UNIBLOC -PD

PUMP ENGINEERING MANUAL

1701 Spinks Drive SE Marietta, GA 30067-8925 USA (770) 218-8900 fax (770) 218-8442 www.info@flowtechdiv.com www.flowtechdiv.com

TECHNICAL MANUAL NO. MANUAL3G.DOC

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INTRODUCTION
The UNIBLOC line of positive displacement pumps are manufactured by TEKNOFLOW Inc./Flowtech Div. located in Marietta, GA USA. The pumps have been designed mainly for the sanitary industries, but are suitable for many industrial applications as well. The information enclosed in this engineering manual will give fundamental information to properly select a UNIBLOC pump. It has also been produced in an effort to educate anyone who may be involved in with the selection and use of a positive displacement pump. If for any reason the information presented is not clear or additional assistance is needed please contact Flowtech or one of our distributors.

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CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Page Fluid Flow Fundamentals......................................................... 4 Fluid Flow in a System ............................................................ 6 Rotary Lobe Pump Fundamentals............................................ 12 Shaft Seals................................................................................ 15 Safety Equipment ..................................................................... 17 Motor and Drive Fundamentals ............................................... 20 LABTOP Integrated Pump Systems........................................ 21 UNIBLOC Performance Data ................................................. 22 Pump Selection Procedure ....................................................... 23 Pipe Friction Loss Chart .......................................................... 25 Pump Performance Charts........................................................ 26 UNIBLOC Dimensions........................................................... 48 Chemical Resistance Information ............................................ 56 Pump Application Data Sheet .................................................. 57

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1. FLUID FLOW FUNDAMENTALS
The following properties and concepts are useful when analyzing a fluid that is going to be handled with a UNIBLOC pump. DENSITY is mass per unit volume and changes inversely with temperature, i.e. density decreases as temperature increases. SI units: Standard units: Density (kg/ m3) = mass (kg) / volume (m3) Density (lbs./ ft3) = mass (lbs.) / volume (ft3)

SPECIFIC GRAVITY, S.G., is the ratio of a fluids density to the density of water. SI units: Standard units: S.G. = Fluid Density (kg/ m3) / 1000 (kg/ m3) S.G. = Fluid Density (lbs./ ft3) / 62.4 (lbs./ ft3)

TEMPERATURE is a measure of a fluids internal energy. SI units: Standard units:

0 0

C F

ABSOLUTE VISCOSITY is a measure of the fluids resistance to a shear force. It is determined by measuring the force needed to rotate a spindle suspended in the fluid. It decreases as temperature increases. SI units: Standard units: kg/ms cPs

KINEMATIC VISCOSITY is a measure of the time it takes a fluid to travel, by the force of gravity, through a vertical tube over a certain distance. SI units: Standard units: (lbs./ ft3) Kinematic Viscosity (m2/s) = Absolute Viscosity (kg/ms) / Density (kg/ m3) Kinematic Viscosity (ft/s) = Absolute Viscosity (cPs) / Density

STATIC HEAD is the pressure at a point in a fluid at rest. FRICTION HEAD is the loss in pressure or energy due to friction. PRESSURE HEAD is pressure (psig or bar) expressed as head (ft. or meters). DISCHARGE HEAD is the pressure at a pumps outlet.
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TOTAL HEAD is the pressure difference between a pumps inlet and outlet. SUCTION HEAD is the inlet pressure of a pump when above atmospheric. SUCTION LIFT is the inlet pressure of a pump when below atmospheric. FLUID TYPES Newtonian Fluids exhibit no change in viscosity as the shear rate, velocity, changes. They include such fluids as water, mineral oil, and syrups.

Non-Newtonian Fluids include several types whose viscosities vary as the shear rate, velocity, changes. Plastic Fluids require an initial force, or yield point, at which they will begin to flow. Pseudo Plastic Fluids decrease rapidly in viscosity as the shear rate, velocity, increases. Their viscosity is independent of time.

Thixotropic Fluids decrease in viscosity, with a constant shear rate, over a period of time. They may also have a yield point and show pseudo-plastic characteristics. They include paints, inks, gels, lotions, and shampoo.

