INTRODUCTION TO PROJECT

CHAPTER1

1.1

OVERVIEW

High pressure triplex plunger pump is the device through which we can generate high pressure water beam using the plunger system. Nowadays many types of plunger pumps are there in the industries like singular plunger pumps, duplex plunger pumps and triplex plunger pumps. They can be operated automatically using different types of technologies like using automation and PLC. [1]

There are many pump designs that fall into the positive displacement category but, for the most part, they can be nicely divided into two basic groups. The reciprocating group operates via pistons, plungers, or diaphragms while rotary pumps use gears, lobes, screws, vanes, and peristaltic action. Their common design thread is that energy is added to the pumped fluid only periodically where, in dynamic pumps, it is added continuously. [1]

A plunger pump is a type of positive displacement pump where the high-pressure seal is stationary and a smooth cylindrical plunger slides though the seal. This makes them different from piston pumps and allows them to be used at high pressures. This type of pump is often used to transfer municipal and industrial sewage. [1]

Plunger pumps are reciprocating pumps that use a plunger to move media through a cylindrical chamber. The plunger or piston is actuated by a steam powered, pneumatic, hydraulic, or electric drive. Plunger pumps are also called well service pumps, high pressure pumps, or high viscosity pumps. Plunger pumps use a cylindrical mechanism to create a reciprocating motion along an axis, which then builds pressure in a cylinder or working barrel to force gas or fluid through the pump. The pressure in the chamber actuates the valves at both the suction and discharge

points. Plunger pumps are used in applications that could range from 70 to 2070 bars. The volume of the fluid discharged is equal to the area of the plunger multiplied by its stroke length. Overall capacity of the plunger pumps can be calculated with the area of the plunger, the stroke length, and the number of plungers and the speed of the drive. The power needed from the drive is proportional to the capacity of the pump. [1]

Seals are an integral part of plunger pumps to separate the power fluid from the media that is being pumped. A stuffing box or packing is used to seal the joint between the vessel where the media is transferred and the plunger. A stuffing box may be composed of bushings, packing or seal rings, and a gland. The reciprocating plunger directly displaces the process fluid. As the plunger and plunger seal are wetted, high operational safety is achieved by optimal selection of plunger material and seal design. [1]

Plunger pumps have a number of components that require the choice of materials based upon wear considerations and contact with the media type. Components may have a number of materials used including bronze, brass, steel, stainless steel, iron, nickel alloy, or other material. For example, piston pumps that function in general service or oil service applications may have an iron cylinder and piston with a steel piston rod. The plunger, discharge valves, and suction valves come in contact with the media type transferred; material choices should be considered based on the fluid transferred. In power applications where continuous duty plunger pumps are needed, solid ceramic plungers may be used when in contact with water and oil, but may not be the appropriate choice for use with highly acidic media types. Plunger Pump Heads up to 7.250 psig Plunger pump heads are preferably used for simple, non-critical fluids. For critical, abrasive, toxic or flammable fluids diaphragm pump heads are recommended. [1]

The head created by a centrifugal pump depends upon the velocity it imparts to the fluid via its impeller. Therefore, for any given impeller diameter and rotational speed, head will be some maximum, unvarying amount. Not so for reciprocating pumps.

Although they will have a maximum operating pressure rating, the maximum pressure (P) attained depends upon the application. Against a closed discharge valve, pressure is limited only by the capability of the driver and the strength of the materials employed. Only the breaking point of some component will limit discharge pressure. Therefore some form of pressure relief must be supplied if an application is capable of exceeding the pressure rating of the pump. [1]

The difference between piston pumps and plunger pumps as compared to rotary piston pumps is the actual mechanism used to transfer the fluid. The piston elements moving along an axis are called axial piston pumps. Rotary piston pumps typically have an internal rotating mechanism that moves the piston. [1]

Pressure Jet pumps is triplex (three plungers), positive displacement, and triplex plunger pumps. We offer both the triplex piston and triplex plunger pumps. With the positive displacement design, each revolution of the crankshaft creates a direct motion in the plunger rods [piston] resulting in a positive output of flow from the pump. This output from the pump [flow] is in direct relation to the speed (here, strokes / minute) of the pump. The plunger diameter and stroke length determine the amount of liquid handled with each stroke and revolution. The discharge pressure is created by the restriction placed upon the flow through nozzles or restrictions downstream. Our triplex plunger pumps deliver a smooth, constant flow and pressure. These high pressure triplex plunger pumps can also be powered by a vary-drive to adjust the flow as needed with changes in demand. The downstream restriction will require adjustment or a valve to regulate the change in flow. [1]

