International Journal of Mechanical Engineering and Technology (IJMET)

Volume 7, Issue 5, September–October 2016, pp.127–132, Article ID: IJMET_07_05_015

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STUDY, DESIGN AND IMPROVEMENT OF PUMPING

SYSTEM EFFICIENCY OF HYDRAULIC PNEUMATIC
RECIPROCATING PUMP
Aakash M. Bodh
Mechanical Engineering, Yeshwantrao Chavan College of Engineering, Nagpur, India.

G. H. Waghmare
Professor, Mechanical Engineering, Yeshwantrao Chavan College of Engineering, Nagpur, India.

ABSTRACT
In general we use three methods for transmitting power from one point to another. Mechanical
transmission is through shafts, gears, chains, belts, etc. Electrical transmission is through wires,
transformers, etc. Fluid power is through liquids or gas in a confined space. We shall discuss a
structure of hydraulic systems and pneumatic systems. We will also discuss the advantages and
disadvantages and compare hydraulic, pneumatic, and mechanical systems. Fluid power is the
technology that deals with the generation, control and transmission of forces and movement of
mechanical element or system with the use of pressurized fluids in a confined system. Both liquids
and gases are considered fluids. In this article the energy analysis of the pneumatic system is
implemented in the simulation model. Previous research has shown the comparison of methods for
the investigation on the energetic behaviour of pneumatic drives and its practical application.
Concerning the analysis of the methods for determination the energy efficiency, the presented
model is based on exergy analysis.
Key words: Exergy, Gases, Hydraulic, liquid, Pneumatic.
Cite this Article: Aakash M Bodh and Prof. G.H. Waghmare, Study, Design and Improvement of
Pumping System Efficiency of Hydraulic Pneumatic Reciprocating Pump. International Journal of
Mechanical Engineering and Technology, 7(5), 2016, pp. 127–132.
http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=7&IType=5

1. INTRODUCTION
Fluid power system includes a hydraulic system (hydra meaning water in Greek) and a pneumatic system
(pneuma meaning air in Greek). Oil hydraulic employs pressurized liquid petroleum oils and synthetic oils,
and pneumatic employs compressed air that is released to the atmosphere after performing the work.
Perhaps it would be in order that we clarify our thinking on one point. By the term “fluid” we refer to air or
oil, for it has been shown that water has certain drawbacks in the transmission of hydraulic power in
machine operation and control. Commercially, pure water contains various chemicals (some deliberately
included) and also foreign matter, and unless special precautions are taken when it is used, it is nearly
impossible to maintain valves and working surfaces in satisfactory condition. In the cases where the

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 Aakash M Bodh and Prof. G.H. Waghmare

hydraulic system is closed (i.e., the one with a self-contained unit that serves one machine or one small
group of machines), oil is commonly used, thus providing, in addition to power transmission, benefits of
lubrication not afforded by water as well as increased life and efficiency of packings and valves. It should
be mentioned that in some special cases, soluble oil diluted with water is used for safety reasons. The
application of fluid power is limited only by the ingenuity of the designer, production engineer or plant
engineer. If the application pertains to lifting, pushing, pulling, clamping, tilting, forcing, pressing or any
other straight line (and many rotary) motions, it is possible that fluid power will meet the requirement.
Fluid power applications can be classified into two major segments:
Stationary hydraulics: Stationary hydraulic systems remain firmly fixed in one position. The
characteristic feature of stationary hydraulics is that valves are mainly solenoid operated. The applications
of stationary hydraulics are as follows: Production and assembly of vehicles of all types. Machine tools
and transfer lines. Lifting and conveying devices. Metal-forming presses. Plastic machinery such as
injection-molding machines. Rolling machines. Lifts. Food processing machinery. Automatic handling
equipment and robots. Mobile hydraulics: Mobile hydraulic systems move on wheels or tracks such as a
tower crane or excavator truck.

2. AIMS AND OBJECTIVES

• To eliminate the need for complicated systems using gears, cams, and levers.
• Motion can be transmitted without the slack inherent in the use of solid machine parts.
• The system should not be subject to breakage as are mechanical parts .
• system mechanisms should not subjected to great wear
• use it for testing purpose
• study of the system
• fabrication of system
• simulation

3. CONCEPTUAL LINE DIAGRAM

Figure 1 Hydraulic Pneumatic Reciprocating Pump

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 Study, Design and Improvement of Pumping System Efficiency of Hydraulic Pneumatic Reciprocating Pump

4. LITERATURE SURVEY
• Paper named” Process simulation of energy behaviour of pneumatic drives" says that In this article the
energy analysis of the pneumatic system is implemented in the simulation model. Previous research has
shown the comparison of methods for the investigation on the energetic behaviour of pneumatic drives and
its practical application .Concerning the analysis of the methods for determination the energy efficiency, the
presented model is based on exergy analysis. Exergy analysis is able to consider all energy losses as well as
the influence of the temperature behaviour on the available useful pneumatic energy.
• Paper named” Design of High Speed Rotary Valves for Pneumatic Applications "says that Valves based on
rotating geometry have long been sought by designers for their simplicity, compactness, and desirable
dynamic properties. Unfortunately, they generally involve tight sealing surfaces with significant relative
motion, making them particularly prone to problems of wear, leakage, and seizure. These inherent
weaknesses are easily overcome in applications involving low pressures or low actuation speeds but become
more significant in applications with high pressures and/or high speeds.
• Paper named “Controller Design for Simulation Control of Intelligent Pneumatic Actuators (IPA) System
says that Intelligent Pneumatic Actuators (IPA) is a system for application that requires better control and
accuracy. The purpose of this paper is to present a controller design for simulation control of an IPA system
using Proportional-Integrative (PI) controller and pole-placement feedback controller. Before the controller
is designed, model identification is used to obtain the plant using transfer function. The flow for the
controller design starts with the theory, mathematical calculation, procedures and the implementation of the
simulation control by using MATLAB software. Furthermore, simulation results are compared and analyzed
to illustrate the performance of the proposed controllers.

