Internal gear pumps are a vital component in many industrial applications and are known for their efficiency, reliability, and versatility in handling a wide range of fluids. This article explores the fundamental operating principles behind internal gear pumps, focusing specifically on the innovative design characteristics of Viking Pump, an industry leader in fluid handling technology. By understanding how these pumps function, including the interplay between gears, fluid dynamics, and mechanical precision, readers will gain insight into why internal gear pumps are favored in everything from chemical processing to food and beverage production. The following sections will break down the mechanics, highlight key features of Viking Pump’s design, and discuss the advantages that make this technology a standout solution in diverse industrial settings.
What are the advantages of using an internal gear pump?
Self-priming capabilities and handling a wide range of viscosities
The unique capability of an internal gear pump to induce suction at the inlet enables the pump to operate effectively under self-priming conditions. Internal gear pumps can pump fluids without having to fucking choke the pump. Because of this, they’re useful for chemical transfers and unloading tanks where suction must always be consistent and effective.
The versatile nature of internal gear pumps also allows effective performance even at viscosity ranges of 1 cP, such as solvents, to over 1 million cP like heavy molasses and polymers. Internal gear pumps utilize only two internal parts to build these pumps. This means that there is very low fluid shear, which enables smooth operation while also avoiding breakdown due to stress factors. Some factors include:
- Rotational Speed: High viscos fluids need reduced speeds so that they achieve insufficient flow while shear is minimized.
- Clearances: Thicker fluids often require adjustable clearances to achieve friction without needless wear.
- Material Compatibility: Stainless steel or cast iron can be used to withstand a range of chemical compositions.
All of these features allow an internal gear pump to work for industries that require a wide range of fluid types to be pumped, making these pumps simple works of art.
Efficient performance with minimal pulsation
Internal gear pumps effectively reduce pulsation and achieve high levels of efficiency by employing smooth flow which is inherent in their design. Their pumps, unlike other types, utilize overlapping gear teeth that maintain a constant flow rate. This feature, greatly mitigates pressure fluctuations therefore is essential for applications in precise chemical dosing or hydraulic systems.
- Flow Rate Deviation: Ensured with a variability of less than ±1%, even with changing operating conditions.
- Pressure Capability: Supports up to 300 PSI (20.7 bar), depending on the model and material specifications.
- Viscosity Handling: Without compromising flow stability, these can efficiently operate within the viscosity range of 1 to 1000000 cP.
- Energy Efficiency: Volumetric efficiency often occurs above 90% due to tight clearances and internal leakages.
Due to precision engineering and the use of materials designed for specific industries, these ranges of technical requirements provide low-pulsation performance across many fluid processing tasks.
Versatility in various industrial applications
Our equipment achieves outstanding flexibility in its application in various industries with different levels of fluid viscosity, flow rates, and operational conditions. As an example, volumetric flow can go as high as 1000000 cP which considers food and beverage and as well as chemical and oil and gas industries. Moreover, high energy efficiency of greater than 90% guarantees low energy cost even in very high demanding situations.
- Efficiency: Savings in cost across operations are achieved due to greater than 90% volumetric efficiency.
- Construction Materials: Designed and built for chemical, high purity, or abrasive slurry applications, engineered using corrosion-resistant, robust construction.
This demonstrates the results of comprehensive testing, advanced engineering, and compliance with industrial norms for varying operational environments.
How does an internal gear pump differ from other positive displacement pumps?
Comparing internal gear pumps to external gear pumps
The difference between internal gear pumps and external gear pumps is in design as well as in the working principles. Internal gear pumps operate using a rotor and an idler where the idler is enclosed within the rotor. This leads to an efficient flow path, which results in reduced pulsations. Due to this configuration, internal gear pumps are more versatile in the range of fluids they can pump. Regarding key technical parameters, internal gear pumps have a flow rate between 0.1 to 150 gpm and efficiently operate under a pressure of 250 psi depending on the application. In addition, the self-priming ability of internal gear pumps is unmatched, where they can achieve suction lifts of 20 feet.
In contrast, external gear pumps use two intermeshing identical gears to displace liquid. Compared to their housings, these pumps are more compact, leading to limited space for internal components. However, in comparison to their internal counterparts, external gear pumps have a more extensive range of pulsation. External gear pumps are robust and best suited for high-precision applications. Their flow rates can vary from 0.1 to 500 gpm, and they can tolerate a pressure of 3000 psi, which is why they are optimal for high-power systems.
These two designs differ based on the technical requirements of viscosity, fluid sensitivity, pressure, and flow rate.
Internal gear pumps vs. centrifugal pumps: When to choose which?
It is the application requirements which dictate whether to use internal gear pumps or centrifugal pumps. Internal gear pumps are most suited for fluids with high viscosity such as diesel, oils, or syrup, since they are not affected by changes in fluid viscosity. They are also quite efficient in low flow, high pressure situations. Their pressure capabilities are 3000 psi while their flow rates can be as low as 0.1 gpm. Additionally, internal gear pumps provide sensitive and high-accuracy delivery for incredible measurement control.
Centrifugal pumps are more appropriate for low viscosity fluids, for example, in water or chemical processes, where the flow is required to be high and the pressure lower. These pumps are most economical for pumping water or other fluids, since their efficiency in large multicellular systems is highest when the pressure requirements do not exceed 150 psi. Furthermore, efficient centrifugal pump designs are maintained when the fluid viscosity is below 500 cP, which makes them easy and cheap to operate and maintain.
In conclusion, my preference for the type of pump used are centrifugal pumps which are suited for high flow, low pressure systems, and internal gear pumps which are more suited for high pressure, high accuracy, and viscous fluid applications.
