Lecture 7

HYDRAULIC PUMPS
Learning Objectives
Upon completion of this chapter, the student should be able to:
 Classify the hydraulic pumps used in the industry.
 Differentiate between positive displacement and non-positive displacement pumps.
 Explain the working and construction of gear, vane and piston pumps.
 Evaluate the discharge parameters of gear, vane and piston pumps.
 Define mechanical, volumetric and overall efficiency of pumps.
 Evaluate the performance parameters of gear, vane and piston pumps.
 Differentiate between internal and external gear pumps.
 Differentiatebetween a bent-axis piston pump and a swash plate.
 State the advantage of balance vane pumps.
 Explain cavitation and various means to control it.
 Explain the importance of noise control in pumps.
 Write a computer program to evaluate the performance of the system.

1.1Introduction
The function of a pump is to convert mechanical energy into hydraulic energy. It is the heart
of any hydraulic system because it generates the force necessary to move the load.
Mechanical energy is delivered to the pump using a prime mover such as an electric
motor.Partial vacuum is created at the inlet due to the mechanical rotation of pump shaft.
Vacuum permits atmospheric pressure to force the fluid through the inlet line and into the
pump. The pump then pushes the fluid mechanically into the fluid power actuated devices
such as a motor or a cylinder.
Pumps are classified into three different ways and must be considered in any discussion of
fluid power equipment.
1. Classification based on displacement:
 Non-positive displacement pumps (hydrodynamic pumps).
 Positive displacement pumps (hydrostatic pumps).

2. Classification based on delivery:

 Constant delivery pumps.
 Variable delivery pumps.

3. Classification based on motion:

 Rotary pump.
 Reciprocating pump.

1.2 Classification of Pumps

1.2.1Classification Based on Displacement

1.2.1.1 Non-Positive Displacement Pumps

Non-positive displacement pumps are primarily velocity-type units that have a great deal of
clearance between rotating and stationary parts. Non-displacement pumps are characterized
by a high slip that increases as the back pressure increases, so that the outlet may be
completely closed without damage to the pump or system. Non-positive pumps do not
develop a high pressure but move a large volume of fluid at low pressures. They have
essentially no suction lift. Because of large clearance space, these pumps are not self-priming.
In other words, the pumping action has too much clearance space to seal against atmospheric
pressure. The displacement between the inlet and the outlet is not positive. Therefore, the
volume of fluid delivered by a pump depends on the speed at which the pump is operated and
the resistance at the discharge side. As the resistance builds up at the discharge side, the fluid
slips back into the clearance spaces, or in other words, follows the path of least resistance.
When the resistance gets to a certain value, no fluid gets delivered to the system and the
volumetric efficiency of the pump drops to zero for a given speed. These pumps are not used
in fluid power industry as they are not capable of withstanding high pressure. Their
maximum capacity is limited to 17–20 bar.These types of pumpsare primarily used for
transporting fluids such as water, petroleum,etc.,from one location to another considerable
apart location. Performance curves for positive and non-positive displacement pumps are
shown in Fig.1.1.
Thetwo most common types of hydrodynamic pumps are the centrifugal and the axial flow
propeller pumps.

Advantages and disadvantages ofnon-positive displacement pumps

The advantages are as follows:

1.Non-displacement pumps have fewer moving parts.

2.Initial and maintenance cost is low.
3. They give smooth continuous flow.
4. They are suitable for handling almost all types of fluids including slurries and sledges.
5.Their operation is simple and reliable.

The disadvantages are as follows:

1.Non-displacement pumps are not self-priming and hence they must be positioned below the
fluid level.
2. Discharge is a function of output resistance.
3.Low volumetric efficiency.

1.2.1.2Positive Displacement Pumps

Positive displacement pumps, in contrast, have very little slips, are self-priming and pump
against very high pressures, but their volumetric capacity is low. Positive displacement
pumps have a very close clearance between rotating and stationary parts and hence are self-
priming. Positive displacement pumps eject a fixed amount of fluid into the hydraulic system
per revolution of the pump shaft. Such pumps are capable of overcoming the pressure
resulting from mechanical loads on the system as well as the resistance of flow due to
friction. This equipment must always be protected by relief valves to prevent damage to the
pump or system. By far, a majority of fluid power pumps fall in this category, including gear,
vane and piston pumps.Performance curves for positive and non-positive displacement
pumps are shown in Fig. 1.1.
Positive displacement pumps are classified based on the following characteristics:

1. Type of motion of pumping element: Based on the type of motion of pumping

element, positive displacement pumps are classified as follows:
 Rotary pumps, for example, gear pumps and vane pumps.
 Reciprocating pumps, for example, piston pumps.

2. Displacement characteristics: Based on displacement characteristics, positive

displacement pumps are classified as follows:
 Fixed displacement pumps.
 Variable displacement pumps.
3. Type of pumping element.

The advantages of positive displacement pumps over non-positive displacement pumps are as
follows:

1. They can operate at very high pressuresof up to 800 bar (used for lifting oils from very
deep oil wells).
2. They can achieve a high volumetric efficiency of up to 98%.
3. They are highly efficient and almost constant throughout the designed pressure range.
4. They are a compact unit, havinga high power-to-weight ratio.
5. They can obtain a smooth and precisely controlled motion.
6. By proper application and control, they produce only the amount of flow required to
move the load at the desired velocity.
7. They have a great flexibility of performance. They can be made to operate over a wide
range of pressures and speeds.

1.2.2 Classification Based on Delivery

1.2.2.1 Constant Delivery Pumps

Constant volume pumps always deliver the same quantity of fluid in a given time at the
operating speed and temperature. These pumps are generally used with relatively simple
machines, such as saws or drill presses or where a group of machines is operated with no
specific relationship among their relative speeds. Power for reciprocating actuators is most
often provided by constant volume pumps.

1.2.2.2Variable Delivery Pumps

The output of variable volume pumps may be varied either manually or automatically with no
change in the input speed to the pump. Variable volume pumps are frequently used for
rewinds, constant tension devices or where a group of separate drives has an integrated speed
relationship such as a conveyor system or continuous processing equipment.

1.2.3Classification Based on Motion

This classification concerns the motion that may be either rotary or reciprocating. It was of
greater importance when reciprocating pumps consisted only of a single or a few relatively
large cylinders and the discharge had a large undesirable pulsation. Present-day reciprocating
pumps differ very little from rotary pumps in either external appearance or the flow
characteristics.
Differences between positive displacement pumps and non-positive displacement pumps are
enumerated in Table 1.1.

Table 1.1 Differences between positive displacement pumps and non-positive displacement
pumps
Positive Displacement Non-positive Displacement
Pumps Pumps

The flow rate does not The flow rate decreases with
change with head head
The flow rate is not much The flow rate decreases with
affected by the viscosity of the viscosity
fluid
Efficiency is almost constant Efficiency increases with
with head head at first and then
decreases

(a)

(b)

Figure 1.1 Performance curves for positive and non-positive displacement pumps
1.3Pumping Theory
A positive displacement hydraulic pump is a device used for converting mechanical energy
into hydraulic energy.It is driven by a prime mover such as an electric motor.It basically
performs twofunctions.First, it creates a partial vacuum at thepump inlet port.This vacuum
enables atmospheric pressure to force the fluid from the reservoir into the pump.Second,the
mechanical action of the pump traps this fluid within the pumping cavities,transports it
through the pump and forces it into the hydraulic system. It is important to note that pumps
create flow not pressure. Pressure is created by the resistance to flow.

Outlet Outlet
Low pressure Outlet valve is High pressure
closed Outlet valve is
Rod moves outward Rod moves inward open

Inlet
valve is
closed
Breather

Strainer

Suction stroke Delivery stroke

Figure 1.2Illustration of pumping theory

All pumps operate by creating a partial vacuum at the intake, and a mechanical force at the
outlet that induces flow. This action can be best described by reference to a simple piston
pump shown in Fig.1.2.

