PUMPS

Principle of operation
Converts mechanical energy : primarily
rotational power (from an electric motor or
engine) into hydraulic energy.
Daya rotasi mekanikal menghasilkan torsi
dan kecepatan, sedangkan daya hydraulic
menghasilkan tekanan aliran yang berlipat.

Symbol

Pumping action
of a simple piston pump

Piston pushed to right, fluid movement closes check

valve 1 and opens outlet valve 2.
Volume of fluid displaced by piston during discharge
stroke called displacement volume of pump

Pump classification

Pump classification

Non-positive displacement
Centrifugal
Axial flow
Radial flow

Positive displacement
Rotary
Reciprocating

Non-positive displacement

Also known as hydro-dynamic pumps

Pressure produced, proportional to rotor speed.
Fluid displaced and transferred using inertia of fluid in
motion
Generally used for low-pressure and high-volume flow
applications (max. pressure capacity limited to 20-30
kgf/cm2).
Cost less and operate with little maintenance (fewer
numbers of moving parts)
Flow output reduced as system resistance (resistance to
flow) increased
Flow rate depends on rotational speed (rpm) also the
resistance of external system.

Non-positive displacement

Rotating impeller imparts

centrifugal force to the
fluid and causes it to move
radially outward.

Generally used in pumping

stations, for delivering
water to homes and
factories.

Also known as hydrokinetic

power generators

Advantages of non-positive
displacement pumps

Low initial cost and minimum maintenance

Simplicity of operation and high reliability

Capable of handling any type of fluid (ex.

sludge and slurries).

Positive displacement
or hydrostatic pumps
Discharge a fixed quantity of oil per
revolution of the pump shaft
Produce flow proportional to their
displacement and rotor speed

Advantages of positive
displacement pumps

Capability to generate high pressures

High volumetric efficiency
Small and compact with high power to
weight ratio
Small changes in efficiency, throughout
pressure range
Wider operating range i.e. the capability to
operate over a wide pressure and speed
range.

Positive displacement
or hydrostatic pumps

Rotary

Gear
Lobe
Gerotor
Vane

Reciprocating (fixed and variable)

Rotary

Gear Pump

Lobe pump

Gerotor pump

Vane pump

Gear pump

Two gears in mesh in order to generate

pumping action
Compact, relatively inexpensive and have
few moving parts
Classified as :
External gear pumps
Internal gear pumps
Lobe pumps and
Gerotor pumps.

External gear pump

Consists of two gears usually equal in size,
which mesh externally and housed in a
pump case.
Each gear mounted on a shaft. Drive shaft
coupled to a prime mover (drive gear)

Gear Pump : Amount of

displacement

Determined by :
number of gear teeth,
volume of fluid between each pair of teeth
speed of rotation.

Fixed volume of fluid delivered by pump for

each rotation.

Gear pump : Analysis evaluates

the theoretical flow rate

Do : outside diameter of the gear teeth

Di : inside diameter of gear teeth
L : width of gear teeth
Vd : displacement volume of the pump
N : speed of the pump
Qt : theoretical pump flow rate.

Gear pump : Graphich Plot

Flow vs speed curve

Flow vs pressure curve at

constant speed

Volumetric Efficiency (v)

Oil from high-pressure tends to leak into

low-pressure through existing clearance.

Ratio of actual flow rate (Qa) and theoretical

flow rate (Qt)

Operating pressures &

capacities

Operating pressures up to 80 kg/cm2 (1138

psi)

Capacities up to 700 liter/min (185 gpm)

Peak pressure conditions :

120 (1707 psi) - 150kg/cm2 (2133psi)

Internal gear pump

Consists of internal gear, regular spur gear,

crescent-shaped seal and external housing.

Power applied to either gear, motion of gears

draws fluid from suction, and forces it around
both the sides of crescent seal.

Internal gear - Advantages

Only two moving parts
Non-pulsating
discharge
Excellent for highviscosity liquids
Constant and even
discharge regardless of
pressure conditions
Operates well in either
direction
Liquids up to 750F /
400C

Can be made to
operate with one
direction of flow with
either rotation
Single adjustable end
clearance
Easy to maintain
Flexible design offers
application
customization
Viscosity 1cPs to over
1,000,000cP.

Internal gear Disadvantages

Usually requires moderate speeds

Medium pressure limitations

Overhung load on shaft bearing

Lobe pump

Gears replaced with lobes, usually consist of

three teeth.
Both lobes driven externally (not contact with
each other).
Quieter than other gear pumps.
Volumetric displacement greater than other
types of gear pumps.
Low-pressure rating
well-suited for shear-sensitive fluids.

