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On
Design, Installation and Fabrication of Reciprocating pump
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
NAME
Submitted By
UNIVERSITY ROLL NUMBER
Contents
Sl. No.
Article
Page
No.
Acknowledgement
Aim of the project
Project plan
01
Reciprocating Pumps
04
04
11
13
Selection of pumps
17
27
Applications
10
References
33
36
ACKNOWLEDGEMENT
We are highly grateful to the authorities of FUTURE INSTITUTE OF
ENGINEERING & MANAGEMENT, KOLKATA for providing this opportunity
to carry out the project work.
We would like to express a deep sense of gratitude & thank profusely to our thesis
guide Dr. Manoj kumar Barai for his sincere & invaluable guidance, suggestions &
attitude which inspired us to submit project report in the present form..
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PROJECT PLAN
Work carried out so far....
v To design the various components of reciprocating pump.
v Selection of raw materials.
.
Future Scope....
v To model the reciprocating pump and analyse it.
v To select pump size based on design calculations..
v To analyse the model as a whole
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INTRODUCTION
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by
mechanical action. Pumps can be classified into three major groups according to the
method they use to move the fluid: direct lift, displacement, and gravity pumps.
Pumps operate by some mechanism (typically reciprocating or rotary), and consume
energy to perform mechanical work by moving the fluid. Pumps operate via many
energy sources, including manual operation, electricity, engines, or wind power, come
in many sizes, from microscopic for use in medical applications to large industrial
pumps.
Mechanical pumps serve in a wide range of applications such as pumping water from
wells, aquarium filtering, pond filtering and aeration, in the car industry for watercooling and fuel injection, in the energy industry for pumping oil and natural gas or
for operating cooling towers. In the medical industry, pumps are used for biochemical
processes in developing and manufacturing medicine, and as artificial replacements
for body parts
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Reciprocating Pumps
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When the pump has three cylinders attached to a single shaft then the pump is called
triple cylinder pump. Crank is set at an angle of 120
DIAPHRAGM PUMPS
Diaphragm pumps are reciprocating positive displacement pumps that employ a
flexible membrane instead of a piston or plunger to displace the pumped fluid. They
are truly self priming (can prime dry) and can run dry without damage. They operate
via the same volumetric displacement principle described earlier. The figure shows
the operational cycle of a basic, hand operated single diaphragm pump. Where its
operation any simpler, it would compete with gravity. The upper portion of the figure
shows the suction stroke. The handle lifts the diaphragm creating a partial vacuum
which closes the discharge valve while allowing liquid to enter the pump chamber via
the suction valve.
During the discharge stroke the diaphragm is pushed downward and the process is
reversed. Hand operated pumps are designed to deliver up to 30 gpm at up to 15 feet
but actual capacity is extremely dependent upon the physical condition of the driver.
Air, engine, and motor drive units are also available and offer capacities to 130 gpm.
Both suction and discharge head vary from 15 to 25 feet .
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During the suction stroke (right to left) the single acting pumps discharge valve
closes and allows fluid to enter the cylinder via the suction valve. When the piston
changes direction (reciprocates) the suction valve closes and water is discharged
through the discharge valve. In the double acting pump, the same sequence occurs
during both strokes and almost twice as much fluid is discharged per unit time.
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Delivery pipe
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Pipe which take water from the cylinder of the pump and provide it to the tank is
called delivery pipe.
Delivery valve
It is one away vale and placed at the point of attachment of delivery pipe with
cylinder. It is open when delivery of water is taking place and closed when suction of
water in taking place
Strainer
It is a filter like parts provided at the end of suction pipe. Its main function is to stop is
solid particles from entering into the pipe
Air vessel
Installed at the suction and delivery pipe and its main function is to give a steady flow
by reducing the frictional head
High efficiency
No priming needed
Can deliver water at high pressure
Can work in wide pressure range
Continuous rate of discharge
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MAIN TERMS:
a) Brake Horsepower (BHP):
required at the pump input shaft in order to achieve the desired pressure and flow.