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Dilatent Fluids increase in viscosity as shear rate increases and is independent of time. They include clays, oxides, and crystalline materials.

2.

FLUID FLOW IN A SYSTEM

As a fluid moves through a system of tanks, pipes, equipment, valves, and fittings the energy in the system is conserved, but changes form. The types of energy are described below. KINETIC ENERGY is due to the motion of a fluid. = 1/2 x mass x velocity2

POTENTIAL ENERGY is due to the height of a fluid. =height x mass x accel. of gravity

PRESSURE ENERGY is internal energy of a fluid which could do work. MECHANICAL ENERGY is put into the fluid by a pump.

FRICTIONAL LOSSES represents the energy lost due to friction as the liquid moves through straight piping, elbows, reductions, valves, strainers, heat exchangers and other equipment.

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The diagram below illustrates how energy changes to the different forms as the fluid moves through the system.

PA A

The starting pressure may be constant atmospheric pressure if the system is open or if it is closed, the pressure inside the supply vessel. At the beginning point there is pressure energy, PA, and potential energy due to the elevation of the supply vessel above the pump.

A-B Moving from A to B the potential energy changes to pressure energy. B-C Potential energy is further changed to pressure energy. However, some of the pressure energy is lost due to friction. C-D Additional pressure energy is lost due to pump frictional losses. Then mechanical energy is added by the pump and pressure energy rises quickly. D-E As the fluid moves to a higher elevation the pressure energy is reduced in the form of frictional losses and the remainder changes to potential energy.

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E-F The remaining pressure energy is changed to potential energy. An analysis of the fluids energy at the inlet must be performed to insure that the fluid is able to enter the pump and to also do so with enough energy to prevent cavitations. The energy available in the fluid in a system is determined by subtracting the fluids vapor pressure from the pressure at the inlet. This Net Inlet Pressure Available (NIPA) may be converted to head to give Net Positive Suction Head Available (NPSHA). The NPSHA must be higher than the Net Positive Suction Head Required (NPSHR).
INLET PRESSURE FLUID VAPOR PRESSURE

NIPA

NIPR

The NPSHR is different for each pump size and is also dependent on each pumps components and the operating conditions of the system. It can only be determined by testing a pump. If the NPSHA is less than the NPSHR the fluid will not enter the pump. If it is high enough to allow fluid into the pump, but less than the fluids vapor pressure then cavitations will occur, resulting in noisy pump operation, vibration, deterioration of the fluid, pump damage, and damage to other system components. The following graphs illustrate under what typical conditions the NPSH values may change. The shade area indicates the safe operating range.

When viscosity is increased the NPSHR and NPSHA is reduced, as well as the safe operating area.

Increasing the pump size decreases the NPSHR and increases the safe operating area.

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Reducing the inlet pipe length, fittings, valves, and elbows and increasing the inlet pipe diameter reduces friction losses and increases the NPSHA, as well as the safe operating area.

Increasing the inlet pressure by elevating the feed vessel or pressurizing it increases the NPSHA and the safe operating area.

Reducing the pump speed decreases the output capacity and moves the running point to a larger safe operating range.

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The illustration above shows an optimized system in which the inlet pressure required has been reduced. The short, large diameter inlet pipe reduces friction from point B to C, which is very important when highly viscous fluids are being pumped. In such cases a pump with a rectangular inlet, which increases the inlet area, is also crucial to proper pump operation.

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The system shown above illustrates the ability of the UNIBLOC pumps to lift liquids. The surface of the liquid in the supply tank at left is located below the pump inlet and thus there is no energy to push the liquid into the pump. Furthermore, an analysis of the total pressure loss from the tank to the pump inlet will yield a negative Net Inlet Pressure Available (NIPA). As a result, a vacuum greater than the negative NIPA must be created in the supply line (B-C) in order to lift the liquid and fill the pump. Priming the pump in this manner may be accomplished by pressurizing the tank such that the negative NIPA is reduced or a positive NIPA is created. The pump may also be run dry to create this vacuum. The standard Class C rotors, or special low clearance rotors (i.e. polymer rotors), and specific shaft seals must be used in this case. The priming ability can be improved if the pump has some fluid in it. This creates a film of liquid between the rotors and the housing, filling the clearances and making the pump more efficient. The chart at left shows how the pumps ability to create a low pressure at the inlet improves the more liquid it initially has inside the housing.

