Design And Fabrication Of Piston Operated Water Pump
International Journal of Engineering Technology, Management and Applied Scienceswww.ijetmas.com June 2017, Volume 5, Issue 6, ISSN 2349-4476Design and Fabrication of Piston Operated Water PumpSenthilkumar S1,Jayaprathap M2, keerthi K G3,kumar M P4Department of Mechanical Engineering,RMK College of Engineering and Technology, RSM Nagar, PuduvoyalABSTRACTThe technology of pneumatics has gained tremendousimportance in the field of automation from old fashionedtimber works, machine shops and space robots .Certaincharacterizes of air have made this medium quitesuitable for used in modern manufacturing andproduction industries. It is therefore important thattechnicians and engineers should have knowledge onpneumatic systems air operated valves accessories.Pneumatic system consists of a compressor plant, pipelines control valves and drive members. The air iscompressed in an air compressor and from thecompressor plant the flow media is transmitted to thepneumatic cylinder through a well laid pipe line system.So keeping in mind about the importance of pneumaticsystem are introducing a project called Automaticpneumatic water pumping system. Here all need is acompressor pneumatic cylinder, pneumatic cylinder,piston pump. The aim of the project is pneumaticoperated piston water pump. The piston is reciprocatedwith the help of a pneumatic cylinder solenoid valve.There are two cylinders are used in this project, one forpneumatic cylinder and another one for hydrauliccylinder. This pumping system also can be used inpumping of water supply in agriculture lands, Industrialpumping and also in domestical applications.1. INTRODUCTIONThe aim of the project is pneumatic operated waterpumping system. Radial plunger pneumaticoperatedwater pumping system are pump in which the pistonis provided for the pumping action. The piston isreciprocated with the help of a pneumatic cylinder.A pump is a Mechanical device whichconverts mechanical energy into hydraulic energy.This pump is classified into two types;1.1 TYPES OF PUMPi.Positive Displacement andii.Non-Positive Displacement pump300In positive displacement pump is the one, inwhich the liquid is transferred positively fromone stage to another stge by the to and frommotion of the plunger or piston of the pump .In non-positive displacement pump the liquid istransferred by the centrifugal force. This force iscause due to the rotary movement of an impeller inthis, our project, pneumatic water pump is ofpositive displacement pump. The salient features ofa pneumatic water pump have been retained in ourproject model and this has been achieved with greatcare.Due to high precision work involved in producingpneumatic water pump besides higher cost thesepumps are not widely manufactured by most of theindustries. The very name itself indicates that itworks with the help of a piston. This piston isreciprocated with the help of a solenoid valve andelectronic timing control unit.1.2 RECIPROCATING PUMPReciprocating pumps are those which cause thefluid to move using one or more oscillating pistons,plungers or membranes (diaphragms).To 'Reciprocate' means 'To Move Backwards andForwards.Areciprocating pump therefore, is onewith a forward and backward operating action.Thesimplest reciprocating pump is the 'piston Pump',which everyone at some time or other will haveused to re-inflate their bike tyres.Reciprocating-typepumps require a system of suction and dischargevalves to ensure that the fluid moves in a positivedirection. Pumps in this category range from having"simplex"one cylinder, to in some cases "quad" fourcylinders or more. Most reciprocating-type pumpsare “duplex” (two) or "triplex" (three) cylinder.Thistype of pump was used extensively in the early daysof steam propulsion (19th century) as boiler feedwater pumps. Reciprocating pumps are nowtypically used for pumping highly viscous fluidsSenthilkumar S, Jayaprathap M, Keerthi K G, Kumar M P