During the suction stroke, the plunger moves to the left, causing the check valve in the suction. Reciprocating positive displacement pump operation line between the reservoir and the pump cylinder to open and admit water from the reservoir. During the discharge stroke, the plunger moves to the right, seating the check valve in the suction line and opening the check valve in the discharge line. The volume of liquid

moved by the pump in one cycle (one suction stroke and one discharge stroke) is equal to the change in the liquid volume of the cylinder as the plunger moves from its farthest left position to its farthest right position. [1]

1.2

MINIMUM REQUIREMENTS

Our project consist both engineering fields combined 1) mechanical field 2) instrumentation and control field. So here are the minimum components required for making the project are been listed MECHANICAL FIELD o electric motor o jetting gun o suction tank o nozzle o HP hose pipe o safety valve o pressure relief valve o pressure gauge o needle valve

INSTRUMENTATION AND CONTROL FIELD o Power cables with color code o Control cables with number tag o SFU (switch fuse unit) o Selector switches o Starter o Over load relay o Timer o Contactor

o Phase failure switch o Push button o Power supply (3-phase) o Voltage indicator o Current indicator

1.3

BRIEF DESCRIPTION OF COMPONENTS

1.3.1 Electric Motor

An electric motor converts electrical energy into mechanical energy. Most electric motors operate through the interaction of magnetic field sand current-carrying conductors to generate force. The reverse process, producing electrical energy from mechanical energy, is done by generators such as an alternator or a dynamo; some electric motors can also be used as generators, for example, a traction motor on a vehicle may perform both tasks. Electric motors and generators are commonly referred to as electric machines. [3]

1.3.2 Nozzle

A nozzle is a device designed to control the direction or characteristics of a fluid flow (especially to increase velocity) as it exits (or enters) an enclosed chamber or pipe via an orifice. A nozzle is often a pipe or tube of varying cross sectional area and it can be used to direct or modify the flow of a fluid (liquid or gas). Nozzles are frequently used to control the rate of flow, speed, direction, mass, shape, and/or the pressure of the stream that emerges from them. [3]

1.3.3 Safety Valve

A safety valve is a valve mechanism for the automatic release of a substance from a boiler, pressure vessel, or other system when the pressure or temperature exceeds preset limits. It is part of a bigger set named pressure safety valves (PSV) or pressure relief valves (PRV). The other parts of the set are named relief valves, safety relief valves, pilot-operated relief valves, low pressure safety valves, vacuum pressure safety valves. [3]

Figure 1 electric motor

Figure 2 Safety valve

1.3.4 Pressure Gauge

Many techniques have been developed for the measurement of pressure and vacuum. Instruments used to measure pressure are called pressure gauges or vacuum gauges. A vacuum gauge is used to measure the pressure in a vacuumwhich is further divided into two subcategories, high and low vacuum (and sometimes ultra-high vacuum). The applicable pressure range of many of the techniques used to measure vacuums has an overlap.

Hence, by combining several different types of gauge, it is possible to measure system pressure continuously from 10 mbar down to 1011 mbar. [3]

1.4

COMPONENTS OF CONTROL PANEL

Control panel is a cabinet which contains electrical components to control the

motors and equipment. [4]

1.4.1 Control Cables

It is used to connect the control circuits. SY Control Cable is a flexible instrumentation cable designed for measuring, control or regulation in the field of process automation. It is a highly flexible multi core cable, with (class 5) copper conductors and a galvanized steel wire braid (GSWB) for mechanical protection. The cable is typically manufactured with PVC insulation, bedding and a transparent PVC sheath. The transparent sheath means signs of deterioration, damage or corrosion can be detected with ease. SY has a voltage rating of 300/500V and meets the requirements of both BS6500 and VDE0250 standards. As well as automation and process control, SY Control Cable is used in the rail and transport industry, building and construction, and transmission, distribution and power networks. Found on assembly and production lines, conveyors, in computer units and machine tool manufacture, SY Cable is designed for use in fixed installations and as an interconnecting cable between fixed and mobile equipment. [4]

