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CONTROLLING POSITIVE DISPLACEMENT PUMPS

© Walter ********, P. Eng., 2000 May 20. walter(at)********(dot)ca

First published in Hydrocarbon Processing , May 1996.


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INTRODUCTION. The positive displacement pump is in some ways an even simpler device to control than the centrifugal pump discussed previously¹. It has the same function, namely to provide the pressure necessary to move a liquid at the desired rate from point A to point B of the process. Figure 2-1 shows a 'generic' process with a positive displacement pump (in this case a gear pump) connected to deliver liquid from A to B.
There is a great variety of positive displacement pumps. They are divided into two broad categories: Rotary and reciprocating. From the controls point of view, however, they are all similar. Their characteristic curve is so simple that it is rarely drawn. It is essentially a straight vertical line, as shown in Figure 2-2. (For some reason PD pump curves are usually shown with the pressure and flow axis exchanged. I will not follow that convention in this article.) All are constant flow machines whose pressure rises to whatever value is necessary to put out the flow appropriate to the pump speed. If the discharge is blocked, the pressure will rise until something yields -- preferably a relief valve. Close examination of the curve shows a slight counter clockwise rotation. This is due to internal leakage.
[IMG]http://www.********.ca/ce2_pdp/2-2.jpg[/IMG]For positive displacement pumps the major cause of leakage is the small amount of reverse flow that occurs before a check valve closes and possibly past the check valve after it is closed. Leakage past the piston is negligible. Diaphragm operated PD pumps have no cylinder to leak past. Rotating PD pumps, such as gear pumps or progressing cavity pumps have internal clearances which permit a small reverse flow, called "slip" or "blowby". There is another reason why the curve may rotate to slightly lower flows at higher discharge pressures: The driver may slow down as the load increases. None of these have a significant affect in curving the slope of the characteristic enough that this slope can be used for control. For most practical purposes the slope is vertical. The system curve of the process is also shown on Figure 2-2. Its intersection with the pump characteristic defines the operating point.
As always, the process controls engineer has the responsibility of matching the capacity of a specific piece of equipment to the demands of the process at every instant in time. Rarely does the actual system curve fall exactly on the one used for design and selection. As with any two port device, there are three locations in which a control valve can be placed: On the discharge, on the suction, and as a recycle valve.
[IMG]http://www.********.ca/ce2_pdp/2-3.jpg[/IMG]DISCHARGE THROTTLING. Discharge throttling does not work! Looking at the process from the point of view of the pump, discharge throttling rotates the system curve counter clockwise so that the modified system curve intersects the pump curve higher up. The additional pressure is dropped through the valve so that the pressure and flow to the process is (almost) exactly the same as before. The "almost" is due the small increase in internal leakage that results in an equally small reduction in flow. An increased wear rate and a shortening of the life of the machine are the only results of this approach. If the pump is seen from the point of view of the process so that the valve is considered part of the pump, the same result is obtained. To obtain a modified pump characteristic curve, the pump curve must be rotated clockwise around the intersection with the pressure axis. The problem is that this hypothetical intersection is far off the top of the operating range. It is the point where the pressure is so high that 100% internal leakage occurs. The machine would self-destruct from excess pressure if one were stubborn enough to attempt to find this point. The rotation of the curve can still be performed on paper and it amounts to a slight shift to the left. Shown in Figure 2-3, it is virtually identical to the unmodified curve. To cut a long story short, you can't control a PD pump with discharge throttling.

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SUCTION THROTTLING. Suction throttling has the same effect on the characteristic curve as discharge throttling and doesn't work either. PD pumps have a Net Positive Suction Head Required (NPSHR) just as centrifugal pumps do. In fact their requirements are even more stringent. Therefore restrictions and pressure drops in the suction lines must be similarly avoided.


RECYCLE CONTROL. This leaves recycle control as the only means of using a valve to control a PD pump. The valve is installed in a line teeing off from the discharge and leading back to the source of the liquid, possibly a surge tank. It must be fail open , of course. Figure 2-5 shows its effects on the characteristic curves. Viewing the process from the point of view of the pump, its effect is to rotate the system curve clockwise around its intersection with the pressure axis. Note that the little "tail" at the bottom left of the modified system curve is due to the flow through the recycle valve before the discharge check valve has opened. The flow through the pump is essentially as before but the pressure to the process has been reduced. Process flow will, of course, also be reduced by the amount flowing through the recycle line.
[IMG]http://www.********.ca/ce2_pdp/2-5.jpg[/IMG]Viewing the pump from the process gives a different perspective on the same phenomenon. This time it is the pump curve that is rotated counter clockwise around its intersection with the flow axis. This modified pump curve gives the effect of greatly increased internal leakage. From the point of view of the process, this is exactly what is happening. Note that I have not used the same operating points in Figure 2-3 as I did in Figure 2-5. It is simply impossible to show any significant reduction in flow on a curve representing the effects of discharge throttling.
Recycle control is an efficient method of control for PD pumps. Since the flow rate is essentially constant, the power requirement is roughly proportional to discharge pressure. Since the effect of recycle is to drop the discharge pressure, it results in significant reductions in power requirement. Nevertheless there is still wasted power in proportion to discharge pressure times recycle flow.
Recycle valves experience rather severe service if the pressure drop is high. Cavitation will destroy them if they are not appropriately selected. Two approaches exist to deal with this problem: The first solution is to drop the pressure in many small stages through the use of many twists and turns in the valve trim. The second is to tolerate the resulting cavitation by shooting the liquid as a jet through a small hole in the middle of a disk. The jet then blasts directly into the discharge piping. The line diameter is often increased immediately downstream of the valve and the wall thickness is also increased. In this way the jet cavitates down the middle of the pipe. It makes a terrific racket.
In either case it may be necessary to put a fixed restriction downstream of the valve. It should be sized so that the ratio of the high to intermediate pressure is the same as the ratio of intermediate to low pressure. Keep in mind that the restriction will reduce the rangeability of the valve by making it act like a quick opening valve. This is because the restriction becomes the dominant factor in the line once the valve is about half way open. From that point on, the valve has little control.
Recycle lines for PD pumps should be run back to the suction vessel. This allows any entrained bubbles to escape. If they do not, they can build up to the point where pump capacity is impaired. It may even vapour lock.


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