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Metering Pump Technology

Bulletin 210
The Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1
Metering Pump Basic Components . . . . . . . . . . . . . 1
Metering Pump Characteristics . . . . . . . . . . . . . . . . 2
Capacity and Pressure Capabilities Chart . . . . . . . . 3
Liquid End Designs . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Packed Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disc Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mechanically Actuated Diaphragm . . . . . . . . . . . 6
Metallic Diaphragm and Critical Service Head . . 7
High Performance Diaphragm -
Advanced Liquid End Design . . . . . . . . . . . . . . . . . . 8
Metering Pump Drive Mechanisms . . . . . . . . . . . . . 10
Hydraulic Bypass . . . . . . . . . . . . . . . . . . . . . . . . . 10
Polar Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CENTRAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Capacity Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 14
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Metering Pump System Components . . . . . . . . . . 16
Other Milton Roy Products . . . . . . . . . . . . . . . . . . 18
The Metering Pump
T
he metering pump is a positive displacement chemical dosing device with the ability to vary capacity manually or
automatically as process conditions require. It features a high level of repetitive accuracy and is capable of pump-
ing a wide range of chemicals including acids, bases, corrosives or viscous liquids and slurries.
The pumping action is developed by a reciprocating piston which is either in direct contact with the process
fluid, or is shielded from the fluid by a diaphragm. Diaphragms are actuated by hydraulic fluid between the piston
and the diaphragm.
Metering pumps are generally used in applications where one or more of the following conditions exist.

Low flow rates in ml/hr or GPH High accuracy feed rate is Corrosive, hazardous, or high
are required demanded temperature fluids are handled
High system pressure exists Dosing is controlled by computer, Viscous fluids or slurries need to
microprocessor, DCS, PLC, or be pumped
flow proportioning

Metering Pump Basic Components


Driver: Driver Mechanism: Flow Adjustment:
The pump is usually driven by an The drive mechanism translates Pump flow rate is adjustable by
AC constant speed motor. Variable the rotary motion of the driver into varying stroke length, effective
speed, pneumatic, reciprocating stroke length, or stroking speed.
and hydraulic drivers movement. Most metering
are also utilized. Industrial duty pumps are
pumps will supplied with
Liquid End: submerge this
portion of the
a micrometer
screw adjustment
The liquid end design and materi-
pump in an similar to the
als of construction are determined
oil bath to assure reliability during one shown here. The micrometer
by the service conditions, and the
continuous operation. can also be replaced by an elec-
nature of the
tronic or pneumatic actuator to
fluid to be
adjust pump flow rate in response
handled. Driver to process signal.
Temperature,
flow rate, fluid
viscosity, cor- Drive Mechanism
rosiveness and
other factors are considered.

Liquid End

Flow
Adjustment

1
Metering Pump Characteristics
One Complete Cycle

1. The pumping action is developed Discharge


by a reciprocating piston. This recip-
rocating motion develops a flow Peak Flow-
p x Average
easily represented by a sine wave. Flow
Actual flow rate is determined by Average
the following formula: Flow
Time
Flow rate = Displacement x
Cycles per unit of time.

Suction

Metering Pump

2. Unlike centrifugal pumps, flow


Centrifugal
rate is not greatly affected by
Flow Q changes in discharge pressure.
Pump

Pressure P

3. The metering pump flow vs. stroke character-


istic curve is linear. It is not, however, necessar-
ily proportional in that 50% stroke setting may
not equal 50% flow. This is due to the fact that
the calibration line may not pass through 0 on
both axes simultaneously. By measuring flow at 2
stroke settings, plotting both points and drawing
a straight line through them, other flow rates vs. Point 1
stroke can be accurately predicted. Q1, S1
The steady state accuracy of a correctly installed
industrial grade metering pump is
generally + 1.0% or better.
Flow
Although a metering pump can generally be Rate
adjusted to pump at any flow rate between 0 and Q
its maximum capacity, its accuracy is measured
over a range determined by the pump's turndown
ratio. Most metering pumps have a turndown
Point 2
ratio of 10:1, which simply means that the pump Q2, S2
is within its accuracy rating anywhere between
10% and 100% of capacity. Centrac is an example
0 50 100
of a new generation metering pump that features
higher accuracy, and a greater turndown ratio of % Setting S
Stroke Length or Driver Speed
100:1. Therefore, this design will accurately dose
anywhere between 1% and 100% of capacity.