1. As the piston moves to the left, a partial vacuum is created in the pump chamber
thatholds the outlet valve in place against its seat and induces flow from the reservoir
that is at a higher (atmospheric) pressure.As this flow is produced, the inlet valve is
temporarily displaced by the force of fluid, permitting the flow into the pump
chamber (suction stroke).
2. When the piston moves to the right, the resistance at the valves causes an immediate
increase in the pressure that forces the inlet valve against its seat and opens the outlet
valve thereby permitting the fluid to flow into the system. If the outlet port opens
directly to the atmosphere, the only pressure developed is the one required to open the
outlet valve(delivery stroke).
1.4Gear Pumps

Gear pumps are less expensive but limited to pressures below 140 bar.It is noisy in operation
than either vane or piston pumps. Gear pumps are invariably of fixed displacement type,
which means that the amount of fluid displaced for each revolution of the drive shaft is
theoretically constant.

1.4.1 External Gear Pumps

External gear pumps are the most popular hydraulic pumps in low-pressure ranges due to
their long operating life, high efficiency and low cost. They are generally used ina simple
machineThe most common form of external gear pump is shown in Figs. 1.3and 1.4 It
consist of a pump housing in which a pair of preciselymachined meshing gears runs with
minimal radial and axial clearance.One of the gears, called a driver,is driven by a prime
mover. The driver drives another gear called a follower.As the teeth of the two gears separate,
the fluid from the pump inlet gets trapped between the rotating gear cavities and pump
housing.The trapped fluid is then carried around the periphery of the pump casing and
delivered to outlet port. The teeth of precisely meshed gears provide almost a perfect seal
between the pumpinlet and the pump outlet.When the outlet flow is resisted, pressure in the
pump outlet chamber builds up rapidly and forces the gear diagonally outward against the
pump inlet. When the system pressure increases, imbalance occurs. This imbalance increases
mechanical friction and the bearing load of the two gears.Hence, the gear pumps are operated
to the maximum pressure rating stated by the manufacturer.
It is important to note that the inlet is at the point of separation and the outlet at the point of
mesh. These units are not reversible if the internal bleeds for the bearings are to be drilled to
both the inlet and outlet sides.So that the manufacturer’s literature should be checked before
attempting a reversed installation. If they are not drilled in this manner, the bearing may be
permanently damaged as a result of inadequate lubrications.

Advantages and disadvantages of gear pumps

The advantages are as follows:

1.They are self-priming.

2.They give constant delivery for a given speed.
3. They are compact and light in weight.
4. Volumetric efficiency is high.

The disadvantages are as follows:

1. The liquid to be pumped must be clean, otherwise it will damage pump.

2. Variable speed drives are required to change the delivery.
3. If they run dry, parts can be damaged because the fluid to be pumped is used as lubricant.
Expression for the theoretical flow rate of an external gear pump
Let
Do =the outside diameter of gear teeth
Di= the inside diameter of gear teeth
L =the width of gear teeth
N=the speed of pump in RPM
VD=the displacement of pump in m/rev
M= module of gear
z=number of gear teeth
= pressure angle
Volume displacement is

VD  ( Do 2  Di 2 ) L
4
Di  Do  2(Addendum  Dendendum)
Theoretical discharge is

QT (m3 /min)  VD (m3 /rev)  N (rev/min)

If the gear is specified by its module and number of teeth, then the theoretical discharge can
be found by

   2 cos 2 20   3
QT  2 Lm2 N  z  1    m /min
  12 

Figure 1.3Operation of an external gear pump

1.4.2Internal Gear Pumps

Another form of gear pump is the internal gear pump, which is illustrated in Fig. 1.5. They
consist of two gears:An external gear and an internal gear. The crescent placed in between
these acts as a seal between the suction and discharge.(Fig.1.6) When a pump operates, the
external gear drives the internal gear and both gears rotate in the same direction. The fluid
fills the cavities formed by the rotating teeth and the stationary crescent. Both the gears
transport the fluid through the pump. The crescent seals the low-pressure pump inlet from the
high-pressure pump outlet. The fluid volume is directly proportional to the degree of
separation and these units may be reversed without difficulty. The major use for this type of
pump occurs when a through shaft is necessary, as in an automatic transmission. These
pumps have a higher pressure capability than external gear pumps.

Figure 1.5Operation of an internal gear pump

1.4.3 Gerotor Pumps

Gerotor pumps operate in the same manner as internal gear pumps. The inner gear rotor is
called a gerotor element. The gerotor element is driven by a prime mover and during the
operation drives outer gear rotor around as they mesh together. The gerotor has one tooth less
than the outer internal idler gear. Each tooth of the gerotor is always in sliding contact with
the surface of the outer element. The teeth of the two elements engage at just one place to
seal the pumping chambers from each other. On the right-hand side of the pump, shown in
Fig. 1.7, pockets of increasing size are formed, while on the opposite side, pockets decrease
in size. The pockets of increasing size are suction pockets and those of decreasing size are
discharge pockets. Therefore, the intake side of the pump is on the right and discharge side on
the left.

Pumping chambers are formed by the adjacent pair of teeth, which are constantly in contact
with the outer element, except for clearance. Refer to Fig 1.7,asthe rotor is turned, its gear
tips are accurately machined sothat they precisely follow the inner surface of the outer
element. The expanding chambers are created as the gear teeth withdraw. The chamber
reaches its maximum size when the female tooth of the outer rotor reaches the top dead
center. During the second half of the revolution, the spaces collapse, displacing the fluid to
the outlet port formed at the side plate. The geometric volume of the gerotor pump is given as
VD  b Z ( Amax  Amin )
where b is the tooth height, Z is the number of rotor teeth, Amax is the maximum area between
male and female gears (unmeshed – occurs at inlet) and Amin is the minimum area between
male and female gears (meshed – occurs at outlet).

Figure 1.7Gerotor gear pump

Example 1.1
The inlet to a hydraulic pump is 0.6 m below the top surface of an oil reservoir. If the specific
gravity of the oil used is 0.86, determine the static pressure at the pump inlet.
Solution: We know that
Pressure   gh
The density of water is 1 g/cm or 1000 kg/m3.
3

Therefore, the density of oil is 0.861 g/cm3 or 860 kg/m3 .

Pressure at the pump inlet is
P= 860  0.6 kg/m 2 = 516 kg/m 2 = 0.0516 kg/cm 2  0.0516 0.981bar
 0.0506 bar
(Note: 1kg/cm  0.981bar .)
2

Example 1.2
A hydraulic pump delivers 12 L of fluid per minute against a pressure of 200 bar. (a)
Calculate the hydraulic power. (b) If the overall pump efficiency is 60%, what size of electric
motor would be needed to drive the pump?

Solution:
(a) Hydraulic power is given by

200 (bar)
Hydraulic power (kW) 12 L/min   4 kW
600
(b) We have

Hydraulic power
Electric motor power (power input) =
Overall efficiency
 Substituting we get

4
Electric motor power (power input) =  6.67kW
0.6

4
Electric motor power   6.67 kW
0.6

Example 1.3
A gear pump has an outside diameter of 80mm, inside diameter of 55mm and a width of
25mm. If the actual pump flow is 1600 RPM and the rated pressure is 95 LPM what is the
volumetric displacement and theoretical discharge.