Lobe pump

Gerotor pump
Inner gear rotor (gerotor element) power
driven and draws outer gear rotor around.
Volumetric displacement : Inner gear one
tooth less than outer gear, space formed
by extra tooth in outer gear.
Lower capacities and pressures than most
other pumps.

Gerotor : Advantages
High Speed
Only two moving parts
Constant and even discharge regardless of
pressure conditions
Operates well in either direction
Quiet operation
Can be made to operate with one direction
of flow with either rotation

Gerotor : Disadvantages

Medium pressure limitations

Fixed clearances

No solids allowed

Vane pumps

Design and construction minimizes amount of

leakage occurs in gear pumps
Using spring or hydraulically loaded vanes slotted
into driven rotor.
Rotor in vane pump connected to the prime
mover.
Pump capacity determined by vane throw, vane
cross-sectional area and speed of rotation.
Lower capacity and pressure ratings
High volumetric efficiencies (reduced leakage).

Vane pumps

Vane - Advantages
Compensates for wear through vane
extension
Can run dry for short periods
Can have one seal or stuffing box
Develops good vacuum

Vane - 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

Vane pump :
Analysis and nomenclature

Dc : diameter of the cam ring

Dr : inside diameter of the
rotor
L : width of the rotor
Vd : displacement volume of
the pump
N : speed of the pump
Emax : maximum possible
eccentricity
E : eccentricity
Vdmax : maximum possible
volumetric displacement.

Actual Volumetric
displacement when
Emax = E.

Vane pumps : Pressure compensation in

variable displacement

From the graph, the

following can be
noticed:
1. Maximum eccentricity
gives maximum flow
2. Flow reduces with
increase in discharge
pressure
3. Zero flow condition
results when the
eccentricity is zero.

Volumetric efficiency lies

between 90 and 95%.

Reciprocating

Piston pump
Axial piston pumps

Radial piston pumps

Piston pump
High-pressure, high-efficiency pumps.
Reciprocating piston draw in fluid when it
retracts in cylinder bore and discharge it
when it extends
Types :
1. Axial piston pumps and
2. Radial piston pumps.

Axial piston pumps

Convert rotary motion of input shaft to axial
reciprocating motion of pistons.
Categorized :
(a) Bent-axis-type piston pumps and
(b) Swash plate-type inline piston pumps.

Axial piston pumps

Bent-axis piston pumps

Reciprocating action of
pistons obtained by
bending axis of
cylinder block so it
rotates at angle
different than drive
shaft.

Cylinder block contains

number of pistons
along periphery.

Volumetric displacement
Varies with offset angle (vary from 0 to
30)
Fixed displacement units usually provided
with 23 or 30 offset angles.
No flow when the cylinder block centerline
is parallel to the drive shaft centerline.
Variable displacement units provided with
yoke and external control mechanism to
change the offset angle.

Axial piston pump :

nomenclature and analysis

: offset angle

S : piston stroke

D : piston diameter

Y : number of
pistons

A : piston area.

Volumetric displacement changes

with offset angle

Swash plate inline piston

pump

Reciprocating motion
of the pistons obtained
by swash plate (either
fixed or variable in its
degree of angle).

For variable
displacement : swash
plate mounted in
movable yoke.

Swash plate angles

Positioning of yoke
accomplished by :
manual operation,
servo control or
compressor control

Maximum swash
plate angle limited
to 17.5

Radial piston pump

piston shoes ride

on eccentric ring
which causes them
to reciprocate as
they rotate

As cylinder barrel
rotates, pistons on
one side travel
outward.

Radial piston pump

Pump performance

Pump efficiencies
comparing the actual hydraulic power output of
pump with mechanical input power supplied by
prime mover

Volumetric efficiency
indicates the amount of leakage

Mechanical efficiency
amount of energy losses that occur in pumps, not
taking into account the leakages
Friction in bearing and other moving parts and
Energy losses due to fluid turbulence.

Volumetric efficiency

Volumetric efficiency (v) given by :

Volumetric efficiencies for different pump

categories :

Mechanical efficiency

Mechanical efficiency (m) given by :

Where
P : measured pump discharge pressure in psi or Pa
Qj : calculated theoretical pump flow rate in gpm or m 3/s
TA : actual torque delivered to the pump in in-lbs or N-m
N : measured pump speed in rpm or rad/s.

Mechanical efficiency
computed in terms of torque

TT : torque required under conditions of

no-leakage
TT : in.lbs or N-m
VD : in in.3 or m3
P : psi or Pa.

Overall efficiency

If volumetric & mechanical efficiencies

known, then overall efficiency :

Pump performance
curves

Specified in the form of

graphs.
Performance
characteristics as
represented by the
graphs :
Change in discharge flow
with change in pump speed
Change in discharge flow
with respect to discharge
pressure
Effect of change in speed
on pump efficiency.