2
Capacity and Pressure Capabilities
Capacity Per HeadGPH

1000

1500

2000

3000
100

150

200

350

500

750
10

20

30

40

50

75
0

5
mRoy XT & XW mRoy XT mRoy XW The maximum capacity of each

mRoy XW
mRoy XT
Maximum Pressure Maximum Maximum
24 1800-3000 psi 1.6 GPH (6 LH) 6.7 GPH (25 LH) pump is determined by gear ratio,
Maximum No. Heads Minimum Minimum piston diameter, and motor RPM.
2 0.4 GPH (1.5 LH) 2.8 GPH (9.8 LH) Maximum pressure rating applies
to smaller piston diameters in each
Centrac S Centrac S model. As the piston diameter and
Maximum Pressure Maximum
9000 psi 39.7 GPH (150 LH) stroking speed increase, pressure
23
Maximum No. Heads Minimum capability decreases. See specific
2 4.0 GPH (15 LH) product data sheet for actual pres-
sure rating at desired flow rate.
Milroyal D Milroyal D Capacities shown are for simplex
Maximum Pressure Maximum pumps. For those pumps that can
3000 psi 53 GPH (200 LH)
8 Minimum be supplied with more than one
Maximum No. Heads
6 0.0081 GPH (0.0307 LH) head, multiply the capacity by the
number of heads to determine
mRoy A & B mRoy A mRoy B total capacity.
13-24
Maximum Pressure Maximum Maximum
350-1500 psi 30 GPH (114 LH) 85 GPH (322 LH)
Maximum No. Heads Minimum Minimum
2 0.065 GPH (.246 LH) 0.475 GPH (1.79 LH)

Milroyal G Milroyal G
Maximum Pressure Maximum Pressure
160 psi 130 GPH (492 LH)
26 Maximum No. Heads Minimum
1 5 GPH (19 LH )

maxRoy B maxRoy B
Maximum Pressure Maximum
150 psi 227 GPH (859 LH)
27 Maximum No. Heads Minimum
1 13.5 GPH (51.1 LH )

MacRoy G & D MacRoy


Maximum Pressure Maximum
175 psi 300 GPH (1135 LH)
121/4- 271/2 Maximum No. Heads Minimum
1 0.018 GPH (0.068 LH)

Milroyal B Milroyal B
Maximum Pressure Maximum
11 7500 psi 500 GPH (1893 LH)
Maximum No. Heads Minimum
0.11 GPH (42 LH)
8

Centrac B Centrac B
Maximum Pressure Maximum
25 1575 psi 550 GPH (2082 LH)
Maximum No. Heads Minimum
2 0.45 GPH (100:1 Turndown)

Milroyal C Milroyal C
Maximum Pressure Maximum
18 7500 psi 2510 GPH (9500 LH)
Maximum No. Heads Minimum
5 0.43 GPH (1.628 LH)

PrimeRoyal PrimeRoyal
Maximum Pressure Maximum
72 30,000 psi 2510 GPH (9500 LH)
Maximum No. Heads Minimum
3 0.43 GPH (1.628 LH)

3
Liquid End Designs
T
he liquid end, which is tures in common. First, the liquid the suction ball check from its seat
referred to as the wetted is drawn into the wetted end by allowing liquid into the pump. At
part of the pump, is selected the rearward motion of a pis- the same time, the piston's motion
to meet the specific service condi- ton, and expelled by the forward and system back pressure hold the
tions of the application. Required motion. To achieve this, the meter- upper check valve (discharge) closed.
flow and pressure ratings are con- ing pump is supplied with check This is then reversed during the
sidered, as well as the physical and valves at the suction and discharge discharge stroke.
chemical properties of the liquid. connection points. The check Check valves are available in sev-
The liquid end's ability to protect valves contain and release the eral different designs and configura-
the environment is also a major chemical based on system condi- tions. The choice of ball or poppet
consideration when dealing with tions and gravity. style is determined by Milton Roy's
toxic or hazardous chemicals. During the suction portion of the Engineering department based on
All liquid ends have several fea- stroke, the motion of the piston lifts capacity of the specific pump.
Discharge Ball
Check Valve
Ball
Check
Seat

Single Double Poppet


Ball Ball Style
Discharge Check Check Check
Piston Valve Valve Valve
Suction
Most pumps feature either single or double ball configuration as standard. The
user can also select single or double ball when the application is better served
Process
Fluid by one or the other. For example, slurries or liquids with large fibers or particles
can cause a single ball to leak if particles are trapped between the ball and seat.
Suction Ball Therefore, a double ball check offers more stability and accuracy. On the other
Check Valve
hand, since each check valve causes some resistance in the flow path even when
open, viscous fluids are better handled with a single ball suction check valve.

Packed Plunger
The packed plunger style liquid end is the only Discharge Ball
Check Valve
liquid end in which the piston is in direct contact
with the process fluid. This direct contact offers
Grease Fitting
a number of advantages, including: high suction
and discharge pressure capabilities; high temper-
ature resistance, and lowest NPSH requirements.
The reciprocating piston requires packing to
seal the wetted parts from the atmosphere. This
simple design is effective, but places limitations
on the use of packed plunger pumps in certain Piston

applications.
Because a small amount of controlled leakage
past the packing must be expected, this style
liquid end should not be used with hazardous or
Packing Lantern Ring
toxic chemicals. Additionally, the friction between
the piston and the packing results in wear that
increases leakage. Periodic packing adjustment Process
Suction Ball Fluid
is necessary to maintain volumetric efficiency. To
Check Valve
avoid problems associated with leakage, consider
a diaphragm style liquid end. Available on: Milroyal B, Milroyal C, Milroyal D, Centrac, and
The packed plunger can handle pressures up Maxroyal.
to 15,000 psi, and temperatures to 600oF (with Standard Materials of Construction: 316 SS, Alloy 20, Cast Steel
special modifications). (larger models)

