Mine Power, Drainage & Material Handling:

A machine is an arrangement design for the purpose of taking energy in some definite form modifying it and
delivering it in another form that is more suitable for work.

 Drainage:
Drainage is the natural or artificial removal of a surface's water and sub-surface water from an area with excess of
water. Drainage means the removal of water from the soil it have two main goals prevention of seepage,
improvement of soil properties.
Methods of drainage:
1. Sealing off water:
2. Drain tunnel:
3. Bailing:
4. Pumping:
 Material Handling:
Materials handling is the art and science involving the moving, packaging and storing of substances in any form.
Material handling is the function of moving the right material to the right place in the right time, in the right
amount, in sequence, and in the right condition to minimize production cost. Some of the other definitions are:
• Materials handling is the movement and storage of materials at the lowest possible cost through the use of
proper methods and equipment.
• Materials handling is the moving of materials or product by any means, including storage, and all movements
except processing operations and inspection.
• Materials handling is the art and science of conveying, elevating, positioning, transporting, packaging and
storing of materials.
1. Hoisting:
Movement of material in vertical direction.
2. Haulage:
Movement of material in horizontal direction.
 Force:
The agent that produces motion/acceleration in a body.
Units:
1. Newton
2. Pound (lb)
3. cwt ( centrome weight) = 112 lb
4. Tons = 2240 lb
5. st ( stone weight) = 14 lb
 Work:
The dot product of force and displacement.
Expression:
W=FxD
Unit:
lb-ft
 Energy:
The ability to do work.
 Kinetic Energy:
K.E = =
 Potential Energy:
P.E = mgh = Wh
 Power:
The rate of performing work is called power. Power of an ordinary person is 2600 ft-lb/min and of horse is 33,000
ft-lb/min.

P= =

Horsepower =
  Electrical horsepower:
Electric unit of power is watt. Watt is defined as the rate of work done when an electric current of ‘I’
ampere flows from one point to another, potential difference being one volt b/w these points.
1 watt = 1 amp x 1 volt
 Mechanical horsepower:
1 mhp = 746 watt
Mhp =
 Indicated horsepower:
It is the input of machine i.e. the horse power generated in the cylinder of an engine by the stroke of the
piston.
Ihp = P = Pressure
A = Area of piston/ cylinder
N = No of stroke/min
L = Length of cylinder/piston in ft
 Brake horsepower:
It is actually the output of an engine. It is determined experimentally by absorbing all the power at the
crankshaft by means of an arrangement known as friction brake dynamometer.
Bhp = R= Effective radius of the wheel
W= Hanging wt in lb’s
N= Number of revolution/min
w= Spring balance pull in lb’s
 Frictional horsepower:
It is the power in the engine which wasted due to frictional resistance of the machine.
Fhp = Ihp - bhp
 Efficiency:

Ratio of the useful work done (output) to the energy supplied (input) is known as modulus of the machine or
useful effect of the machine or mechanical efficiency or simple efficiency of the machine.

Eff =
=
=
Mechanical Eff =
Electrical Eff =
 1 watt = as 1 hp = 746watt
 1 kw = 1.34 hp
 DC current: hp if dc current is utilized:
Hp = =
 AC current : two types of AC current:
o Single phase : hp = when % eff is not given = 1
√
o Triple Phase: hp =
 Compressor:
It is a device which take definite amount of air, compress it and then deliver at a definite pressure.
It is used for producing high pressure air. Also for cooling purposes of high buildings.
Merits of compressed air:
i. Compressed air is less susceptible to damage by moisture/air.
ii. Air time and flow can be easily maintained and extended.
iii. Leakage can be easily detected and repaired.
iv. Air power is more safe in gaseous.
v. More economical when used as power then other sources.
vi. Driving locomotives and pneumatic converyors.
Demerits of compressed air:
i. Less efficient then electrically produced power.
 Laws of compressed air:
1. Boyle’s Law:
Pα
P= and pressure is absolute pressure = atm p + gauge p
P1V1 = P2V2 Atm pressure= 14.7 lb = 15 lb
2. Charles Law:
VαT
V = PT
So Absolute temp = 460o + Fo
3. Perfect/ideal gas equation:
= nR = constt
=
Finding value of R = Putting standard atm temp = 32 + 460
Standard atm pres = 14.7 x 144
Standard atm vol = 12.4 ft3
n=1
R = 53.35
 Mode of compression:
There are two modes of compression
1. Isothermal compression:
Air or other gas when compressed from a pressure P1 to a higher pressure P2 without change of
temp is called isothermal process. A gas is said to be compressed isothermally. Such are the
condition to which boyles law is strictly applicable. It is necessary for a gas to compress
isothermally so that the heat produced during compression by the conversion of mechanical
energy into heat energy must be removed by some cooling process as fast as it is produced.
Let us consider an isothermal compression by means of PV diagram. Suppose that the volume of
free air V1 drawn at pressure P1 is compressed isothermally by a piston in a cylinder.
The pressure is increased from P1 to a higher pressure P2 and volume is reduced to V2 from V1 .