1.4.2 Switch Fuse Unit

The basic supply will connected to this incomer. It also called as SFU (Switch Fuse Unit). It contains one handle with fuse unit. Once it is turned ON the supply will pass to the next stage through fuse if any major fault occurs in

side panel board, it will trip and it isolate supply. Switch Fuse Unit comprises of vitreous steatite porcelain rewire able fuses or HBC fuse fittings complete with their conducting parts. The switch is fitted with sturdy side operating &Front operating handle with quick make-break type mechanism. [4]

1.4.3 Analog Timer Switch

Technical Specifications: Type Operating Voltage Supply Frequency Power consumption Ambient Temperature Clock accuracy Switching contact Power reserve Shortest Switching Time : - Daily - Weekly Contact rating : - Resistive - Inductive (cos = 0.6) - Incandescent Lamp Manual Over-ride 16 A / 250 V AC 8 A / 250 V AC 1350 W Provided 15 Min 2 Hrs FM/1 Quartz 240 V AC 45 - 65 Hz 2 VA -20 C to 550C 2.5 sec / day at 200C 1 C/O contact - AgCdO 150 Hrs

Table 1: Technical specification

Figure 3 SFU

Figure 4 Analog Timer Switch

1.4.4 Phase Failure Relay

Three-Phase Monitoring If, for any reason, the motor windings draw more current than they are rated for, excess heat is generated, causing deterioration of the motor insulation. This deterioration is irreversible and cumulative. Eventually, the windings will short to the motor housing, causing motor failure. The reaction

time of thermal overload units may be too slow to provide effective protection from the excess heat generated by high current. A phase failure relay, by limiting the over current will help to: Increase motor life Reduce the very costly repair or replacement of motors Minimize downtime due to motor problems Reduce the risk of electric shock or fire due to the shorting out of motor windings

Types of Protective Relays There are two major types of protective relays for three-phase systems: current sensing and voltage sensing. The advantages of current sensing protective relays over voltage sensing relays are that they are not fooled by back EMF (Electromotive Force) which accompanies a phase failure on motor loads and they also can detect an abnormal condition on either the line side or load side in a branch circuit in which the relay is used. Voltage sensing devices can only detect abnormal conditions on the line side of where the relay is connected. However, a voltage sensing relay has an important advantage in that it can detect an abnormal condition independent of the motors running status. A current sensing device requires the motor to be running before an abnormal condition can be detected. Therefore, a voltage sensing device will provide pre-start protection while a current sensing device will not. Other advantages of voltage sensing devices are that they are easy to install, are generally less expensive because they do not need current transformers, and require only voltage connections so that they may be applied independent of the system load.

Phase Failure Detection A phase failure may occur because of a blown fuse in some part of the power distribution system, a mechanical failure within the switching equipment, or if one of the power lines open. A three-phase motor running on single phase draws all of its current from the remaining two lines. Attempting to start a three-phase motor on single phase will cause the motor to draw

locked-rotor current and the motor will not start. The reaction time of thermal overload units may be too slow to provide effective protection from the excessive heat generated in the motor windings when a phase failure occurs. Protecting a three-phase motor against phase failure is difficult because a lightly loaded three phase motor operating only on single phase will generate a voltage, often called regenerated voltage or back EMF, in its open winding almost equal to the lost voltage. Therefore, voltage sensing devices which monitor only the voltage magnitude may not provide complete protection from a phase failure which occurs when the motor is running. A greater degree of protection can be obtained from a device which can detect the phase angle displacement accompanying a phase failure. Under normal conditions, the three-phase voltages are 120 degrees out of phase with respect to one another. A phase failure will cause a phase angle displacement away from the normal 120 degrees.