4
Disc Diaphragm
The disc diaphragm liquid end The hydraulic and process fluids ered redundant since this design is
has a Teflon diaphragm which pass through carefully engineered extremely durable.
acts as a barrier between the holes in the contour plates in order Because the process fluid must
piston and the process fluid. The to come into contact with the pass through relatively small holes
piston's pumping motion is applied diaphragm. Relief and refill valves in the contour plate, the disc dia-
to hydraulic fluid which causes the control the volume of hydraulic phragm liquid end is not the best
diaphragm to flex back and forth fluid. An automatic air bleed valve choice for slurries. With the excep-
as the piston reciprocates. continuously purges air from the tion of the mRoy P design, disc
The hydraulically actuated dia- hydraulic fluid. diaphragms are usually not the best
phragm operates with equal pres- The diaphragm style pump is choice when pumping viscous fluids.
sure between the hydraulic and sealed. It therefore is an excel- The disc diaphragm is capable of
process fluids. This eliminates dia- lent choice for hazardous, toxic, handling fluids where the required
phragm stress, since the pressure or corrosive chemicals. For extra injection pressure is 3500psi or
is essentially equal on both sides at protection, double diaphragm and greater and the fluid temperature
all times. Two contour plates encase leak detection modifications are exceeds 250oF.
the diaphragm to contain its travel. available, although they are consid-

Discharge Ball Automatic


Check Valve Air-Bleed Valve

Relief Valve

Contour
Plates Teflon
Diaphragm
Piston
Process
Fluid

Hydraulic
Fluid

Reservoir Suction Ball


Hydraulic Check Valve
Fluid

Available on: mRoy A, mRoy B, Milroyal B, Milroyal C


Standard Materials of Construction: 316 SS, Alloy 20, Plastic

5
Liquid End Designs
Mechanically Actuated Diaphragm Design

T
he Milton Roy Family of mechanically-actuated diaphragm pump is called the MacRoy Series G. They
represent the best balance between low pump cost and high quality performance. Because it has zero
diaphragm leakage, it makes a great pump for critical and otherwise expensive chemicals or where envi-
ronmental issues are involved. The mechanically-actuated series is an excellent choice where slurries and abrasive
chemicals are required up to the pump's maximum flow and pressure ranges. They are also well tolerant of high
viscosity liquids providing an economical solution for a variety of difficult applications.
Mechanically-actuated pumps are only limited to flow as a experienced by a liquid having off-
operate with a plunger directly matter of wetted end volume. gas characteristics. Some of these
attached to the diaphragm. This Maximum life of the pump can liquids that can generate off-gases
attachment generally takes place be achieved by replacing the as a result of pressure losses are
from a bolt and clamp being diaphragm at the recommended NaOCl, H2O2, and some specialty
placed through the plunger and service interval. Leak detection chemicals. Mechanically-actuated
through the diaphragm. The direct can be easily found from the pumps work well in these applica-
attachment of the piston to the air-filled chamber residing gener- tions providing 10:1 turndown as
diaphragm connects the pump's ally at atmospheric pressure on a standard across the product line.
drive and motor to the liquid end. the drive side of the liquid end. The addition of VFD technology
The motion of the pump drive This provides the least expen- and remote stroke control will
moves the plunger back and forth, sive leak detection option in bring the turndown as high
thereby causing suction from the the marketplace. as 100:1.
supply tank and pumping the fluid As with any chemical where gas Mechanically-actuated diaphragm
of choice through the attached binding can be a problem, it is rec- pumps are easily maintained
conveyance infrastructure. This ommended that a degassing valve and provide years of service for
series of pumps generally find be used to release off-gases from little effort.
pressure peaks at 175 PSI, but the agitation or pressure changes

Check Valve
Assembly

Oil Seal

Diaphragm

Slotted Pan Diaphragm Cap


Head Screw

Diaphragm
Head
Diaphragm

Process
Fluid
Set Screw

Check Valve
Assembly

Available on: MacRoy, Standard Materials of Construction: 316 SS, Alloy 20, Plastic

6
Metallic Diaphragm Liquid End and Critical Service Head

T
he Milton Roy Series of Metallic Diaphragms are unparalleled for use in critical, high pressure appli-
cations such as oil and gas platforms and specialty industrial applications. They are especially useful
where temperatures and pressures of both the environment and the process chemical can be vari-
able or otherwise difficult. The Metallic diaphragm lines are preferred for their longevity and durability in
many difficult applications.

Metallic diaphragm metering traditional materials. The metal diaphragms because of their high
pumps are hydraulically-actuated design of the diaphragm also man- reliability and longevity. In any appli-
in the same manner and style as a ages difficult chemicals such as cation where critical service is
standard hydraulically-actuated drive abrasives, slurries and other special required, the Milton Roy Metallic
liquid end. However, the teflon or requirements compounds easier Diaphragm is the product of choice
other usual diaphragm material is and more efficiently than its more for these chemical dosing situations.
replaced with a special metal alloy standard version.
particular to the application to Many oil and gas offshore drill-
produce higher pressures than more ing platforms require metallic

O-Ring

Screws
Diaphragm Diaphragm
Head
Suction Ball Backup
Displacement O-Ring O-Ring
Check Valve Chamber
Backup
O-Ring
O-Ring

