important aspect to considered.

117

6.0 Future works

Several improvement can be done in this test for a better test result such as:

1. Develop LabView program based on the concept of Valvelink program by Fisher to

evaluate the hysteresis of control valve. Suitable and accurate sensor is required to

measure the percentage of valve opening precisely and accurately.

2. Use pressurize tank instead of control valve to vary the pressure in pump test. So the

maximum and minimum head can be obtained accurately.

3. For both pump and valve test, individual isolated test rig is suggested. The test rig

construction must according to the standard or guideline by America Petroleum Institute

(API) or other acceptable standards.

118

7.0 References

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123

8.0 Appendices

Appendix A

Figure 73: datasheet of CP800

124

Figure 74: CP25 datasheet.

125

Appendix B 1.1.1 FLOW COEFFICIENT, RANGEABILITY AND INHERENT GAIN TEST

Objective of this test is to determine the flow characteristic by developing the Kv versus

percentage of opening valve (0% - 100%) graph and to know the rangeability for every

flow control valves involved. The test rig shows in Figure 1 below as design by standard

ANSI/ISA-75.02-1996 in order to calculate practically the Kv of incompressible fluid

(water) [51].

Figure 75:Kv test rig [51].

According to the mathematical equation outlined by the ANSI/ISA-75.01, value of rated

Kv can be calculated using the equation 1 below [51]:

𝐾𝑣 =𝑞

51.9𝐹𝑝(

𝐺𝑓

∆𝑝)0.5 (Eq 1)

Where:

Kv: valve flow coefficient measured in cubic meters per hour (𝑚3 ℎ𝑟⁄ ).

q: rated volumetric flowrate measured by FT in cubic meters per hour (𝑚3 𝑚𝑖𝑛⁄ ).

Fp: piping geometry factor. This dimensionless variable considered as 1 if no

other reducer or expander attached to the test specimen.

126

Gf: liquid specific gravity at upstream condition. This dimensionless variable can

be obtained by equation 2.

Last calculation in this test is rangeability. Rangeability is the ratio of highest Kv to the lowest

Kv can can be obtain by Equation 4 below [52]:

Rangeability = ℎ𝑖𝑔ℎ𝑒𝑠𝑡 𝐾𝑣

𝐿𝑜𝑤𝑒𝑠𝑡 𝐾𝑣 (Eq 4)

Control valve inherent gain is the change in rated Kv divided by change in rated percentage of

valve travel. If 0 is used as initial value for both Kv and percentage of valve travel, inherent gain

can be calculated as [51, 52]:

Inherent gain = 𝑟𝑎𝑡𝑒𝑑 𝐾𝑣

𝑟𝑎𝑡𝑒𝑑 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑜𝑓 𝑣𝑎𝑙𝑣𝑒 𝑜𝑝𝑒𝑛𝑖𝑛𝑔 (Eq 5)

Test procedure

1. Setup the test rig as in Figure 76.

2. Adjust the tested valve opening percentage to 10%.

3. Adjust the upstream throttling valve until the pressure at PT1 exceed the value as in

Table 2.

4. Record the measurement at flowing water temperature (TT), water flowrate (FT),

upstream pressure (PT1) and downstream pressure (PT2).

5. Calculate the differential pressure across the tested control valve.

6. Calculate the value of Gf using Equation 2.

7. Calculate the value of Kv using Equation 1.

8. Repeat steps 2 to 7 for 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% and 100% of

opening valve.

9. Calculate the value of rangeability using Equation 4.

10. Calculate the inherent gain using Equation 5.

11. Plot graph Kv and inherent gain versus percentage of opening valve.

127

Appendix C

Figure 76: Moody chart.

128

Appendix D

Figure 77: Kv value for Badger valve.

Figure 78: Kv value for Baumann 24000 valve.

0

1

2

3

4

5

6

0 20 40 60 80 100

Kv

(m3

/hr)

valve opening (%)

Badger's RCV characteristic curve

0

1

2

3

4

5

6

7

8

9

0 20 40 60 80 100

Kv

(m3

/hr)

valve opening (%)

Baumann's 24000 CV characteristic curve

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ENGINEERING HONOURS THESIS · Pump PU01 or PU02 will be used separately to pump the water into Tank...

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