A Seminar Report On

“HYDRA-CELL PUMPS”

DEPARTMENT OF CHEMICAL ENGINEERINGLAXMINARAYAN INSTITUTE OF TECHNOLOGY

RASHTRASANT TUKADOJI MAHARAJ NAGPUR UNIVERSITY,NAGPUR.

2009

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SUBMITTED BY PRANALI NARAYANE

VII SEMESTER B. TECH.(Chemical Engineering)

UNDER THE GUIDANCE OF

Dr. K.V. KORANNE(Department of Chemical Engineering)

L. I. T., Nagpur.

CERTIFICATE

This is to certify that Ms. Pranali K. Narayane

has completed seminar entitled ‘Hydra Cell

Pumps ’ under the supervision of Dr. K.V.

Koranne. This work is submitted in the partial

fulfillment of the requirements for the degree of

Bachelor of Technology in Chemical Engineering

of Rashtrasant Tukadoji Maharaj Nagpur

University, Nagpur.

Date: Dr. K.V.KORANNEPlace: Nagpur (Department of Chemical Engineering)

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ACKNOWLEDGEMENT

I wish to avail this opportunity to express

my gratitude towards my guide DR.K.V. KORANNE

for his help and suggestions, which lead to the

improvement of the work and without whose help this

work, would not have been completed.

And last but not the least I am thankful to

all other teachers for their cooperation and concern.

Place: Nagpur.

Date: Pranali Narayane

(VII SEMESTER, B.Tech CE)

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INDEX

Sr. No. Topics Page No.

1. What are pumps 5

2. Classification of pumps 5

3. Hydra cell Pumps 6

4. Hydra-cell features 7

5. Working 7-9

6. Various hydra-cell pumps 10

7. Specification 11-12

8. Design specifications 13-17

9. Key benefits 18-20

10. Case studies 21-22

11. Applications 23

12. Conclusion 24

13. Bibliography 25

THE HYDRA CELL-PUMPsIntroduction:

What Are Pumps?

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A pump is a mechanical device used for transportation of fluids from one location to another location. In pumps the mechanical energy is converted into pressure energy. A wide variety of pumps are used for transportation of fluids.

Classification of Pumps:-

Hydra Cell Pumps:-

For more than 25 years Wanner Engineering has been manufacturing a truly unique and one-of-a-kind industrial pump - The Hydra-Cell. 

The Wanner Engineering Hydra-Cell Pump is a unique, sealless, positive displacement pump for demanding industrial applications.  It was designed, in-part, as an alternative to pumps that have cups, packing

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and mechanical seals - which are the most troublesome parts of most positive displacement pumps. 

Hydra-Cell's are available in both horizontal and vertical configurations and are used to provide flow rates from 0.1 to 38 GPM at pressures from 50 to 2500 PSI.

The unique design of the Hydra-Cell Pump is not dependent on the fluid being pumped for internal lubrication. In-fact, all the bearings and moving parts are isolated from the fluid being pumped. This is why we can reliably pump chemicals, abrasives, slurries, viscous products, seawater, re-circulated water and many other fluids, either hot or cold. Pumps are available with both metallic and non-metallic pump ends and can be direct driven with electric, pneumatic or hydraulic motors.

Hydra-Cell Features:

1. Flows from 0 - 37 GPM at pressures to 2500 PSI can be handled.

2. Wide choice of materials for pump heads, diaphragms and valve assemblies.

3. Short lead times. 4. Robust construction for long life in difficult industrial

applications. 5. Runs dry indefinitely. 6. Sealless design provides leak-free operation. 7. Non-pulsing flow eliminates expense of pulsation

dampeners and reduces pipe strain. 8. Accurate, repeatable and linear flow. 9. High volumetric efficiencies.

10. Low power consumption. 11. Minimal maintenance - no cups, packing or seals 12. Hydraulically balanced unstressed diaphragms

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13. Low repair costs.