International Journal of Engineering Technology, Management and Applied Scienceswww.ijetmas.com June 2017, Volume 5, Issue 6, ISSN 2349-4476including concrete and heavy oils, and specialapplications demanding low flow rates against highresistance.Fig. 1.2 Reciprocating Pump1.3 CENTRIFUGAL PUMPReciprocating pump is a positive displacementpump, which causes a fluid to move by trapping aFixed amount of it then displacing that trappedvolume into the discharge pipe. The fluid enters apumping chamber via an inlet valve and is pushedout via a outlet valve by the action of the piston ordiaphragm. They are either single acting;independent suction and discharge strokes or doubleacting; suction and discharge in both directions.During the suction stroke the piston moves left thuscreating vacuum in the Cylinder. This vacuumcauses the suction valve to open and water entersthe Cylinder. During the delivery stroke the pistonmoves towards right. This increasing pressure in thecylinder causes the suction valve to close anddelivery to open and water is forced in the deliverypipe. The air vessel is used to get uniformdischarge.Reciprocating pumps are selfpriming and aresuitable for very high heads at low flows. Theydeliver reliable discharge flows and is often used formeteringduties because of constancy of flow rate.The flow rate is changed only by adjusting the rpmof the driver.The piston pump is one of the most commonreciprocating pumps and, prior to the developmentof high speed drivers which enhanced the popularityof centrifugals, it was the pump of choice for abroad range of applications. Today, they are mostoften seen in lower flow, moderate (to 2000 PSI)pressure applications. Its close cousin, the plunger301pump, is designed for higher pressures up to 30,000PSI.The major difference between the two is the methodof sealing the cylinders. In a piston pump thesealing system (rings, packing etc) is attached to thepiston and moves with it during its stroke.The sealing system for the plunger pump isstationary and the plunger moves through it duringits stroke.A centrifugal pump is of a very simple design. Thetwo main parts of the pump are the impeller and thediffuser. Impeller, which is the only moving part, isattached.a shaft and driven by a motor. Impellersare generally made of bronze, polycarbonate, castiron, stainless steel as well as other materials. Thediffuser (also called as volute)converted to pressureby specially designed passageways that direct theflow to the discharge of the pump, or to the nextimpeller should the pump have a multi-stageconfiguration.The pressure (head) that a pump will develop is indirect relationship to the impeller diameter, thenumber of impellers, the size of impeller eye, andshaft speed. Capacity is determined by the exitwidth of the impeller. The head and capacity are themain factors, which affect the horsepower size ofthe motor to be used. The more the quantity ofwater to be pumped, the more energy is requiredFig. 1.3Centrifugal Pump2. CONCEPTOF MECHANISMThe air is compressed in an air compressorand from the compressor plant the flow media istransmitted to the pneumatic cylinder through a welllaid pipe line system. So keeping in mind about theSenthilkumar S, Jayaprathap M, Keerthi K G, Kumar M P
International Journal of Engineering Technology, Management and Applied Scienceswww.ijetmas.com June 2017, Volume 5, Issue 6, ISSN 2349-4476importance of pneumatic system are introducing aproject called Automatic pneumatic water pumpingsystem. Here all need is a compressor pneumaticcylinder, connecting links and a control system. Theaim of the project is pneumatic operated waterpumping system, radial plunger pneumatic waterpumping system are reciprocating pump is providedfor the pumping action. The piston is reciprocatedwith the help of a pneumatic cylinder solenoidvalve. There are two cylinders are used in thisproject, one for pneumatic cylinder and another onefor hydraulic cylinder.The two outlet ports are connected to anactuator (Cylinder). The pneumatic activates is adouble acting, single rod cylinder. The cylinderoutput is coupled to further purpose. The piston endhas a water horning effect to prevent sudden thrustat extreme ends. The end of the cylinder two Nonreturn valve is connected for both of the side. OneNon return valve for suction side and another onenon return valve are for delivery side.2.1 WORKING PRINCIPLEThese pumps deliver a highly pulsed flow. If asmooth flow is required then the discharge flowsystem has to include additional features such asaccumulators. An automatic relief valve set at a safepressure is used on the discharge side of all positivedisplacement pumps.The performance of a pump is characterized by itsnet head h, which is defined as the change inBernoulli head between the suction side and thedelivery side of the pump. h is expressed inequivalent column height of water.Fig.2.1DIAPHGRAM PUMP302A reciprocating pump is a class of positivedisplacement pumps which includes the pistonpump, plunger pump and diaphragm pump. Whenwell maintained, reciprocating pumps will last foryears or even decades; however, left untouched,they can undergo