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3. ROTARY LOBE FUNDAMENTALS

The UNIBLOC pump is a rotary lobe pump that moves fluid by creating a low pressure cavity at the inlet side which draws fluid into the pump. The lobes, or rotors, then close the cavity as they turn in the housing. As the rotors mesh at the outlet port the fluid is squeezed out of the pump.

The UNIBLOC pump delivers a constant volume over time, with very small pulsations. Other types of positive displacement pumps, however, have great variations in the discharge flow which result in pulsations with large amplitudes as found with peristaltic pumps or high frequency pulsations as is common with gear or multi-lobe pumps.

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PERISTALTIC PUMPS

GEARPUMPS

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The shape of the rotors in the UNIBLOC pump has been designed to maximize its efficiency. The long arc shape of the rotors makes a long seal as it sweeps around the rotor housing cavity minimizing slip. SLIP, or backflow, in a rotary lobe pump is a condition in which liquid moves backwards from the high pressure, outlet, side of the pump to the low pressure, inlet, side. To prevent galling and wear, the rotors have been designed such that they do not touch each other, the housing, or the cover. A thin space is thus created through which fluid may move. This movement of fluid is called slip and is an indication of the efficiency of a pump. A pump with a higher rate of slip will have less output.

The slip rate increases very quickly as the clearances increases. It is proportional to the clearance cubed (C3).

Slip decreases quickly as the fluid viscosity increases.

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Slip increases as pressure increases.

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The energy level (temperature) of the liquid that remains inside the pump increases as slip increases.

The fluid that squeezes through these thin spaces is subject to high shear stress and may damage the product if it is sensitive to such a stress. However, such degradation of the product can be minimized o or eliminated with the proper pump size and speed. The UNIBLOC pumps may also be used to meter low viscosity liquids if conditions are suitable. At low pressures and high speed the percentage of slip is low compared to the actual amount that exits the pump. Therefore, at a constant speed the pump will deliver a constant capacity which can be determined by measuring the number of revolutions the pump shaft turns. The system should de designed so that its pressure is also constant, as shown below.

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4. SHAFT SEAL OPTIONS

SINGLE MECHANICAL SEAL Available for all pump sizes. Operating speed up to 1500 rpm. Maximum viscosity 5,000-100,000 cPs. Available seal materials are stainless steel, carbon, and silicone carbide. Sanitary, high speed, high pressure, can run dry for very short periods, long life.

FLUSHED SINGLE MECHANICAL SEAL Available for all pump sizes, except the 200, 250, and 275 . Operating speed up to 1500 rpm. Maximum viscosity 5,000-100,000 cPs. Available seal materials are stainless steel, carbon, and silicone carbide. Sanitary, high speed, high pressure, can run dry, long life.

DOUBLE MECHANICAL SEAL Available for all pump sizes, except the 200, 250 and 275. Operating speed up to 1500 rpm. Maximum viscosity 5,000100,000 cPs. Available seal materials are stainless steel, carbon, and silicone carbide. Sanitary, high speed, high pressure, can run dry, long life.

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SINGLE O-RING SEAL Available for all pump sizes. Operating speed up to 300 rpm. Maximum viscosity 500,000-1,000,000 cPs depending on the product type. Inexpensive, low speed, moderate pressure, easy to replace, works well with sticky liquids, can not run dry.

DOUBLE O-RING SEAL Available for all pump sizes, except 200, 250, and 275. Operating speed up to 300 rpm. Maximum viscosity 500,000-1,000,000 cPs depending on the product type. Inexpensive, low speed, moderate pressure, easy to replace, works well with sticky liquids, can run dry for short periods.

DOUBLE O-LIPTM SEAL Available for all pump sizes, except 200, 250, and 275. Operating speed up to 500 rpm. Maximum viscosity 100,000-1,000,000 cPs depending on the product type. Moderate speed, moderate pressure, very durable, easy to replace, works well with sticky liquids, can run dry, long life.

