PROJECT PPTON

DESIGN, INSTALLATION AND FABRICATION OF RECIPROCATING PUMP

UNDER THE GUIDANCE OFDR. MANOJ KUMAR BARAIASSOCIATE PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERINGFUTURE INSTITUTE OF ENGINEERING &

MANAGEMENT,KOLKATA-700150, INDIA

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ACKNOWLEDGEMENTWe are highly grateful to the authorities of FUTURE INSTITUTE OF

ENGINEERING & MANAGEMENT, KOLKATA for providing this opportunity

to carry out the project work.

We would like to express a deep sense of gratitude & thank profusely to our thesis

guide Dr. Manoj kumar Barai for his sincere & invaluable guidance, suggestions &

attitude which inspired us to submit project report in the present form..

We are also thankful to other faculty members of Mechanical department, FIEM,

Kolkata for their intellectual support. Our special thanks are due to our

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TEAM MEMBERS• SOURAV JANA

• JAMES BABY

• KRISHNENDU PRAMANIK

• MD SHABBIR

• SUPRIYA GHOSAL

• ANIRBAN BISWAS

• KUNAL ADHIKARI

• ARNAB DEB

• SANJU KUMAR SANJAY

• PRAMOD SINGH

• SANDEEP KUMAR

• ARNAB MAITRA

• RAHUL KUMAR

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OBJECTIVES

Construct a demonstration facility consisting reciprocating pump.

Install & test the performance of pump.

Facilitate civilians by providing water for various purposes.

To socialize the technology.

Theoretical knowledge into practical knowledge.

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CLASSIFICATION

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CONSTRUCTIONAL DETAILS

Piston or plunger

Crank and Connecting rod

Suction pipe

Delivery pipe

Suction and Delivery valve

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DETAILED DRAWING

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WORKING PRINCIPLE

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PERFORMANCE

MAJOR TERMSBrake Horsepower(BHP)

Capacity(Q)

Pressure(Pd)

Mechanical efficiency(Em)

Displacement(D)

Slip(s)

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MINOR TERMSValve Loss(VL)

Speed(n)

Pulsations

Net Positive Suction Head Required(NPSHR)

Net Positive Suction Head Available(NPSHA)

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SELECTION CRITERIA OF PUMPList the important considerations in the selection of a pump for any given application

Flow rate requirement

Operating speed of pump

Pressure rating

Performance/application

Reliability

Cost

Noise level of the pump

Oil compatibility

Type of pump control

Pump contamination tolerance

Availability of pump and parts11

DESIGNING OF DIFFERENT COMPONENTS

SPEED OF THE MOTOR= 1800 RPM

DIA OF MOTOR’S PINION= 5CM

DIA OF GEAR= 18CM

NOW, THE REDUCED SPEED OF GEAR= 500 RPM

CRANK’S DIA =30CM

CONNECTING ROD’S LENGTH= 30CM

CYLINDER’S LENGTH= 40CM

INNER DIA OF CYLINDER=15CM

OUTER DIA OF CYLINDER=17CM

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LENGTH OF PISTON ROD= 50CM

DIA OF PISTON= 15CM

THICKNESS OF PISTON= 5 CM

WE KNOW THAT,

VELOCITY OF THE CRANK = VELOCITY OF PISTON

RECIPROCATING SPEED OF PISTON= 2*L* N=80N CM/S

VELOCITY OF CRANK=3.14*30*500/60=785.4CM/S

SO, 80N=785.4

=)N = 9.82=10

FLOWRATE =3.14*(15^2)/4*2*40*10 = 0.1413 CUM/S

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NET FLOW VELOCITY = 20 M/S

C.S AREA OF VALVES=Q/V=3.14*D^2/4

=)D =.095M=95MM

BY THIS WAY WE CAN,

GET THE VALUE OF DIA OF ONE WAY DIRECTIONAL VALVENO. OF ONE

WAY DIRECTIOINAL VALVE =4

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MATERIAL USED IN MAKING OF THE PUMP

Piston Head: Generally made grey cast iron.

Valves: They are also made of steel, but a little

improved form which has the stiffness and less wear

and tear. Brass can also be used.

Piston pin: Usually made of Case Hardened steel alloy

containing nickel, chromium and molybdenum.

Piston Rings: Made of grey cast iron or alloy cast iron

because of their good wearing properties.

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MAINTENANCES

• The piston rings which are used are always in direct contact with the liner

body and hence they wear a lot, so periodic replacement is necessary.

• The valves are important components and proper care should be taken as

there might be possibilities of leakage.

• The gland packing from where the shaft comes out of the cylinder has to be

taken care of in order to prevent leakage.

• In coupling or the cross head of the pump by which the piston gets the linear

motion will also have to be checked for misalignment and wear and tear.

