Durable Materials Used in Construction of Plunger Pumps

Plunger pumps require durable materials that can withstand the pressure of the pumped liquid. Ideally, the plunger and housing should be made of steel or bronze, which are corrosion resistant and have high tensile strength.

The suction cavitation characteristic of the plunger chamber is displayed in Figure (7). The biggest pressure drop occurs in Region E owing to the fastest length increase rate of the plunger chamber.

Material compatibility

The material used in the construction of a plunger pump is an important factor that determines how the pump will perform. The base and housing (cylinder) materials should be sturdy enough to withstand the conditions in which the pump will operate. The materials that come into contact with the pumped medium should also be chemically and oxidation resistant. Cast iron has high tensile strength and durability, while steels and stainless-steel alloys offer corrosion resistance and have higher pressure ratings than plastics.

Plunger pumps are ideal for applications where there is a need to transport liquid media at varying pressure levels and flow rates. They can handle a range of liquids, from detergent slurries and carbon mashes to cleaning pneumatic plunger pump solutions. They are able to achieve these varying pressure stages through the oscillating movement of a piston within a hydraulic seal.

Unlike diaphragm pumps, which use flexible membranes, pneumatic plunger pumps are composed of rigid parts and can create much higher pressures without the wear and tear that is common in other types of pumps. They can also be used to transfer viscous and thick liquids, such as oil or grease.

The Williams “V” Series plunger pump uses a mechanical piston to precisely inject a variety of different kinds of chemicals. The pump is powered by a MK XIIA Controller that generates the pneumatic pulses that stroke the plunger. It is able to produce a 100:1 turndown and can inject volume ranging from 3 to 45 strokes per minute.

Design considerations

If the fluid is highly acidic or basic, special consideration should be given to its compatibility with the pump’s components. The materials of the cylinder, housing and plunger must all be resistant to corrosion from the fluid. The plunger must also be made of a material that can withstand the pressure and temperature of the liquid it will be pumping. This is because a pump will be under a lot of pressure and a lot of stress. If the pump will be used with corrosive media, a stuffing box will be needed to ensure the seal can hold up against the aggressive characteristics of the liquid.

The suction characteristic of an axial plunger pump is a function of the sucked water, the gas-phase volume fraction, and the rotational speed. A numerical simulation of the suction characteristic shows that the vapor volume fraction decreases as the length of the plunger chamber increases. It is possible to reduce cavitation in an axial plunger pump by changing the swash plate angle and the cylinder radius. However, this will also affect the theoretical flowrate of the pump.

Another important design consideration is the piping and any auxiliary equipment. The piping must be large enough to accommodate the pressure rating of the pump, as well as any other auxiliary equipment. The pump must be able to handle the piping system’s maximum temperature rating, as well. In systems with a by-pass that routes back to the pump inlet, a thermal relief valve will be required.

Efficiency

A pneumatic plunger pump uses a pressure differential between the exterior and internal fluid to draw liquids into the cylinder and create a compressed state. This results in high volumetric efficiency for the pump. In addition, they consume less power than their centrifugal counterparts. This reduces energy costs and environmental impact, which is a benefit for companies looking to optimize production processes and pursue sustainability goals.

The efficiency of a plunger pump is calculated by dividing the actual torque pneumatic plunger pump manufacturer required to drive it by its theoretical maximum torque. This can be done using a mechanical/hydraulic efficiency calculator. To obtain accurate calculations, the calculator should take into account all leakage paths in the pump. Leakage losses are usually constant, but they can skew the calculated efficiency if not addressed.

In order to achieve high efficiency, the plunger’s cavity wall must be made from an extremely hard material. The same goes for the seals, which must be able to withstand extreme pressure. This is important because these parts are in direct contact with the media being pumped.

It’s also essential to choose a plunger pump with a well-designed stuffing box. This component separates the fluid being pumped from the power fluid by sealing the interface. Choosing a pump with a good stuffing box will minimize the risk of water-oil mixing, which could damage bearings and other components within the drive.

Maintenance

The plunger of a pneumatic pump is a solid component that reciprocates inside the cylinder and aids the pumps ability to suck and discharge liquids. It is typically made from nickel alloy, bronze, brass or iron. Plunger pumps are used in many industries for transferring various media types such as industrial chemicals, food and beverage, pharmaceuticals and waste water. Valves within the pump direct the medium and prevent backflow. The materials used in the construction of these components must be able to handle wear and interaction with the media being transferred.

As with all pumps there is a need for regular maintenance to ensure that it continues to perform as designed. This may involve resolving a number of issues such as;

Check for leakage, inefficiency, vibration and noise (which could be caused by cavitation). Differential Pressure – check the operating pressure to ensure that it is positioned on the best efficiency point curve. Vibration – check that the vibration levels are within the design limits. Noise – if there is a high pitched squeal or sound of gravel grinding it could be an indication that the one way valves in the reversing mechanism are stuck. In this case the plunger rod will need to be removed, cleaned and reinstalled. Then, the reversing valves should be checked and adjusted as required.