Definition of pump:

A pump is an item of mechanical equipment that moves liquid from onearea to

another by increasing the pressure of the liquid to the amount needed to
overcome the combined effects of friction, gravity and system operating
pressures.

Pumps are divided into two fundamental types based on the manner in which
they transmit energy to the pumped media: kinetic or positive displacement

Different between positive displacement and kinetic:

 positive displacement and kinetic (or dynamic or rotodynamic). Positive

displacement pumps are batch delivery, periodic energy addition devices whose fluid
displacement volume (or volumes) is set in motion and positively delivers that batch
offluid from a lower to higher pressure irrespective of the value of that higher
pressure.
 Kinetic pumps are continuous delivery, continuous energy addition devices
that buildup kinetic energy in the rotating element or impeller and convert most of
that energy intostatic energy to a point where the fluid delivery to the higher
pressure level commences.Unlike positive displacement pumps the delivery is
affected by the value of the dischargepressure that must be overcome. On the
other hand, the kinetic pump will deliver anincreasing amount of liquid as the
discharge pressure is lowered, whereas the positive displacement pump delivery is
fixed.

Types of pumps:

1.1 Displacement pumps:

1.1.1 Gear pump:

Operation:

Gear pumps belong to a positive displacement rotary group, and are made by
enclosing two or more gears in a close-fitting housing. A driver turns a shaft
connected to one of the gears, causing it to rotate. This gear drives the other gear
through the meshing of the teeth of the two gears, just as with power
transmission gears.As the gears rotate, on one side, the teeth are coming out of
mesh with each other .As a tooth is pulled out of the space between two teeth of
the other gear, it creates a vacuum. Since the housing forms a seal all around the
set of gears, the liquid that rushes into this space to fill this void has to come in
through the pump’s suction port. Once the spaces between gear teeth are filled
with liquid, the liquid rides in these pockets, trapped in place by the housing, until
it reaches the discharge side of the pump. The liquid stays in place between the
teeth until it reaches the other side of the gear mesh, where the teeth are coming
together. Then, when a tooth from the other gear comes into the space between
the teeth, the liquid there is forced out. Since the housing still forms a seal around
the gears, the only place for the displaced liquid to go is out the pump’s discharge
port. The pump thus operates like a conveyor belt, with the pockets of liquid
between the gear teeth being picked up at the gear mesh, carried to the other
side, and dropped off at the other side of the mesh.
Type of gear pump:

1. External gear pump:

External gear pumps are a popular pumping principle and are often
used as lubrication pumps in machine tools, in fluid power transfer
units, and as oil pumps in engines.

External gear pumps can come in single or double (two sets of

gears) pump configurations with spur (shown), helical, and
herringbone gears. Helical and herringbone gears typically offer a
smoother flow than spur gears, although all gear types are relatively
smooth. Large-capacity external gear pumps typically use helical or
herringbone gears. Small external gear pumps usually operate at
1750 or 3450 rpm and larger models operate at speeds up to 640
rpm. External gear pumps have close tolerances and shaft support
on both sides of the gears. This allows them to run to pressures
beyond 3,000 PSI / 200 BAR, making them well suited for use in
hydraulics. With four bearings in the liquid and tight tolerances,
they are not well suited to handling abrasive or extreme high
temperature applications.

Operation:

1. As the gears come out of mesh, they create expanding volume

on the inlet side of the pump. Liquid flows into the cavity and is
trapped by the gear teeth as they rotate.

2. Liquid travels around the interior of the casing in the pockets

between the teeth and the casing -- it does not pass between the
gears.

3. Finally, the meshing of the gears forces liquid through the outlet
port under pressure.

Advantages

• High speed
• High pressure
• No overhung bearing loads
 • Relatively quiet operation
• Design accommodates wide variety of materials

Disadvantages

• Four bushings in liquid area

• No solids allowed
• Fixed End Clearances

Applications
 Various fuel oils and lube oils
 Chemical additive and polymer metering
• Chemical mixing and blending

2- Internal Gear Pump

nternal gear pumps are exceptionally versatile. While they are

often used on thin liquids such as solvents and fuel oil, they excel at
efficiently pumping thick liquids such as asphalt, chocolate, and
adhesives. The useful viscosity range of an internal gear pump is
from 1cPs to over 1,000,000cP.