rigorous wear and tear.2.2SINGLE ACTING CYLINDERSingle-acting cylinders (SAC) use the pressureimparted by compressed air to create a driving forcein one direction (usually out), and a spring to returnto the "home" tion. More often than not, this type ofcylinder has limited extension due to the space thecompressed spring takes up. Another downside toSACs is that part of the force produced by thecylinder is lost as it tries to push against the spring.One major issue engineers come across workingwith pneumatic cylinders has to do with thecompressibility of a gas. Many studies have beencompleted on how the precision of a pneumaticcylinder can be affected as the load acting on thecylinder tries to further compress the gas used.Under a vertical load, a case where the cylindertakes on the full load, the precision of the cylinderis affected the most. A study at the National ChengKung University in Taiwan, concluded that theaccuracy is about 30 nm, which is still within asatisfactory range but shows that the compressibilityof air has an effect on the system2.3DOUBLE ACTING CYLINDERDouble-acting cylinders (DAC) use the force of airto move in both extend and retract strokes. Theyhave two ports to allow air in, one for outstroke andone for instroke. Stroke length for this design is notlimited, however, the piston rod is more vulnerableto buckling and bending. Additional calculationsshould be performed as well.Oninstroke, the samerelationship between force exerted, pressure andeffective cross sectional area applies as discussedabove for outstroke. However, since the crosssectional area is less than the piston area therelationship between force, pressure and radius isdifferent. The calculation isn't more complicatedthough, since the effective cross sectional area ismerely that of the piston surface minus the crosssectional area of the piston rod.2.4MULTISTAGETELESCOPINGCYLINDERTelescoping cylinders, also known as telescopiccylinders can be either single or double-acting. TheSenthilkumar S, Jayaprathap M, Keerthi K G, Kumar M P
International Journal of Engineering Technology, Management and Applied Scienceswww.ijetmas.com June 2017, Volume 5, Issue 6, ISSN 2349-4476telescoping cylinder incorporates a piston rodnested within a series of hollow stages of increasingdiameter. Upon actuation, the piston rod and eachsucceeding stage "telescopes" out as a segmentedpiston. The main benefit of this design is theallowance for a notably longer stroke than would beachieved with a single-stage cylinder of the samecollapsed (retracted) length. One cited drawback totelescoping cylinders is the increased potential forpiston flexion due to the segmented piston design.Consequently, telescoping cylinders are primarilyutilized in applications where the piston bearsminimal side loadingIn a momentum transfer pump, gas molecules areaccelerated from the vacuum side to the exhaustside (which is usually maintained at a reducedpressure by a positive displacement pump).Momentum transfer pumping is only possible belowpressures of about 0.1 kPa. Matter flows differentlyat different pressures based on the laws of fluiddynamics. At atmospheric pressure and mildvacuums, molecules interact with each other andpush on their neighboring molecules in what isknown as viscous flow. When the distance betweenthe molecules increases, the molecules interact withthe walls of the chamber more often than with theother molecules, and molecular pumping becomesmore effective than positive displacement pumping.This regime is generally called high vacuum.Molecular pumps sweep out a larger area thanmechanical pumps, and do so more frequently,making them capable of much higher pumpingspeeds. They do this at the expense of the sealbetween the vacuum and their exhaust. Since thereis no seal, a small pressure at the exhaust can easilycause backstreaming through the pump; this iscalled stall. In high vacuum, however, pressuregradients have little effect on fluid flows, andmolecular pumps can attain their full potential.The two main types of molecular pumps arethe diffusion pump and the turbomolecular pump.Both types of pumps blow out gas molecules thatdiffuse into the pump by imparting momentum tothe gas molecules. Diffusion pumps blow out gasmolecules with jets of oil or mercury, whileturbomolecular pumps use high speed fans to pushthe gas. Both of these pumps will stall and fail topump if exhausted directly to atmospheric pressure,so they must be exhausted to a lower grade vacuumcreated by a mechanical pump.303As with positive displacement pumps, the basepressure will be reached when leakage, outgassing,and backstreaming equal the pump speed, but nowminimizing leakage and outgassing to a levelcomparable to backstreaming becomes much moredifficult.Fig 2.2PNEUMATIC CYLINDER2.6 ENERGY LOSSES IN PIPE FITTINGSWhen a fluid flows through a pipe lineconsisting of straight pipe and fittings, there is adefinite loss of pressure due to friction, This loss ofhead is often considerable and has been investigatedmany times.There two types ofEnergy losses. Major energy losses Minor energy losses sudden expansion sudden contraction bond in pipe pipe fitting An obstruction in pipe2. 