Solution: We have
Outside diameter Do  80 mm
Inside diameter Di  55 mm
Width d  25mm
Speed of pump N = 1600 RPM
Actual flow rate = 95 LPM
Now
QA  95 LPM  95 103 m3 /min

VD   ( Do 2  Di 2 )  L
4

VD   (0.0802  0.0552 )  0.025  6.627 105 m3 / rev
4

Theoretical flow rate


QT   ( Do 2  Di 2 )  L  N
4

=  (0.0802  0.0552 )  0.025 1600
4
= 0.106 m3 /min

Example 1.4
Calculate the theoretical delivery of a gear pump. Module of the gear teeth is 6mm and width
of gear teeth is 25mm. Number of teeth on driver gear is 18 and pressure angle of the gear is
20 . Pump speed is 1000 RPM. Volumetric efficiency is 90%.

Solution: If the gear is specified by its module and number of teeth, then the theoretical
discharge can be found by
    2 cos   3
QT  2 Lm 2 N  z  1    m /min
  12  
   2 cos 2 20   3
 2 (0.025)(6 103 ) 2 1000  18  1    m /min
  12 
 0.1118 m3 /min

Example 1.5
Calculate the theoretical delivery of a gear pump. Module of the gear teeth is 6mm and width
of gear teeth is 65mm. Number of teeth on driver gear is 16 and pressure angle of the gear is
20 . Pump speed is 1600 RPM. Outer diameter of gear is 108 mm and Dedendum circle
diameter is 81 mm. Volumetric efficiency is 88%at 7 MPa.

Solution: If the gear is specified by its module and number of teeth, then the theoretical
discharge can be found by
   2 cos 2 20   3
QT  2 Lm 2 N  z  1    m /min
  12 
   2 0.9392  3
 2 (0.065)(6 103 ) 2 1600  16  1    m /min
  12 
 0.416 m3 /min

Alternatively we can use


VD   ( Do 2  Di 2 )  L
4


QT   (0.1082  0.0812 )  0.065 1600  0.416 m3 /rev
4

1.5Lobe Pumps

The operation of lobe pump shown in Fig.1.9 is similar to that of external gear pump, but
they generally have a higher volumetric capacity per revolution. The output may be slightly
greater pulsation because of the smaller number of meshing elements.

Lobe pumps, unlike external gear pumps,have both elements externally driven and neither
element hasany contact with the other.For this reason, they are quieter when compared to
other types of gear pumps. Lobe contact is prevented by external timing gears located in the
gearbox.Pump shaft support bearings are located in the gearbox, and because the bearings are
out of the pumped liquid, pressure is limited by bearing location and shaft deflection. They
do not lose efficiency with use. They are similar to external gear pumps with respect to the
feature of reversibility.
Stages of operation of Lobe pump

1.As the lobes come out of mesh, they create expanding volume on the inlet side of the
pump.Liquid flows into the cavity and is trapped by the lobes as they rotate.

2.Liquid travels around the interior of the casing in pockets between the lobes and the casing
(it does not pass between the lobes).

3.Finally, the meshing of the lobes forces the liquid through the outlet port under pressure.

Lobe pumps are frequently used in food applications because they are good at handling solids
without inflicting damage to the product. Solid particle size can be much larger in lobe
pumps than in other positive displacement types.Because lobes do not make contact, and
clearances are not as close as in other positive displacement pumps, this design handles low-
viscosity liquids with diminished performance.Loading characteristics are not as good as
other designs and suction ability is low.High-viscosity liquids require reduced speeds to
achieve satisfactory performance.Reductions of 25% of rated speed and lower are common
with high-viscosity liquids.
1.5.1Advantages

The advantages of lobe pumps are as follows:

1. Lobe pumps can handle solids, slurries, pastes and many liquid.
2. No metal-to-metal contact.
3. Superior CIP(Cleaning in Place) /SIP(Sterilization in Place) capabilities.
4. Long-term dry run (with lubrication to seals).
5. Non-pulsating discharge.

1.5.2Disadvantages
The disadvantages of lobe pumps are as follows:

1. Require timing gears.

2. Require two seals.
3. Reduced lift with thin liquids.
1.5.3Applications
Common rotary lobe pump applications include, but are not limited to, the following:

1. Polymers.
2. Paper coatings.
3. Soaps and surfactants.
4. Paints and dyes.
5. Rubber and adhesives.
6. Pharmaceuticals.
7. Food applications.

1.6Screw Pumps

These pumps have two or more gear-driven helical meshing screws in a closefitting caseto
develop the desired pressure. These screws mesh to form a fluid-type seal between the screws
and casing.
A schematic diagram of a screw pump is shown in Fig 1.10. A two-screw pump consists of
two parallel rotors with inter-meshing threads rotating in a closely machined casing. The
driving screw and driven screw are connected by means of timing gears. When the screws
turn, the space between the threads is divided into compartments. As the screws rotate, the
inlet side of the pump is flooded with hydraulic fluid because of partial vacuum.When the
screws turn in normal rotation, the fluid contained in these compartments is pushed uniformly
along the axis toward the center of the pump, where the compartments discharge the fluid.
Here the fluid does not rotate but moves linearly as a nut on threads. Thus, there are no
pulsations at a higher speed; it is a very quiet operating
pump.
3. and carried
4. To the along in these
discharge spaces

1. As this screw
rotates

2. This screw also

rotates and oil is
drawn here

Ina screw pump, a chamber is formed between thread and housing as shown in Fig.1.11. The
following expression gives the volumetric displacement

π 2  α sin 2α 
VD  ( D  d 2 )s  D 2   s
4 2 2 
Dd
Heres is the stroke length and cos(α) 
2D

Figure 1.11Volumetric displacement of a screw pump

Advantages and disadvantages of screw pump

Theadvantages are as follows:

1.They are self-priming and more reliable.

2. They are quiet due to rolling action of screw spindles.
3.They can handle liquids containing gases and vapor.
4. They have long service life.

The disadvantages are as follows:

1.They are bulky and heavy.
2.They are sensitive to viscosity changes of the fluid.
3. They have low volumetric and mechanical efficiencies.
4. Manufacturing cost of precision screw is high.
 Lecture 8
HYDRAULIC PUMPS [CONTINUED]

1.7 Vane Pumps

There are two types of vane pumps:

1. Unbalanced vane pump: Unbalanced vane pumps are of two varieties:

 Unbalanced vane pump with fixed delivery.

 Unbalanced vane pump with pressure-compensated variable delivery.

2. Balanced vane pump.

1.7.1 Unbalanced Vane Pump with Fixed Delivery

A simplified form of unbalanced vane pump with fixed delivery and its operation are shown
in Figs. 1.12 and 1.13. The main components of the pump are the cam surface and the rotor.
The rotor contains radial slots splined to drive shaft. The rotor rotates inside the cam ring.
Each radial slot contains a vane, which is free to slide in or out of the slots due to centrifugal
force. The vane is designed to mate with surface of the cam ring as the rotor turns. The cam
ring axis is offset to the drive shaft axis. When the rotor rotates, the centrifugal force pushes
the vanes out against the surface of the cam ring. The vanes divide the space between the
rotor and the cam ring into a series of small chambers. During the first half of the rotor
rotation, the volume of these chambers increases, thereby causing a reduction of pressure.
This is the suction process, which causes the fluid to flow through the inlet port. During the
second half of rotor rotation, the cam ring pushes the vanes back into the slots and the trapped
volume is reduced. This positively ejects the trapped fluid through the outlet port. In this
pump, all pump action takes place in the chambers located on one side of the rotor and shaft,
and so the pump is of an unbalanced design. The delivery rate of the pump depends on the
eccentricity of the rotor with respect to the cam ring.
 Figure 1.12Simple vane pump

1.7.4 Pressure-Compensated Variable Displacement Vane Pump (an Unbalanced Vane

Pump with Pressure-Compensated Variable Delivery)

Figure 1.14 Operation of a variable displacement vane pump

Schematic diagram of variable displacement vane pump is shown in Fig.1.14.Variable

displacement feature can be brought into vane pumps by varying eccentricity between the
rotor and the cam ring. Here in this pump, the stator ring is held against a spring loaded
piston.The system pressure acts directly through a hydraulic piston on the right side. This
forces the cam ring against a spring-loaded piston on the left side. If the discharge pressure is
large enough, it overcomes the compensated spring force and shifts the cam ring to the left.
This reduces the eccentricity and decreases the flow. If the pressure continues to increase,
there is no eccentricity and pump flow becomes zero.