Detail B
Diaphragm
Head Bolts /Nuts

Set Screws
Plunger Sleeve

Plunger

Plunger
Adapter
Nut

Process
Fluid

Hydraulic
Fluid

Available on: Milroyal C and PrimeRoyal: 316 SS, Alloy 20, Plastic
7
High Performance Diaphragm...
T
he High Performance Diaphragm liquid end, HPD, combines all of the best characteristics of traditional
liquid ends into one technologically advanced design. Its operating characteristics and simplicity of opera-
tion make it the best pump to consider first for most metering pump applications.
HPD operation is similar to the disc diaphragm in that it is hydraulically actuated and utilizes the same
shape and diaphragm. It is similar to a tubular diaphragm in the respect that the process fluid has a straight
through path through the liquid end. Its low NPSH requirements are similar to that of a packed plunger
liquid end. But the primary advantages of the HPD are the unique design features that separate it from tra-
ditional designs.

The MARS Advantage Discharge


tour plate, required by traditional disc
diaphragm liquid ends, places limita-
A hydraulically actuated diaphragm Process Contour Plate
tions on the types of process fluids
liquid end design requires a refill Hydraulic Side the pump can handle (such as slur-
system to compensate for hydraulic Contour Plate
ries) since the process fluid must also
fluid that bleeds past the piston or Hydraulic Fluid pass through contour plate holes.The
through an air bleed valve during nor-
process contour plate also creates a
mal operation. Hydraulic fluid is also
pressure loss which raises the NPSH
expelled from the chamber through
requirement of the liquid end.
the internal relief valve when the sys- Piston
tem experiences excess pressure, and
therefore must also be replenished.
The HPD features a Mechanically Process Diaphragm
The MARS System
Actuated Refill System (MARS) that Fluid The MARS System eliminates the
offers a number of advantages over Suction need for a process contour plate by
traditional refill systems.To under- Traditional Liquid End with Process assuring that the hydraulic fluid can
stand the advantages of MARS, tra- and Hydraulic contour Plates (refill only be refilled when the diaphragm
system not shown) has traveled all the way back to the
ditional refill systems must first be
explored. hydraulic contour plate. The dia-
phragm presses against the MARS
valve, which only then permits a pop-
Traditional Designs pet valve to open from the vacuum
Traditional designs use a system created by insufficient hydraulic fluid.
that refills the chamber when a (See the illustration lower right)
vacuum is created by the inability of Hydraulic overfill is therefore
the diaphragm to move beyond the impossible. With the process con-
hydraulic contour plate. It also refills tour plate gone, the straight through
when the suction is momentarily or path of the process liquid makes the
permanently starved by accidental HPD a perfect choice for slurries
valve closure, insufficient NPSH, or and viscous materials. It also lowers
other similar occurrences. When this the NPSH requirements of the pump,
happens, the hydraulic fluid chamber is since pressure loss through a process
overfilled because a vacuum has been contour plate is eliminated.
created even though the diaphragm Typical Contour Plate(Section cutaway) The MARS system also simplifies
has not been able to travel rearward. to come into contact with the dia- HPD start-up. Unlike other hydrau-
To avoid diaphragm rupture due to phragm. The pattern and size of these lic liquid ends, the refill valve does
overfilled hydraulic oil, a process side holes requires careful engineering to not need adjustment. Additionally,
contour plate stops the diaphragm's maintain the contour plate strength since the HPD hydraulic fluid can-
forward travel, and forces the hydrau- required to withstand the force of the not be overfilled, there is no need
lic relief valve to open, thus expelling diaphragm experienced at operating to perform delicate procedures to
the excess fluid. pressure. synchronize hydraulic fluid balances
The contour plate is a concave The hydraulic contour plate does (a difficult task required for tubular
(actually, concavo-convex) disc that not cause any problems in pump and other double diaphragm liquid
supports the diaphragm and limits its operation since the hydraulic fluid ends). With the HPD, you just fill
travel. The plate has a series of holes passes easily through the contour the reservoirs, and turn it on.
bored through it to permit the fluid plate holes. However, a process con-

8
...Advanced Liquid End Technology
HPD Preshaped Composite Diaphragm

T
he HPD features a pre-
Milroyal B shaped PTFE/elastomer
HPD Low Flow
composite disc diaphragm.
On the process side, the chemi-
cal resistance of PTFE is utilized.
Full side view of HPD Liquid
On the hydraulic side, the elasto-
End on MilRoyal Drive mer imparts favorable elastic and
mechanical factors.
Air Bleed/Relief Valve The composite diaphragm elimi-
Standard Materials: nates the inherent problems of
316SS. Alloy 20, Plastic. pure PTFE diaphragms. PTFE tends
to cold flow when compressed
between two metal parts (such as
those required to seal the hydrau-
lic side from the process side).
MARS Valve
The HPD composite diaphragm
Poppet features an integral "O" ring seal
around the perimeter of the dia-
Mechanically Actuated
phragm, which provides a better
Refill System (MARS) Piston seal between hydraulic and process
fluids than conventional diaphragm
Composite
Diaphragm materials.
The HPD is capable of handling
pressures up to 3025 psi and tem-
Removable peratures up to 300oF (with spe-
Check Valve cial modifications).
Hydraulic Refill Line

PTFE Elastomer

Process Hydraulic Reservoir Hydraulic


Fluid Fluid Fluid
Preshaped
Available on: Milroyal B, Milroyal C, Milroyal D, Centrac and Maxroyal. Composite
Standard Materials of Construction: 316SS, Alloy 20, Plastic. Diaphragm.