FLUSHED DOUBLE O-LIPTM SEAL Available for all pump sizes, except 200, 250, and 275. Operating speed up to 500 rpm. Maximum viscosity 100,000-1,000,000 cPs depending on the product type. Moderate speed, moderate pressure, very durable, easy to replace, works well with sticky liquids, can run dry for long periods, long life.

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FLUSHED SEALS Seals provided with flush housings must be fitted with flushing systems that will cool and lubricate them, otherwise the seals will NOT OPERATE CORRECTLY. The flushing system also provides a barrier of protection between the environment and the pumped media. The o-ring and double o-lip seals may be filled with a lubricating grease that is approved for contact with the pumped media instead of using the following flushing systems. The piping arrangements and system components are recommended for satisfactory operation of the seals and to insure containment of the pumped liquid.
FLUSH OUTLET CONTROL VALVE (i.e diaphragm valve) PRESSURE GAUGE

FLUSH INLET FLUSH OUTLET SHUT OFF VALVE CHECK VALVE CONTROL VALVE (i.e diaphragm valve)

PRESSURE GAUGE

CHECK VALVE

SHUT OFF VALVE FLUSH INLET

HORIZONTAL PUMP PORTS (recommended piping arrangement)

VERTICAL PUMP PORTS (recommended piping arrangement)

FLUSH OUTLET FLUSH OUTLET CONTROL VALVE (i.e diaphragm valve) PRESSURE GAUGE CONTROL VALVE (i.e diaphragm valve) PRESSURE GAUGE

The illustrations at left show alternative methods of arranging the flushing system and its components. Although not ideal, they are adequate for less critical pump applications.

CHECK VALVE SHUT OFF VALVE FLUSH INLET

CHECK VALVE SHUT OFF VALVE FLUSH INLET

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5. SAFETY EQUIPMENT
RELIEF VALVE

Positive displacement pumps can develop pressures in excess of safe operating parameters if a restriction or blockage occurs in the discharge line. An external bypass line with a relief valve, as shown at left, is highly recommended.

RELIEF VALVE

If such an arrangement is not practical a cover with a relief valve, shown at left, is available for all pump sizes except the 200, 250, and 275. Its bypass flow capacity, however, is much smaller than an external line and therefore the fluid that re-circulates through the relief valve will heat up very quickly. Also, once the valve opening pressure is reached the bypass and system pressures will increase more rapidly than if an external line is used.

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PRESSURE SENSING DEVICES Dial pressure and/or vacuum gauges installed at the inlet and outlet of the pump will provide a quick visual indication of the status of the system. A pressure switch at the pump outlet is connected to the pumps electric motor and will stop the motor in case the system pressure exceeds the set point of the switch. Pressure transducers can be coupled to a variable frequency drive which can modulate the speed of the motor and the pump thereby controlling the system pressure. STRAINERS Depending on their size, particles in a product can damage a pump. Open systems may also be at risk for the introduction of foreign objects. A properly selected strainer mounted on the pumps inlet side will eliminate any materials that could interfere with safe operation. Caution must be used, however, since the strainers can fill with debris restricting or blocking flow to the pump. ISOLATION VALVES Shut off valves mounted on the inlet and outlet sides of the pump will isolate it from the system. The pump can then be serviced or removed without having to empty the system.
PRESSURE RELIEF VALVE PRESSURE GAUGE

FLOW

FLOW

STRAINER SHUT OFF VALVE

CHECK VALVES Check valves should be used to prevent backflow since the pumps, when stopped, will allow some liquid and air to flow through it.

CHECK VALVE

CHECK VALVE

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6. MOTOR AND DRIVE FUNDAMENTALS

The following section has been provided to give some brief guidelines when selecting a motor to drive the UNIBLOC pumps. When making a motor selection the environment in which it will be operating must be analyzed as its use may be restricted by government codes. The pumps typically operate below the base speeds of most motors and therefore require a speed reducer in conjunction with the motor. There are many types of arrangements to drive the pumps, but a direct drive type, shown below, is most recommended.