It is defined as the following formula:
BHP = (Q Pd) / (1714 Em) 102
Pumps Reference Guide where:
BHP = brake horsepower
Q = delivered capacity (gpm US)
Pd = developed pressure (psi)
Em = mechanical efficiency (% as a decimal)
b) Capacity (Q): The capacity is the total volume of liquid delivered per unit
of time. This liquid includes entrained gases and solids at specified conditions.
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pressure.
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s = stroke of pump, (in.) (half the linear distance the plunger or piston moves linearly
in one revolution)
MINOR TERMS:
g) Valve Loss (VL): Valve loss is the flow of liquid going back through the valve
while it is closing and/or seated. This is a 2% to 10% loss depending on the valve
design or condition.
h) Speed (n): Design speed of a power pump is usually between 300 to 800 rpm
depending on the capacity, size, and horsepower. To maintain good packing life,
speed is limited to a plunger velocity of 140 to 150 ft/minute. Pump speed is also
limited by valve life and allowable suction conditions.
pumping capacity, and pressure, there is a specific value of NPSHR. A change in one
or more of these variables changes the NPSHR. It is a good practice to have the
NPSHA (available) 3 to 5 psi greater than the NPSHR. This will prevent release of
vapor and entrained gases into the suction system, which will cause cavitations
damage
in the internal passages.
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SELECTION
Selecting between Centrifugal Pumps and Positive Displacement Pumps
Pumps are in general classified as Centrifugal Pumps (or Roto-dynamic pumps) and
Positive Displacement Pumps
Centrifugal Pumps (Roto-dynamic pumps)
The centrifugal or roto-dynamic pump produce a head and a flow by increasing the
velocity of the liquid through the machine with the help of the rotating vane
impeller. Centrifugal pumps include radial, axial and mixed flow units.
Centrifugal pumps can be classified further as
in-line pumps
submersible pumps
self-priming pumps
axial-flow pumps
regenerative pumps
Power pumps
Steam pumps
The Centrifugal Pump has varying flow depending on the system pressure or
head
The Positive Displacement Pump has more or less a constant flow regardless
of the system pressure or head. Positive Displacement pumps generally makes
more pressure than Centrifugal Pump's.
Liquids with high viscosity fills the clearances of Positive Displacement Pumps
causing higher volumetric efficiencies and Positive Displacement Pumps are better
suited for higher viscosity applications. A Centrifugal Pump becomes very inefficient
at even modest viscosity.
Mechanical Efficiency
The pumps behaves different considering mechanical efficiency as well.
Changing the system pressure or head has little or no effect on the flow rate in
a Positive Displacement Pump
Changing the system pressure or head may have a dramatic effect on the flow
rate in a Centrifugal Pump
Negative slip will occur when delivery pipe is short, suction pipe is long and
pump is running on high speed.
A positive displacement pump makes a fluid move by trapping a fixed amount and
forcing (displacing) that trapped volume into the discharge pipe. Some positive
displacement pumps use an expanding cavity on the suction side and a decreasing
cavity on the discharge side.
In this curve we see the flow rate is almost constant in spite of pressure difference,
but in centrifugal pump the flow rate is changing due to pressure difference. This is the
advantage of reciprocating pump over centrifugal pump.
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Pulsation Analysis
Features include:
Operating conditions. An operating condition analysis to assess the pumps
operation across the entire operating envelope. The standard service evaluates up to
20 operating conditions.
Pulsation levels. An evaluation of the pulsation levels given varying performance of
the pump valves. Pulsation levels are drastically influenced by the behaviour of the
pump valves
Upset conditions. Reporting of the effect of upset conditions such as pulsation
levels when a pump valve fails, thus deactivating a plunger throw. Vibration and
pulsation characteristics are greatly influenced by the number of fluid ends active.
Pressure drop. As a standard feature BETA will assess static and total pressure
drop. Total pressure drop includes dynamic pressure drop losses.
