Piston Pump Basics
Fluid Handling
Equipment
Fluid Handling
Accessories
Fluid Handling
Technology
Factors Effecting
Pump
Performance
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Industrial Technologies -Process- Marketing Desk 02-2006
Fluid Handling Equipment
Pump Design
Pump Types
Pump
Operation
Pump
Components
Air Motors
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Industrial Technologies -Process- Marketing Desk 02-2006
Pump Design
Inline Pumps
Divorced Design
Pumps
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Inline Pumps
n
n
Inline Pumps have a direct
connection between the
Motor and Lower End
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Often used with
low viscosity
lubricants
Down Tube
coupled to Air
Motor casting
Divorced Design Pumps
n
n
n
Prevents contamination of
Air Motor when Lower
needs repair
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Motors and
Lower Ends are
separate from
each other
Tie rods
connect Motor
to Lower End
Eases Repair
Pump Types
Basic Pumps
Two-Ball Lower
End Pumps
Four-Ball Lower
End Pumps
Chop-Check
Lower End
Pumps
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Basic Pumps
n
n
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For low-volume
delivery of light
viscosity fluids
Ratios range
from 1:1 to 2:1
Two-Ball Pumps
n
n
n
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Lower end
contains two
ball checks that
control fluid
flow
Most common
type of pump
configuration
Used with light
to medium
viscosity fluids
Four-Ball Pumps
n
n
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Lower End
contains four
ball checks that
control fluid
flow
Used with low
viscosity fluids
in high flow
applications
Chop-Check Pumps
n
n
Chop-Check pumps are often
mounted on rams to transfer fluids
Industrial Technologies -Process- Marketing Desk 02-2006
Checks are
mechanically
pushed onto
seats to control
fluid flow
Used in extrusion
applications with
medium to high
viscosity fluids
Pump Operation
Two-Ball Lower
End Pumps
Four-Ball Lower
End Pumps
Chop-Check
Lower End
Pumps
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Two-Ball Lower Operation
Upstroke As Piston
rises, fluid is pulled
into pump. Fluid
above ball check is
lifted out of pump
Downstroke The
lower ball seats to
close off the pump.
Fluid is displaced by
the plunger, passing
through the upper
check, to the outlet.
Upstroke
Downstroke
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Four-Ball Lower Operation
Upstroke: Fluid passes
the lower left ball check
into pump. Upper left
check is seated. The
upper right check rises
as fluid exits the pump.
The lower right check is
forced onto it’s seat.
Downstroke: The lower
left ball is seated. The
upper left ball rises as
fluid exits the pump.
The upper right check is
seated, while fluid is
drawn into the pump
past the lower right
check.
Upstroke
Downstroke
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Chop-Check Lower Operation
Upstroke: The lower
check rises and the
primer plate pulls fluid
into the pump. Fluid
exits the pump when the
upper check seats and
rises with the plunger.
Downstroke: The lower
check seats and the
upper check opens.
Fluid exits the pump
through the upper
check. Meanwhile, the
primer plate extends
into the fluid. It will pull
fluid into the pump
when the plunger rises.
Upstroke
Downstroke
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Pump Components
Packing
Assemblies
Tube & Plunger
Springs
Wet Cup
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Packing Assemblies
n
n
n
Packings are located in the
Body Casting and on the
Plunger Rod
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Seal movement
of plunger rod
“V” packings for
higher viscosity
fluids
Cup packings
for low viscosity
fluids
Tube-Plunger
n
n
Typical Plunger Rod (less
packings) and Tube
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The Plunger
moves within
the Tube
The Plunger
transfers fluid
from the inlet to
the pump’s
outlet
Springs
n
n
Coil Spring
Wave Spring
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n
Compensate for
normal wear of
the packings
caused by pump
usage
Wave Springs
offer excellent
service in hardduty use
Coil Springs are
used to pump
lighter viscosity
fluids
Wet-Cup
n
n
Typical Wet-Cup Assembly
Industrial Technologies -Process- Marketing Desk 02-2006
Use of Wet-Sol
in Wet-Cup
keeps Plunger
Rod wetted
This helps
prolong packing
life
Air Motors
10” & 12”
Air Motor
“N” Series Pump
2” & 3”
4”1/4 - 6” 8”
Air Motor
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Creates
reciprocating
motion to drive
pump
Aro manufactures
several styles of
Air Motors
n 200 Series
n “N” Series
n 4¼” 6” & 8”
n 10” & 12”
Air Motor Operation
200 Series Motors
“N” Series Motors
4¼” 6” & 8”
Motors
10” & 12” Motors
Industrial Technologies -Process- Marketing Desk 02-2006
“N” Series Motors
Upstroke: Air passes by
main piston, through
Spool A. This raises both
Spool B and main piston.