7 SELECTION OF PNEUMATICSMechanization is broadly defined as thereplacement of manual effort by mechanical power.Pneumatic is an attractive medium for low costmechanization particularly for sequential (or)repetitive operations.Many factories and plants already have acompressed air system, which is capable ofproviding the power (or) energy requirements andthe control system (although equally pneumaticcontrol systems may be economic and can beadvantageously applied to other forms of power).The main advantage of an all pneumatic system areusually economic and simplicity the latter reducingmaintenance to a low level. It can also have outstanding advantages in terms of safety.Senthilkumar S, Jayaprathap M, Keerthi K G, Kumar M P
International Journal of Engineering Technology, Management and Applied Scienceswww.ijetmas.com June 2017, Volume 5, Issue 6, ISSN 2349-44762.8 THE SIZE (INSIDE DIAMETER) OF THEPIPESmaller pipe causes a greater proportionofthe water to be in contact with the pipe, whichcreates friction. Pipe size also affects velocity.Given a constant flow rate, decreasing pipe sizeincreases the water’s velocity, which increasesfriction.2.9 THE ROUGHNESS OF THE INSIDE OFTHE PIPEPipe inside wall roughness is rated by a“C” factor,which is provided by the manufacturer. The lowerthe C value, the rougher the inside and the morepressure loss due to friction2.9.1FABRICATED MODEL DIAGRAMFig 2.3FABRICATED DIAGRAM3. RESULTS AND DISCUSSION3.1 SPECIFICATIONSPumps are commonly rated by horsepower, flowrate, outlet pressure in feet (or metres) of head, inletsuction in suction feet (or metres) of head. The headcan be simplified as the number of feet or metresthe pump can raise or lower a column of water atatmospheric pressure. From an initial design pointof view, engineers often use a quantity termed thespecific speed to identify the most suitable pumptype for a particular combination of flow rate andhead.Positive displacement designs are the ones whichdeliver a fixed amount of flow through themechanical contraction and expansion of a flexiblediaphragm. These pumps are ideal in many304industries that manage high viscosity liquids, orwhere sensitive solids are also present.Recommended water pumps to be used for low .Positive displacement water pumps or rotary pumpare very efficient, due to the fact that they removeair from the lines, thus eliminating the need to bleedthe air from the lines.In addition, these pumps aregreat when dealing with high viscosity liquids.As any equipment, positive displacement waterpumps also present some drawbacks. These types ofpumps require that the clearance between therotating pump and the outer edge must be veryclose. This causes that the rotation occurs at veryslow speeds; otherwise, if the pump is operated athigher speed, the liquids might erode and willeventually reduce the efficiency of the water pumpThere are two general types of water pumps:centrifugal pumps and positive displacement designtype. Both types follow the same purpose, which isto move water from one point to anothercontinuously. These two major components have awide variety of options that might be useddepending on your project specific needs3.2 PUMP MATERIALPump material can be of Stainless steel ( SS 316 orSS 304) , cast iron etc. It depend upon theapplication of pump. In water industry for pharmaapplication, SS 316 is normally used. As at hightemperature stainless steel give better result.Thiscolumn presents a discussion between myself andpump users regarding some of their questions,concerns and preferences about materials ofconstruction that they consider for theirapplications. Some of this feedback comes fromprevious articles published in Pumps &Systems.Ienjoyed your recent article about using a specialtymaterial to help improve the efficiency andreliability of a multistage pump. I was interested inyour selection of the Graphalloy material. I haveused Vespel CR6100 to reduce running clearancesfor efficiency gains and rotor stabilityimprovements. Do you have experience usingVespel? If so, what comparisons can you makebetween this and Graphalloy? When would yourecommend one over the other? Any experiencesyou can share would be greatly appreciate.Senthilkumar S, Jayaprathap M, Keerthi K G, Kumar M P
