PumpClinic

METERING PUMPS

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The metering pump is a positive displacement chemical dosing device with the ability to vary capacity manually or automatically as process conditions require. It features a high level of repetitive accuracy and is capable of pumping a wide range of chemicals including acids, bases, corrosive or viscous liquids and slurries. The pumping action is developed by a reciprocating piston, plunger or diaphragm which is either in direct contact with the process fluid, or is shielded from the fluid by a diaphragm. Diaphragms may be activated by direct mechanical link or by hydraulic fluid. Metering pumps are generally used in applications where one or more of the following conditions exist: Low flow rates are required High system pressure exists High accuracy feed rate is demanded Dosing is controlled by computer, microprocessor, DCS, PLC, or flow proportioning Corrosive, hazardous, or high temperature fluids are handled Viscous fluids or slurries need to be pumped

METERING PUMP CHARACTERISTICS

1. The pumping action is developed by the reciprocating action. This reciprocating motion develops a flow sine wave. Actual flow rate is determined by the following formula:

Figure 1

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2. Unlike centrifugal pumps, flow rate is not greatly affected by changes in discharge pressure.

Figure 2 3. The metering pump flow vs. stroke characteristic curve is linear. It is not however, necessarily proportional in that 50% stroke setting may not equal 50% flow. This is due to the fact that the calibration line may not pass through 0 on both axes simultaneously. By measuring flow at 2 stroke settings, plotting both points and drawing a straight line through them, other flow rates vs. stroke can be accurately predicted. The steady state accuracy of a correctly installed industrial grade metering pump is generally +/- 1.0% or better. Although a metering pump can generally be adjusted to pump at any flow rate between 0 and its maximum capacity, its accuracy is measured over a range determined by the pump's turndown ratio. Most metering pumps have a turndown ratio of 10:1 which simply means that the pump is within its accuracy rating anywhere between 10% and 100% of capacity. Some newer designs of metering pumps feature higher accuracy, and a greater turndown ratio of 100:1. Therefore, this design will accurately dose anywhere between 1% and 100% of capacity.

Figure 3

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METERING PUMP DESIGN

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LIQUID END The liquid end design and materials of construction are determined by the service conditions, and the nature of the fluid to be handled. Temperature, flow rate, fluid viscosity, corrosiveness and other factors are considered. DRIVE MECHANISM The drive mechanism translates the rotary motion of the driver into reciprocating movement. FLOW ADJUSTMENT Pump flow rate is adjustable by varying stroke length, effective stroke length or stroking speed. Most metering pumps are supplied with a micrometer screw adjustment similar to the one shown here. The micrometer can also be replaced by an electronic or pneumatic actuator to adjust pump flow rate in response to a process signal DRIVERS The pump is usually driven by an AC constant speed motor. Electromagnetic drive is available in small flow pumps.

Figure 4 DRIVE MECHANISMS Metering pumps can be powered by a variety of drivers however, the almost universal driver is an electric motor. The motor speed is normally reduced to pump design speed by the use of gearing built into the pump power end. This rotary power is converted to a linear motion through one of three methods: a crank mechanism with either fixed (Figure 5) or variable (Figure 6) stroke length an eccentric or cam arrangement (Figure 7)

Depending on the type of adjustable output flow mechanism used, the power can be utilised on both the forward thrust of the crank and the back thrust of the crank. The eccentric or cam arrangement, however, can provide power in only one direction. Metering pumps with solenoid power ends (Figure 8) are another type of drive and create linear, reciprocating motion using electromagnets. The solenoid type could be considered the ideal power end as it does not require any type of transmission to convert motion from rotary to linear. Another advantage is that it has in built overload protection as the pump simply stops at excessive load. A disadvantage is that availability is limited to very small powers.