In addition to their wide viscosity range, the pump has a wide

temperature range as well, handling liquids up to 750°F / 400°C.
This is due to the single point of end clearance (the distance
between the ends of the rotor gear teeth and the head of the
pump). This clearance is adjustable to accommodate high
temperature, maximize efficiency for handling high viscosity liquids,
and to accommodate for wear.

Operation:

1. Liquid enters the suction port between the rotor (large exterior
gear) and idler (small interior gear) teeth. The arrows indicate the
direction of the pump and liquid.

2. Liquid travels through the pump between the teeth of the "gear-
within-a-gear" principle. The crescent shape divides the liquid and
acts as a seal between the suction and discharge ports.

3. The pump head is now nearly flooded, just prior to forcing the
liquid out of the discharge port. Intermeshing gears of the idler and
rotor form locked pockets for the liquid which assures volume
control.

4. Rotor and idler teeth mesh completely to form a seal equidistant

from the discharge and suction ports. This seal forces the liquid out
of the discharge port.
Advantages

• Only two moving parts

• Only one stuffing box
• Non-pulsating discharge
• Excellent for high-viscosity liquids
• Constant and even discharge regardless of pressure
conditions

disadvantages

• Usually requires moderate speeds

• Medium pressure limitations
• One bearing runs in the product pumped
• Overhung load on shaft bearing

Applications

• All varieties of fuel oil and lube oil

• Resins and Polymers
• Alcohols and solvents
• Asphalt, Bitumen, and Tar
• Polyurethane foam (Isocyanate and polyol)

1.1.2 Lobe Pump

Lobe pumps are used in a variety of industries including, pulp and

paper, chemical, food, beverage, pharmaceutical, and
biotechnology. They are popular in these diverse industries
because they offer superb sanitary qualities, high efficiency,
reliability, corrosion resistance, and good clean-in-place and
sterilize-in-place (CIP/SIP) characteristics.

These pumps offer a variety of lobe options including single, bi-wing,

tri-lobe (shown), and multi-lobe. Rotary lobe pumps are non-
contacting and have large pumping chambers, allowing them to
handle solids such as cherries or olives without damage. They are
also used to handle slurries, pastes, and a wide variety of other
liquids. If wetted, they offer self-priming performance. A gentle
pumping action minimizes product degradation. They also offer
reversible flows and can operate dry for long periods of time. Flow
is relatively independent of changes in process pressure, so output
is constant and continuous.

Operation:

Lobe pumps are similar to external gear pumps in operation in that

fluid flows around the interior of the casing. Unlike external gear
pumps, however, the lobes do not make contact. Lobe contact is
prevented by external timing gears located in the gearbox. Pump
shaft support bearings are located in the gearbox, and since the
bearings are out of the pumped liquid, pressure is limited by bearing
location and shaft deflection.

1. As the lobes come out of mesh, they create expanding volume on the inlet side of
the pump. Liquid flows into the cavity and is trapped by the lobes as they rotate.

2. Liquid travels around the interior of the casing in the pockets between the lobes
and the casing -- it does not pass between the lobes.

3. Finally, the meshing of the lobes forces liquid through the outlet port under
pressure.

Advantages

• Pass medium solids

• No metal-to-metal contact
• Superior CIP/SIP capabilities
• Long term dry run (with lubrication to seals)
• Non-pulsating discharge

Disadvantages

• Requires timing gears

• Requires two seals
• Reduced lift with thin liquids

Applications

• Polymers
• Paper coatings
• Soaps and surfactants
• Paints and dyes
1.1.3 Progressing cavity pump

This type of pump transfers fluid by means of the progress, through the
pump, of a sequence of small, fixed shape, discrete cavities, as its rotor is
turned. This leads to the volumetric flow rate being proportional to the
rotation rate and to low levels of shearing being applied to the pumped
fluid. Hence these pumps have application in fluid metering and pumping
of viscous or shear sensitive materials. The cavities taper down toward
their ends and overlap with their neighbours, so that, in general, no flow
pulsing is caused by the arrival of cavities at the outlet, other than that
caused by compression of the fluid or pump components.