1.7.5 Balanced Vane Pump with Fixed Delivery

A balanced vane pump is a very versatile design that has found widespread use in both
industrial and mobile applications. The basic design principle is shown in Fig. 1.15. The rotor
and vanes are contained within a double eccentric cam ring and there are two inlet segments
and two outlet segments during each revolution. This double pumping action not only gives a
compact design, but also leads to another important advantage: although pressure forces
acting on the rotor in the outlet area are high, the forces at the two outlet areas are equal and
opposite, completely canceling each other. As a result, there are no net loads on shaft
bearings. Consequently, the life of this type of pump in many applications has been
exceptionally good. Operating times of 24000 h or more in industrial applications are
widespread. In more severe conditions encountered in mobile vehicles, 5000–10000 h of
trouble-free operation is frequently achieved.

Figure 1.15 Operation of a balanced vane pump

1.7.2 Advantages and disadvantages of Vane Pumps

The advantages of vane pumps are as follows:

1. Vane pumps are self-priming, robust and supply constant delivery at a given
speed.
2. They provide uniform discharge with negligible pulsations.
3. Their vanes are self-compensating for wear and vanes can be replaced easily.
4. These pumps do not require check valves.
5. They are light in weight and compact.
6. They can handle liquids containing vapors and gases.
7. Volumetric and overall efficiencies are high.
8. Discharge is less sensitive to changes in viscosity and pressure variations.

The disadvantages of vane pumps are as follows:

 1. Relief valves are required to protect the pump in case of sudden closure of delivery.
2. They are not suitable for abrasive liquids.
3. They require good seals.
4. They require good filtration systems and foreign particle can severely damage pump.

Advantages and disadvantagesofbalancedvane pumps

The advantages of balanced vane pumps are as follows:

1. The balanced pump eliminates the bearing side loads and therefore high operating pressure
can be used.
2.The service life is high compared to unbalanced type due to less wear and tear.

The disadvantages of balanced vane pumps are as follows:

1. They are fixed displacement pumps.

2. Design is more complicated.
3. Manufacturing cost is high compared to unbalanced type.

1.7.4 Expression for the Theoretical Discharge of Vane Pumps

Let DC be the diameter ofa cam ring in m, DRthe diameter of rotor in m, L the width of rotor
in m, e the eccentricity in m, VD the pump volume displacement in m3/rev and emax the
maximum possible eccentricity in m.

From geometry (Fig.1.13) the maximum possible eccentricity,

D  DR
emax  C (1.1)
2
Themaximum value of eccentricity produces the maximum volumetric displacement

VD(max)  ( DC2  DR2 ) L (1.2)
4
Using Equation (1.1), Equation (1.2) can be simplified as

VD(max)  ( Dc  Dg )( Dc  Dg ) L
4


< VD(max) 
( Dc  Dg )(2emax ) L
4
The actual volumetric displacement occurs when emax  e . Hence,

VD(max)  ( DC  DR )e L m3/rev
2
When the pump rotates at N rev/min (RPM),the quality of discharge by the vane pump is
given by
QT  vD  N
Theoretical discharge
 
QT  ( DC  DR )e L m3/min
2

Example 1.6
A vane pump has a rotor diameter of 63.5 mm, a cam ring diameter of 88.9 mm and a vane
width of 50.8 mm. What must be eccentricity for it to have a volumetric displacement of
115cm3?

Solution: Volumetric displacement is

 D  DR 
VD    C  Le
 2 
whereDcis the diameter of the cam ring, DR is the diameter of the rotor, e is the eccentricity
and L is the width of the vane pump. So we have
0.0889  0.0635
115 106     e  0.0508
2
Therefore eccentricity
e  9.456 103 m  9.456 mm

1.8Piston Pumps
Piston pumps are of the following two types:

1. Axial piston pump:These pumps are of two designs:

 Bent-axis-type piston pump.

 Swash-plate-type piston pump.

2. Radial piston pump.

1.8.1Bent-Axis-Type Piston Pump

Schematic diagram and detailed cut section of bent axis type piston pump is shown in
Fig.1.16. It contains a cylinder block rotating with a drive shaft. However,thecenterline of the
cylinder block is set at an offset angle relative to the centerline of the drive shaft.Thecylinder
block contains a number of pistons arranged along a circle.The piston rods are connected to
the drive shaft flange by a ball and socket joints. The pistons are forced in and out of their
bores as the distance between the drive shaft flange and cylinder block changes. A universal
link connects the cylinder block to the drive shaft to provide alignment and positive drive.
The volumetric displacement of the pump depends on the offset angle . No flow is produced
when the cylinder blockis centerline.can vary from 0to a maximum of about 30.For a
fixed displacement, units are usually provided with 23 or 30 offset angles.

1.8.2 Swash-Plate-Type Piston Pump

Schematic diagram of swash plate type piston pump is shown in Fig. 1.17. In this type, the
cylinder block and drive shaft are located on the same centerline. The pistons are connected
to a shoe plate that bears against an angled swash plate. As the cylinderrotates,the pistons
reciprocatebecausethe piston shoesfollow the angled surface of the swash plate. The outlet
andinlet ports are located in the valve plate so that the pistons pass theinlet as they are being
pulledout and pass the outlet as they are being forced back in. This type of pump can also be
designed to have a variable displacementcapability. The maximumswash plate angle is
limited to 17.5° by construction.

Figure 1.17Operation of a swash-plate-type piston pump

1.8.4 Volumetric Displacement and Theoretical Flow Rate of an Axial Piston Pump

Figure 1.19(a) shows in and out position of the pistons of axial piston pump.Figure1.19(b)
gives schematic diagram of stroke change with respect to offset angle.

Letθ be an offset angle, S the piston stroke in m, D the piston circle diameter, Y the number of
pistons, A the piston area inm2, N the piston speed in RPM and QT the theoretical flow rate in
m3/min.
 (Maximum displacement)

(Partial displacement)

(No displacement)
(No stroke)

(b)
Figure 1.19Stroke changes with offset angle

From a right-angled triangle ABC [Fig. 1.19(b)]

BC S
tan   
AB D
 S  D  tan  (1.3)
The displacement volume of one piston = ASm3
Total displacement volume of Ynumber of pistons = YASm3
VD  YAS (1.4)
From Eqs. (1.3) and (1.4), we have
VD  YAD tan  m3 /rev (1.5)
Theoretical flow rate is
QT  DANY tan  m3 /min

Example 1.7
What is the theoretical flow rate from a fixed-displacement axial piston pump with a nine-
bore cylinder operating at 2000 RPM? Each bore has a diameter of 15 mm and stroke is 20
mm.

Solution: Theoretical flow rate is given by

QT  Volume  RPM  Number of pistons

  D2  L  N  n
4
 2000
=  0.0152  0.02  9
4 60
= 10.6 × 103 m3 /s
  1.06 LPS = 63.6 LPM

1.9Comparison of Hydraulic Pumps

Pump design with a wide range of operating characteristics are available. A designer must
select carefully to achieve a circuit design that meets the functional objective while
minimizing total cost which includes both ownership cost and operating cost over the life of
component. Pump selection is important decision in circuit design. Designer must compare
the various options available and then choose the optimum pump. Table 1.2 gives a typical
comparison of all pumps.

The major factor in adopting a pump to a particular system is the system’s overall needs. It
would be wrong to use a pump with high delivery in a system that requires only a
lowdelivery rate. On the contrary, using a pump that must produce at its peak continuously
just to meet the minimum requirements of the system is equally wrong. Making either of
these mistakes produces a poor system due to excessive initial pump costs or maintenance
cost.