If we plot the corresponding value of P and V as determined by Boyles law. It is found that the
curve drawn to these point will be of shape AB. The AB curve is called isothermal curve. The
workdone during isothermal process is equal to the are of the PV diagram
W = PV
= 331.2 P1V1 log
Hp =
2. Adiabatic compression:
A gas is said to be compressed adiabatically when there is no transfer of heat to or from the air/gas during
it compression. In the other words the mechanical energy converted into heat during its compression is
allowed to the air/gas to increase its temperature. Final temperature of air depend on initial temp and also
on the degree of compression.
Pure adiabatic compression is never attained in the practice b/c there must be heat loses. Similarily shock
loses and frictional loses can’t be prevneted. Adiabatic curve obey boyles law when:
 PVr = constant and r = 1.14
r = ratio of specific heat and constant pressure to the sp. Heat
at constant volume.
P1 =P2
If temperature is to find:
= b/c

=
=
= b/c r = 1.408
If pressure is to be find:
= b/c = so, to both sides

= b/c, r = 1.408
Work done by adiabetic compression:
W =144 [ {P1V1 - P1V1} ]
Hp =
 Problem:
i. An air compressor compress and deliver 1000ft3 feed air per minute. From P=15 lb/in2 to final guage
pressure of 75 lb/in2. Find the isothermal & adiabatic horsepower.
Given that:
 V1 = 1000 ft3
 P1 = 15 lb/in2
 Guage pressure P2 = 75 lb/in2
 Absolute press = 15 + 75 = 90 lb/in2
 Iso Hp =?
 Adiabatic hp =?
Solution:
Isothermal Work done : W = 331.2 P1V1 log

= 331.2 (15) (1000) log

= 3865855.412 lb.ft
Isothermal HP =
= = 117.147

Adiabatic Work done : W = 144 [ {P1V1 - P1V1} ]

= 144 [ (15)(1000) - (15)(1000) ]

= 23827836.87 lb.ft
Adiabatic Hp =
= = 722.05
 Assignment Problems:
i. Suppose that your own weight is 10 st. 10 lb., and that you carry a weight of 0.5 cwt. Upstairs to a height
of 20 feel. Calculate the total work done in ft-lbs.
Given that:
 Own weight = 10st + 10lb b/c 1 st = 14 lb
= 10 (14lb) +10lb = 150lb
 Carrying weight = 0.5 cwt b/c 1 cwt = 112lb
= 0.5 x 112 = 56lb
 Height = 20ft
 Solution:
Work =FxD
= 56 x 20
=1120 lb.ft
ii. The voltmeter and ammeter attached to 3-phase circuit read 550 volts and 100 amps, respectively. The
power factor being 0.8. What is the HP input?
Given that:
 V = 550v
 I = 100amp
 P.F = 0.8
 HP =?
Solution:
√
3-phase HP = b/c efficiency not given = 1
√
=
= 102.155
iii. A motor when supplied with 3-phase current at 400-volts, develops 30 HP at an efficiency of 90% and
power factor 0.8. What is current in amperes?
Given that:
 V = 400v
 HP = 30
 %efficiency= 90% = 0.9
 P.F = 0.8
 I =?
Solution:
√
3-Phase HP =
Re-arranging in terms of I :
I =
√
=
= 44.92 amp
iv. A rope brake is fitted to a flywheel 6ft in effective diameter and running at 220 rpm. The difference in the
pull at the two ends of rope is 444.8lbs. What is the Brake HP developed?
Given that:
 Diameter of flywheel = 6ft
o Radius = 3ft
 Speed = 220 rpm
 Difference pull (W-w) = 444.8 lb
 BHP =?
Solution:
BHP =
= b/c W-w = 444.8
= 55.86
v. A quantity of the gas occupies a volume of 60 ft3 at a gauge pressure of 25 lbs. per sq inch. And
temperature of 80.6°F. it is compressed to a volume 24 ft3 and its temperature is raised to 260.6 °F. what
is the final absolute pressure?
Given that:
 V1 = 60 ft3
 Guage press= 25 lb/in2
o Abs pressure = Atm press + guage pressure
= 15 + 25 = 40 lb/in2
 Temp T1 = 80.6 F0
o Abs temp = 460 + measured temp
= 460 + 80.6 = 540.6 F0
 V2 = 24 ft3
 T2 = 260.6 F0
o Abs temp = 460 + measured temp
= 460 + 260.6 = 720.6 F0
  P2 =?
Solution:
=
Re-arranging for P2 :
P2 =
=
= 133.3 lb/in2