Working :- ( fig.1)

The drive shaft (1) is rigidly supported by (2) a large tapered roller bearing at the rear of the shaft and a smaller bearing at the front of the shaft. Sandwiched between another pair of large bearings is (3) a fixed angle cam or wobble plate. As the drive shaft turns, the wobble plate moves, oscillating forward and back (converting rotary motion into linear motion). This complete pumping mechanism is submerged in a lubricating oil bath.

The Hydra-Cell pistons (4) are alternately displaced by the wobble plate. The pistons are filled with oil on their rearward stroke. A ball check valve in the bottom of the piston ensures that the Hydra-Cells remain full of oil on their forward stroke. The oil held in the Hydra-Cell pressurizes the back side of the diaphragms (5) and causes them to flex forward and back as the wobble plate moves, thus providing the pumping action.

To provide long trouble free diaphragm life, the Hydra-Cell hydraulically balances the diaphragm over the pump's complete pressure range. The diaphragm actually faces only a 2 PSI pressure differential no matter at what pressure the fluid is being delivered.

Each diaphragm has its own pumping chamber which contains an inlet and outlet self-aligning check valve assembly (7). As the diaphragms retract, fluid enters the pump through a common inlet (6) and passes through one of the inlet check valves. On the forward stroke, the diaphragm, equally spaced 120° from one another, operate sequentially to provide a constant, virtually pulse-free flow of fluid.

Hydra-Cell's are very efficient (typical operation is at or above 85% efficiency) and can be driven (belt, gear, or direct) by electric, air, or hydraulic motors. This allows system designers ultimate flexibility in selecting drives for their machines. The Hydra-Cell's efficiency offers substantial energy savings to users when compared to

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other types of positive displacements pumps. The pumps are available in flow rates from 0.5 to 40 GPM (2 to 170 LPM) at discharge pressures from 30 to 2500 PSI (2 to 83 BAR).

(Fig.1)

VARIOUS HYDRA-CELL PUMPS:

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Specification of various Hydra-Cell pumps:-

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Pump Model

Maximum Flow

Maximum Pressure

Typical Applications

No. of diaphragms

Horizontal / vertical

F20 Series

1 GPM 1500 PSI

Precise metering and injection

1 Horizontal

D03 Series

3 GPM 1200 PSI

Precise metering and spraying

3 Horizontal

D04 Series

3 GPM 2500 PSI

Hot water pressure washing, machine tool coolant

3 Horizontal

D10 Series

8 GPM 1000 PSI

Metering, washing, transfer, our most versatile pump

3 Vertical

D12 Series

8 GPM 1000 PSI

Machine tool coolant, the "vertical version of the D10"

3 Horizontal

D15/17 Series

13 GPM 2500 PSI

Machine tool coolant, inlet fogging, hot water pressure washing, descaling

3 Horizontal

H25 Series

20 GPM 1000 PSI

Lime slurry, spray drying, wax and resin pumping, chemical transfer

3 Horizontal

D35 Series

35 GPM 1200 PSI

Abrasive slurry pumping, in-plant cleaning systems,

5 Horizontal

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vehicle washing, paper mill applications, gas cooling

M03 Series

3 GPM 1200 PSI

Precise metering and spraying

3 Horizontal

Design Specifications:-

1.Chemical Compatibility:-Chemical compatibility of the pump materials of construction with the pumped fluid is a critical design consideration. Factors that must be reviewed as part of chemical compatibility include:

1. Temperature2. Concentration3. Presence of other chemicals

2.Temperature:-

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Temperature is an involved issue in the selection of a pump. Factors that must be reviewed as part of this evalutation include:

1. Stability of fluid2. Fluid end components3. Hydraulic end lubricity4. Vapour pressure

3.Inlet Pressure:-Inlet pressure to the pump is determined by the design of the pump system:

1. flooded (gravity fed)2. suction lift3. pressure fed.

The preferred design is a gravity fed flooded system.