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Figure 5

Figure 6

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Figure 7

ADJUSTMENT SCREW

Figure 8

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LIQUID END Metering pumps generally fall into five basic types: Piston with packed seal Plunger with gland packed seal Mechanically actuated diaphragm Hydraulically actuated diaphragm Hydraulically actuated tube

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Both the piston packed pump and the plunger packed pump allow some degree of leakage past their dynamic seals. In some cases this is not an objectionable shortcoming; in other cases, it can be very objectionable and, in most instances, costly as well. Diaphragm and tube pumps are seal/less and therefore overcome this potential problem. It is often possible to multiplex pumps i.e. coupling or ganging of two or more liquid ends and use only one driver. The main purposes of multiplexing are: provide greater flow or pressure without significantly increasing the driver size provide exact proportioning or synchronization between heads provide greater turndown ratio i.e. flow control range reduce pulsations

PISTON WITH GLAND PACKED SEAL This type of pump is rarely used these days. The piston is driven by either a crank, a connecting rod, or a crosshead driven by the crank. The piston provides the liquid flow and is designed to displace a measured volume of liquid with a high degree of accuracy as it reciprocates within the pump (Figure 9). Rings or packing located on the piston move back and forth with the piston to effect a dynamic seal with the inside diameter of the cylinder and a static seal with the outside diameter of the piston. Packing on the connecting rod provides at static seal so that it becomes double acting and displacement may occur on both directions. This provides double the flow of single acting pumps.

Figure 9. Piston packed pump

The forward travel of the piston reduces the internal volume of the liquid chamber, displacing the metered liquid out the discharge check valve. The pressure required to move the liquid through the discharge check valve is also applied to the suction check valve, forcing it into a closed position, ensuring correct flow direction

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The reverse travel of the piston decreases the pressure within the liquid chamber by enlarging the internal volume of the chamber. This change of pressure results in a rapid closing of the discharge check valve caused by the external pressure acting on the valve and allows the suction check valve to open because of an external pressure under the check valve that can be either above or below atmospheric pressure. The accuracy of the reciprocating metering pump is achieved by the previously described predetermined controlled piston travel of the pump, the control of the strokes per minute, and the precise opening and closing of the check valves. The inaccuracy, on the other hand, is caused by leakage past the piston packing and the check valves.

PLUNGER WITH GLAND PACKED SEAL The plunger packed pump is very similar to the piston packed pump except for the packing design and location. The packed plunger, unlike the packed piston, has the packing installed in a stationary gland in the inside diameter of the cylinder. There is no moving or dynamic seal located on the plunger. As the plunger reciprocates within the pump, a dynamic seal is made between the outside diameter of the plunger and the inside diameter of the packing, and a static seal is made between the outside diameter of the packing and the inside diameter of the stuffing box (Figure 10). There is a strong trend to leak free (diaphragm and tube) metering pumps, however plunger pumps continue to be used. The main reasons are that plunger pumps are cheaper, can develop higher discharge pressures and are more suitable for extreme temperature conditions.

Figure 10 Plunger with packed gland MECHANICAL ACTUATED DIAPHRAGM To overcome the leakage problem, a diaphragm pump can be used. The power side of the pump and the capacity control are the same as was previously described for other types of reciprocating pumps. However, in place of a piston rod or plunger, the mechanical diaphragm pump uses a connecting rod fastened to the centre of a diaphragm. The mechanical diaphragm pump's principle of positive displacement output is similar to that of the piston plunger pump except that the diaphragm becomes the displacement measuring element, as it moves back and forth in the fluid chamber (Figure 8). HYDRAULIC DIAPHRAGM PUMP The hydraulically balanced diaphragm pump is a hybrid design that provides the principal advantages of the other three pump types. Like the other pumps, its power end and capacity control are common. This, however, is where the similarity ends, since the piston or plunger does not come into contact with the