Figure 5 Phase failure relay

1.4.5 Contactor
Contactor is an essential component in the control panel. It actuates when the signal from the controller (PLC, Relay logic) comes. It is similar to relay. It is costlier than relay. It is used for a higher load. A contactor is an electrically controlled switch used for switching a power circuit, similar to a relay except with higher current ratings. A contactor is controlled by a circuit which has a much lower power level than the switched circuit. Contactors come in many forms with varying capacities and features. Unlike a circuit breaker, a contactor is not intended to interrupt a short circuit current. Contactors range from those having a breaking current of several amperes and 24 V DC to thousands of amperes and many kilovolts. The physical size of contactors ranges from a device small enough to pick up with one hand, to large devices approximately a meter (yard) on a side. [4]

Figure 6 Contactor

1.4.6 Voltage and Current Indicator

Figure 7 Current & voltage indicator

1.4.7 Relays
Since relays are switches, the terminology applied to switches is also applied to relays. A relay will switch one or more poles, each of whose contacts can be thrown by energizing the coil in one of three ways:

Normally-open (NO) contacts connect the circuit when the relay is activated; the circuit is disconnected when the relay is inactive. It is also called a Form A contact or "make" contact. NO contacts can also be distinguished as "earlymake" or NOEM, which means that the contacts will close before the button or switch is fully engaged.

Normally-closed (NC) contacts disconnect the circuit when the relay is activated; the circuit is connected when the relay is inactive. It is also called a Form B contact or "break" contact. NC contacts can also be distinguished as "late-break" or NCLB, which means that the contacts will stay closed until the button or switch is fully disengaged.

Change-over (CO), or double-throw (DT), contacts control two circuits: one normally-open contact and one normally-closed contact with a common terminal. It is also called a Form C contact or "transfer" contact ("break before make"). If this type of contact utilizesmake before break" functionality, then it is called a Form D contact.

The following designations are commonly encountered:

SPST Single Pole Single Throw. These have two terminals which can be connected or disconnected. Including two for the coil, such a relay has four terminals in total. It is ambiguous whether the pole is normally open or normally closed. The terminology "SPNO" and "SPNC" is sometimes used to resolve the ambiguity.

SPDT Single Pole Double Throw. A common terminal connects to either of two others. Including two for the coil, such a relay has five terminals in total. DPST Double Pole Single Throw. These have two pairs of terminals. Equivalent to two SPST switches or relays actuated by a single coil. Including two for the coil, such a relay has six terminals in total. The poles may be Form A or Form B (or one of each).

DPDT Double Pole Double Throw. These have two rows of change-over terminals. Equivalent to two SPDT switches or relays actuated by a single coil. Such a relay has eight terminals, including the coil.

The "S" or "D" may be replaced with a number, indicating multiple switches connected to a single actuator. For example 4PDT indicates a four pole double throw relay (with 14 terminals). EN 50005 are among applicable standards for relay terminal numbering; a typical EN 50005-compliant SPDT relay's terminals would be numbered 11, 12, 14, A1 and A2 for the C, NC, NO, and coil connections, respectively.

Figure 8 relay switches

Figure 9 3-phase supply

AIMS AND OBJECTIVES

CHAPTER-2

Our aim about the project is to gain the knowledge about the working style of industries and companies. Our objectives are by using the knowledge and ideas of the project we can understand about the working status of the industries at higher levels. By preparing the project at industrial level we can implement our theoretical knowledge into the practical level and this is our main objective to improve our self at practical based from theoretical knowledge through the project. Our project mainly consists two parts of field, first is mechanical field and second is instrumentation and control field. Therefore by our project we can understand about the necessity of other field to implement own field into the industrial base.

Here are our main objectives to be done during the project work Automatic start / stop pump. Auto/manual working mode Manual back up Protects pump by Motor Protection Devise (M.P.D) against 1. Over load 2. High voltage 3. Low voltage 4. Dry running (no load protection) Lack phase protection Ultra low voltage protection Pump installed protection Friendly wire connection Easy installation and simple debug

BRIEF HISTRY OF WORK

CHAPTER-3

3.1 Introduction to control panel

Control panel of our project is mainly made for controlling the high pressure triplex plunger pump. Our triplex plunger pump is worked on three-phase power supply. According to our requirement we had made our control panel for controlling plunger pump as well as protecting the plunger pump from damages causes by threephase connection. Fig. 8 shows the inner view of control panel for high pressure triplex plunger pump.

Inner side of control panel contains power supply connections, switch fuse unit for any kind of over voltage supply, phase failure relay, analog time switch, contactor and motor connections. Control wires are also connected to the outer side of the panel as shown in fig.10 which shows outer side of the panel.