One should use a pump that is suited to the system, whether a gear pump which has fewer
moving precision parts or a piston pump whichhas many parts fitted to close tolerance and is
therefore more expensive.

Table 1.2

Pressure Discharge(LPM) MaximumSpeed Overall

(Bar) (RPM) Efficiency
Gear pump 20–175 7–570 1800–7000 75–90
Vane pump 20–175 2–950 2000–4000 75–90
Axial piston pump 70–350 2–1700 600–6000 85–95
Radial piston
pump 50–250 20–700 600–1800 80–92

1.10Pump Performance

The performance of a pump is a function of the precision of its manufacture. An ideal pump
is one having zero clearance between all mating parts. Because this is not possible, working
clearances should be as small as possible while maintaining proper oil films for lubrication
between rubbing parts. The performance of a pump is determined by the following
efficiencies:
1. Volumetric efficiency (  v ):It is the ratio of actual flow rate of the pump to the
theoretical flow rate of the pump. This is expressed as follows:
 Actual flow rate of the pump
Volumetric efficiency (v ) =
Theoretical flow rate of the pump
Q
 A
QT

Volumetric efficiency (  v ) indicates the amount of leakage that takes place within the
pump.This is due to manufacture tolerances and flexing of the pump casing under designed
pressure operating conditions.
For gear pumps,  v = 80%–90%.
For vane pumps,  v = 92%.
For piston pumps,  v = 90%–98%.

2. Mechanical efficiency (  m ): Itis the ratio of the pump output power assuming no leakage
to actual power delivered to the pump:

Pump output power assuming no leakages

Mechanical efficiency (m ) =
Actual power delivered to the pump

Mechanicalefficiency(  m ) indicates the amount of energy losses that occur for reasons other
than leakage. This includes friction in bearings and between mating parts. This includes the
energy losses due to fluid turbulence. Mechanical efficiencies are about 90%–95%. We also
have the relation
p QT
m 
TA N

wherep is the pump discharge pressure in Pa or N/m2, QT is the theoretical flow rate of the
pump in m3/s, TA is the actual torque delivered to the pump in Nm and N is the speed of the
pump in rad/s.
It (  m ) can also be computed in terms of torque as follows:

Theoretical torque required to operate the pump

m =
Actual torque delivered to the pump
T
 T
TA
The theoretical torque ( TT ) required to operate the pump is the torque that would be required
if there were no leakage.
The theoretical torque ( TT ) is determined as follows
VDN  3 N 
TT (N m)  m  2  = N m
2π  m 
The actual torque ( TA ) is determined as follows
 P N m/s
Actual torque TA (N m)   Nm
ω  rad / s 
whereω = 2πN/60. HereNis the speed in RPM.

3. Overall efficiency (o ):It is defined as the ratio of actual power delivered by the pump to
actual power delivered to the pump

Actual power delivered by the pump

Overall efficiency (o ) 
Actual power delivered to the pump
Overall efficiency ( o ) considers all energy losses and can be represented mathematically as
follows:
Overall efficiency (o )  vm
Q pQT
 ηo  A 
QT TA N

Example 1.8
A gear pump has an outside diameter of 82.6 mm, inside diameter of 57.2 mm and a width of
25.4 mm. If the actual pump flow is 1800 RPM and the rated pressure is 0.00183 m3 /s, what
is the volumetric efficiency?

Solution: We have
Outside diameter Do  82.6 mm
Inside diameter Di  57.2 mm
Width d  25.4 mm
Speed of pump N = 1800 RPM
Actual flow rate = 0.00183 m3 /s
Theoretical flow rate
 N
QT   ( Do 2  Di 2 )  d 
4 60
 1800
=  (0.08262  0.05722 )  0.0254 
4 60
= 2.125  10 3
Volumetric efficiency is
0.00183
v = 100  86.11%
2.125 103

Example 1.9
A pump having a volumetric efficiency of 96% delivers 29 LPM of oil at 1000 RPM. What is
the volumetric displacement of the pump?

Solution:
 Volumetric efficiency of the pump  v = 96%
Discharge of the pump = 29 LPM
Speed of pump N  1000 rpm
Now
Actual flow rate of the pump Q
v =  A
Theoritical flow rate of the pump QT
29
 0.96 
QT
 QT  30.208 LPM
Volumetric displacement
Q 30.208 103  60
VD  T 
N 60 1000
 30.208 106 m3 / rev  0.0302 L / rev

Example 1.10
A positive displacement pump has an overall efficiency of 88% and a volumetric efficiency
of 92%. What is the mechanical efficiency?

Solution: Theoverall efficiency is

ηo  η m  η v
η 88
 ηm  o =  100 = 95.7%
η v 92

Example 1.11
Determine the overall efficiency of a pump driven by a 10 HP prime mover if the pump
delivers fluid at 40 LPM at a pressure of 10 MPa.

Solution:

Output power  pQ
m3 /s 1 min
 10 10 N/m  40 L/min 
6 2

1000 L/s 60 s
 6670 W
746 W
Input power  10 HP   7460 W
1 HP
Now

Pump output power

ηo 
Pump input power
6670
  0.894  89.4%
7460
Example 1.12
How much hydraulic power would a pump produce when operating at 140 bar and delivering
0.001 m3/s of oil? What power rated electric motor would be selected to drive this pump if its
overall efficiency is 85%?

Solution:
Operating pressure of the pump = 140 bar
Flow rateQ = 0.001m3/s. Now
Power of pump  Pressure ×Flow rate
 140  105  0.001
 14 kW
Overall efficiency of pump ηo  85%
Power to be supplied is
Power of pump 14 kW
  16.47 kW
ηo 0.85

Example 1.13
A pump has a displacement volume of 98.4 cm3. It delivers 0.0152 m3/s of oil at 1000 RPM
and 70 bar. If the prime mover input torque is 124.3 Nm. What is the overall efficiency of
pump? What is the theoretical torque required to operate the pump?

Solution:
Volumetric discharge  98.4 cm3
Theoretical discharge is
N 1000
QT VD   98.4   1.64 103 m3 /s
60 60
Volumetric efficiency is
1.52 103
ηv  100 = 92.68 %
1.64 103
Overall efficiency is
Q  pressure 1.52 103  70 105  60
ηo  A =  100 = 81.74%
T ω 124.3  2 1000  π
The mechanical efficiency is
η 81.74
ηmechanical  overall   88.2
ηvolumetric 92.78
Now
Theoretical torque = Actual torque × ηmechanical = 124.3 × 0.882 = 109.6 Nm
Note: Mechanical efficiency can also be calculated as
pQT
m 
T
70 105 N/m 2  0.00164 m3 / s

1000
124.3 (N m)   2 rad/s
60
 0.882  88.2%
 Lecture 9
HYDRAULIC PUMPS [CONTINUED]
1.11 Pump Performance Curve

Pump performance characteristics are first analyzed independently of the rest of hydraulic
system and then as a part of the system. Both sets of data are valuable to the designer.
Analyzing the pump by itself gives an indication of its capabilities and performance based on
the speed of rotation, internal geometry, cost factors, etc., whereas analyzing pump
performance in system essentially determines pump system compatibility. In the first case,
the system designer may observe performance curves to see if a specific pump has the
pressure and volume flow rate to operate a given set of actuators. In a second instance, the
system designer may be computing the noise, vibration, cavitation and flow characteristics of
a specific pump before or after installation to determine if the pump and existing system are
compatible. Where the two are necessarily complimentary, in practice much of hands-on
work is completed independently. Pump performance characteristics are interpreted from data
in tabular form and then graphed.