Piping restraint or mechanical review. This includes an evaluation of pipe support
locations using charts, empirical calculations, and good engineering design practices.
Water Hammer Analysis, also known as a transient surge analysis for liquid
systems, is another optional study that is sometimes required when reciprocating
pump and piping systems are affected by transient events such as power outages,
valve swings, check valve slam, and other causes. Some operators require an
investigation of transients in the system to ensure integrity under upset conditions.
The transient pressures can create serious risks for piping integrity including pipe
rupture, pipe collapse, cavitation, column separation, and check valve slam. The
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transient events created are known generally as water hammer, but as this
phenomenon can happen with any liquid, other terms are fluid hammer, or dynamic
pressure surge.
Water Hammer Transient Studies are recommended for:
Any liquid piping system in the design stage to evaluate pipe system integrity under
transient conditions
Predicting water hammer in pump systems for regular operating and upset scenarios
(e.g., Loss of power)
Predicting transients due to valve swings, sudden valve openings, new streams
coming online, or other operating changes
Pump system upgrades to flow and available head
Systems with high consequence of failure, such as hazardous fluids, safety,
environmental
Calculating resultant transient forces on pipes to determine stress levels
Any existing system where high vibration or shocks are occurring with valve
closures or pump shutdowns
help insure that an acceptable gasket surface is available to obtain a good seal, and
prevent breaking when the bolts are tightened. Occasionally, a system will require
increase pressure containment capabilities at connections. The use of raised face
(R.F.) flanges allows more pressure to be concentrated on a smaller gasket area.
However, care must be taken when tightening bolts on R.F. flanges. If not properly
tightened and torqued to the manufacturers recommendations, the flanges can pivot
along the edge of the raised face. This can cause distortion in the pump volute, as
well as possibly cracking or breaking a flange.
EXPANSION JOINTS
Expansion joints can be used when the piping system can expect axial movement
due to thermal expansion of the liquid. The expansion joints will assist in preventing
the pump from being shifted out of alignment. Typically, they are installed in lowpressure systems. Important to the reliability of the pump and piping system is the
need for proper selection and installation. An expansion joint can be installed on the
suction and discharge side of a pump. The location should be on the opposite side of
the piping support, or anchor, away from the pump. If the expansion joint is placed
between the anchor and the pump, a force could be caused that would be more than
the pump or the system could handle. The force would be equal to the area of the
maximum expansion joint inside diameter multiplied by the pressure in the pipe. In
addition, according to HI1 , if the joint is not properly aligned with the pipe, the
shear force and torsion may be transmitted to the equipment. To insure that the
expansion joints are effective in the piping system, they must be sized properly and
the material of construction must correspond with the application. Although these
joints provide relief of axial pipe movement, they are not as flexible as many
perceive. The pump and system can also be subjected to excessive forces due to poor
expansion joint sizing.
ISOLATION VALVE
An isolation valve, or shutoff valve, should be installed in the discharge pipe. It
assists in the priming of the pump, starting the pump, and for isolation, as may be
required for pump maintenance. Except for axial and mixed flow pumps, the
isolation valve should be closed before stopping pump, especially if no check valve
is installed. An isolation valve should not be used for the throttling of the pump.
Throttling of the discharge isolation valve contributes to a substantial waste of
energy in the pump. Should an existing discharge valve be found to be throttling the
pump excessively, a correctly sized pump should be installed, or some other variable
speed drive should be considered.
CHECK VALVE
A check valve is utilized in a pump system to prevent back flow of the liquid when
the pump is stopped. This reverse flow could cause damage to the pump, from the
impeller becoming loose for example, or cause difficulty in re-priming the pump.
The check valve is located in the discharge line, between the pump and isolation, or
shutoff, valve, and on the far side of the expansion joint, away from the pump. It
should never be installed in the suction line. A check valve is a flow restrictor in the
piping, and will cause a pressure drop.