MARS System Operation


D D D

A C A C A C

B B B

Figure 1 Figure 2 Figure 3


Diaphragm (A) and piston (C) are Diaphragm (A) and piston (C) are full Diaphragm (A) and piston (C) are full
full forward. Mars valve (B) in for- rearward. Mars valve (B) is also rear- rearward, once again forcing Mars valve
ward position holds poppet valve (D) ward due to diaphragm position, thus (B) to its rearward position, which allows
closed, preventing refill line hydraulic freeing poppet (D) to open if required. poppet (D) to open if required. Low oil
oil from entering the chamber. Poppet (D) is shown closed, indicating volume creates a vacuum and opens pop-
hydraulic oil refill is not required. pet, permitting hydraulic fluid to enter the
chamber from the refill line.

9
Metering Pump Drive Mechanisms
All Milton Roy drive mechanisms feature gears that are submerged in an oil bath to assure long life. Capacity
can be adjusted while the pump is running or stopped, + 1.0% accuracy over a 10:1 turn-down ratio.

Hydraulic By-Pass
The hydraulic by-pass mechanism features a piston with a constant stroke length that pumps hydraulic fluid,
thus transferring the pumping motion to a diaphragm. Therefore, this type of drive can only mate with a hydrauli-
cally actuated diaphragm liquid end.
Capacity is varied by changing the location of a hydraulic by-pass port over the piston's path of travel. If the
port is positioned at 50% of the piston's stroke length, hydraulic fluid will be relieved through the port during the
first half of the piston's stroke, and pumped against the diaphragm during the remaining half. This type of drive is
often called "hydraulic lost motion," because a portion of the piston's travel does not transmit pumping energy
when the capacity adjustment is less than 100%. Both the mRoy and the Maxroy are hydraulic by-pass style
pumps. Both develop reciprocating piston motion by way of a worm gear set and eccentric.

mRoy A, mRoy B Motor


By-Pass Control
Plunger
By-Pass Port

In the mRoy, the piston pumps


hydraulic fluid, which either forces Eccentric
Control Discharge
the diaphragm to flex, or is relieved Valve
through the by-pass port. A control
valve positions the port based on a
desired capacity setting.
The mRoy drive with its standard Diaphragm
disc diaphragm liquid end features:
Stroke
Simplex or Duplex liquid ends Length
Worm Gear Set
Maximum capacities ranging
between 0.43 GPH and 85 GPH The mRoy drive with
(170 GPH Duplex) its standard disc dia- Reservoir Hydraulic Hydraulic Suction
Process
Maximum pressures up to 1800 psi phragm liquid end. Fluid Fluid Fluid

maxRoy B
In the maxRoy, capacity is varied by positioning a stroke adjust sleeve over by-pass ports bored through the hollow
piston. When operating at 100%, the ports are covered, which traps hydraulic fluid in the hydraulic pumping chamber.
Once trapped, the piston's pumping action forces the hydraulic fluid to flex the diaphragm.
A cup valve, which is attached to the diaphragm, closes all hydraulic paths to the diaphragm when it has reached
the full forward position. This eliminates a process contour plate, as well as excessive hydraulic pressure on the
diaphragm, since any excess hydraulic fluid in the hydraulic pumping chamber cannot reach the diaphragm, and is
forced through the internal relief valve to the
fluid reservoir.
Discharge Capacity Adjustment
Diaphragm By-Pass
Ports The maxRoy drive features:
Maximum flow rates between 135 GPH
and 227 GPH
Eccentric
Maximum discharge pressures of 150 psi
The maxRoy is an excellent choice for
mid-range metering pump capacity at low
pressure. Its design is more economical than
Hydraulic high pressure pumps in the same capacity
Fluid range, without sacrificing ruggedness and
Cup Valve Stroke Adjust accuracy. The "straight through" process fluid
Sleeve
Hydraulic Oil Piston Worm Reservoir Hydraulic path allows maxRoy to be applied to many of
Suction in Pumping Chamber Gear Set Fluid the same services as the HPD liquid end.