Basic control panel contains much kind of relays and protection devices which can automatically control any kind of devices. But our project has less devices to control therefore our panel contains less number of controlling components and we have made our panel as our specific requirement.

Outer part of panel contains many controlling devices like automatic start/stop push button switch, three-phase supply connections, three-way switch for auto/manual/off mode control, power supply connection selection switch, supply current and voltage indication.

Figure 10 inner view of control panel

Figure 11 outer view of control panel

3.2 Wiring Diagram of Control Panel

Fig.12 shows the inner wiring diagram of the control panel. Fig.13 shows the outside view and wiring diagram. Fig.14 shows the control panel dimension diagram. Fig .15 shows the relay logic diagram for motor control.

As shown in figure 12 we have to give 3-phase power supply to the ON-OFF control device where the switch is there for on or off the supply to the motor. From ON-OFF device as we switch on power supply switch current pass through the SFU (switch fuse unit) which protect the motor from over voltage. From SFU three color tagged wire are going. They all three wire are tagged as red, yellow and blue. From them red wire is connected to contactor 1L1 contact, yellow wire is connected to the phase failure relay and blue wire is connected to the 5L3 contact of the contactor.

All other connection of other wires are indicated in the wiring diagram of control panel and tagged as numbers in control panel wiring.

3.3 Description of working of components

From the beginning three phase connection is been made with three phase connector as shown in control panel. After that current and voltage pass through SFU for safety and protection of pump. Then it passes through the contactor. Relay logic diagram for contactor is shown in fig. 16.

A contactor has three components. The contacts are the current carrying part of the contactor. This includes power contacts, auxiliary contacts, and contact springs. The electromagnet (or "coil") provides the driving force to close the contacts. The enclosure is a frame housing the contact and the electromagnet. Enclosures are made of insulating materials like Bakelite, Nylon 6, and thermosetting plastics to protect and insulate the contacts and to provide some measure of protection against personnel

touching the contacts. Open-frame contactors may have a further enclosure to protect against dust, oil, explosion hazards and weather. Magnetic blowouts use blowout coils to lengthen and move the electric arc. These are especially useful in DC power circuits. AC arcs have periods of low current, during which the arc can be extinguished with relative ease, but DC arcs have continuous high current, so blowing them out requires the arc to be stretched further than an AC arc of the same current. The magnetic blowouts in the pictured Albright contactor (which is designed for DC currents) more than double the current it can break, increasing it from 600 A to 1,500 A. Sometimes an economizer circuit is also installed to reduce the power required to keep a contactor closed; an auxiliary contact reduces coil current after the contactor closes. A somewhat greater amount of power is required to initially close a contactor than is required to keep it closed. Such a circuit can save a substantial amount of power and allow the energized coil to stay cooler. Economizer circuits are nearly always applied on direct-current contactor coils and on large alternating current contactor coils. A basic contactor will have a coil input (which may be driven by either an AC or DC supply depending on the contactor design). The coil may be energized at the same voltage as the motor, or may be separately controlled with a lower coil voltage better suited to control by programmable controllers and lower-voltage pilot devices. Certain contactors have series coils connected in the motor circuit; these are used, for example, for automatic acceleration control, where the next stage of resistance is not cut out until the motor current has dropped. Phase Reversal Detection Phase reversal can occur when maintenance is performed on motor-driven machinery, when modifications are made to the power distribution system, or when power restoration results in a different phase sequence than before the power outage. Phase reversal detection is important if a motor running in reverse may damage the driven machinery or injure personnel. The National Electric Code (NEC) requires phase reversal protection on all equipment transporting people, such as escalators or elevators.

Voltage Unbalance Detection Voltage unbalance can occur when incoming line voltages delivered by the power company are of different levels, or when single-phase loads such as lighting, electrical outlets and single-phase motors are connected on individual phases and not distributed in a balanced way. In either case, a current unbalance will result on the system which shortens motor life and diminishes motor efficiency. An unbalanced voltage applied to a three-phase motor can result in a current unbalance in the motor windings equal to several times the voltage unbalance. This will increase the heat generated, a major cause of rapid deterioration of motor insulation.