REDUCER
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A pipe reducer is a fitting that allows a change in the diameter of the pipe in the
system. The information in this section is also applicable to a pipe increaser. It is
important to properly size and install a reducer to insure that smooth flow through
the system is not disturbed, causing damage to the equipment or the system.
STRAINER
The function of a strainer in a pumps suction piping is to keep solids out of the
pump and the pumping system. A strainer can be used in most all pumps, except in
large units. For the larger pumps, a temporary strainer can be installed for the start
up of a new installation. This temporary strainer can be left in place until the system
is clean and construction debris is removed. Strainers will cause a moderate pressure
drop in the system, until it begins to clog and accumulate solid materials. At this
point, the pressure drop across the strainer will increase, and may cause the pump to
starve. Ideally, the pipe on the up stream and down stream side of the strainer should
be tapped and used to monitor the pressure drop. After some experience, a set point
can be determined when the strainer requires cleaning. The cleaning of the strainer
can then be added to a routine maintenance schedule. The size of the strainer should
be chosen so that the open or free area of the strainer is three (3) times the suction
pipe area.
FOOT VALVES
Foot valves are used on the suction side of a pump to provide suction lift for pumps
that are not self-priming. They act as a check valve, maintaining liquid in a pumps
suction line. A foot valve can fail the pumping system when it loses its sealing
capabilities and begins to leak. In addition, it may fail the system if solids or some
other type of foreign matter prevents it from closing properly. If a pump is utilizing a
foot valve for priming from a suction lift, the failure of the foot valve will cause the
pump to run dry because of the lack of liquid in the pump and suction line. Operating
with no liquid in the pump may possibly cause catastrophic damage to the unit.
PIPING DESIGN CONSIDERATIONS
In addition to the considerations that must be made with the various system
components, the design and fabrication of the suction and discharge piping must
followed according to best practices of the industry. As with any project, it is
important that the piping design and fabrication is done right the first time. If it is not
done following recommended practices, it will be difficult and expensive to
correcting the future. DESIGN The first consideration in the design of a piping
system is the sizing of the pipe. The capacity must be established not only for the
entire process or system, but for the individual branches as well. The design flow
should not be oversized by a large margin to prevent throttling of valves and wasting
energy. The goal of selecting the pipe size of the system is maximize the pipe sizes
used, while minimizing the costs of the pipe. As pipe sizes are increased, the system
head loss, due to friction, is decreased. Additional consideration must be made for
pumping viscous materials. Viscous materials have a greater friction loss than water
in the same size pipe. Many of the references in this article have friction charts that
assist in pipe size selection for various flow rates. The size of the suction and
discharge piping should be at least the size of the pump connections. Suction pipe
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should be one (1) to two (2) sizes larger than the pump connection, never smaller. A
reducer can be used to in the suction line to allow for the suction pipe that is
oversized. The overall design of the piping system should be as straight and as short
as possible, with a minimal about of bends or turns in the system. Sudden changes in
pipe diameter will cause turbulence and head loss in a system, and, therefore, should
be avoided. A final design consideration for the piping system is for the ease of
pump removal for repair. As a pump will eventually require removal and
maintenance, the piping system should be designed to allow technicians to work on
the pump at the site, as well as remove it safely. Liberal spacing should be
maintained around the equipment.
during fabrication, a simple method to determine if pipe flange faces are parallel is to
see if you can visibly see a difference in the flange face planes. If the gap between
the faces is visible and is not even, then it will cause pipe strain. Other causes of pipe
strain, that may impose a force and torque on the pump, include thermal growth, an
inadequate piping design and support system, pressure surges, and water hammer.