Figure 1.20 shows a graphical representation of a typical positive displacement pump. Figure
1.20(a) represents the relationship between input power and pump output flow of a variable
displacement piston pump as a function of pump speed.Observe the linear relationship
between the discharge flow and pump speed. Figure 1.20(b) gives curves of overall and
volumetric efficiencies as a function of speed. Performance curves of radial piston pump are
given in Fig.1.20(c). Discharge flow of these pumps is nearly constant over a broad pressure
range.Discharge flow can be varied infinitely between the point of inflection on the constant
discharge portion of the curve and zero flow.

Flow

Power

(a)
 (b)

(c)
Figure 1.20Pump performance curves

1.12Pump Noise

Pump noise is an important parameter used to determine the performance. Any increase in
noise indicates increased wear and eventually pump failure. Pumps are good generators but
poor radiators of noise. Noise is not just the sound coming directly from the pump, but also
from the vibration and fluid pulsation produced by the pump. Pumps are small in size and
hence, they are poor radiators of noise. Reservoirs, electric motors and piping being largerin
size are better radiators. Hence,a pump-induced vibration can cause audible noise greater than
that coming from the pump. Fixed displacement pumps are less noisy than variable
displacement pumps because of their rigid construction.
 Figure 1.21 Pumpnoise characteristics
As can be seen from Fig.1.21, the pump speed has a strong effect on noise compared to
displacement and pressure. To reduce the noise levels, electric motors are used and the most
advantageous combination of size and pressure is selected to produce the needed power.

1.13Pump Cavitation
During the working of a positive displacement pump, vacuum is created at the inlet of the
pump. This allows atmospheric pressure to push the fluid in. In some situations, the vacuum
may become excessive, and a phenomenon known as cavitation occurs. When the pressure of
the liquid reaches a low enough level, it vaporizes or boils. Cavitation is the formation of oil
vapor bubbles due to a very low pressure (high vacuum) on the inside of the pump. The low
pressure also causes air, which is dissolved in the oil to come out of the solution and form
bubbles. These air and oil vapor bubbles collapse when they reach the outlet side of the
pump, which is under a high pressure. The collapsing of these vapor bubbles causes
extremely high localized pressure and fluid velocity. These pressures are so high that they
cause pitting of metal and consequently decrease the life and efficiency of the pump.

1.13.1 Factors Causing Cavitation

Cavitation is caused by the following factors:

1. Undersized plumbing.
2. Clogged lines or suction filters.
3. High fluid viscosity.
4. Too much elevation head between the reservoir and the pump inlet.

1.13.2 Rules to Eliminate (Control) Cavitation

Following are the rules to control cavitation:

1. Keep suction line velocities below 1.2 m/s.

2. Keep the pump inlet lines as short as possible.
3. Minimize the number of fittings in the inlet line.
4. Mount the pump as close as possible to the reservoir.
5. Use low-pressure drop inlet filters.
6. Use proper oil as recommended by the pump manufacturer.
Example 1.14
Calculate the pipe bores required for the suction and pressure lines of a pump delivering 40
L/min using a maximum flow velocity in the suction line of 1.2 m/s and a maximum flow
velocity in the pressure line of 3.5 m/s.

Solution:Consider the suction line

Flow = Average velocity × Flow area
Flow through pipe
Area of pipe =
Velocity of flow
Now
Flow = 40 LPM = 40/60 LPS = 40/60 × 103 m3/s
40  103
Area of pipe = = 0.555 × 103 m2
60  1.2
Let the bore of the pipe be of diameter D. Then
3 πD 2
Area of pipe  0.555 10 m  2

4
 D = 0.0266 m
Minimum bore suction pipe = 26.6 mm.
Note: in all calculations great care must be taken to ensure that units are correct.
Alternatively, if a flow velocity of 1m/s is used then suction pipe bore can be of diameter 29
mm. The required diameter of the pressure line can be calculated in a similar manner taking
the flow velocity as 3.5 m/s. Here the minimum bore of pressure pipe is equal to 15.6 mm.
It is unlikely that a pipe having the exact bore is available, in which case select a standard
pipe having a larger bore. Alternatively, a smaller bore pipe may be chosen but it will be
necessary to recheck the calculation to ensure that the flow velocity falls within the
recommended range. That is, a standard pipe with an outside diameter of 20 mm and a wall
thickness of 2.5 mm is available. This gives an internal diameter of 15 mm.
Flow through pipe
Flow velocity =
Area of pipe bore
Now
π
Area of pipe bore = 152 mm2  177 mm2  177  106 m2
4
So
60  103
Flow velocity =  3.77 m / s
60  177  106
This is satisfactory. It is also important to ensure that the wall thickness of pipe is sufficient
to withstand the working pressure of the fluid.

1.14Pump Selection
The main parameters affecting the selection of a particular type of pump are as follows:

1. Maximum operating pressure.

2. Maximum delivery.
3. Type of control.
4. Pump drive speed.
5. Type of fluid.
6. Pump contamination tolerance.
 7. Pump noise.
8. Size and weight of a pump.
9. Pump efficiency.
10. Cost.
11. Availability and interchangeability.
12. Maintenance and spares.

1.14.1 Maximum Operating Pressure

This is determined by the power requirement of the circuit, the particular
application,availability of components, type of fluid and to some extent the environment and
level of labor both using and maintaining the equipment.

In general, the higher the operating pressure, the higher the component cost and the lower the
choice of components. The main advantage of higher working pressures is the reduction in
fluid flow rates for a given system power, resulting in smaller pumps, smaller bore pipes and
smaller components. The disadvantage is that at higher working pressures, the
compressibility of the fluid used can have considerable adverse effects where precision
control is required over a wide range of loads.

The general tendency is toward increased operating pressures. Typical maximum pressures
for fewapplications are given in Table 1.3. The operating pressures of pumps depend to some
extent on the fluid used. A fire-resistant fluid is generally not as good lubricant as a mineral
oil. So to give a reasonable pump life expectancy when using a fire-resistant fluid, the
maximum operating pressure must be reduced and it is advisable to consult the pump
manufacturer.

The maximum operating pressure and range of flow rates for different types of currently
available hydraulic pumps are shown in Table 1.4.The figures given cover a range of sizes
and makes; maximum valuesof delivery and pressure are not applicable to one pump.

Table 1.3System maximum pressure in relation to application

Application Pressure (bar)

Machine tool 200

Mechanical 250
handling
Mobile 300
Press work 800
 Table 1.4Operating pressure and size ranges for hydraulic pump types
Maximum
Maximum Min. Noise
Delivery Speed(RPM)
Pump Type Pressure Filtratio Pulsation Level( η (%)
(L/min)
n(µm) dB)
From To From To From To
External gear 40 300 0.25 760 500 3000 100 High 90 70–90
Internal gear 100 210 0.6 740 3000 4000 100 Low 85 75–90
65–80
Vane 50 140 6 360 500 3000 50 Low 80
Balanced vane 140 175 2 620 500 300 50 Low 85 70–90
Axial piston 80–90
200 350 1 1450 200 2000 25 High 90
(swash plate)
Axial piston 50–90
250 350 17 3500 200 2000 25 High 90
(bent-axis)
Radial piston 350 1720 0.3 1000 200 2000 50 High 90 80–90

1.14.2 Maximum Delivery

The pump system selected must be capable of delivering the maximum flow rate demanded
by the circuit. If the circuit demand is reasonably constant, a fixed displacement pump is
chosen. When the demand is at a series of fixed levels, a multi-pump system is used. For
demands which vary within a relatively narrow band, a variable displacement pump is used.
If there is a wide variance in system demand, an accumulator circuit may best satisfy the
requirements.
Pump capacities are stated by manufactures for a particular viscosity fluid at given operating
temperatures and pressures. Any increase in temperature and hence a reduction in viscosity or
an increase in operating pressure causes more leakage across the pump and consequently
reduces the pump delivery. As the pump wears the leakage will increase.It is usual to select a
pump with a capacity about 10% higher than that required to make an allowance for the
reduction in volumetric efficiency with wear. Pumps are available with flows from a fraction
of 1 LPM to–1000 LPM and above.