International Journal of Engineering Technology, Management and Applied Scienceswww.ijetmas.com June 2017, Volume 5, Issue 6, ISSN 2349-4476A great multitude of materials can be used for pumpbushings, including metals (bronze, hardenedsteels), hard coatings, non-metals (thermoplastics,thermosets, composites) and ceramics. All havebenefits and shortcomings, such as resistance totemperature, thermal or mechanical shock,machinability, galling resistance, dimensionalstability, swelling, chemical resistance, abrasiveresistance and price.It would be good to have a three-dimensionaltabulation listing these materials on one column(say, horizontal), versus properties on the other(vertical), and application (pumped fluid) inside thetable, for some sort of visual pick-and-chooseguide. I am not aware of such table.In practice, it is difficult to select an all-around bestchoice. The main reason is unfamiliarity of the endusers with the multiple products that exist and usersbeing cautious against over-zealous salesman tryingto sell them a bushing material for their applicationwhich may not be appropriate for what they pump.3.3 PUMPING POWERThe power imparted into a fluid will increase theenergy of the fluid per unit volume. Thus the powerrelationship is between the conversion of themechanical energy of the pump mechanism and thefluid elements within the pump. In gen
compressor pneumatic cylinder, pneumatic cylinder, piston pump. The aim of the project is pneumatic operated piston water pump. The piston is reciprocated with the help of a pneumatic cylinder solenoid valve. There are two cylinders are used in this project, one for pneumatic cylinder and another one for hydraulic cylinder.
For the analysis of piston input conditions and process of analysis, a lot of literature survey has been done. Comparative study is done to select best material. . gas pressure and the working condition may cause the failure of piston such as piston side wear, piston head or crown cranks and piston over heating-seizure and so on. Therefore .
A piston is a component of reciprocating IC engines. It is the moving component with in a cylinder and is made of gas-tight by piston rings. In an engine, piston is used to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod. Piston endures the cyclic gas pressure and the inertial forces at work, and this working
How A Piston Works Proprietary and Confidential 8 ① Incoming pressure to the upper chamber seals the piston down over the main seat Moving the handle causes the piston to slide up, releasing water into the fixture The piston re-seats as the upper chamber re-pressurizes Sloan Piston Valves are also "non-hold open" design ② ③
surface of the piston. Pistons fail mainly due to mechanical stresses and thermal stresses. Analysis of piston is done with boundary conditions, which includes pressure on piston head during working condition and uneven temperature distribution from piston head to skirt. Jadhav failure of piston due to various thermal and mechanical stresses is
for the simple piston and reduced skirt length piston. by changing the geometry of the piston and it is suggested that which piston is better for same thermal load. Steady state thermal analysis of the Piston have been done in ANSYS 14.5. KEYWORDS . Thermal stress, ANSYS 14.5, Heat flux, Thermal analysis. 1.INTRODUCTION
Intake valve Outlet valve Piston Cylinder Piston rod Crank shaft. 5 Industry and trade need safe solutions: Therefore, BOGE piston compressors . Piston compressor Compressed air receiver Refrigerant dryer Piston Compressors. 6 The K Series: compact, cost efficient, consistently oil free.
Temperature at the center of piston head T. c 260. 0. c to 290. 0. c Temperature at the edge of piston head T. e 185. 0. c to 215. 0. c Maximum gas pressure p 15.454N/mm. 2 Bore or outside diameter of piston D 57mm Thickness of piston headt. h 5.45mm. Piston rings
ceasing of piston due low heat dissipation and failure due to High combustion pressure. Therefore it must be designed to withstand from damage that is caused due to extreme heat and pressure of combustion process. So, reason can be find out Stress analysis and thermal analysis of existing design of piston and piston rings 1.2 Objectives :