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INSTALLATION

• reciprocating pump installation height and flow regulation reciprocating pump

starts without irrigation liquid, due to the reciprocating pump self-priming,

but the suction on the vacuum height in tandem with pump mounting area

atmospheric pressure, the nature and temperature of the liquid changes, the

reciprocating pump installation height, there are certain restrictions. The

reciprocating pump traffic of not use the valve of the discharge conduit to

adjust the bypass pipe should be used or a change in the reciprocation

frequency of the piston to change the stroke of the piston to achieve. before

the start of the reciprocating pump valve discharge pipe must be open.

reciprocating pump piston connected to the crankshaft by the connecting rod

and the prime mover. The prime mover electricity] machine, steam engine can

also be used. reciprocating pumps are suitable for high head, low flow, high

viscosity liquid transportation, but not suitable for transporting corrosive

liquids. Sometimes directly driven by a steam engine, the transportation of

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DISCHARGE OF PUMP PER SECOND:THE DISCHARGE OF A DOUBLE ACTING RECIPROCATING PUMP/SECOND= VOLUME OF WATER DISCHARGE

IN ONE REVOLUTION * NO OF REVOLUTION PER SECONDSO IT CAN BE WRITTEN AS= [ Π/4*D^2+Π/4(D^2-D^2)]*L*N/60

IF ‘D’ THE DIAMETER OF THE PISTON ROD IS VERY SMALL AS COMPARED TO THE DIA OF THE PISTON, THEN IT CAN BE NEGLECTED AND DISCHARGE OF PUMP/SEC,

Q=2*Π/4*D^2*LN/60=(2ALN)/60 AS Π/4*D^2= CROSS SECTION AREA OF THE PISTON OF THE CYLINDER.N= R.P.M OF CRANK & L= LENGTH OF THE STROKE= 2*R

WORK DONE BY A DOUBLE ACTING RECIPROCATING PUMP:WORK DONE PER SECOND= WEIGHT OF WATER DELIVERED* TOTAL HEIGHT= ΡG* DISCHARGE/SEC8TOTAL

HEIGHT= ΡG*(2ALN)/60*(HS+HD)= 2ΡG*(ALN/60)*(HS+HD)

POWER REQUIRED TO DRIVE THE DOUBLE-ACTING PUMP IN KW:P=(WORK DONE PER SECOND)/1000

=2ΡG*ALN*(HS+HD)/60000 18

CHARACTERISTICS OF RECIPROCATING PUMP

Slip of Reciprocating pump: Slip of a pump is defined as the difference between

the theoretical and actual discharge of the pump. The actual discharge of the

pump is less than the theoretical discharge due to leakage. The difference of

theoretical and actual discharge of the pump is known as SLIP of the pump.

Hence the mathematical expression is-

Slip=Qth-Qact

But slip is mostly expressed as percentage slip which is given by,

(1-Qact/Qth)*100= (1-Cd)*100

Where Cd=Co-efficient of discharge

Negative slip of the reciprocating pump: If the actual discharge is more than theoretical

discharge, the slip of the pump become negative. In that case slip of the pump is

known as Negative Slip.

Negative slip will occur when delivery pipe is short, suction pipe is long

and pump is running on high speed.

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CHARACTERISTICS OF RECIPROCATING PUMP

A positive displacement pump makes a fluid move by trapping a fixed amount andforcing (displacing) that trapped volume into the discharge pipe. Some positivedisplacement pumps use an expanding cavity on the suction side and a decreasingcavity on the discharge side.

In this curve we see the flow rate is almost constant in spite of pressuredifference, but in centrifugal pump the flow rate is changing due to pressuredifference. This is the advantage of reciprocating pump over centrifugal pump.

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PUMP EFFICIENCY• The ratio of the power imparted on the

fluid by the pump in relation to the

power supplied to drive the pump.

• Volumetric efficiency :

(Discharge volume / Suction volume)-slip

Discharge Pressure

Rat

io, r

C S

r = (VC+VS)/VS =1+(VC/VS)

Mechanical efficiency : loss occurs while overcoming

mechanical friction in bearing and speed reduction.

Speed of piston= (stroke)*(rpm)/(30000).

(mm)

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ADVANTAGE & DISADVANTAGES OF RECIPROCATING PUMP

Advantages of Piston Pumps

• Reciprocating pumps will deliver fluid at high pressure (High Delivery Head).

• They are 'Self-priming' - No need to fill the cylinders before starting.

Disadvantages of Piston Pumps

• Reciprocating pumps give a pulsating flow.

• The suction stroke is difficult when pumping viscous liquids.

• The cost of producing piston pumps is high. This is due to the very accurate sizes of the cylinders and pistons. Also, the gearing needed to convert the rotation of the drive motor into a reciprocating action involves extra equipment and cost.

• The close fitting moving parts cause maintenance problems, especially when the pump is handling fluids containing suspended solids, as the particles can get into the small clearances and cause severe wear. The piston pump therefore, should not be used for slurries.

• They give low volume rates of flow compared to other types of pump.

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APPLICATIONS OF RECIPROCATING PUMP

• Oil & Gas Industries

• Power Plants

• Petrochemicals and Refineries

• Sugar Industries

• Soap and Detergent Industries

• Food and Beverage

• Water Treatment Plants

• Cryogenic Application

• Miscellaneous

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REFERENCES

www.scribd.com

Engineering_Design_Guideline__Pump_Rev3.pdf

Energy Conservation in Pumps.ppt

PUMPS - TYPES & OPERATION

Fluid mechanics & machinery Laboratory

Positive Displacement Pumps (Part One) Reciprocating Pumps

Reciprocating Pump files

Fluid mechanics and hydraulic machines-by R K BANSAL24

Thank you

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