vi. A certain volume of air at temperature of 80 °F is allowed to expand adiabatically to twice of its initial
volume. What is temperature of expended air gauge?
Given that:
 T1 = 80 F0
o Abs temp = 460 + 80 = 540 F0
 V1 = V1
 V2 = 2V1
 T2 =?
Solution:
As adiabatic relation b/w temp & volume:
=
= Putting V2 = 2V1
T2 = 460.98
 Law of actual compression:
In the ordinary case of air compression the law of the pressure-volume curve is similar to the laws governing
isothermal and adiabatic compression, the essential difference being that the exponent of v in the formulan PVn=C
has a value between i and 1.408. The value of n depends mainly on the rate at which heat is abstracted from the air
during the process of compression, and that is dependent on whether the compressor is double-acting or single-
acting, at least that generalization appears to tx' justifie by a study of diagrams taken from compressors working
under ordinary conditions.
a. Single stage air compression:
A compression in which air is compressed by a single cylinder and piston is called single stage air
compressor. In single stage compressor air is compressed in a single stage. Consider the following
diagram for single stage air compressor:

Work done = P 1V 1 [
b. 2nd Stage of air compression:
The air is pressurized to reach to the required pressure in two stages. It is pressurized in two cylinders one
low pressure horizontal cylinder and the other high pressure vertical cylinder. Two stage air compression
is driven by means of a built or it can be connected to an electric motor or diesel engine. Air is
compressed in two stages instead of a full compression in single cylinder.
Let P1V1 be the condition of air entering low pressure cylinder.
Let P2V2 be the condition of air entering high pressure cylinder.
And P3V3 be the final pressure and volume of air after compression.
Now the total work required to drive the compressor/cycle will be sum of work required in each cylinder.
Work done = W = P1V1 [ +( -2]
H.P = where N = rpm

 Efficiency of compression:
i. Volumetric efficiency:
It is the ratio of actual volume of air drawn during the suction stroke to the swept volume of cylinder.
Volume of air drawn must be reduced to a STP condition. And it value ranges from 60% to 90%.
V.E = Swept volume = area x length of cyl
 ii. Isothermal/Compression efficiency:
It is the ratio of theoretical power required to compress air to the actual power required in the cylinder.
Theoretical is always greater than actual. Its value is mostly 70%.
I.E =

iii. Mechanical efficiency:

Its value is mostly 90%.
M.E =

iv. Overall efficiency:

It is product of compression & mechanical efficiency. Or it the ration of isothermal HP to IHP of
engine/motor. Its value ranges from 60% - 70%.

O.E =
 Types of compressor:

i. Reciprocating:
In a reciprocating compressor, a volume of air is drawn into a cylinder, it is trapped, and compressed by
piston and then discharged into the discharge line. The cylinder valves control the flow of air through the
cylinder; these valves act as check valves.
Reciprocating is further classified on basis of working principle and construction:
a. Working principle:
i. Single acting R.C:
It is a compressor that has one discharge per revolution of crankshaft. They are the
reciprocating compressor which has piston working only in one direction. There is one
suction and delivery stroke per revolution of crank.
ii. Double acting R.C:
It is a compressor that completes two discharge strokes per revolutions of crankshaft.
Most heavy-duty compressors are double acting. As from its name it uses its both sides to
compress the air. These types of compressors have two sets of suction/intake and
delivery/exhaust valve on both sides of the piston .As the piston moves up and down,
both sides of the piston is utilized in compressing the air. The intake and exhaust valve
operates corresponding to the movement of the piston or with the stroke of the
compressor. The air is compressed accordingly and delivered continuously as compared
 to single acting air compressor. Here both of sides are effectively used for compressing
the air.