This continues until
piston passes upper air
port.
Downstroke: Air shifts
Spool A, exhausting air
below main piston and
Spool B. “B” shifts,
transferring air to top of
main piston. Piston will
continue downward until
passing lower air ports.
At that time “A” will shift
again, creating upstroke
conditions
Upstroke
Downstroke
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4¼”, 6” & 8” Air Motors
Upstroke: Air lifts main
piston until it contacts
pilot rod. Rod lifts valve
assembly until air charge
shifts valve. Air is now
directed to top of main
piston
Downstroke: Air pushes
down main piston until it
contacts pilot rod. Rod
pulls down valve
assembly until air charge
shifts valve. Air is now
directed to top of main
piston
Upstroke
Downstroke
Industrial Technologies -Process- Marketing Desk 02-2006
10” & 12” Air Motors
Upstroke: Air flows to
large end of valve
assembly, shifting valve
to the right. Air lifts
main piston until it
contacts pilot rod. When
rod cuts off air to valve,
it shifts. Air now passes
to top of main piston
Downstroke: Air pushes
down main piston until it
contacts pilot rod. When
rod falls, it supplies air
to large end of valve.
The valve then shifts,
directing air to bottom
of main piston, creating
an upstroke condition
Upstroke
Downstroke
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Fluid Handling Accessories
Fluid
Regulators
Control
Handles
Follower Plates
Mounting
Styles
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Fluid Regulators
n
n
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Downstream
Regulators are
used to control
fluid pressure
beyond the
regulator
Regulators can
be used to
smooth out
pulsation in a
pumping
system
Control Handles
n
n
Flow Gun for low
viscosity fluids
Metered Gun dispenses
set quantity of fluid
Grease Gun
Manual Extrusion Gun
for high viscosity fluids
Industrial Technologies -Process- Marketing Desk 02-2006
Used at the
final dispensing
point
Types of
Control Handles
include
–
–
–
–
Flow Guns
Grease Guns
Metered Guns
Extrusion
Guns
Follower Plates
n
n
n
Extrusion Pumps with Follower Plates for
5-gallon or 55-gallon drums
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Used to keep
extrusion pump
primed
Follower seals
drum from air
and other
contaminants
Follower pushes
material toward
pump inlet
Mounting Styles
Wall Mounts
Drum Covers
Floor Mounts
Lifts
Rams
Cart Mounts
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Wall Mounts
n
n
Wall mounted pumps located
next to fluid containers
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Used with light
to medium
viscosity fluids
Fluid is pumped
from drum
using a siphon
hose
Drum Covers
n
n
n
Typical oil pump mounted in the
bung of a drum cover
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Protect fluid
from outside
contaminants
Only the pump
down tube is
submerged
Commonly used
with oil or
grease pumps
Floor Mounts
n
n
n
Floor mounted
Extrusion Pump
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Used when fluid
is stored in a
bulk container
Gravity feeds
material into
pump
Locate pump as
close to
container as
possible
Lifts
n
n
n
Lift Mounted
Extrusion Pump
Industrial Technologies -Process- Marketing Desk 02-2006
An internal
cylinder lifts the
pump from an
empty container
Used with
medium to high
viscosity fluids
Eases change
over of empty
fluid containers
Rams
n
n
n
Two Post Ram package used
with high viscosity fluids
Industrial Technologies -Process- Marketing Desk 02-2006
Cylinders exert
downward force,
pushing pump
into fluid
Used with
medium to high
viscosity fluids
Single-Post or
Two-Post Rams
available
Cart Mounts
Allow a pump to be
moved to different
locations within a
work site
Pump often uses a
siphon hose to draw
material from a
nearby container
Cart-Mounted Pump Package
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Fluid Handling Technology
Ratio
Changing Ratio
Fluid
Characteristics
Packing Types
Types of Steel
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Industrial Technologies -Process- Marketing Desk 02-2006
Ratio
The difference in
effective size
between the air
motor piston and
the lower end
plunger rod
Higher ratio pumps
produce higher fluid
pressures
Ratio Calculation:
Ratio x Air Inlet
Pressure = Fluid
Outlet Pressure
Comparison of relative Air Motor Piston and
Plunger Rod sizes
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Changing Ratio
Increase Ratio by
changing Air Motors
Change Motor:
650483-343
Lower:
66300-G43
Motor:
4¼”
Ratio:
11:1
Delivery:
4.6-GPM
Change Lower:
650484-P43
Motor:
4¼”
Lower:
66301-P43
Ratio:
22:1
Delivery:
2.4-GPM
650683-343
66300-G43
6”
23:1
4.6-GPM
650485-P43
4¼”
66302-P43
30:1
1.5-GPM
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Increase Ratio by
changing lower
ends
Swap units within
inventory to meet
application needs
Fluid Characteristics
Viscosity
Specific Gravity
Abrasiveness
Corrosiveness
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Fluid Characteristics: Viscosity
n
n
n
Low viscosity fluids flow freely, while
high viscosity fluids do not
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Viscosity is the
measure of
fluid’s
resistance to
flow
Aro measures
viscosity in
terms of
“centipoise.”