The effects of pipe strain include:
Coupling misalignment
Cracking of the piping nozzles or pump casing
Distortion of pump casing and bearing housing
Excessive vibration
False appearance of soft foot conditions during alignment
Inconsistent alignment data
Leakage at the pump flanges
Shortened mechanical seal and bearing life
Wear ring contact
Standard industry practices recommend that the pipe be run from the pump to a point
several feet away, where the final pipe connection can be made. During the
fabrication, temporary braces and supports should be used to maintain the piping and
fittings in place while the system is being completed. During fabrication of the pipe,
the piping should never be drawn into place by force, as with ratchet pullers or chain
hoists. This may cause strain, breakage, distortion, or misalignment, and may affect
the operation or damage the equipment. The pipe should not be connected to the
pump until grout has cured and pump/driver/base bolts have been tightened. After
the fabrication of the piping system is completed, the pump installation is complete,
and the connections are made to the pump, the shaft should be rotated to insure there
is no binding. The alignment should be checked to determine the absence of pipe
strain. The piping should be corrected if pipe strain is present and causing
misalignment.
SUPPORT
Besides proper fabrication of a piping system, it is important to properly support the
pipe as well. If no pipe support exists, the pipe strain will induce stress into the
equipment and support system. In determining the proper support of the piping
system, the forces and moments of the piping system must be calculated. The
calculations must include the weights of the pipe, the liquid in the pipe, and the pipe
insulation. Thermal expansion and contraction must also be taken into account. The
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suction and discharge piping must be anchored, supported, and restrained near the
pump to avoid the forces and movements of the system being applied to the pump.
The pipe should be anchored close to the pump flanges on suction and discharge to
prevent vibration and putting strain on the piping. A system of hangers and braces
should be used to support the piping system. The hangers and braces should be
installed in a manner such that they do not have to be removed during normal
maintenance on the equipment. Long pipe runs should be supported at unequal
distances to prevent resonant vibrations from occurring in the system. After the
piping has be installed and supported, the alignment should be rechecked. The piping
should then be adjusted if there is any significant change to the equipment s last
alignment readings.
OTHER PIPING CONSIDERATIONS
Pressure gauges should be mounted on the suction and discharge of the pump. The
gauges not only provide a means of monitoring the equipment, but also can be used
in troubleshooting problems. The gauges MUST be mounted before any valves or
fittings. If placed after valves or fittings, false pressure readings of the pump output
will be observed and will not provide accurate information. Simple vents and drains
should be used with pumping systems, unless handling a corrosive or toxic product.
Vents should be installed on the pump casing as well as system piping high points to
allow the pump and system to be completely filled. A drain will remove product out
of the pump and away from the site when repairing the equipment. When positive
displacement pumps are used in a system, a means of pressure relief must be
installed in the system. Without some type of pressure relief, the system pressure
will continue to build when the pump is operating against a closed discharge. The
weakest point in the system will eventually fail, causing damage or injury. The rules
for design of piping systems for pumping slurries may not necessarily apply as for
water-like liquid. Light slurries do act similar to water. However, heavy slurries
dont act like water. Heavy slurries are considered as liquids with greater than
20%solids by volume. Typically, additional power and higher velocities are required
to move heavy slurries. These systems also see greater wear to the pipe, fittings and
equipment. The proper design of piping systems handling heavy slurries is very
detailed and is more than can be covered in this article.
SUMMARY
Proper sizing of the piping system will result in the lowest overall pumping system
life cycle cost. This requires finding the optimum balance between pipe purchase and
installation costs and energy costs associated with the pipe frictional losses. It should
further be noted that the frictional losses created by piping systems can require larger
pumps, motors, and power supplies to overcome the losses than if larger pipe were
used. Pump discharge pressure will also be greater when frictional losses are
excessive. Proper design and fabrication will ensure that the equipment will be
reliable and will not fail due to the effects of the piping system.