4.NPSH (Net Positive Suction Head):-Two NPSH values are involved in pump selection:

1. NPSHr (required head)2. NPSHa (available head)

NPSHa must be equal to or greater than NPSHr. If not, the pressure in the pump inlet will be lower than the vapor pressure of the fluid, and cavitation will occur.

5.Calculating NPSHa:-

Following formula is used to calculate NPSHa:

NPSHa = Pt + Hz - Hf - Ha – Pvp

where:Pt = Atmospheric pressure Hz = Vertical distance from the liquid surface to the pump centreline (if liquid is below pump centreline, Hz is a negative value)Hf = Friction losses in suction pipingHa = Acceleration head at pump suctionPvp = Absolute vapour pressure of liquid at pumping temperature

Calculating Accleration Head (Ha):-

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Use the following formula to calculate Ha losses. Subtract this figure from the NPSHa, and compare the result to the NPSHr of the appropriate Hydra-Cell pump

Ha = L x V x N x C K x G

Ha = Accleration head (ft of liquid)L = Actual length of suction line (ft) – notequivalent lengthV = Velocity of liquid in suction line (ft/sec);[V = GPM x (0.408 ÷ pipe I.D.2)]N = RPM of crank shaftC = Constant determined by type of pump:(0.066 for the Hydra-Cell pump)K = Constant of compensate for compressibility of the fluid – use:

1.4 for de-aerated or hot water 1.5 for most liquids 2.5 for hydrocarbons with high compressibility

G = Gravitational constant (32.2 ft/sec2)

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Minimizing Acceleration Head:-• Keep inlet lines less than 6 ft (1.8 m) long• Use appropriate size I.D. inlet hose• Use flexible hose (low pressure hose, non-collapsing) for inlet lines.• Minimize fittings (elbows, valves, tees, etc.)• Use suction stabilizer on the inlet

6.Calculating Horsepower(kW):-

7.Material of construction:-

For F-series pumps :- Cast Iron to Polypropylene

For D-03, D-10, D-15, H-25, D-35, D-12;- Cast Iron Brass 316 Stainless Steel Hastelloy Polypropylene

**rpm equals pump shaft rpm. HP/kW is required application power. Use caution when sizing motors with variable speed drives.

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Key Benefits:-

1.They are sealless:- There are no cups, packing or mechanical seals in Hydra-Cell Pumps.  All the sliding and rotating parts are isolated from the pumped fluid.  This enables you to pump

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solids laden (dirty) fluids, very hot or cold fluids and also lets the pump run dry! 

2.Reliability:- Hydra-Cell's have up to 30% fewer parts than other common industrial pumps.   Less parts equates to less maintenance.   If there are mechanical seal problems or replacing stators and rotors on a regular basis one ought to really consider switching to Hydra-Cell Pumps.

3.Smooth, Consistent Flow:-   Since Hydra-Cell's are positive displacement pumps, each rotation displaces a fixed amount of fluid.  These pumps are often used in conjunction with variable speed motor controls as metering pumps - reliably dosing or transferring fixed amounts of fluid in a process.  Unlike piston pumps and other reciprocating pumps, Hydra-Cell's provide a smooth, virtually pulsation-free flow rate.  With the exception of certain membrane and plastic piping applications, pulsation dampeners are required

4.Multiple diaphragms reduces pulsation:- Another commonality among most metering pump designs is the single diaphragm configuration, responsible for the non-linear flow accepted as a “necessary evil” of metering systems. Hydra-Cell Metering Solutions pumps have as many as five diaphragms per liquid end, each with a corresponding set of valves and pistons. The virtually “pulse-free” flow characteristics of these multi-diaphragm pumps reduce acceleration losses and pipe strain. This can remove the need for dampeners in the system and expand application opportunities to those requiring linear flow. To illustrate the effects of pulsation, Wanner Engineering conducted a test of a Hydra-Cell Metering Solutions multi-diaphragm pump and a typical, single hydraulically balanced diaphragm metering pump. Operating under identical flow and pressure conditions to record the pressure traces, the

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results were dramatic. (Figure 4)

Hydra-Cell pump is capable of producing the same capacity ratings as large multiplex systems, while still meeting performance standards for steady-state accuracy, linearity and repeatability.