Viscosity will
determine if a
lift or ram is
needed
Fluid Characteristics: Specific Gravity
n
Fluids with a lower Specific Gravity
will float on top of “heavier” fluids
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Specific Gravity
is the
relationship
between the
weight of a
volume of fluid
compared to
the same
volume of water
Fluid Characteristics: Abrasiveness
n
n
Plunger Rod with severe wear caused by pumping
abrasive fluids
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Abrasiveness is
the ability of a
fluid to wear
the surface it
contacts
Abrasive fluids
can
dramatically
shorten the life
span of a pump
lower end
Fluid Characteristics: Corrosiveness
n
n
Ball check distorted by
corrosion
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The ability of a
material to
chemically react
with other
materials
The
corrosiveness of
a material is
indicated by it’s
pH factor
Packing Types
U.H.M.W.-PE
(Ultra-High)
Teflon®
Thiokol Leather
Glass-filled
Teflon
Packings selection is based on
fluid compatibility and abrasion
resistance
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Packing Types: U.H.M.W.-PE
n
n
n
Stack of Ultra-High Molecular
Weight Polyethylene packings
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Ultra High
Molecular Weight
Polyethylene is a
good all purpose
packing
Common uses
are with ink,
acids and some
solvents
DO NOT use with
fluid
temperatures
over 170°F
(77°C)
Packing Types: Teflon
n
n
Stack of Teflon packings
Industrial Technologies -Process- Marketing Desk 02-2006
Chemically
compatible with
all fluids
Excellent
corrosion
resistance, but
poor abrasion
resistance
Packing Types: Thiokol Leather
n
n
Complete Spring/Packing
Assembly, with Leather and
U.H.M.W.-PE “v” packings
Industrial Technologies -Process- Marketing Desk 02-2006
Chemically
compatible with
all fluids
Excellent
corrosion
resistance, but
poor abrasion
resistance
Packing Types: Glass-Filled Teflon
n
n
Glass-Filled Teflon Packing
used in a 650132-C Pump
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Used with acids,
solvents and
corrosive
materials
Used in smaller,
200-series
pumps
Types of Steel
Hardened Carbon
Steel
304 or 316
Series Stainless
400 Series
Stainless
17-4 Series
Stainless
Tungsten
Carbide
Steel Treatment
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Hardened Carbon Steel
n
n
n
NM2304A-11 N-Series Pump
with Carbon Steel construction
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Excellent
abrasion
resistance
Not suitable for
water-borne
fluids
Can be hardchrome plated
for longer
service-life
304 or 316 Series Stainless
n
n
NM2304B-11 N-Series Pump
constructed of 316 Series Stainless
Industrial Technologies -Process- Marketing Desk 02-2006
Excellent
corrosion
resistance with
acids and
water-borne
fluids
Provides fair
abrasion
resistance
400 Series Stainless
n
n
650863-X4D-B pump with a
400-Series Stainless Plunger
Industrial Technologies -Process- Marketing Desk 02-2006
Provides good
abrasion
resistance
Can be heat
treated or hardchrome plated
for longer
service-life
17-4 Series Stainless
n
n
n
650484-X43 “Integrity” pumps
feature 17-4 Series Stainless
Plunger Rods
Industrial Technologies -Process- Marketing Desk 02-2006
Corrosion
resistance equal
to 304 SS
Good for waterborne fluids
Can be heat
treated or hardchrome plated
for longer
service-life
Tungsten Carbide
n
n
Tungsten Carbide Seat and
Stainless Ball Check Assembly
from an Integrity Lower End
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Powdered
metal produced
by adding
carbon
The hardness
and wear
resistance make
it excellent for
use in wear
items like ball
checks and
seats
Steel Treatment
Hard-Chrome
Plating
Passivation
Electropolish
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Hard-Chrome Plating
n
n
Many plunger rod assemblies are HardChrome Plated to improve abrasion resistance
Industrial Technologies -Process- Marketing Desk 02-2006