b. Construction (or arrangement of the cylinders):

i. Horizontal:

ii. Vertical:
Same as horizontal but stood in vertical form.
ii. Turbo-rotary:
It has a rotating part which imparts its kinetic energy to the air and converts it into pressure energy. The
impart of the kinetic energy is done with the help of the centrifugal force. The parts include impellar,
diffuser, casing and valve. This type of air compressor includes centrifugal compressor and axial flow
compressor.
a. Centrifugal Compressor:
In this compressor centrifugal force is used to compress the air. It contains mainly three main
parts i.e. impeller, diffuser and involute casing. It is the most commonly used type of air
compressor in different areas.
b. Axial flow compressor:
It is a compressor in which the air which is to be compressed moves axially during its
compression. Axial flow compressor can continuously provide compressed gas.
 Electric Power:
Electric power is the rate, per unit time, at which electrical energy is transferred by an electric circuit. The SI unit
of power is the watt, one joule per second. Electric power is usually produced by electric generators, but can also
be supplied by sources such as electric batteries.
Mathematiclly:
P = IV
P = I2R
P=
 Power factor & power factor correction:
Power factor (P.F) is the ratio between actual power to the apparent power. Power Factor is a measure of how
efficiently electrical power is consumed.
P.F= = kw/kva
Power factor is expressed as a number between 0 to 1.0 (or as a percent from 0% to 100%).
For a purely resistive load the power factor is unity. Active and reactive power are designated by P &Q
respectively. The average power in a circuit is called active power and the power that supplies the stored energy in
reactive elements is called reactive power.
Power factor correction:
Power factor correction is the process of increasing the power factor to near unity without altering the original
load. The power factor of a network is a measure of how efficiently the power is used and power factor correction
is technology and equipment used to ensure this is as efficient as possible. In order to eliminate line losses, the
power factor correction device must be mounted at the inductive load.
Most loads on an electrical distribution system fall into one of three categories; resistive, inductive or capacitive.
In most plant, the most common is likely to be inductive. Typical examples are transformer, fluorescent lighting
and AC induction motors. All inductive loads require two kinds of power to operate:
1. Active power (KW) - to produce the motive force.
2. Reactive power (KVAR) - to energize the magnetic field.

The operating power from the distribution system is composed of both active (working) and reactive (non-
working) elements. The active power does useful work in driving the motor whereas the reactive power only
provides the magnetic field.
It is not usually necessary to reach unity, i.e. Power Factor 1, since most supply companies are happy with a PF of
0.95 to 0.98.
By installing suitably sized switched capacitors into the circuit, the Power Factor is improved and the value
becomes nearer to 1 thus minimizing wasted energy and improving the efficiency of a plant or power factor can be
increased by synchronous motor or Synchronous generators.

Load Flow Analysis:

The power flow study (also known as load-flow study) is an important tool involving numerical analysis applied
to a power system.
A power flow study usually uses simplified notation such as a one-line diagram and per-unit system, and focuses
on various forms of AC power (i.e. voltages, voltage angles, real power and reactive power).
Load flow (power flow) analysis is a basic analysis for the study of power systems. It is used for normal, steady-
state operation. It gives you the information what is happening in a system.
It is an answer to some fundamental questions, which power system engineer or electrical engineer can have:
 What are voltage levels in all power system nodes during operation?
 Are power system elements (transformers, generators, cables etc.) overloaded?
 What are the weakest points of network?
 Power Cable:
Cable: Denotes a bundle of wires. e.g: A wire rope is a type of cable
Electrical cable is a bundle of electrical conductors used for carrying electricity. In electro-technology, cable
means an insulated electrical conductor used for transmitting electrical energy. Typical mining and concentrator-
plant power requirements today are ~120 MW for a 100,000-t/d (metric tons per day) plant. When we use electric
cables, we need to consider the following three things:
 Support the cable: (if on floor cover it , if on roof support it)
 Insulation
 Earthing: (to utilize the excess or false current)
Types of cables:
a. Shaft Cable
b. Road Cable
c. Trailing Cable (also called portable cable: that are connect to mining machinery)