10
Polar Crank

T
he unique polar crank drive piston to the full forward position at between zero and maximum stroke
is the heart of the Milroyal the end of the discharge stroke. As for extremely accurate controlled
series metering pump. It is the crank continues to rotate, the volume pump settings.
considered the most advanced and angle of the crank causes the con-
reliable variable stroke length drive necting rod to pull the crosshead The Milroyal polar crank drive
available in high pressure/high flow and piston until it reaches the full features:
industrial duty metering pumps. rearward position at which point Maximum capacity ranges
In the polar crank drive, a high the connecting rod has reached the between 0.033 GPH (125mL/hr.)
speed worm gear reduces the RPM bottom of the rotation cycle. and 2510 GPH depending on
supplied by the motor, and provides Regardless of the stroke length frame size, stroking speed, and
the lower RPM to a rotating crank. A setting, the top of the rotation cycle plunger diameter
connecting rod with spherical bear- always forces the crosshead and the Discharge pressures up to
ings on each end links the crank to piston to the full forward position 7500 psi
the crosshead and piston assembly. at the end of each discharge stroke.
The worm gear and crank assembly This assures complete scavenging Up to 8 pumps multiplexed
pivots in an arc about the worm shaft of the liquid end during each stroke and driven by one motor
center to change stroke length. The cycle. HPD, packed plunger, disc
piston stroke length is determined by The angle of the polar crank can diaphragm, or tubular
the angle of the assembly. be adjusted in infinite increments diaphragm liquid ends
For example, when the pump is at
zero stroke, the worm/crank assem-
bly is in a vertical position. (Figure 1) Connecting
Lubricating Oil
Relief Valve
The crank then rotates in a vertical Rod
Worm Shaft
plane and one end of the connecting
rod revolves with it. The crosshead Cross
Worm
and the piston remain stationary Figure 1 Head
Rotating Gear Micrometer
because no reciprocating action is Zero Stroke Crank Capacity
produced. When the pump is adjust- Control
ed full stroke (or maximum capacity),
Stroke
the rotating crank is moved to its Length Worm Gear
maximum angle from the vertical axis. Discharge
Rotating Crank
(Figure 2) At the top of the rotation Lubricating Oil
cycle the connecting rod is pushed
forward, moving the crosshead and Figure 2 Suction
This illustration demonstrating the
Full Stroke polar crank at full and zero strokes

Pressurized Lubrication System


To achieve a high thrust capac- tem. This positive oil pressure lubri- crosshead. During the suction (rear-
ity and extend component life, the cation ensures long bearing life and ward) stroke the lubricant is trapped.
Milroyal B and C polar crank drives permits the Milroyal pump to operate It is then forced through the cross-
feature a pressurized lubrication sys- at very high suction and discharge head, into the crosshead connecting
Piston
Lubricating Oil pressures. rod bearing, through the hollow con-
Relief Valve As the cross- necting rod, and finally to the crank
head moves connecting rod bearing. By forcing the
Worm Shaft forward during oil through this path, every moving
the discharge part is lubricated during every com-
Worm Gear stroke, oil from plete cycle of the pump.
the reservoir To reduce the wear of moving parts
is drawn up and extend oil life, a magnetic strainer
through a ball cleans the oil before it enters the
Crosshead Lubricating Oil Micrometer check into a
Stroke
pressurized system.
Magnetic Strainer Connecting Rod Adjustment cavity in the

11
CENTRAC The Automatic Process
Advanced Drive Technology

C
entrac represents a new result is a metering pump that boasts Centrac is different from tradi-
concept in metering pump twice the accuracy over a turndown tional designs in many ways. The
drive design. It is the first ratio ten times greater than tradi- most significant way is the close
true innovation in metering pump tional designs. relationship between the driver
drives to be introduced in decades. Centrac's name clearly announces and drive mechanism and how they
Centrac was developed by combin- its capabilities: enhance overall pump performance.
ing the highest level of gear reduction CENT-100:1 turndown ratio To understand Centrac better, these
design, and the latest technology in R-Response & Reliability two design elements and their inter-
electronic variable speed drives.The AC - + 0.5% steady state accuracy dependence need to be explored.

Centrac's Unique Gear Reduction System


Centrac's impressive operating reciprocating motion, this gear set
characteristics are the result of a runs quietly and efficiently with few
unique constant stroke length drive moving parts. All moving parts are
mechanism that depends on a spe- submerged in oil to ensure long life.
cial electronic variable speed drive The graph below indicates the
to vary pump flow rate. This offers greatest advantage of Centrac's
a number of advantages. special gear design. The flat torque
Traditional designs utilize worm curve (vs. the worm gear set) allows Operator Control Station
gear sets to convert motor rotation Centrac to operate at or below
to reciprocating motion through 1% of speed without placing extra Centrac's Advanced
an eccentric or similar mechanism. demand on the motor, thus permit- Electronic Variable
Worm gears are the best choice ting Centrac's 100:1 turndown ratio.
when the drive mechanism is The simple drive mechanism also Speed Drive
required to allows Centrac to be Conventional AC and DC variable
incorpo- + easily duplexed within speed drives are limited to turn-
rate a vari- Motor Drive Gear Low Speed the same housing down ratios between 5:1 and 30:1.
able stroke (18 to 1800 RPM) Eccentric & Gear
by adding a second This is insufficient to take advantage
length piston and liquid end of the turndown capabilities of
adjustment. Piston opposite the primary Centrac's gear design.
They oper- + liquid end. Centrac's New technology in brushless DC
ate well at capacity can therefore motors and controllers has created
high rotary be doubled economi- advanced drives capable of strong
speeds, due cally and efficiently. operation at low speeds. Centrac's
Block transfers Rotating Eccentric
to an oil Motion to Reciprocating Motion variable speed
shield that CENTRAC Scotch drive delivers
develops Yoke Drive rated torque
between at less than
200 100:1 Turndown
the gear surfaces. Unfortunately, they 10:1 Turndown 1% (100:1
% of Motor Torque Required

lose that shield at lower speeds, 180


turndown)
which causes wear and raises motor yp of maximum
T

ica
lo
torque requirements. This limits 160 f Wo rated RPM
rm
worm gears to a 10:1 turndown G ea
r Pum
while main-
ratio. p Drives taining steady
140
Centrac, on the other hand, uti- state speed
lizes a special helical gear set. Since 120 control at bet-
there is no need for stroke length Typical of CENTRAC ter than +
adjustment, the gear set is very 100% 0.1%. It is the
simple. Also, helical gears are known Full 0 10 20 50 100 175 200 1700 1800 perfect match
for operating with low noise and Load for Centrac's
Motor Speed-RPM
low friction. Combined with a basic drive mecha-
Torque vs. Motor Speed-CENTRAC and Worm Gears nism.
scotch yoke mechanism to develop