5. Life cycle cost:-

Life Cycle Cost is the measure of the true cost of a pump - from purchase to scrapping. It includes energy consumption and the costs of repair and routine maintenance, as well as the original purchase outlay. Life cycle cost of hydra-cell pumps is low as compared to other pumps(Figure 1).

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Why are Hydra-cell pumps preferred over other pumps!

Let us consider some case studies wherein the hydra-cell pumps are compared with various other pumps

CASE STUDIES:-

1.Hydra-cell Vs Piston Pump:-

A Danish company making extrusion machinery for production of animal feeds experimented for various pumps which would effectively handle liquids which are generally abrasives, some contain solids. Since flowrates varied widely there was a necessity of a pump capable of 15:1 turndown ratio. None of pumps was satisfactory. Piston pump was better but there were problems of seal

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wear, consequent falling of accuracy and poor

repeatability. So the company was looking for a sealless pump. Hydra-cell D-10 met the criteria and was fitted on all extruders(home and export). This model is able to pump full required range of liquids delivering output from 80-1225 l/hr

2.Hydra-cell Vs High pressure metering pump:-

In a German chemical plant a high pressure metering pump was used. It was delivering aqueous emulsion with 40% solids to atomising nozzles at temp upto 80deg c but was costing 10000 euros to maintain and repair. The Hydra-cell D-25 pump that replaced it, delivered the same 60 bar pressure and flowrate, but with lower pulsation –resulting in a more homogenous product Following 3 month trial, it showed no signs of wear and over next 2 years no repairs were needed.

3.Hydra-cell Vs Gear Pumps:-

A Mumbai manufacturer of heat exchangers used gear pumps to handle a machine tool coolant in one of its machining centres. Though these pumps were of good quality, these high pressure pumps were subjected to wear and tear caused by metal particles in the fluid. Replacing gear pumps by the D35 Hydra-cell pumps allowed no risk of contact between drive end of pump and pumped fluid. It also avoided the problems of wear thereby reducing machine downtime, increasing operational efficiency and generating cost savings.

4.Hydra-cell Vs Centrifugal pumps:-

German chemical company had been using a magnetic drive centrifugal pump. This pump needed a 55kW motor to transfer polystrol into a process line from a remote storage tank over a distance of 5.8 km. However after a careful consideration of several units, company replaced this pump by Hydra-cell D35

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This pump needed only a 13.2kW motor. It has a clear price advantage and its pumping efficiency is double that of its competitorsAPPLICATIONS:-

Agriculture Chemical and General Industrial Processing Cleaning and Washing Emissions Food Industry AND Food Process/In-Plant Cleaning Hot Water Lawn Care Metering and Dosing Oil & Gas Production Paper Mill Pumping Abrasive Slurries Reverse Osmosis Salt Water Spray Drying Abrasives Water & Wastewater

CONCLUSION:-

Sealless pumps enable charged and dirty liquids to be processed without need for fine filtration

Need little maintenance and can operate continuously at high pressure.

Pulsation is low, so dampeners may not be required Hydra-Cell Sealless pumps can handle solids up to

500 microns, or more System costs are reduced Maintenance is simplified.

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Energy savings-Compact and highly efficient (80-85%), Hydra-Cell Sealless pumps can be fitted with a smaller motor than would be required by many bigger pumps for equivalent flows and pressures.

The Hydra-Cell Sealless pumps are tolerant of small solids, resistant to chemical and corrosive attack.

BIBLIOGRAPHY:-

1)Chemical engineering world/June 2008/Pg.No. 64-70

2)www.hydra-cell.com 3)www.fluidproducts.com 4)www.wannereng.com 5)www.GlobalSpec.com6)www.innovativepumps.com7)www.oberread.com

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