Advantages
• High suction lift capabilities

• Gentle pumping action so thatvery little shear is imparted to the liquid being pumped
• Ability to handle low or high viscosityproducts with or without solids
• Pressure stability over a wide speed range
• Flows are directly proportional to the speed,for easy pumping control
Applications
* Viscous chemical pumping

* Grout/Cement Pump

* Lubrication oil pump

* Marine Diesel fuel pump

* Mining slurry pump

* Oilfield Mud motors

1.1.4 Vane Pump

While vane pumps can handle moderate viscosity liquids, they excel at
handling low viscosity liquids such as LP gas (propane), ammonia,
solvents, alcohol, fuel oils, gasoline, and refrigerants. Vane pumps have
no internal metal-to-metal contact and self-compensate for wear, enabling
them to maintain peak performance on these non-lubricating liquids.

Operation:
begins with the rotating and stationary parts of the pump defining a
given volume or cavity of fluid enclosure. This enclosure is initially
open to the pump inlet but sealed from the pump outlet and
expands as the pump rotates. As rotation continues, the volume
progresses through the pump to a point where it is no longer open
to the pump inlet but not yet open to the pump outlet.It is in this
intermediate stage where the pumping volume or cavity is
completely formed.Depending on the particular pump, there can be
more than one cavity in existence at any one time. As this happens,
fluid also fills the clearances between the pumping elements and
pump body, forming a seal and lubricating the pumping elements as
they in turn pump the fluid. Rotation continues and the cavities
progress, moving fluid along the way. Soon a point
is reached where the seal between the captured fluid volume and
outlet part of the pump is breached. At this point the vanes, gears,
or lobes force the volume of captured fluid out of the pump. While
this is happening, other cavities are simultaneously opening at the
inlet port to receive more fluid in a continual progression from
suction to discharge ports.

Advantages

• Handles thin liquids at

relatively higher pressures
• Compensates for wear
through vane extension
• Sometimes preferred
for solvents, LPG
• Can run dry for short
periods
• Can have one seal or
stuffing box
• Develops good
vacuum

Disadvantages

• Can have two stuffing

boxes
• Complex housing and
many parts
• Not suitable for high
pressures
• Not suitable for high
viscosity
• Not good with
abrasives

Applications
 • Aerosol and Propellants
• Aviation Service - Fuel Transfer, Deicing
• Auto Industry - Fuels, Lubes, Refrigeration Coolants
• LPG Cylinder Filling
• Alcohols
• Refrigeration - Freons, Ammonia
• Solvents

1.1.3 Peristaltic pump

A rolling action of a cam that squeezes the liquid through a softplastic or
rubber tubegenerates the flow in this pump . Transportingslurries
embodies the most common use of this pump.

1.1.4 Reciprocating-type pumps

There are two general types of reciprocating pumps. The piston pump and
the diaphragm pump.

These types of pump operate by using a reciprocating piston or

diaphragm. The liquid enters a pumping chamber via an inlet valve and
is pushed out via a outlet valve by the action of the piston or
diaphragm.Reciprocating pumps are generally very efficient and are
suitable for very high heads at low flows.

This type of pump is self priming as it can draw liquid from a level below
the suction flange even if the suction pipe is not evacuated.The pump
delivers reliable discharge flows and is often used for metering duties
delivering accurate quantities of fluid.

The reciprocating pump is not tolerant to solid particles and delivers a

highly pulsed flow. If a smooth flow is required then the discharge flow
system has to include additional features such as accumulators to provide
even flows.Reciprocating pumps designed for delivering high pressures
must include methods for releasing excessive fluid pressures. The pumps
should include for built in relief valves or relief valves should be included
in the fluid circuit which cannot be isolated from the pump.

Type of Reciprocating pump:

1-Piston Pumps

piston pump can be based on a single piston or, more likely, multiple
parallel pistons. The pistons are reciprocated using cams or
crankshafts. The stroke is generally adjustable. This type of pump
can deliver heads of up to 1000 bar. The largest sizes of piston pumps
 can deliver flows of 40m3 /hr. In practice these pumps are more likely
to be used for metering low flow rate fluids at more modest pressures
in laboratories and chemical process plants. Piston pumps are not
generally suitable for transferring toxic or explosive media.

2-diaphragm pump:
Diaphragm pumps are a class of displacement pumps featuring
flexible membranes in
combination with check valves that are used to move fluids into and
out of pumping chamber.These pumps are used extensively in
transfer and metering applications requiringflows of up to 300
gallons per minute (1150 liters per minute). They are quite
versatile,handling a wide variety of fluids including chemicals, dry
powders, food additives, glues,paints, pharmaceutical products,
slurries, tailings, and wastewater. A distinguishing feature of all
diaphragm pumps is the absence of seals or packing, meaning they
can be usedin applications requiring zero leakage. There are three
main categories of diaphragmpumps:
1) mechanically driven,
2) hydraulically driven, and
3) air-operated.