 Conductors:
Mostly copper & aluminum.
Conductor screen:
The main purpose of conductor screen is to maintain a uniformly divergent electric field, and to contain
the electric field within the cable core. Conductor screen is semi-conducting material because semi-
conducting materials do not conduct electricity well enough to be a conductor but will not hold back
voltage.
Fillar:
Fillers are used to give a cable a more rounded and smooth construction and to give the inside of the cable
a cleaner appearance. Additionally, it strengthens a cable, so that when a cable is moved or flexed, you
can control the conductors moving inside of the cable. Most importantly filler material supports the
cable’s outer layers. Plastic is one of the most common filter materials and is available in numerous sizes
Bedding & armour:
Over the bedding, armouring is provided which consists of one or two layers of galvanised steel wire or
steel tape. Its purpose is to protect the cable from mechanical injury while laying it and during the course
of handling. Steel wire armour provides mechanical protection, which means the cable can withstand
higher stresses, be buried directly and used in external or underground projects.
 Insulators:
o Thermoplastic & Thermosetting:
Thermo-plastic Thermosetting
Thermoset Curing Process Thermoplastics Curing Process
Thermoset plastics contain polymers that cross-link Thermoplastics pellets soften when heated and become
together during the curing process to form an more fluid as additional heat is applied. The curing process
irreversible chemical bond. The cross-linking process is completely reversible as no chemical bonding takes
eliminates the risk of the product remelting when heat is place. This characteristic allows thermoplastics to be
applied, making thermosets ideal for high-heat remolded and recycled without negatively affecting the
applications such as electronics and appliances. material’s physical properties.
Features & Benefits Features & Benefits
Thermoset plastics significantly improve the There are multiple thermoplastic resins that offer
material’s mechanical properties, providing various performance benefits, but most materials
enhances chemical resistance, heat resistance and commonly offer high strength, shrink-resistance and
structural integrity. Thermoset plastics are often easy bendability. Depending on the resin,
used for sealed products due to their resistance to thermoplastics can serve low-stress applications such
deformation. as plastic bags or high-stress mechanical parts.
 Pros Pros
More resistant to high temperatures than Highly recyclable
thermoplastics Aesthetically-superior finishes
Highly flexible design High-impact resistance
Thick to thin wall capabilities Remolding/reshaping capabilities
Excellent aesthetic appearance Chemical resistant
High levels of dimensional stability Hard crystalline or rubbery surface options
Cost-effective Eco-friendly manufacturing
Cons Cons
Cannot be recycled Generally more expensive than thermoset
More difficult to surface finish Can melt if heated
Cannot be remolded or reshaped
Polyethylene, polypropylene, polyvinyl chloride, Epoxy resin, melamine formaldehyde, polyester resin
polystyrene, polybenzimidazole, acrylic, nylon and and urea formaldehyde.
Teflon EPR :( Ethylene propylene rubber)
XLPE: (cross-linked polyethylene)
o Plastic:
Plastic’s electrical and insulation properties make it a popular material for wiring, cabling,
sleeving and electrical shielding products. Plastics for electrical insulation exhibit dielectric
strength, thermal performance, high insulation and corrosion, water and heat resistance, making
them ideal for safe, high performance electrical components. They provide flexibility for wiring
and cabling applications and rigidity for conduits and housings. Compounds can be formulated to
comply with industrial and regulatory safety standards. The plastic is s/t labeled with the
following:
 T: Thermo-plastic  M: Mineral oil
 H: Heat resistance:  A: Asbestos
 W: Water resistance  N: Nylon Jacket
o Paper:
Papers are paper types that are used as electrical insulation in many applications due to pure
cellulose having outstanding electrical properties. Cellulose is a good insulator and is also polar,
having a dielectric constant significantly greater than one. Electrical paper products are classified
by their thickness, with tissue considered papers less than 1.5 mils (0.0381 mm) thickness, and
board considered more than 20 mils (0.508 mm) thickness.
o Enamel: Wood+magnesium
Gives appearance, flexibility, adherence and chemical inertness.
o Mineral Oil ( mixture of high alkanes):
Mineral oil is generally effective as a transformer oil, but it has some serious disadvantages, of
which the worst is its high flammability.Mineral oil is also an environmental contaminant, and its
insulating properties are rapidly degraded by even small amounts of water.
o Silk/Cotton:
A thermal insulator is a material that does not conduct heat well. By minimizing heat energy
transfer from one material to another, insulation prevents heat from escaping or entering an
enclosed area. The air surrounding and within cotton fibers makes cotton balls good insulators.
Silk isn't a great insulator. When exposed to a somewhat humid atmosphere it has significant
electrical conductivity.