If a belt drive is to be used, a separate bearing support, as shown below, should be used to prevent damage to the pump.

Drives may be divided into two groups, constant speed and variable speed. Constant speed drives are most functional when achieving an exact flow is not critical. They can not compensate for changes in system conditions. If the design capacity of the system is an absolute minimum then the next higher motor speed should be selected. In such a case, the pumps output capacity will increase, but so will the system pressure drop and required power. The system should be reevaluated to insure that the pump will operate within its design parameters and that the motor can supply the additional power. Constant speed drives with belts offer some flexibility to change operating speeds by changing the size of the pulley or sheave. Variable speed drives are used when the pumps output capacity must be exact. They are able to compensate for system changes. Mechanical variable speed drives use belt or friction disc technology to vary the speed of the motor. Hydraulic drives provide high torque capabilities over broad speed ranges. Pneumatic motors provide a low cost variable speed alternative, but have speed adjustment limitations. However, they are particularly useful when explosion proof requirements must be met. Electronic variable speed drives vary the frequency supplied to the AC motor to change its speed. They can provide a very wide and accurate range of operating speeds. However, attention must be paid to torque requirements since the motor supplied torque changes with speed. An AC motor produces the largest torque at its base frequency, normally 60 or 50 Hz. As frequency, or speed, decreases, its output torque and power decreases linearly. At low speeds the motor may require additional cooling or a motor with a higher power rating may have to be used. When the speed goes above the base frequency, power remains constant, but torque decreases slowly.
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7. LABTOP INTEGRATED PUMP SYSTEMS
Flowtech provides a program of complete pump and drive packages for laboratory scale applications to small scale manufacturing. They are compact, plug in the wall, ready to use units incorporating variable speed control, gearmotor, and the Flowtech UNIBLOC pumps. Capacity ranges from 0.05 GPM (0.2 LPM) to 50 GPM (189 LPM) are available. These small units have become especially popular in many laboratories. They are able to perform at pressures exceeding 45 psig (3 bar) and as a result have replaced many peristaltic pumps. The integrated pump systems may be operated at the unit with a NEMA 4 keypad or from another location by using the speed controllers remote functions. These units provide flexibility in any scale up program and once their capacity has been exceeded, the larger UNIBLOC pumps can then be incorporated. Please contact Flowtech for more information.

LA B TO P
2

LA B TO P

LA B TO P

Capacity to 6.2 gpm (24 lpm)

LA B TO P
2

LA B TO P

300 350

LA B TO P

300 350

Capacity to 18 gpm (68 lpm)

LA B TO P

400 450

Capacity to 50 gpm (189 lpm)

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8. PUMP PERFORMANCE DATA
The data contained in the capacity charts is representative of tests that have been performed on many pumps over several years. Due to variations in system conditions and normal manufacture some deviation may occur. For this reason, all UNIBLOC pumps are factory tested to insure that each pump will meet or exceed the application parameters. A test certificate is sent with each pump that leaves the factory. The following table should be used as a first estimate of the pump model needed. The capacity listed is the highest that a particular size is able to produce. However, the charts must be consulted to verify that a pump model will be able to safely accommodate a certain viscosity, pressure, speed, and capacity.

UNIBLOC MODEL 200 250 275 300 350 400 450 500 550 575 600 650 675

STAND. CONN. SIZE 1/2 or 3/4 3/4 1 1 1.5 1.5 2 2.5 3 4 4 or 6 6 8

CAPACITY gallons/100 rev. (liters/100 rev.) 0 8 (3 1) 1.1 (4.2) 1.4 (5.3) 2.8 (10.6) 4.0 (15.1) 8.1 (30.7) 10.9 (41.3) 22.1 (83.6) 28.5 (108) 36.1 (137) 52.2 (198) 79.6 (301) 107 (405)

MAX. SPEED (rpm) 1000 1000 1000 1000 1000 900 900 800 800 700 600 500 400

MAX. OPERATING PRESSURE psig (bar) 100 (6 9) 100 (6.9) 80 (5.5) 200 (13.8) 175 (12.1) 250 (17.2) 175 (12.1) 300 (20.7) 210 (14.5) 150 (10.3) 300 (20.7) 275 (19.0) 175 (12.1)