Under voltage Under voltage may occur if the power supplied by the local power company is overloaded, causing the voltage to drop, which is known as a brown out. An under voltage condition can also occur in remote areas at the end of long power lines. As the voltage available to the motor is decreased, the current drawn by the motor increases, resulting in generated heat which deteriorates the motor insulation.

Figure 16 contactor relay logic

Figure 17 working of phase failure relay

Figure 18 working of phase failure relay

Interfacing Phase Failure Relays With Shunt Trip Circuit Breakers Phase failure relays are often used to control a shunt trip circuit breaker. When this is done, care must be taken to insure that the shunt trip circuit always has an adequate source available. This can be accomplished by using the diagram below.

If a phase failure occurs on L2 or L3, the shunt trip coil will draw power from L1 through the control relay (CR) contacts and phase failure relay contacts (which will change state upon detecting a phase failure). If a phase failure occurs on L1, the control relay (CR) contacts change state. The shunt trip coil will now draw power from L2 through the CR contacts and phase failure relay contacts. If the control relay coil or contacts, the phase failure relay contacts, or the shunt trip coil does not have the same voltage rating as the motor, control transformers may be interposed where needed.

Figure 19 working of phase failure relay

Figure 20 working of analog time switch

Literature Review

Chapter-4

There are some inventions had been done by many manufacturing companies and industries before manufacturing the triplex plunger pump like singular plunger pump, duplex plunger pump etc. Singular plunger pump is a design in which only one cylinder is used for the stroke. In this pump fluctuation in the indication is very high in the flow meter and pressure indicator. It also has very low efficiency compare with triplex plunger pump. Its volumetric and mechanical structure is also very pure. Singular plunger pump is become more costly when we control it using automation because control panel board is very costly for this pump. It also cannot give high pressure and flow like as triplex plunger pump gives. Duplex plunger pump has many advantages compare with singular plunger pump like it give low fluctuation, work on the high load etc. but it is not enough for accurate results for the industry. So better and more efficient pump which can handle all the needs of the industry and very useful for them had to be made like as triplex plunger pump. In the control panel for this type of pump there is no overload protection and is not accurate compare to the triplex plunger pump. Triplex plunger pump without control panel has many limitations. Triplex plunger pump without control panel is cannot give the over load protection, no load protection. Even when the liquid did not pass through the pump, pump was in working condition. So it damages the parts of the triplex plunger pump. The motor did not stop while the motor rotate with no load. Even we cannot automatic control the pump; we have to control it manually. It is work on DC power supply, so it is necessary to have a control panel for it. Triplex plunger pump with relay devices has many limitations. In hazardous areas we cannot change any infected parts or start/stop the device by going in that location. So by using PLC we can control it in hazardous areas from another place.

REFERENCES

Chapter-5

5.1 BOOKS
1. A.K. THERAJA & B.L. THERAJA, TEXT BOOK OF ELECTRICAL TECHNOLOGY IN S.I.UNIT. (VOLUME 2), S.CHAND PUB. NEW DELHI. 2. JOHN W. WEBB AND RONALD A.REIS, PROGRAMMABLE LOGIC CONTROLLERS : PRINCIPLES AND APPLICATIONS, PRENTICE HALL INDIA PUB.

5.2 WEBSITES

http://en.wikipedia.org/wiki/Programmable_logic_controller http://en.wikipedia.org/wiki/Microcontroller
http://plcplc.info/html/90/PLC_in_the_mixing_of_the_practical_application of_production_control.html

BIBLIOGRAPHY

CHAPTER5

[1]A History of Mechanical Inventions, Abbott Payson Usher, Courier Dover Publications, 1988, ISBN 048625593X, 9780486255934 [3] "Principles And Practice Of Plumbing", by John Joseph Cosgrove [4] Instrumentpedia, powered by Blogger.http://instrumentpedia.blogspot.com/2011/03/what-is-controlpanel-what-are_14.html [5] Wikipedia (2009), PLC http://en.wikipedia.org/wiki/Programmable_logic_controller [6] M. A. Laughton, D. J. Warne , Electrical Engineer's Reference book, 16th edition, Newness, 2003 Chapter 16 Programmable Controller [7] Manufacturing Automation. 12 September 2008.