1.14.3 Type of Control

Various types of pump controls are available such as manual servo control, pressure
compensated control, constant power control and constant flow control. The choice of control
is dependent upon the circuit requirement such as complexity, accuracy of control, cost, type
of machining operation,etc.The designer has to choose carefully the type of control after a
detailed study of system characteristics.

1.14.4Pump Drive Speed

Amajority of pumps are driven directly from the prime mover – electric motor or internal
combustion engine–so the proposed drive speed is known. The fluid delivery rate is
proportional to the speed of rotation. Each design has a minimum and maximum operating
speed: the faster the pump runs, the shorter its life.

1.14.5Types of Fluid
Pumps are designed to operate within a particular range of fluid viscosity. Mineral oils of the
correct viscosity work satisfactory with most pumps provided the oil is clean. Operating with
synthetic or water-based fluids reduces the working life of a pump that relies on the hydraulic
fluid to lubricate the bearings and moving parts. When any fluid other than a mineral oil is to
be used, it is advisable to seek the pump manufacturer’s advice.
1.14.6Fluid Contamination
Any fluid contamination causes pump damage. Precision pumps with very fine clearances are
more susceptible to damage. If a contaminated fluid has to be pumped, such as in a cleanup
loop, particular attention must be paid to pump selection. Non-precision gear pumps, lobe
pumps and gerotor pumps are the most dirt tolerant.Whichever type is used, a strainer must
be fitted in the suction line. In the case of precision pumps, the manufacturer’s
recommendation on filtration must be followed; otherwise the life of pump will be drastically
reduced and the maker’s warranty voided.

1.14.7Pump Noise
Noise has become increasingly important environmentally. Operating levels vary
considerably between the pumps of the same type but of different makes.The manufacturers
are working on those aspects which most affect the emission of noise– port plate design,
bearings, flow passages, pressure controls, materials and methods of mounting. Generally, the
sound generated increases with speed and pressure. Certain kinds do, however, propagate
lower noise levels, in particular, those with internal gears. A multi-stage internal gear pump is
marketed by one manufacturer under the name Q pump, with Q signifying quiet.

Example 1.15
The intensity (in units of W/m2) of the noise of a pump increases by a factor of 10 due to
cavitation. What is the corresponding increase in noise level in decibels?

Solution:
I (final)
dB increase  10  log  10  log10  10 dB
I (initial)

1.14.8Size and Weight of a Pump

Generally, not only the overall size and weight of a hydraulic system is important in mobile
installations, but also the whole system is important, as the size and weight of a pump is only
part of the whole system. In a mobile hydraulic field, the trend is to reduce the weight of the
hydraulic system by increasing the operating pressure,reducing the size of the reservoir and
using efficient oil coolers.
The best power-to-weight ratios can usually be achieved in the 200–300 bar operating
pressure range. The actual sizeand weight of a pump depend upon the particular
manufacture’s design. Very light compact units have been developed for use in the aerospace
industry but these tend to be extremely expensive.

1.14.9Efficiency
Reciprocating pumps tend to have higher efficiencies than rotary pumps. The actual
efficiency depends on design, operating pressure, speed and fluid viscosity.Table1.5gives an
indication of the range of efficiencies of various types of pumps.
Table 1.5Efficiency ranges of pumps
Pump Type Volumetric Efficiency Overall Efficiency
Piston
Plunger in line  99  95
Radial  95  90
Axial  95  90
Precision gear pumps  95  90
Vane pump  90  80

1.14.10Cost
The initial cost of a pump is usually of secondary importance to running and maintenance
costs.Gear pumps are cheaper, vane and piston pumps are expensive.

1.14.11Availability and Interchangeability

A number of gear pump manufacturers produce units to CETOP and SAE standards so far as
the external dimensions are concerned. This gives direct interchangeability between gear
pumps of different manufacturers. The shafts, mounting flanges and port connections of most
of the other types also comply with various international standards allowing a degree of
interchangeability.

1.14.12Maintenance and Spares

In every type of pump, the components involved in pumping worn out after a time and need
replacing. In gear pumps, it is usual to replace the entire pump. With some types of vane
pumps, the wear parts are grouped together as a cartridge that can easily be replaced without
dismantling the pump drive. In the case of piston pumps, it may be advisable to ensure that
the manufacturer offers a fast overall service for critical applications to carry a spare pump in
stock.

Example 1.16
A pump has a displacement volume of 120 cm3. It delivers 0.0015 m3/s at 1440 RPM and 60
bar. If the prime mover input torque is 130 Nm. What is the overall efficiency of the pump?
What is the theoretical torque required to operate the pump. The pump is driven by an electric
motor having an overall efficiency of 88%. The hydraulic system operates 12 h/d for 250
days per year. The cost of electricity is Rs 8 per kWh. Determine the yearly cost of electricity
to operate the hydraulic system. The amount of the yearly cost of electricity that is due to the
inefficiencies of the electric motor and pump.

Solution: Given volumetric displacement, VD = 120 cm3 , QA  0.0015 m3 /s, N  1440 rpm ,
P  60 bar , input torque TA  130 N m .

Total number of working hours available  250  12  3000 h

Volumetric displacement in m3/rev is

3
120 cm3  1 m 
VD =    0.000120 m /rev
3

rev  100 cm 
Theoretical dischargecan be calculated as

1440
QT  VD N  0.000120 rev/s  0.00288 m3 /s
60

Now we can calculate the volumetric efficiency as

Q 0.0015
v  A   52.08%
QT 0.00288

Mechanical efficiency is given by

pQT 60 105  0.00288 17280
m     88.2%
TA 2 19603
130 1440 
60
Note the product TA gives power in units of Nm/s (W) where TA has a unit of Nm and shaft
speed has units of rad/s.
The overall efficiency is
ηo  m v  0.882  0.5208  0.459  45.9%

Alternativelyoverall efficiency can also be calculated as

pQA 60 105  0.0015 9000
ηo     45.9%
TA 130 1440  2  19603
60
Now since the mechanical efficiency is known, we can calculate the theoretical torque as

TT  TA m  130  .882  114.7 N m

Thus, due to mechanical losses within the pump, 130 Nm of torque are required to drive the
pump instead of 114.7 Nm.

First we calculate the mechanical input power the electric motor delivers to the pump.

Pump input power (kW) isgiven by

2
TA  130 1440   19603 W  19.603 kW
60

Next we calculate the electrical input power.

Electric motor input power is given by

Electric motor output power 19.603
  22.28 kW
Electric motor overall efficiency 0.88
So
Yearly cost = Power rate  Time per year  Unit cost of electricity
= 22.28  12 h/d  250 d/y  8 Rs/kWh
= Rs 534627
The total loss equals kW loss due to electric motor plus the kW loss due to pump. Thus, we
have
Total loss  (1  0.88)  22.28  (1  0.459) 19.603
 2.674  10.61  13.284 kW

Yearly cost due to inefficiencies is

13.284
 534627 Rs/year  318760 Rs / year
22.28
Since
13.284
 59.2
22.28
we conclude that 59.2% of the total cost of electricity is due to inefficiency of the electric
motor and pump. This also means that only 49.8% of the electrical power entering the electric
motor is transferred into hydraulic power at the pump outlet port.