12
Metering Pump
Motor Mount
Crosshead Eccentric Cage Eccentric

Liquid
End
Mounting Optional Duplex
Surface Configuration

Driver Shaft
Gear Assembly
Main Gear

Centrac's variable speed drive lic fluid volume remains constant. Centrac's features include:
features: When the hydraulic balance is dis- 100:1 turndown ratio
100:1 turndown ratio turbed, as in variable stroke length
designs, the full result of dosage + 0.5% steady state accuracy
+ 0.1% steady state speed changes can take minutes or hours. Instant response to dosage
control Centrac's instant response provides changes
smart commutation - permits smoother operation in closed loop Simple but robust design for
accurate feedback signal or automated systems. It also assures reliability
no brushes (low maintenance) proper dosage at all time in systems Precise feedback signal
constant torque at low speeds - requiring very close dosage tolerance.
Efficient drive sizing
permits efficient driver sizing
Mates with advanced HPD liquid
Accuracy end for maximum performance
Centrac's + 0.5% steady state
100:1 Turndown Ratio accuracy over its full turndown
Capacity range between 0.45
The flexibility of a 100:1 turn- GPH minimum and 1100 GPH
ratio is a result of the constant maximum
down ratio permits Centrac to
stroke length, and the precise speed
be applied where a wide range of Discharge pressures up to
control of Centrac's drive. This level
dosage rates are required. It also 1575 psi
of accuracy provides maximum
provides built-in growth potential
chemical economy while assuring Economical duplex configuration
by pumping efficiently in systems
stable automatic operation and opti- availability
requiring a fraction of the pump's
mum process quality. Compact design higher capacity
capacity for the short term dur-
ing start-up or early phases of an in a small footprint
expanding project. Centrac provides
all this without compromising accu- Connection Diagram Motor Control
Optional Remote
racy or drive power. Operator Control
Drive Motor

Response Speed
(Flow Rate)
Centrac responds instantly to Output
Signal
changes in dosage rate. Its con-
stant stroke length does not upset
the balance within the liquid end AC Input Power Remote Speed (Flow Rate)
hydraulic system, that is, hydrau- Control Signal

13
Capacity Adjustment
M
etering pumps allow the user to vary capacity as the process requires. All Milton Roy metering pumps
permit adjustment whether the pump is running or not.
With the exception of the Centrac (see Centrac drive), Milton Roy pumps are supplied with a manual
micrometer for performing manual capacity adjustments. Depending on the type of drive mechanism and the
application requirements, one of several capacity adjustment options can be supplied.

Manual Micrometer
The manual micrometer can be
used to adjust the metering pump's
capacity anywhere between 0 and
100%. While not directly propor-
tional to flow, this calibrated adjust-
ment can be used to accurately set
pump capacity based on the pump
performance curve within + 1.0% Manual
over the turndown ratio. Micrometer

Electronic Actuator
Option Available for: mRoy A & B, MaxRoy, Milroyal B & C
The Milton Roy Electronic Actuator responds to electronic process signals or remote manual adjust-
ments. In addition, a local handwheel is provided to permit manual adjustments when unpowered.
Milton Roy's electronic actuator is different from electric actuators in that it utilizes electronic
limits. It is built around stepper motor technology, which allows it to travel precisely to position
without overshoot or hunting.
This design also provides superior operating characteristics such as:
100% duty cycle
+ 0.5% position accuracy or better
low maintenance
Remote control stations are available for local/remote selection and manual capacity adjustment.
Specifications:
NEMA 4 (Explosion proof
available) 1-5 VDC stroke position
4-20 mA input signal output signal
standard Single phase 50/60
Direct or reverse acting cycle 115 VAC
Electronic Actuator on mRoy A

Pneumatic Actuators
Option Available for: mRoy A & B, Milroyal B & C
Automatic systems that supply a pneumatic process signal benefit from the Milton Roy
pneumatic actuator. A separate air control panel is available for remote control and auto/
manual switching.
Specifications:
3-15 or 3-27 psi pneumatic signal
Direct or reverse acting
Requires 60 psi supply air pressure

Pneumatic Actuator

14
Modifications
Double Diaphragm With Diaphragm Rupture Detection System
Milton Roy's diaphragm liquid ends tion, the two diaphragms are pushed
are, by design, leakproof and durable. tightly together and are separated
In some applications, however, added only around their outside edge by
assurance is desired to protect the the intermediate ring. The rupture
pump from hostile chemicals, or detection system senses a pressure
protect the process from contami- only when a diaphragm ruptures. The
nation by hydraulic fluids. For these system is not affected by changes in
situations, Milton Roy has developed pump discharge pressures.
a highly reliable diaphragm rupture This system is available for mRoys,
detection system. maxRoys, MacRoys, and HPD's. A
The system consists of two sepa- different design centered around
rate diaphragms, a hollow interme- sensing changes in conductivity
diate ring, and a pressure gauge or is also available for a number of
switch. During the normal opera- liquid ends.