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pumped fluid, and the actuation of the diaphragm is by hydraulic power instead of mechanical power (Figure6). The measuring piston or plunger reciprocates within a precisely sized cylinder at an established stroke length, displacing a volume of hydraulic liquid, not the product liquid. The hydraulic liquid is stable and has excellent lubricating qualities. The piston uses the hydraulic oil to move the diaphragm forward and backward, causing a displacement that expels the product liquid through the discharge check valve and, on the suction stroke, takes in an equal amount through the suction check valve. The diaphragm isolates the liquid product being contained within the liquid chamber and check valves. These are the only parts that must be made of chemically compatible material. The diaphragm's only job is to separate two liquids. It normally does no work, carries no load, and pumps no liquid; rather it serves as a moving barrier between liquids during periods of pressure imbalance. It is simply a moving partition with pressure hydraulically balanced on both its sides; on one side is the liquid product and on the other side is the hydraulic oil. At full deflection, the diaphragm undergoes total combined stresses well within the endurance limit of the diaphragm material. Contoured support plates are provided on either side of the diaphragm to ensure that stresses are kept within limits. When properly installed and working within the recommended temperature range and not affected by corrosion or abrasion, the diaphragm has an unlimited life. As previously stated, the piston or plunger handles only hydraulic oil. Conventional seals are used on the piston or plunger, which does not require power flushing and complicated drain systems as are found on conventional piston or plunger pumps handling corrosive or hazardous liquids. Even the slightest leakage past the piston is replaced on the suction stroke through the automatic functioning of a compensation system, which draws in replacement oil from the oil reservoir (Figure 11).

Figure 11 Function of oil make-up valve

Any excess pressure within the hydraulic system or the liquid product chamber is relieved through the automatic action of a pressure relief valve. This valve blows off oil, under excess pressure ahead of the piston, back into the oil reservoir. This valve blows off oil, under excess pressure ahead of the piston, back into the oil reservoir (Figure 12).

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Figure 12 Function of pressure relief valve The vacuum and pressure compensator systems actually perform three important functions that the other described types of metering pumps cannot do unless auxiliary equipment is added to their piping systems. As described previously, they compensate for any leakage occurring within the hydraulic system of the pump, ensuring a balanced diaphragm movement. In addition, they serve to protect the process system from an over-pressure condition produced by the pump. For instance, the positive displacement pump, because of its design, must over pressure the system to the point of damaging the pump, bursting pipes, or damaging other downstream equipment should an operator mistakenly close a shut-off valve downstream from the pump. The hydraulic diaphragm pump will, however, relieve any pump-produced pressure beyond the set pressure of the pressure relief valve, thus avoiding the dangerous build up of pressure. The compensation system also serves to protect the pump from a closed suction line or a partially clogged strainer in the suction line. Should this occur, the backward movement of the diaphragm is prevented and the vacuum relief system would automatically open to relieve the starved suction condition within the pump. In doing so, however, a surplus of hydraulic oil enters into the system between the diaphragm and piston. As the piston starts forward on its discharge stroke, the diaphragm is displaced forward and will come into contact with the contoured dish support plate in the process liquid chamber, because of the surplus oil drawn into the hydraulic chamber. At the moment of diaphragm contact with its support plate, an over-pressure condition starts to develop within the hydraulic system. The pressure relief valve now opens to relieve the surplus oil back into the hydraulic reservoir, preventing a dangerous build up of pressure. The interaction of the two compensation systems continue stroke after stroke to activate a fluid-clutch-type action to prevent overloading of the pump's power end until the condition plugging the suction or discharge lines is found and corrected.