 Cable type on basis of flexibility:

On a broader note cables can be easily divided into two categories, Flexible cables and Solid conductor cables.
Solid cables have a solid conductor which makes the wire rigid and strong. Due to the rigidity these wires have
lower rate of flexibility thus prone to breakage if continuously flexed at a certain point. Smaller the radius of the
conductor of a cable more flexibility can be expected from the cable. Flexible cables, also called as continuous
flex cables, as the name suggest can flex or bend according to the requirement without sustaining damage. The
following are two types of flexible cable:
i. Trailing:
These are 5-core cable. First three for 3-phase current, the fourth for pilot(transmission &
communication purpose) & fifth for earth.
ii. Plaible:
It may have 3,4 core cable.
 Color Coding:
Different colors used are: green, black, brown, blue, yellow, white, red.
 Old System Metric System
3-core White/red/blue Brown
Pilot Black Blue
Earth Green Green/yellow
 Selection of mining cable (on basis of function):
i. Power
ii. Signal
iii. Data Transmission
iv. Short fire
v. Mining control cable
 Mine Drainage:
Drainage is the natural or artificial removal of a surface's water and sub-surface water from an area with excess of
water. Drainage means the removal of water from the soil it have two main goals prevention of seepage,
improvement of soil properties.
Methods of drainage:
1. Sealing off water:
2. Drain tunnel/Adit:
3. Bailing:
4. Pumping:
 Pumping:
The following are the two types of pumps:
a. Centrifugal pump
b. Reciprocating pump

Both centrifugal and reciprocating pumps are most common type of pumps used to move fluid and increase its
pressure. Centrifugal pump which is also known as rotary pump used kinetic energy of impeller to force the fluid
and increase its kinetic energy. This kinetic energy suddenly converts into pressure energy which move fluid
upward. These are used in household pumps for domestic water supply. Reciprocating pumps are one of the
positive displacement pumps which contain a piston cylinder device. Water is trapped into the cylinder during
suction stroke and force out during exhaust stroke. It is mostly used to pump high viscous fluids.
Centrifugal Pump:
The hydraulic machine which converts the mechanical energy into hydraulic energy is called Pumps. The
hydraulic energy is in the form of pressure energy, If the mechanical energy is converted into pressure energy by
means of a centrifugal force acting on the fluid, the hydraulic machine is called a centrifugal pump.
Main Parts of Centrifugal Pump:
 Impeller
 Casing
 Suction pipe with a foot valve
 strainer and
 Delivery pipe
Reciprocating Pump:
A reciprocating pump is a hydraulic machine which converts the mechanical energy into hydraulic energy.
This is a positive displacement pump. Here a certain volume of liquid is collected in the enclosed volume and is
discharged using pressure to the required application. Reciprocating pumps are more suitable for low volumes of
flow at high pressures. The reciprocating pump having two types: 1. Single-acting reciprocating pump and 2.
Double acting reciprocating pump.
Main Parts or Component of Reciprocating Pump:
 Suction Pipe
 Suction Valve
 Delivery Pipe
 Delivery Valve
 Cylinder
 Piston and Piston Rod
 Crank and Connecting Rod
 Strainer
 Air Vessel
Reciprocating pump types:
1. Single acting:

In this pump, A cylinder, in which a piston moves forward and backwards. The piston is reciprocating by
means of the connecting rod. The connecting rod connects the piston and the rotating crank. the crank is
rotating by means of an electric motor.
The suction and delivery pipes with suction and delivery valve are arranged to the cylinder.

The suction valve allows the water to the cylinder and

The delivery valve leaves the water from the cylinder.
As the crank rotates, during the first stroke of the piston (called suction stroke), the water enters into the
cylinder. In a suction stroke, the crank is rotating from A to C (from 0° to 180°) the piston is moving towards
the right side of the cylinder. Due to this, the vacuum creates in the cylinder. This vacuum causes the suction
valve to open and the water enters the cylinder.