Comparison of pump
performance parameters

Cavitation in pumps

Presence of entrained air bubbles in the

hydraulic fluid or vaporization of the
hydraulic fluid
To minimize the effect of cavitation:

Maintaining short pump inlet lines

Maintaining suction line velocities below 1.5
m/s (4.9 ft/s)

Positioning of the pump as close to the

reservoir as possible

Minimizing the number of inlet line fittings

Using low-pressure drop filters and strainers

in the inlet side

Using the proper oil as per the

recommendations of the manufacturer.

Pump maintenance

Necessary to carry out periodic

maintenance activities from time to time
though its established fact that pumps like
gear pumps generally maintenance free

Factors affecting the

performance of pumps

Presence of foreign particles

filter element provided to ensure clean oil (should be
periodically replaced).

Foams and bubbles

Usually foaming of oil is due to one or more of the following
reasons:
Use of the incorrect type of oil
A high or low oil level
Air entering the suction side of pump, which could be due to loose
pump bolts or damaged gaskets
Water mixing with oil.

Overheating of oil
Temperature limit of overheating : around 90 C.

Wrong selection of oil.

Comparison of various pump

performance factors

Pump selection

Pumps selected based on :

Flow rate requirement
Operating speed
Pressure rating
Performance
Reliability
Maintenance
Cost and
Noise.

Pump selection : Sequence of

operations

Selection of the appropriate actuator (cylinder or

motor) based on the load encountered.
Determining the flow-rate requirements :
Calculate flow rate required to drive the actuator
Specified distance
Time limit.

Determination of the pump speed and selection of the

prime mover
flow rate calculations helps determine the pump size
(volumetric displacement).

Selection of the pump-type based on the application.

Selection of system pressure requirements
Determination of total power to be delivered by the pump.

Maintenance practice
Cleaning of parts
Inspection of gears
Cleaning, installation of seals
Inspecting castings and machined
surfaces
Gaskets, seal rings and 0-rings

Cleaning of parts

Dont use caustic soda solution for steam

cleaning
All parts (except bearings) dried with
compressed air
Steam-cleaned parts coated with oil (preferably
with the same type of oil used for system)
Ensuring none of oil passages blocked.
Passages are to be thoroughly cleaned by
working a piece of soft wire back and forth
Flushed with mineral spirit and later dried with
compressed air.

Inspection of gears

Inspect the gear for scuffed (lecet), nicked (takik),

burred (terbakar) or broken teeth.
Removed by a soft honing stone (batu asah)
If cant : Replace gear.

Any damage to original tooth shape that might caused

due to wear, then replaced gear.
Inspect the thrust face (sisi dorong) of gears for
scratches and burrs.
Removed with soft honing stone
If cant : replace the gear.

If pitting (lubang-lubang kecil akibat kavitasi) on gear

tooth affected area > 1/3rd of whole area, replace the
gear.

Cleaning, installation of
seals

Cleaning of seals

Oil seals made of quality material like ester

rubber
wiped with cloth, wet with petroleum-based
solvents
solvents such as trichloroethylene, benzol,
acetone and all kinds of aromatics which are
harmful to seals especially the ones made of
polyacrylate rubber are avoided.
Stored insulated from direct sunlight and
moisture. The
Storage period maximum 2 years

Oil seal installation

Coating seal lip with lubricating oil or grease
Prevents dry friction during initial period of seal's
movement.

Coating circumference of the seal with adhesive

or sealant. Ensured that adhesive/sealant doesnt
contact with lip.

Inspecting castings and

machined surfaces

Inspect bores for scratches, burrs and dirt.

Ensure removal of scratches and burrs with
crocus cloth.
Ensure replacement of part has scratches or
grooves.
Inspect mounting surfaces for scratches and burrs.
Removed by soft stone or crocus cloth.
If difficult to remove, replaced part.
Inspect castings or housings that cracked.
All machined surfaces examined on periodic
basis, determine damage lead to leakage.

Gaskets, seal rings and 0rings

All gaskets, seal rings and o-rings that has
been disassembled are to be replaced.
Both faces of gasket are to be examined for
sticking foreign matter or scratches and the
same removed.
Both surfaces of gasket are to be coated
with liquid gasket.

Each brand of liquid gasket has its own drying

time

To remove seal ring, install thin blade into

seal ring groove, work one edge of seal ring
out that it can grasped with fingers and
removed.
Lightly coat the seal ring contact surface
with a lubricant during the installation.
If lip type seal rings are used, ensure that
the main lip faces the direction of the oil
pressure.