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DESIGN CALCULATIONS
Speed of the motor= 1800 rpm
Dia of motors pinion= 5cm
Dia of gear= 18cm
Now, the reduced speed of gear= 500 rpm
Cranks dia =30cm
Connecting rods length= 30cm
Cylinders length= 40cm
Inner Dia of cylinder=15cm
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(1)
where
p = static pressure
= density
v = flow velocity
g = acceleration of gravity
h = elevation height
wshaft = net shaft energy per unit mass for a pump, fan or similar
wloss = loss due to friction
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The system head visualized in the System Curve is a function of the elevation - the static head
in the system, and the major and minor losses and can be expressed as:
h = dh + hl
(1)
where
h = system head
dh = h2 - h1 = elevation (static) head - difference between inlet and outlet of the system
hl = head loss
A generic expression of head loss is:
hl = k q2
(2)
where
q = flow rate
k = constant describing the total system characteristics - including all major and minor losses
Increasing the constant - k - by closing some valves, reducing the pipe size or similar - will
increase the head loss and move the system curve upwards. The starting point for the curve at no flow, will be the same.
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Increasing the impeller diameter or speed increases the head and flow rate capacity - and the
pump curve moves upwards.
The head capacity can be increased by connecting two or more pumps in series, or the flow
rate capacity can be increased by connecting two or more pumps in parallel.
Selection of Pump
A pump can be selected by combining the System Curve and the Pump Curve:
The operating point is where the system curve and the actual pump curve intersect.
Carry Out
When a pumps operates in the far right of its curve with poor efficiency - the pumps carry out.
Shutoff Head
Shutoff head is the head produced when the pump operates with fluid but with no flow rate.
Churn
A pump is in churn when it operates at shutoff head or no flow.
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Reciprocating pump has a wide range of applications in the Oil and Gas
Industries Form Production to Drilling to Operations:
2.
Petrochemicals and Refineries are two core industries that have applications of
reciprocating pumps
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Axial piston pumps are used to power the hydraulic systems of jet aircraft, being geardriven off of the turbine engine's main shaft, The system used on the F-14 used a 9piston pump that produced a standard system operating pressure of 3000 psi and a
maximum flow of 84 gallons per minute.
They are also used in some pressure washers. For example Krcher has several
models powered by axial piston pumps with three pistons.
3.
Due to the hydrostatically balanced parts it is possible to use the pump with
various hydraulic fluids like mineral oil, biodegradable oil, HFA (oil in water), HFC
(water-glycol), HFD (synthetic ester) or cutting emulsion. That implies the following
main applications for a radial piston pump:
machine tools (e.g., displace of cutting emulsion, supply for hydraulic equipment
like cylinders)
test rigs
automotive sector (e.g., automatic transmission, hydraulic suspension control in
upper-class cars)
plastic- and powder injection moulding
wind energy
4.
Hand pump
Hand pumps are manually operated pumps; they use human power and
mechanical advantage to move fluids or air from one place to another. They
are widely used in every country in the world for a variety of industrial,
marine, irrigation and leisure activities. There are many different types of hand
pump available, mainly operating on a piston, diaphragm or rotary vane
principle with a check valve on the entry and exit ports to the chamber
operating in opposing directions. Most hand pumps have plungers or
reciprocating pistons, and are positive displacement
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REFERENCES
http://www.engineeringtoolbox.com/pumps-t_34.html pumps
http://www.engineeringtoolbox.com/positive-displacementpumps-d_414.html positive displacement pump
https://www.google.co.in/search?q=PLUNGER+PUMPS&safe
=off&espv=2&source=lnms&tbm=isch&sa=X&ved=0ahUKEw
jGroSRpbLJAhUCTI4KHdahAFEQ_AUIBygB&biw=1366&b
ih=623#imgrc=bCSya4TlU3cI3M%3A Plunger pump with
splash lubrication
http://www.green-mechanic.com/2014/07/classification-ofreciprocating-pump.html classification of reciprocating pump
www.google.com
www.scribd.com
Engineering_Design_Guideline__Pump_Rev3.pdf
Energy Conservation in Pumps.ppt
PUMPS - TYPES & OPERATION
Fluid mechanics & machinery Laboratory
Positive Displacement Pumps (Part One) Reciprocating Pumps
Reciprocating Pump files
Fluid mechanics and hydraulic machines-by R K BANSAL
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