Application Engineering: Custom Modifications


Milton Roy offers a wide variety of standard pumps to satisfy most applications. In addition, our Applications
Engineering department is capable of supplying specialty engineered products.
Capabilities include:
Special liquid end materials
including diaphragms, diaphragm
heads, check valves, etc.
Special piston diameters
High temperature or pressure
modifications
Unique multiplex arrangements
Application counseling
Special sensors, indications, or
instrument interface
Special drive modifications or
gear ratios

15
Metering Pump System Components
Proper metering pump system operation depends upon the selection of appropriate system components.
Milton Roy offers high quality accessories to suit your application requirements.

1.Safety Relief Valves 2.Back Pressure Valves 3.Pulsation Dampeners


Most piping systems require the To prevent unmetered liquid from The metering pump's reciprocat-
use of an external safety valve to free-flowing through the pump, ing motion provides a pulsating dis-
protect the piping from over-pres- metering pump systems require a charge flow. Applications requiring a
sure. Diaphragm pumps feature greater pressure in the discharge steady flow can eliminate over 90%
internal safety valves to protect the line than the suction or inlet line. of the pulsations with a pulsation
pump, but external safety valves are When the process does not supply dampener. Dampeners are available
still recommended. Milton Roy pro- a minimum of 25 psi above the suc- for pressures to 1000 psi. Sizing is
vides safety relief valves to match tion pressure, a back pressure valve based on cubic inch/stroke displace-
the operating pressures of all pumps is required. Standard back pressure ment of the specific pump.
we manufacture. Standard safety valves are available in specialty steel,
relief valves are available in specialty 316 ss, alloy 20 and PVC .
steel, 316 SS, alloy 20, and PVC.

4.Calibration Columns 5.Mixroy Mixers 6.Tank Chemical


All Milton Roy metering pumps
are factory tested. Once installed,
Accurate dosing requires proper
mixing of the solution being
Feed Systems
Milton Roy offers tanks (in most
pump calibration should be periodi- pumped. Mixroy mixers are direct available tank capacities) in steel,
cally determined to verify proper drive, high speed units designed for stainless steel, and polyethylene.
operation, especially after the mixing medium and low viscosity They are also available with pumps
performance of any maintenance. fluids and dispersion of light solids. and mixers mounted, plumbed, and
Milton Roy calibration columns
ready for installation.
provide an inexpensive means of
assuring pumping accuracy.

16
Typical Installation

1
To Process Safety
Valve

5
3
Pulsation
Dampener

Ball
2 4
Back
Valve Pressure
Valve
Calibration
Columns
6
Tank

Ball Ball
Pump Valve Valve
Ball
Valve

7
Strainer

Tank Cover

Pipe
Wire Plug
Screen
Wire
Fiberglass Screen

Balls
Lower
Housing

Bushing Pipe
Plug

7.Strainers/SludgeTraps 8.Chemical Dosing Systems


The metering pump's check valves should be Milton Roy offers the "RoyPak" family of chemical
protected from particles and debris by installing a dosing pre-engineered systems. The standard RoyPak
strainer in the suction line. provides manual control and all accessories to allow
When pumping concentrated sulfuric acid, a sludge for proper operation.
trap is required to trap sludge particles while providing The RoyPak Setpoint paces the dosing from your
easy cleaning or flushing. single input. The RoyPak Setpoint Plus uses a line of
Foot valves and strainers are available for applications instruments to provide a full closed-loop solution.
that pump fluid from replaceable drums. "Y" type
strainers can also be supplied for in-line protection in
standard systems.

17
Other Milton Roy Products
Streaming Current Detector
M ilton Roy's Streaming Current Detector
(SCD) is used to monitor and control
coagulants in water or wastewater treatment.
The SCD is an on-line instrument, therefore
consistent effluent quality is assured.
In addition to water and wastewater treat-
ment, the SCD is widely used in paper making,
petroleum, food, chemical, and other industries
where close control of coagulant or charge
altering chemicals are beneficial.

The Milton Roy Family of


Streaming Current Detectors

Electronic Actuators
A broad line of electronic actuators, similar to those used on Milton Roy pumps, is available for control valve
actuation and other applications requiring precision and dependability. These advanced electronic actuators out-
perform standard electric designs by utilizing stepper motor technology.

Milton Roy's electronic actuators offer the following advantages:


100% duty cycle
Electronic limit switches
Direct to position operation-no
hunting or overshoot
Rotary or linear designs
AC and DC units
Responds to 4-20 mA, split range,
digital and other process signals
Maximum torque - 3800 in-lbs
(317 ft-lbs)
Maximum thrust - 1100 lbs
Optional controllers and failsafe units

18
Notes
Notes
Bulletin 210
Revision C 7/08

Teflon is a registered trademark of


E. I. du Pont de Nemours and company
or its affiliates.

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