5. OPERATING EFFICIENCIES
5.1. General
Water pumping stations will normally operate automatically to satisfy the hydraulic requirements of the
system. Supervisory or remote control of electric motors will be provided on the larger installations to
reduce operator time and to provide a means for optimal control of energy costs, and to allow for energy
conservation measures. For optimal control of energy costs, particularly for larger pump stations, the
control system will allow the operators to schedule pump operations so that station electrical consumption
is minimized at the same time adequate storage for fire protection and system pressures are maintained.
Energy costs comprise the major component of the operating costs of water supply systems. The largest
quantity of energy is usually consumed by treated water pumping stations. The overall operating cost
associated with a particular pump station will be dependent upon the following factors: the pumps, the
distribution system, the pump drivers, and the governing energy rate schedule. The design analysis for the
distribution system and pump station and the cost evaluation will consider these factors.

5.2. Pump Operations

Three different problem areas are usually encountered in any attempt to improve pump operations of an
existing pump station: inefficient pumps, inefficient pump combinations, and inefficient pump scheduling.
The efficiency of a single pump is the ratio of water horsepower produced by the pump to the input
horsepower, usually electrical. This efficiency should be measured at several flow rates. It is not always
physically practical to measure flow rates after pumps are installed in existing installations. However, if
this information can be obtained and the pump is shown to satisfy its original performance specification,
there is still no assurance that it will operate efficiently in the system. The efficiency of a pump running
alone can be much different than when running in conjunction with other pumps. With multiple pump
operation the actual flow produced will depend upon the head differences between the suction header and
discharge header. The relationship between these heads and the flow rate is referred to as the system head
curve and is a function of tank water level on each size of the pump, pipe carrying capacity near the pump,
location of water users

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 Aakash M Bodh and Prof. G.H. Waghmare

6. ANALYSIS FIGURES
Following results shows Total deformation and total stress are under Permissible values

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 Study, Design and Improvement of Pumping System Efficiency of Hydraulic Pneumatic Reciprocating Pump

7. PIPING CONFIGURATIONS TO IMPROVE PUMPING SYSTEM EFFICIENCY

There are several steps involved in optimizing the configuration of a pumping system. These include
determining the proper pipe size, designing a pip-ing system layout that minimizes pressure drops, and
selecting low-loss components. To determine the proper pipe size, designers must balance the initial cost
of the pipe against the cost of pushing fluid through it. Larger pipes create less friction loss for a given
flow rate; however, larger pipes also have higher material and installation costs. Unfortunately, designers
often overlook the energy costs of using small piping and focus on the initial cost when sizing system
piping.
Similarly, system piping should be configured with an awareness of the energy costs associated with
poor flow profiles. Although piping system layouts are usually dictated by space constraints, there are
often opportunities to minimize unnecessary pressure drops by avoiding sharp bends, expansions, and
contractions and by keep-ing piping as straight as possible. For example, orienting valves and system
equipment so that they are in line with the pipe run is one useful rule of thumb.
Low-loss components provide another opportunity to minimize life-cycle costs during system design.
As with pipe sizing, it is necessary to balance initial costs with future energy costs. For example, system
components such as valves can be cost-effective when life-cycle costs are taken into consideration.
In many cases, the selection of a particular type of valve is guided by service requirements such as
sealing capability under various pressures, the number of times a valve is opened and closed, hand wheel
torque, and the consequences of valve stem leakage. However, for applications in which service
requirements are comparatively light, the valve is selected on a first-cost basis at the expense of high flow
loss. For example, globe valves are usually selected because of their low cost and simplicity. However,
these valves have a relatively high flow loss coefficient caused by the flow path through the valve. Thus,
one way designers can improve system life-cycle costs is to consider the cost of flow losses.
Valves are often sized incorrectly. Designers often specify a pressure drop across the valve at the
design point that is larger than necessary. This results in an undersized valve and energy loss. Further,
process designers sometimes specify a maximum system flow that is much greater than normal flow. This
also results in an excessive pressure drop across the valve at normal operating conditions.

8. HEAD IN FLUID DYNAMICS

In fluid dynamics, head is a concept that relates the energy in an incompressible fluid to the height of an
equivalent static column of that fluid. From Bernoulli's Principle, the total energy at a given point in a fluid
is the energy associated with the movement of the fluid, plus energy from pressure in the fluid, plus energy
from the height of the fluid relative to an arbitrary datum. Head is expressed in units of height such as
meters or feet.
The static head of a pump is the maximum height (pressure) it can deliver. The capability of the pump
at a certain RPM can be read from its Q-H curve (flow vs. height).
Head is equal to the fluid's energy per unit weight. Head is useful in specifying centrifugal
pumps because their pumping characteristics tend to be independent of the fluid's density.
There are four types of head used to calculate the total head in and out of a pump:
• Velocity head is due to the bulk motion of a fluid (kinetic energy).
• Elevation head is due to the fluid's weight, the gravitational force acting on a column of fluid.
• Pressure head is due to the static pressure, the internal molecular motion of a fluid that exerts a force on its
container.
• Resistance head (or friction head or Head Loss) is due to the frictional forces acting against a fluid's motion
by the container.

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 Aakash M Bodh and Prof. G.H. Waghmare

9. RESULTS
Thus we have studied hydraulic pneumatic reciprocating pump. When we use it for testing purpose, it can
be used for both hydraulic and pneumatic pumps. It is found more efficient.
From the simulation it is found that the pump is bearing an equivalent stress and also total deformation
is under desired limits.

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