Example 1.17
For the fluid power system of Fig. 1.22, the following data are given:

Cylinder piston diameter 0.203 m

Cylinder rod diameter 0.102 m
Extending speed of cylinder 0.0762 m/s
External load on a cylinder 178000 N
Pump volumetric efficiency 92%
Pump mechanical efficiency 90%
Pump speed 1800 RPM
Pump inlet pressure −27600 Pa

(i)The total pressure drop in the line from the pump discharge port to the blank end of the
cylinder is 517000 Pa.
(ii) The total pressure drop in the return line from the rod end of the cylinder = 345000 Pa.
Determine the
(a) Volumetric displacement of the pump.
(b) Input power required to drive the pump.
(c) Input torque required to drive the pump.
(d) Percentage of pump input power delivered to the load.
 Motor

Check valve Cylinder

F
Breather
Pump External
load

Reservoir
Directional control Valve

Figure 1.22</figure caption>

Solution:
(a) Volumetric displacement of pump.
Qpump-actual  Apiston Vpiston ext

  0.2032  0.0762  0.00247 m3 /s
4
= 2.47 LPS
Qpump-actual 0.00247 m3
Qpump-theoretical    0.00268
Vol 0.92 s

Now
Qpump-theoretical  VD N
1800
 0.00268 VD 
60
 VD  0.0000893 m  0.0893 L
3

(b) Input power required to drive the pump

Pump output power = (p)Qactual
 pblank-end  Apiston  prod-end  ( Apiston  Arod )  Fexternal load on cylinder
 
 pblank-end   0.2032  345000   (0.2032  0.1022 )  178000
4 4
 pblank-end  5758000 Pa  5758 kPa
Pump output power = {(5758  517  27.6)0.00247}  15.6 kW
Pump output power 15.6
Pump input power =   18.8 kW
 v  m 0.92  0.90

(c) Input torque required to drive the pump

Pump input power is
 rev 1min 2 rad
T   T 1800   188 rad/s
min 60 s
Now
18800 W  T 188 rad/s
So torque required to drive pump is T = 100 Nm.
(d) Power delivered to load is
Fexternal load on cylinder Vcyl.ext
= 178000 0.0762 = 13600 W = 13.6 kW
Percent of pump input power delivered to load = 13.6/18.8 100 = 72.3%

Example 1.19
The system of in Example 1.17 contains a fixed displacement pump with a pressure relief
valve set at 6871 kPa. The system operates 20 h/d for 250 days in a year. The cylinder is
stalled in its fully extended position 70% of the time. When the cylinder is fully extended,
0.0633 LPS leaks past its piston.
(a) If the electric motor driving the pump has an efficiency of 85% and the cost of electricity
is Rs 10 per kWh, find the annual cost of electricity for powering the system
(b) It is being considered to replace fixed displacement pump with a pressure-
compensated pump (compensator set at 6871 kPa) that cost Rs 250000
more. How long will it take for the pressure-compensated pump to pay for
itself if its overall efficiency is same as fixed displacement pump?

Solution
(a)Annual cost of electricity for powering the system
pblank-end  5758000 Pa  5758 kPa
The total pressure drop in the line from the pump discharge port to the blank end of the
cylinder is 517000 Pa.
Pump inlet pressure = −27600 Pa
Pump discharge pressure = 5758000 Pa  517000 Pa  27600 Pa  6247.4 kPa
Pump input power = 18.8 kW
Electric motor input power = 18.8/0.85 = 22.1 kW
Thus with the cylinder fully extended (pressure relief valve set at 6871 kPa) we have
6871
Electric motor input power =  22.1  24.3 kW
6247.4
Thus, the yearly cost of electricity is
Yearly cost = Power rate × Time per year × Unit cost of electricity
= 0.30 × 22.1 (kW) 20 h/d  250 d/yr  10/kWh + 0.70 24.3 20 250 10
= Rs 1182000/year
(b) The fixed displacement pump produces 2.47 LPS at 6871 kPa when the cylinder is fully
extended. Leakis 0.0633 LPS through the cylinder plus 2.407 LPS through the relief valve.
Thus, when the cylinder is fully extended, we have power lost with a fixed displacement
pump
pQ = 6871  0.00247 = 16.97 kW
Hence, the electric motor input power is
16.97
 24.1
0.828  0.85
The overall efficiency of the pump 82%.The pressure-compensated pump would produce
only 0.0633 LPS at 6871 kPa when the cylinder is fully extended. For this case we have the
power lost with pressure-compensated pump is
pQ = 6871 × 0.0000633 = 0.44 kW
Hence, the electric motor input power is
0.44
 0.63 kW
0.828  0.85
Thus, the kW power saved while cylinder is fully extended = 24.1−0.63 = 23.47 kW
Savings per year = 23.47 0.70  20 250 10 = Rs 821450 per year
Time to pay for pump = Rs 250000/821450 = 0.3 years
Objective-Type Questions
Fill in the Blanks

1. Non-positive displacement pumps are primarily ______type units that have a

______clearance between rotating and stationary parts.
2. Flow rate of pump does ______ with head in the case of a positive displacement pump,
while it ______ with head in the case of a non-positive displacement pump.
3. In a lobe pump, the output may be slightly ______ because of the smaller number of
______ elements.
4. In a screw pump, there are no pulsations at ______ speed; it is a very quiet operating
pump.
5. In a balanced vane pump, the rotor and vanes are contained within a ______ eccentric cam
ring and there are ______ inlet segments and two outlet segments during each revolution.

State True or False

1. The volumetric capacity of a positive displacement pump is less than that of a non-positive
displacement pump.
2. Too low elevation head between the reservoir and the pump inlet causes cavitation.
3. Efficiency is almost constant with the head in the case of non-positive displacement
pumps.
4. The sole purpose of pumps is to create pressure.
5. Mechanical efficiency indicates the amount of energy losses that occur for reasons other
than leakage.

Review Questions

1. What is a positive displacement pump? In what ways does it differ from a centrifugal
pump?
2. Define the source of hydraulic power (pump).
3. Explain the working principle of a pump.
4. Pumps do not pump pressure. Justify this statement.
5. What is the function of a pump in a hydraulic system?
6. How is the pumping action in positive displacement pumps accomplished?
7. How the volumetric efficiency of a positive displacement pump is determined?
8. List the advantages of hydrostatic pumps over hydrodynamic pumps.
9. Give the classification of hydrostatic pumps used in a fluid power system.
10. What is the difference between a fixed displacement pump and a variable displacement
pump?
11. What types of pumps are available in variable displacement designs?
12. How can the vane pump/piston pumps be made as variable displacement pumps?
13. Name three designs of external gear pumps.
14. Name two designs of internal gear pumps.
15. What are the advantages of screw pumps over other gear pumps?
16. Why is the operation of screw pump quiet?
17. How can the unbalanced vane pump be used as a variable displacement pump?
18. What is a pressure-compensated vane pump and how does it work?
19. What is meant by a balanced design vane pump?
20. Name the important considerations when selecting a pump for a particular application.
21. Why a gear pump cannot be used as a variable displacement pump?
22. How can the displacement of an axial piston pump be varied?
23. What is pump cavitation and what is its cause?
24. How is pressure developed in hydraulics systems?
25. Why centrifugal pumps are rarely used in fluid power systems?
26. Draw the graphical symbols for the fixed displacement and variable displacement pumps.
27. Which parameters affect the noise level of a positive displacement pump?
28. What is meant by the pressure rating of a positive displacement pump?
29. Name the four rules that control or eliminate cavitation of a pump.
30. Comment on the relative comparison in performance among gear, vane and piston pumps.
31. What are the two ways of expressing a pump size?
32. What are pump characteristic curves? Draw the same for the positive displacement
pumps.
33. How is the capability of a variable displacement pump affected by the addition of
pressure compensation?
34. Name the three principal ways in which noise reduction can be accomplished.

35. What are the most common things apart from pressure or speed that can cause a pump to
fail? Explain each.
36. Where are external gear pumps used?

Answers
Fill in the Blanks

1.Velocity, large
2.Not change, decreases
3.Greater pulsation,meshing
4.Higher;
5.Double, two

State True or False

1.True
2.False
3.False
4.False
5.True