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DOSING PUMPS
CONTENTS
I. II. INTRODUCTION, features of a dosing pump PRINCIPLES GOVERNING FLOW AND PRESSURE FOR A DOSING PUMP
2.1. Flow 2.2. Velocity and acceleration of fluid 2.3. Pressure
III.
IV.
NPSH
4.1. Introduction 4.2. NPSH Calculations 4.3. The general case of non-viscous fluids 4.4. Improving the NPSH conditions 4.5. NPSH tests
V.
VI.
PULSATION DAMPERS
6.1. Balancing pot 6.2. Constant level tank 6.3. Pulsation dampers 6.4. Determining the damper
VII.
TYPICAL INSTALLATIONS
7.1. Schematics of typical installations 7.2. Particular case of slurries 7.3. Particular case of aerated liquids
VIII.
viscosity cp
stroke/mm Fig. 1
End:
Velocity is zero: as suction valve closes, fluid speed reduces. Acceleration is a maximum: liquid column is being stopped - fluid inertia creates an overpressure at the suction valve.
Middle:
Velocity is a maximum: greater than three times the mean velocity. Viscous friction loss is a maximum and causes an overpressure. Acceleration is zero: fluid is in motion.
2.3. Pressure
Fig. 2 Pressure fluctuations in the suction and discharge lines results from the pulsating flow and associated
acceleration phenomena. Figure 3 illustrates the effect of a simplex single acting pump.
DISCHARGE
Middle:
Velocity is a maximum: greater than three times the mean velocity. Viscous friction loss is a maximumand causes a depression. Acceleration is zero: fluid is in motion.
SUCTION
Fig. 3
IV - NPSH
4.1. Introduction
NPSH (Net Positive Suction Head) relates to the available hydraulic energy at a given point in a system when centrifugal pump (constant flow) is installed. The system will have an Available NPSH and the pump will require a certain NPSH to function. The required NPSH will thus be a characteristic of the chosen pump. Similarly, a dosing pump requires an NPSH value less than the available NPSH for its correct performance.
However, the calculations made for a centrifugal (based on constant flow) will no longer apply. In fact, for a dosing pump, friction losses due to viscosity should be calculated for maximum fiuid velocity: 3.14 ( ) times the mean value. Also acceleration effects must be included and they depend on pump and characteristics of the suction line (Iength and diameter, etc). In addition, unlike most centrifugal pumps, a dosing pumpss
performance can be affected by the discharge system. (see section 3.2). Thus a knowledge of the installation (or assumptions) is necessary to calculate the NPSH available and therefore to determine the performance of the pump in the system.
NPSH available and NPSH required abbreviated in future to NPSHa and NPSHr .
NPSHa in metres of liquid column (mlc) with: : specific gravity of fluid Ha : physical height in metres Pa, Tv : pressures in bar abs. Some diaphragm pumps with hydraulic lost motion require a minimum static NPSHa. This is so for Dosapro mROY and MAXROY pumps (MILTON ROY EUROPE).
Fig. 4
In the schematic installation shown in figure 4, the Bernouilli formula describes the conservation of energy. Applied to an incompressible,
viscous fluid whose motion is not constant, results in the formula being written:
Z = 0.016
LQN d
L Q
with: P g H L V 1 2 d TV : static pressure : fluid density : acceleration due to gravity : physical height : lenght of pipe : fluid velocity : specified load loss coefficient : pipe loss coefficient : pipe diameter : vapour pressure at pumping temperature.
d N
: total lenght of pipe in meters (m) : mean flow in liters per hour (l/h) : diameter of the pipe in millimeters (mm) : stroke speed of the pump in strokes per minute (spm)
Friction loss Y
Friction loss in the suction can usually be obtained from standard table/ graphs, but be careful: maximum flow rate is 3.14 times the mean flow. Calculation is also possible by using the formula: Le Q d4
Y = 3.63
Y is expressed in mlc with: : equivalent pipe lenght in meters : viscosity in centipoise Q, , d : l/h, s.g, mm. Le
H = kZ Fig. 5
Note
In general, for non viscous fluids, friction losses Y are small compared to acceleration losses, since they are out of phase, have no effect since k = 1. Refer to paragraph 4.3.
If this condition is not met the pump will cavitate and may lose its prime resulting in: - Loss of flow and accuracy - Noise and vibration - Increased wear.
NPSHr
Conclusion:
It is necessary to keep these pressures below the maximum rated for the pump, or any single component, to prevent mechanical failure, or overloaded motor, etc.
Pmax = Pa +
LAW OF PRESSURE
Ensure that this dynamic pressure at point B (reached at the end of the suction stroke) is less than the static discharge line pressure Pd, otherwise overflow may take place.
During discharge:
Pmin = Pr + (Hd - Zd) 10.2 This Pmin is minimum pressure at D, at the end of the discharge phase and must remain above Pa to ensure there is no overflow. Pmax = Pa + (Ha + Za) 10.2 Also check Pmin is above the vapour pressure of the process fluid or the hydraulic oil (where applicable).
Fig. 3
The maximum pressure is that at the point B at the entry to the liquid end.
During Discharge:
Pmax = Pd + (Hd + Hd + NPSHr) 10.2
Hd is the geometric height of discharge. This maximum pressure is corresponding to pressures C1 or C2.