In the next stroke called delivery stroke, the water leaves the cylinder. In the delivery stroke, the crank is
rotating from C to A (from 180° to 360°) the piston is moving to the left side of the cylinder. Due to this, the
pressure of the liquid increases inside the cylinder. This pressure causes the suction valve to close and
delivery valve to open. Then the water is forced into the delivery pipe and raised to a required height.
2. Double acting:

In this, the water is acting on both sides of the piston as shown in the figure. Thus two suction pipes and two
delivery pipes are required for a double-acting pump. When there is a suction stroke on one side of the piston,
at the same time there is a delivery stroke on the other side of the piston.

Hence for one complete revolution of the crank, there is two delivery stroke and the water is delivered to the
pipes by the pump during these two delivery strokes.
Question: Discuss the characteristic features and comparison of different reciprocating
and centrifugal pumps.

Ans:
Centrifugal Pumps
A centrifugal pump is a rotating machine in which flow and pressure are generated dynamically. The energy
changes occur by virtue of two main parts of the pump, the impeller and the volute or casing. The function of
the casing is to collect the liquid discharged by the impeller and to convert some of the kinetic (velocity)
energy into pressure energy. Centrifugal pumps are subdivided into several categories, as shown in above
Figure
Types based on direction of flow:
1. Radial Flow:
The impeller discharges fluid at right angles to the shaft axis. In this centrifugal pump in which the pressure is
developed wholly by centrifugal force. The radial type pumps are used for the application of high head and
low discharge.

2. Axial Flow:
The flow through impeller is parallel to shaft axis low head and very high discharge. The axial flow type
pumps are used for the application of medium head and high discharge.
In this centrifugal pump in which the pressure is developed by the propelling or lifting action of the vanes of
the impeller on the liquid.

3. Mixed Flow :
Mixed flow pumps borrow characteristics from both radial flow and axial flow pumps.
As liquid flows through the impeller of a mixed flow pump, the impeller blades push the liquid out away from
the pump shaft and to the pump suction at an angle greater than 90˚ (direction somewhere b/w axial and
radial). The impeller of a typical mixed flow pump and the flow through a mixed flow pump are shown in
Figure
Comparison:
Radial Axial Mixed

Direction of flow 90˚ Parallel Diagonal (0˚- 90˚)

Amount of Centrifugal High Medium Low

Force required

Discharge Pressure Medium Low High

Quantity of discharge Medium High High

Advantages -Compact size -High capacity

-High speed

Disadvantages -Low suction lift

capacity

-Low discharge

Reciprocating pumps:
In a reciprocating pump, a piston or plunger moves up and down. During the suction stroke, the pump cylinder
fills with fresh liquid, and the discharge stroke displaces it through a check valve into the discharge line.
Reciprocating pumps can develop very high pressures. Plunger, piston and diaphragm pumps are under these
types of pumps.

Types:
 1. Plunger / piston type pumps:
These consist of a cylinder with a reciprocating plunger/piston. The suction and discharge valves are mounted
in the head of the cylinder. In the suction stroke the plunger retracts and the suction valves open causing
suction of fluid into the cylinder. In the forward stroke the plunger pushes the liquid out of the discharge
valve. Efficiency and common problems. The plunger contains the cross head, driven by a cams haft
arrangement. The capacity of the pump can be adjusted by changing the stroke, the rotating speed of the
pump, or both. The stroke of the pump is changed by the eccentric pin setting. These types pumps used for the
application of sewage, sludge, scum, clarifier thickener underflow. It can be applied for transfer and for
metering service. Such pumps are available in single- and multi cylinder models.
Plunger vs Piston:
i. Tool employed for pushing the fluid (piston or plunger).
ii. Sealing system:
In a piston pump the sealing system (rings, packing etc) is attached to the piston and moves with it during is
stroke. The sealing system for the plunger pump is stationary and the plunger moves though it during its stroke.
As shown in the figure.

2. Diaphragm pumps :
The diaphragm pump differs from the piston or plunger-type reciprocating pump in that the fluid being
pumped is completely isolated from the reciprocating mechanism by a diaphragm, thereby eliminating leakage
along the piston rod and plunger.
The diaphragm is a flexible membrane which acts as the liquid displacement component. The diaphragm can
be made of flexible metal or nonmetallic materials such as plastic, rubberor neoprene, depending on the fluid
being pumped.
These type of pumps are quite versatile, handling a wide variety of fluids like food additives, chemicals, dry
powders, slurries, pharmaceutical products, and wastewater etc. The advantages in diaphragm pumps is the
absence of seals or packing, meaning they can be used in applications requiring zero leakage.
Comparison:
Piston/Plunger Diaphram
Construction Piston or plunger for pushing fluid Diaphram for pushing fluid