Hydraulically operated diaphragm pump

The hydraulically operated diaphragm metering pump is used for similar duties as the
piston pump.It has some significant advantages compared to the piston pump in that
he design does not require glands or piston seals The diaphragm in the hydraulically
operated diaphragm pump shown below is actuated using a plunger pump
arrangement. This provides full support of the diaphragm allowing high pressure
operation. The pump can include for duplex diaphragms with the interface being
monitored for failure of the diaphragm in contact with the fluid. This type of pump
can be used for pumping toxic and explosive fluids. The pump can deliver heads of
up to 700 bar and transfer flows of up 20 m 3 /hr. These pumps require continuous
monotoring as the diaphram is under high fatigue loading and the inlet and outlet
valves are subject to erosion and blocking

Air Operated Pump

The air operated pump is generally a low cost work horse pump used for transferring
any type of liquid including sludge. The inlet and outlet valves are often low cost
easily replaced flap or ball valves. The pump is comprises two circular chambers
each split by a large elastomeric diaphagm. The two diaphragm centres are
mechanically coupled together with a shaft. An interlocked valve admits air pressure
to one side of one of the chambers and exhaust the air from the opposite side of the
other chamber. This causes both diaphagms to move. One diaphragm pushing fluid
out through a non return valve. The other diaphragm drawing fluid in through a non
return valve. On completion of a full stroke the valve reverses the air supply and
exhaust directions causing the diaphragms to move back. The diaphragm which was
pushing fluid out of the pump now sucks fluid and the diaphragm admitting fluid now
pushes fluid out. The system is therefore double acting.

The pump capacity is limited by the air pressure available (generally 7 bar) and the
design of the diaphragm. An elastomeric diaphragm has a limited life and will only
operate for a few million cycles. A flow rate of about 40 m3 /hr is a reasonable
maximum achievable flow with a larger pump. For any air operated diaphragam pump
the higher the flow the lower the discharge head possible.

Advantages

 asily transfers high viscosity fluids.

 Can easily suck in from a depth of four metres.
 Does not need pre-filling with fluid.
 Is air operated and therefore explosion-proof.
 Does not spoil the properties of chemicals.

1.2.1 Dynamic pumps (Kinetic pumps)

1.2.1 centrifugal pump:

is a rotating machine in which flow and pressure are generated dynamically. The inlet is not walled off
from the outlet as is the case with positive displacementpumps, whether they are reciprocating
or rotary in configuration. Rather, a centrifugalpump delivers useful energy to the fluid or
“pumpage” largely through velocitychanges that occur as this fluid flows through the impeller
and the associated fixed passagewaysof the pump; that is, it is a “rotodynamic” pump. All
impeller pumps are rotodynamic, including those with radial-flow, mixed-flow, and axial-flow.

A centrifugal pump consists of a set of rotating vanes enclosed

within a housing or casing that is used to impart energy to a fluid
through centrifugal force. Thus, stripped of all refinements, a
centrifugal pump has two main parts:

(1) a rotating element, including animpeller and a shaft

(2) a stationary element made up of a casing, casing cover,
andbearings.

In a centrifugal pump, the liquid is forced by atmospheric or other

pressure into a set
of rotating vanes. These vanes constitute an impeller that
discharges the liquid at its
periphery at a higher velocity. This velocity is converted to pressure
energy by means of a volute or by a set of stationary diffusion vanes
surrounding the impeller periphery. Pumps with volute casings are
generally called volute pumps,
while those with diffusion vanes are called diffuser pumps. Diffuser
pumps were once
quite commonly called turbine pumps, but this term has become
more selectively applied to the vertical deep-well centrifugal diffuser
pumps usually referred to as vertical turbinepumps. operating at
rated capacity (the capacity at which best efficiency is obtained).
Impellers are classified according to the major direction of flow in
reference to the axis
of rotation. Thus, centrifugal pumps may have the:
• Radial-flow impellers
• Axial-flow impellers
• Mixed-flow impellers, which combine radial- and axial-flow
principles.

Pump CONTROLS:

Pump control in the broadest sense gives the pump user

(1) the flow rate, pressure or liquid level
(2) protection for the pump and system against damage from the
pumped
liquid
(3) administrative freedom in decisions on operations and
maintenance.