A thin
chromium coat
is deposited on
metal
components
Process
improves
protection
against
abrasion and
component
wear
Passivation
n
n
Industrial Technologies -Process- Marketing Desk 02-2006
Stainless Steel
parts are
dipped in nitric
acid to remove
iron deposits
left from the
machining
process
Process helps
prevent fluid
contamination
Electropolish
n
n
n
n
Industrial Technologies -Process- Marketing Desk 02-2006
Stainless parts
are dipped in an
electrically
stimulated bath
Removes surface
blemishes and
metal deposits
Process produces
a highly polished,
easily cleaned
surface
Helps prevent
fluid
contamination
Factors Effecting Pump Performance
Fluid Compatibility
Air Supply
Lubrication
Priming
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Industrial Technologies -Process- Marketing Desk 02-2006
Fluid Compatibility
n
n
Seal on Follower-Plate ruined by
fluid incompatibility
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An important
influence on
pump
performance
All pump parts
must be
compatible with
the fluid and
solvent used in
an application
to be successful
Air Supply
n
n
n
Filter-Regulator-Lubricator on
Piston Pump package
Industrial Technologies -Process- Marketing Desk 02-2006
Low air
pressure results
in inadequate
fluid pressure
from the pump
Excessive air
can result in
wear and
exaggerate the
hammering
effect of pump
cycling
Poor air quality
can lead to
pump failure
Lubrication
Filtered and
lubricated air will
allow the air motor
to run more
efficiently
Use SAE 90-wt, nondetergent oil, at no
more than 1-drop
per minute
(Aro Part #62274)
If an airline lubricator is needed,
use only a 90-wt Non-Detergent oil
Industrial Technologies -Process- Marketing Desk 02-2006
Priming
Packings can easily
be damaged during
the priming process
There is no fluid to
cool or lubricate the
packings, and they
quickly overheat
Cycle the pump
slowly when
priming, until fluid
has covered the
packing assembly
This model lower end features a
bleed valve to help purge air
during the priming process
Industrial Technologies -Process- Marketing Desk 02-2006
Piston Pump Selection
n
Industrial Technologies -Process- Marketing Desk 02-2006
Information
needed to
select a piston
pump for a
given
application
Pump Selection Factors
Fluid Parameters
Application Data
Outlet Plumbing
Information
Air Inlet
Pressure
Performance
Curves
Calculations
Selection Check
List
Industrial Technologies -Process- Marketing Desk 02-2006
Fluid Parameters
Fluid Viscosity
Fluid
Compatibility
Abrasiveness of
Fluid
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Fluid Viscosity
n
Viscosity of Common Products:
Water
1 Centipoise (cP)
Beer
3 cP
SAE 30 Motor Oil
200 cP
Ketchup
50,000 cP
Petroleum Jelly
64,000 cP
Tooth Paste
190,000 cP
Peanut Butter
250,000 cP
Generally, Chop-Check pumps are needed
for fluids with viscosities over 10,000
centipoise
Industrial Technologies -Process- Marketing Desk 02-2006
n
n
Viscosity is the
fluid’s
resistance to
flow
Piston pumps
are used with
low to high
viscosity fluids
Because they
create higher
fluid pressures,
they can move
higher viscosity
fluids
Fluid Compatibility
n
n
Industrial Technologies -Process- Marketing Desk 02-2006
Components
must be
compatible with
the fluid being
moved and the
solvent used to
flush the pump
Incompatibility
can result in
premature
pump failure
Abrasiveness of Fluid
n
n
Plunger Rod with severe wear caused by
pumping abrasive fluids
Piston Pump components are often
Hard-Chrome plated to reduce wear
caused by moving abrasive fluids
Industrial Technologies -Process- Marketing Desk 02-2006
Abrsiveness is
the ability of a
fluid to wear
the surface it
contacts
Abrasive fluids
can
dramatically
shorten the life
span of a pump
lower end
Application Data
Transfer
Extrusion
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Transfer Applications
650133 mounted in a small
tote tank
Industrial Technologies -Process- Marketing Desk 02-2006