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FLOW ADJUSTMENT Flow control can be achieved in a number of ways, however the most common are as follows. 1. Changing the stroke rate within the pump by changing internal gearing in the drive mechanism. This is done at time of pump manufacture and further changes cannot be made after pump installation. 2. Changing the stroke rate by changing the driver speed. When the driver is an electric motor, using a frequency inverter will achieve this result. With solenoid operated pumps, this can be done by setting the switching on the solenoid. 3. Changing the stroke length. This can be achieved in a number of ways and is dependent on the pump construction. Details are given below. 4. Adjustable cranks and hydraulic bypass have also been used in the past but are rarely seen these days. STROKE LENGTH ADJUSTMENT There are two main categories of stroke length adjustment mechanisms - lost motion and full motion. Each of these designs changes the way in which the internal piston travels within the piston cylinder. Adjustments can be made manually as shown in all the diagrams below or adjustments can be automatic with the use of electric or pneumatic actuators. A 4-20 mA electric or 3-15 psig pneumatic process signal would be required for the actuators. LOST MOTION (Figures 13, 14 and 15) Smaller pumps (low flow) are typically of the lost motion stroke length mechanism design. The pump motor turns the worm shaft which, in turn, rotates the eccentric gear within the pump gearbox. The cam rotates with the eccentric gear and actuates the piston via the cam follower. On each discharge stroke of the pump the cam follower pushes the piston towards the pump reagent head displacing the pump diaphragm. After the piston reaches its full forward position the piston is retracted via spring force. Displacement per stroke is controlled through limiting the rearward travel of the piston. Adjusting the stroke length mechanism extends and / or retracts the internal adjustment screw. When a stroke length of less than 100% is desired the internal adjustment screw is rotated and the rearward piston travel is limited based on the stroke length setting. As a result there is no contact with the cam for a portion of the cam rotation and the piston stops moving until the cam rotates to a position in which contact is re-established with the cam follower.

Figure 13

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Figure 14

Figure 15 The flow characteristics produced from a lost motion style of pump are shown below. As indicated, the flow at 100% stroke length can be represented as a sine wave. When the stroke length is decreased the maximum amplitude of each stroke is maintained while the full potential volume per stroke is decreased.

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LOST MOTION FLOW CURVE

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DISCHARGE

100% STROKE LENGTH 60% STROKE LENGTH

- - (

360 270

SUCTION

FULL MOTION (Figures 16,17 and 18) Pumps with larger flow requirements are typically handled by full motion pumps. Full motion pumps rely on internal linkages for the adjustment of stroke length. The pump motor turns the worm shaft which, in turn, rotates the eccentric gear within the pump gearbox. The eccentric gear transmits motion to a connecting rod which is attached to an oscillating housing. The oscillating housing is stationary at its top the resulting motion is similar to that of a pendulum. Within the oscillating housing exists a housing block which is, in turn, connected to a connecting rod. The connecting rod is attached to the piston. It can be seen from Figure 16 that when the housing block is at its full bottom position (100% stroke length) the piston will maximize its horizontal movement. As a result the pump will produce its greatest potential displacement per stroke. When the housing block is adjusted to its full top position (0% stroke length) the piston will be stationary and, as a result, the pump will produce no flow. Adjustment of stroke length is actually an adjustment of the housing block position within the oscillating housing this adjustment will determine how far back and forth the piston can travel and, as a result, the volume per stroke that the pump can produce.

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Figure 16

Figure 17

Figure 18

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FULL MOTION FLOW CURVE Full motion flow characteristics are detailed below. As with lost motion pumps the flow characteristic at 100% stroke length can be characterized as a sine wave. Adjustment of stroke length decreases the sine wave amplitude (displacement per stroke).

100% STROKE LENGTH 60% STROKE LENGTH

With the use of variable speed motors and drives many metering pumps are controlled through variable speed in lieu of stroke length. The flow characteristics of full motion and lost motion pumps are identical if stroke length is maintained at 100% and motor speed is used to adjust flow. Instead of changing volume (amplitude) per stroke the adjustable motor speed will modify strokes per minute (frequency). The resulting output will be identical regardless of stroke length type. Finally, a discharge pulsation dampener is a typical recommendation for all styles of metering pumps. The discharge pulsation dampener transforms a diaphragm metering pump's reciprocating flow to laminar flow. As a result, the flow characteristics downstream of a metering pump, regardless if it is lost motion or full motion, will be identical when a discharge pulsation dampener is installed.

Acknowledgements: Metering Pump Handbook (Pulsafeeder Inc) www.pulsa.com www.miltonroy.com

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