Control System Types :

Pump control systems range in complexity from single

handoperated
valves to highly advanced, automatic flow control or pump speed
control systems.
Pump type and drive type are factors in control system choice. For
centrifugal pumps,
either change of speed or change of valve setting can control the
desired variable. For positive displacement pumps, whether
reciprocating, rotary, screw, or other type, control is by change in
speed, change in setting of bypass valve, or change in
displacement. The lastmentioned method is found in metering and
hydraulic drive pumps. Although this chapter considers only control
systems having valves as final control elements, the sensing
elements discussed also serve in pump speed control systems.
Pump control systems divide readily into two types: on-off and
modulating. The on-off system provides only two conditions: a given
flow (or pressure) value or a zero value. Avalve is therefore either
open or closed, and a pump driver is running or not. The
modulatingsystem, on the other hand, adjusts valve setting or
speed to the needs of the moment. Either type of system can be
automatic or manual.

System Essentials:
 All control systems have
1. A sensing or measuring element
2. A means of comparing the measured value with a desired value
3. A final control element (a valve) to produce the needed change in
the measured variable
4. An actuator to move the final control element to its desired
position
5. Relaying or force-building means to enable a weak sensing signal
to release enough
force to power the actuator

OPEN-LOOP CONTROL:

The simplest mode of automatic control is open-loop control, in

which
the pump speed (or displacement in some pump types) or the
control valve setting is
adjusted to and held at a desired value calculated or calibrated to
produce the required
output of flow, level, or pressure. The calculation can result in a cam
for the controller or positioner or a particular characterization of a
valve plug. In operation, only the deviationof the input variable from
its desired value is measured and the control system adjusts the
input variable to eliminate the deviation. Because the output
variable is not measured, a change in the conditions on which
calculation or calibration was based will introduce output errors.
Change of input variable can be done manually or by another
control system.

CLOSED-LOOP CONTROL :

closed-loop control system eliminates much of the error of the open-

loop system. In the basic closed-loop, or feedback, system, the
output variable is measured and the value compared with an
arbitrary desired or set value. If the comparison reveals an error, the
pump speed or control valve setting is changed to correct the
error.Large-capacity water tanks or lag in the control system can
introduce delays in stablishmentof the new output value, and the
system can therefore overcorrect and oscillate back and forth unless
design prevents this.

ON-OFF CONTROL:

The simplest closed-loop systems operate on-off between fixed

limits,such as water level or pressure. The on-off action is at the
extremes of a wide or narrow band that can be set at any point in
the range. For example, a tank level control may work in an on-off
band of 1 in (2.54 cm) or 10 in (25.4 cm) at any level in a tank that
is 5 ft (1.5m) deep.
FIGURE 2.1 - Pump classification.

Progressive cavity pump

This pump has been referred to as a single-end, single-rotor type of
screw pump where the pumping elements comprise a single rotor and a
stator. The stator usually has a double helical internal thread with a
pitch twice that of the single helical stator. This results in two leads on
the stator, and one on the rotor.
As the rotor rotates inside the stator, two cavities form at the suction
end of the stator, with one cavity closing as the other opens. The
cavities progress in a spiral from one end of the stator to the other. The
result is a flow with relatively little pulsation, and the shear rates will
also be low in comparison to radial pump styles.
The compressive fit between the rotor and stator creates seal lines
where the two components contact. The seal lines keep the cavities
separated as they progress through the pump with each rotation of the
rotor. The elastomeric stator and stainless steel rotor allow the pump to
handle large solid particles in suspension and a certain percentage of
abrasives.
The manner in which the rotor turns within the stator complicates the
mechanical design of PC pumps. As the rotor turns in the stator, the
centerline of the rotor orbits about the centerline of the stator. This
eccentric motion means the pump must be fitted with universal joints
to transmit power from the concentric rotation of the drive shaft to the
eccentrically rotating rotor. These joints must transmit torsional and
thrust loads. Designs of this drive mechanism range from simple balland-
pin mechanisms to heavy-duty sealed gear couplings.

Advantages of centrifugal pumps:

1-Generate a steady flow of liquid

2-high flow rates are possible

3-Low cost of replacement parts

4-Slurries can be pumped by it

5- can be operated against a closed discharge valve

Disadvantages of centrifugal pumps:

1-Not self-priming

2-cannot be used for viscous liquids

3-cavitation can cause wear and loss of efficiency