Efficiency Less More

Capacity 50-200 30 – 130 gpm

Power Consumption Low

Suction & Discharge head 20-40ft 15-25 ft

Leakage More Less

-Therefore require sealing system -Doesn’t require sealing system

Fluid Not isolated(direct contact) from Isolated from mechanical parts

mechanical parts

Viscosity Less viscous High Viscous

Fluid type Non hygienic Hygienic

Usage For pumping: For pumping:

Sewage, scum and metering fluid Additive, chemicals etc

 Pump’s mathematical expressions:
 Reciprocating Pump:
 Relation b/w size of engine & cylinder of pump:
P x 0.7584 Ed2 = 0.434H x 0.7584D2 P = Effective pressure lb/in2
d = Dia of engine (in)
E = Mechanical efficiency
H = Total head (total height water to be pumped)
D = Dia of pump piston (in)
PEd2 = 0.434 HD2
 Capacity of RP (gallon/min):
G = 0.034 D2LNE D = Dia of cyl (in)
N = No. of stoke
E = Volumetric efficiency
L = Length of stroke (ft)[ "Stroke length", the distance
travelled by the piston in each cycle.]
 Horsepower:
HP = G = Capacity (gall/min)
H = Total head (ft)
BHP =
 Input Efficiency:
Input efficiency =
Numerical-1:
A relative double acting piston pump has diameter of cylinder 9-in and stroke length of 2 ft. It runs at speed of 30
rpm & slip is 10%. Calculate the discharge of RP pump in gal/min.
Given that:
 Dia of piston (d) = 9 in
 Stroke length (L) = 2 ft
 Speed of stroke = 30 rpm
 Number of stroke:
Speed of stroke = 30
NxL = 30 b/c L = 2
Hence N = 15
 Slip (means losses) = 10%
 Hence efficiency = 90%
Solution:
G = 0.034 D2LNE
G = (0.034)(9)2(2)(15)(0.9)
G = 74.358 gal/min
Numerical-2:
A 3-throw run pump 12-in dia having stroke length of 24-in. The crankshaft runs at speed of 40 rpm. Calculate the
discharge (gal/min) assuming efficiency of 0.9.
Given that:
 Dia of piston (d) = 12-in
 Stroke length (L) = 24-in = 24(1/12) = 2-ft
 Speed of stroke = 30 rpm
 Number of stroke:
Speed of stoke = 40
NxL = 40 b/c L = 2
Hence N = 20
 Efficiency = 90%
Solution:
G = 3[0.034 D2LNE] b/c 3-throw run pump, so multiplying 3
2
G = 3 [(0.034)(12) (2)(20)(0.9)]
G = 528.768 gal/min
 Numerical-3:
Find the BHP of moter required to derive a pump in raising 300 gal/min against total head of 440-ft. Assuming the
efficiency of pump to be 80%. Find HP-input if efficiency of motor is 90%.
Given that:
 Capacity (G) = 300 gal/min
 Efficiency of pump = 80%
 Efficiency of motor = 90%
 Total Head (H) = 440-ft
Solution:
i. BHP =
BHP =
= 50
ii. Input efficiency =
=
= 55.5
Numerical-4:
Give suitable dimension of differential pump to deal with 1000 g/min with a slip of 3% & valves are mechanically
controlled having speed of 400 rpm. Find the pump diameter.
Given that:
 Speed (NL) = 400 rpm
 Slip =3%
o Hence efficiency = 97 % = 0.97
 Capacity (G) = 1000 gal/min
 Dimension: =?
o If not given then we find length of the stroke too. But it is given to find diameter.
Solution:
G = 0.034 D2LNE
1000 = 0.034 D2 (400) (0.97)
D = 8.7 ft
 Centrifugal Pump:
 Theoretical Lift:
H= V1= Velocity of water
if μ is not given then; Φ = Angle b/w direction of in & out going water.
μ= μ = Radial velocity.
Q = Discharge
A = Circumference area
 Efficiency:
Mano-metric efficiency:
η = h = gross head
= H = Theoretical lift
= 0.6 – 0.85
If h is not given: ha = actual head
 h = h a + hs + h d hs = suction head
 h = eH hd = distance head
e = efficiency of machine while manometic is efficiency of
the whole process.