When a back pressure valve is used, the NPSH calculation incorporates the additional counter pressure. In some cases, the calculation result shows an impossibility, the only remedy being is a pulsation damper. The combined effect of dampers, back pressure/loading valve and
Y Friction loss
H Total loss
Triplex unit (1) Suction Pulsation damper (2) Discharge Pulsation damper (2)
3Q
0.5 Z
0.5 Z + Y
0.2 Z
0.2 Y
0.2 Z + 0.2 Y
0.05 Z
0.15 Y
0.05 Z + 0.15 Y
VI - PULSATION DAMPERS
A pulsation dampening device attenuates both flow and pressure pulsations caused by a reciprocating dosing pump. Its effect is to reduce the inertia effects as shown in figure 6.
NPSH calculations can now be made for the section of pipe between the pot and the pump. Often the pot can be used as a calibration device or as a means of allowing heavily aerated fluids to gas-off. To size the pot use, 15 to 20 times the pumps swept volume. Fig. 7
Fig. 8
10
Principle similar to a balancing pot, plus: - (in left sketch): gravity fed with float valve - (in right sketch): pump fed by a transfer pump or pressurised bulk storage with high and low level control - calibration service can be used as well as gas-release - sizing is similar to a balancing pot: 15 to 20 times pumps swept volume.
Fig. 9
In time, when the pulsations have become too large, simple re-charge the vessel with gas. Unlike the previous system, the pump may be kept running.
11
Other versions can be used with PTFE diaphragms, bellows or metal pistons, but there are limitations to their use.
Dosing pump installations rarely require such systems since the frequency of pulsations is so low, eg. a triplex pump running at 150 SPM reaches 15 Hz.
Fig 11
Fig. 13
Fig. 12
12
Precharge at 60% Max temperature 40C Volume equal to 15 stroke volumes of the dosing pump Residual dampening ratio 5%
6.4.5. Corrosion
Materials for the vessel body and separator must be selected to be compatible with the process fluid.
Fig. 15
13
Fig. 18
Fig. 18: Long pipe lengths requiring the use of dampers: balancing pot, pulsation damper...The back-pressure valve creates an artificial counterpressure of 2 Bar minimum; it is not necessary if existing pressure is greater.
Fig. 16
Fig. 16: The pump is located above the tank and fitted with a footvalve (for easier priming). Lines are short on both suction and discharge; suction line is vertical and with a diameter at least equal to the rated connection diameter to the dosing pump; the injection nozzle isolates the pump and reagent from the main flow.
Fig. 19
Fig. 17
Fig. 17: The injection nozzle (or a back-pressure valve) creates an artificial resistance allowing accurate dosing.
Fig. 19: Natural siphoning effect is avoided by using a back-pressure valve A, adjusted so as to maintain the pressure differential H. The pump has a flooded suction and it is necessary to fit a shut off valve and a filter on suction line.
14
Fig. 20
Fig. 21
Fig. 20: A pump with a high nominal stroke speed (over 140 strokes/ min) often requires the installation of a pulsation dampener on the discharge line (and possibly in addition a back-pressure valve), once the pipe length exceeds 10 meters.
Fig. 21: Pumping with high suction pressure (for example liquefied gas) with a back-pressure valve to avoid a natural siphonning effect. The NPSH calculation is quite important in the case of pumping liquefied gas in gas-Iiquid equilibrium condition.
Fig. 23 Fig. 22
Fig. 23: Risk of gas accumulation and loss of prime. Fig. 22: Suction line too long. Suction lift too high cavitation.
Fig. 24
Fig. 24: Risk of siphoning effect. The pump non return, suction and discharge valves cannot stop siphoning.
Remedies: plan for the pipe length on discharge side increase diameters use a damper install a foot valve and a back pressure valve.
Remedies: arrange for a connection on the tank bottom (use a filter) or vertical suction from above the tank through a footvalve.
Remedies: use a back-pressure valve install a valve on the suction line (case of a flooded suction).
15
Fig. 25
Fig. 27
Fig. 27: Installation of a gas-freeing pot on the pump suction line (thus avoiding frequent loss of prime) and an inclined connection line between pump and gas-freeing pot to facilitate gas-freeing
low level
100mm
Preparation tank
200 mini
Fig. 26
to waste
Standard working cycle 1. Agitation of the product in the preparation tank. 2. Pumping 3. When stopped - plan a 15 minute flushing cycle: 3.1. open the water flushing system 3.2. flush while pump is in operation 3.3. shut off MILTON ROY EUROPE PIC valve (item 1) 3.4. stop the process
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8.3. Repeatability
This characterizes the capacity of a pump to always deliver the same flow for same stroke setting:
8.5.1. Proportionality
Dosing pumps always deliver a flow greater than the rated flow indicated in brochures with correction of speed and pressure factors. Moreover, the flow curve, even if perfectly linear, is always shifted in comparison with the proportional theoretical straight line, as shown by figure 31:
Fig. 29
8.2. Linearity
This characterizes the alignment of the flow measured for different settings:
API 675 standard stipulates that repeatability must remain within a 3 % range of the rated flow.
Fig. 31
This characteristic should be allowed for in the case of open loop regulation managed by a single set point.
Fig. 28
API 675 standard stipulates that flow points measured are within a 3 % range of rated flow.
Fig. 30
API 675 standard stipulates that repeatibility must remain within 1%.
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Fig. 32 Fig. 33
Usually one notices a 0.4 % (plunger pumps) to 1.5 % (certain diaphragm pumps) flow drop for each 10 Bars.
The same level of relative error may not be reached on the full scale of adjustment. In the range 0-10 % relative errors are much more higher.
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NPSH leaflet - Ref. 1NPS 900 401N - 03/06 - Rev. B - No copy allowed.