Often involve
intermittent
pump operation
Factors to
consider:
n Viscosity
n Plumbing
Length
n Required Flow
n Air at Pump
Extrusion Applications
n
n
n
Industrial Technologies -Process- Marketing Desk 02-2006
Transfer of
medium to high
viscosity fluids
Extra
equipment
(rams, etc) is
often needed
Consider:
Viscosity
Required Flow
Dispensing
Method
Air at Pump
Outlet Plumbing Information
n
n
n
Industrial Technologies -Process- Marketing Desk 02-2006
Check if hard
plumbing or
tubing is used
Know the
length of
plumbing in the
system
Know the
internal
diameter of the
plumbing used
Air Inlet Pressure
n
n
Module/Air 2000 F-R-L used to treat air
feeding a piston pump application
Multiply Air Inlet Pressure by Pump Ratio
to determine Fluid Outlet Pressure
Industrial Technologies -Process- Marketing Desk 02-2006
Inadequate
inlet pressure
can result in
poor pump
performance
There must also
be adequate
pressure for
accessories like
rams or mixers
Performance Curves
n
n
n
Industrial Technologies -Process- Marketing Desk 02-2006
Use curves to
determine if a
pump can meet
the application
requirements
The X-Axis
indicates flow
The Y-Axis
indicates fluid
pressure
Check Fluid Flow
Example Calculation:
Back Pressure=800
Air=90 psi
Flow=1.8 gpm
Plot 800 psi on yaxis until it meets
the 90 psi line. Plot
down to the x-axis
(flow)
In this example, the
pump is capable of
delivering around
1.8-gpm
1.8
Industrial Technologies -Process- Marketing Desk 02-2006
Check Air Consumption
Example Calculation:
Back Pressure=800
Air=90 psi
Flow=1.8 gpm
Plot 1.8-gpm on the
x-axis. Move up
until you intersect
the 90-psi curve,
then plot over to
the right axis
The pump will use
about 20SCFM of air
in this application
1.8
Industrial Technologies -Process- Marketing Desk 02-2006
Check Cycle Rate
Example Calculation:
Back Pressure=800
Air=90 psi
Flow=1.8 gpm
Plot 1.8-gpm on the
x-axis. Move up
until you intersect
the top line of the
chart.
15
To deliver 1.8-gpm,
the pump will cycle
roughly 15-times
per minute
1.8
Industrial Technologies -Process- Marketing Desk 02-2006
Calculating Pressure Drop (ΔP)
n
P =  x Q x L x .000245  (i.d.)4
 = fluid viscosity
Q = delivery required gpm
L = outlet plumbing length
.000245 = equation constant
(i.d.)4 = plumbing internal diameter to
the fourth power
P = 15,000 x 3.0 x 55 x .000245  1
 = 15,000 centipoise (cP)
Q = 3.0-gpm
L = 55 ft.
.000245 = equation constant
(i.d.)4 = 1”
P = 606.375-psi
The pump must develop roughly 606.375-psi
of fluid pressure to complete the application
Industrial Technologies -Process- Marketing Desk 02-2006
n
n
Rough
calculation of
pressure pump
must overcome
within plumbing
to transfer fluid
This calculation
is an estimate
Call ARO if you
have questions
Calculating Ratio
n
Required Ratio = P ÷ PSI
P= pressure drop within plumbing
system
PSI = air pressure available at pump
n
Required Ratio = 606.375 ÷ 85 = 7.1
P = 606.375-psi (from previous slide)
PSI = 85-pounds air pressure at pump
Ratio = 7.1:1 (round up to 8:1)
At least a 8:1 ratio pump will be needed for
this application.
Now select a pump model based flow
requirements and fluid compatibility
Industrial Technologies -Process- Marketing Desk 02-2006
n
Calculating the
ratio needed for
a given
application
Divide Pressure
Drop (ΔP) by
the air pressure
available
Again, if you
have questions,
all ARO
Pump Selection Checklist
n
Fluid Parameters
Required Flow:__________
Fluid Viscosity:__________
Plumbing Data
Internal Diameter:_______
Piping Length:__________
Inlet Piping Length:______
Air Inlet
Pressure @ Pump:_______
Application Data
Continuous Duty:________
Intermittent Use:________
If you feel uncertain about your pump selection, call
Aro for help!
Industrial Technologies -Process- Marketing Desk 02-2006
n
Basic data to
make an initial
pump selection
Use this data,
the ARO fluid
compatibility
guide and the
pressure drop
calculations to
make an initial
pump selection