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9. PUMP SELECTION PROCEDUE
In making an initial selection, the following liquid and system parameters must be determined. The information may then be used to select the proper pump size using the charts in Section 8. - differential pressure between the the pump inlet and discharge - liquid viscosity - liquid temperature - capacity Once this initial selection is made, other liquid characteristics such as whether it is Newtonian or nonNewtonian and whether it is shear or speed sensitive may be necessary to make the final selection with a Flowtech representative. To illustrate the proper use of the charts, the following parameters will be used. Differential Pressure: 40 psig Viscosity: 10 cPs Capacity: 20 GPM
3

3 5

The chart shown at right, found in Section 7, is used to find the pump operating speed and the required horsepower. Beginning with viscosity at point 1, find the 7 intersection with the applications differential pressure at point 2. A line drawn parallel to the charts pressure gives the viscosity adjusted pressure line 3-3. This line intersects the capacity at point 4. A straight line down from this point will intersect the speed axis at point 5, which gives an operating speed of 770 rpm. The same line intersects the Fluid Power graph at point 6, or 0.5 hp. It also intersects the Viscosity Power graph at point 7, or 1.4 hp. Their sum is 1.9 hp and is the minimum power at the pumps drive shaft required to operate under these conditions. The power requirement can also be expressed as torque, which is defined as the moment of forces required to turn a pumps drive shaft.

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Torque = F (force) x L (length) The torque is calculated using the following formulas. T (in-lbs.) = hp x 5250 rpm x 12 T (Nm) = 0.746 x hp x 9550 rpm This torque must not exceed the torque limit of the pump shaft shown in the table below. If it does, then a larger pump must be selected.

UNIBLOC MODEL 200 250 275 300 350 400 450 500 550 575 600 650 675

MAX. PUMP DRIVE SHAFT TORQUE AT MAX. DESIGN PRESSURE in-lbs. (Nm) 248 (28) 212 (24) 212 (24) 841 (95) 743 (84) 2,753 (311) 2,700 (305) 13,135 (1484) 12,612 (1425) 10,170 (1149) 33,633 (3800) 30,438 (3439) 22,074 (2494)

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PIPE SIZE/TYPE
2" 3" 4"

CAPACITY (gpm)

10

E UL RY A D E 0 IT N CH 4 1.5" SA 1" S

20 30

50 6"

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100

200 300 400 500

8"

10. PIPE FRICTION LOSS CHART

PRESSURE DROP (psi)

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1 10

50

100

500 1,000

5,000 10,000

50,000 100,000

VISCOSITY (cps)

2 3 4 5 5 7 10

10

20 30 40 50 70 100 200

15 20

Example: 1. Given 20 cps 2. Move up to pipe size/type (3") 3. Left to capacity (100 gpm) 4. Down to pipe length (200 ft.) 5. Right to give pressure drop (5 psi)

30 40 50

0 10

0 20

PIPE LENGTH (feet)

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G H
UNIBLOC MODEL

L
200-0 200 250

J C
275

M F B J
300
UNIBLOC MODEL

49
G H
400 450 350

M D B
550 500

L A

C
575

575

M F

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50

UNIBLOC MODEL

600

650

675

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300

350

400

450

500

550

575

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600

650 2

675

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3001

3501

4001

4501

5001

5501

5751

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2 2 1

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600

650

675

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500

550

575

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650

675

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13. CHEMICAL RESISTANCE INFORMATION

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14.
PREPARED FOR Fluid Name or Type Fluid Viscosity (cps) Environment Temperature Max. Particle Size % Solids Operating Capacity Inlet Pressure Outlet Pressure Supply Pipe Length Supply Pipe Size Discharge Pipe Length Discharge Pipe Size Other Fluid Characteristics

PUMP APPLICATION DATA SHEET

Product Temp. Cleaning Temp. Type of Cleanser Seal Type Required Seal Material Required Horizontal or Vertical Ports

B
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