What are the common applications for internal gear pumps?
Industries that benefit from internal gear pump technology
It is the high versatility, accuracy, and capability to process highly viscous fluids that make internal gear pumps popular in many sectors of many industries. These features of internal gear pumps make them ideal for application in the chemical and petrochemical industries where flow rates must be maintained precisely and materials like resins and polymers are very viscous. EBBI internal gear pumps are particularly efficient in this sector because they can operate with viscosities between 100 cP to over 50,000 cP.
Further, the internal gear pumps in the food and beverage industry help in the transportation of products like chocolate and syrups as the pumps ensure that hygiene is maintained and the product’s viscosity is not compromised. Lubrication systems in machinery also benefit from this kind of internal gear pump, as it has the capability to handle pressures of up to 300 psi, which allows for efficient penetration of oil.
Lastly, I would like to point out their application in the coatings and paint industry where the abrasive nature of the fluids and the viscosity requires controlled flow rate with accurate flow rate. The distinct functionality and reliability these pumps offer across these industries showcases their relevance which drives the demand for these pumps.
Specific fluids and materials ideal for internal gear pumps
Like all pumps, internal pump gears are specially designed to accommodate a range of fluids such as hydraulic oils, diesel/fuels, polymers, and even asphalt and chocolate, which tend to be on the higher side of the viscosity range. The pump’s design allows for efficiency while reducing unnecessary wear and tear. The internal pump gears can efficiently work with both low and high viscosity substances from a low range of thin liquids to gases.
- Operating Temperature: Typically, fluids with a temperature ranging between -40 degrees F to 600 degrees F (-40 to 315 degrees C) can be handled, but this depends on the material construction and seal.
- Abrasion Resistance: Ensures capability to manage abrasive fluids through robust construction materials and hardened steel for substances like coats, paints, etc.
- Pressurised Environment: Able to perform under 300 psi with immediate effect, ensuring efficiency when tackling high-pressure conditions.
- Flow Rate Control: Adjustments towards the flow rate can be made, all while maintaining process accuracy. Ideal for food production chemicals and equipment.
Making precise adjustments to all these factors makes internal gear pumps a reliable solution for tasks requiring both accuracy and precision.
How do you maintain and troubleshoot an internal gear pump?
Regular maintenance tips for optimal performance
To maintain the necessary and effective work of an internal gear pump, I concentrate on the following aspects of maintenance:
- Always Check Internally: I listen to the internal noise alongside the perception of motion to determine the level of wear on rotors, gears, and casing. When components misalign or wear out, I know that a peculiar rotation noise coupled with unusual vibrations will occur.
- Lubricating Provisions: To guarantee proper functioning, the device cannot be overheated. In this case, friction has to be reduced to a bare minimum.
- Seal Examination: For a shaft seal that has cracks or leakage, the likelihood of contamination, as well as pressure drops, is high. If the seal is close to wearing, then I replace it.
- Routine Cleaning: As part of maintenance, cleaning pumps is helpful in freeing any build-up of gunk within the unit and aiding in preventing the unit from being blocked particularly when dealing with abrasive liquids.
- Flow and Pressure Rate Monitoring: When measuring flow rate alongside the operational pressure, 300 psi maximum is the value set in the specifications.
- Changing Damaged Parts: After a certain period, essential elements such as bearings or rotors might get damaged because of wear and tear or excessive use. I change these parts as required in order to keep the pump precise and its functioning dependable.
By methodically applying these maintenance techniques and observing operational conditions, I am able to guarantee the life and productivity of the internal gear pump. At the same time, I reduce the amount of unnecessary downtime.
Identifying and addressing common pump failure issues
In dealing with pump failure issues, my approach is to understand the issue deeply and take reasonable actions and meet technical standards:
- Cavitation of Pump: Cavitation occurs when vapor bubbles are produced in the liquid, resulting from low inlet pressure or by excessive suction lift. My measure of solving it is ensuring an adequate Net Positive Suction Head (NPSH) by reducing suction lift, increasing inlet pressure, and ensuring an appropriate pipe size pair to improve flow. Cavitation damage must be avoided by maintaining an NPSH above the qualified value provided by the pump manufacturer.
- Leakages Problems: Leaks are commonly caused by defective seals and assembled components. I do clean checks on mechanical seals to ascertain wear and then replace them with properly specified components in regards to range of temperature and pressure, for example seals that are rated for 300 psi and made from liquid compatible material.
- Overheating: Unrelenting overheating may be a result brought about by poor lubrication or obstructed systems. I track the temperature on the pump sheath with the rated zone. I also ensure that lubricating materials meet required conditions by the manufacturer. Lastly, I unclog the fluid pathway to enable free flow of coolant.
- Decreased Flow Rate: A drop in flow rate is often the result of filtered out residues, or internal wearing. I complicate or substitute filters and conduct a thorough inspection on components like rotors and bearings. I replace the components like specified by the manufacturer so that the utmost functional efficiency can be restored when wear exceeds the tolerances specified.
By approaching these problems in an organized manner for resolution with the appropriate technical interventions, I am able to guarantee that the pump works within the required performance standards in an efficient and reliable manner.
What factors affect the flow rate and efficiency of an internal gear pump?
Impact of gear design and clearance on pump performance
The performance of an internal gear pump rests on the design and clearance of the gears because flow rate and efficiency are altered. To determine the volumetric capacity and the pump’s minimal slippage, I reviewed the profile of the gear and the geometry of the tooth. For instance, volumetric efficiency will be improved, and backflow will be reduced with the machining of precise and tight gears.
Clearance is also important to the efficiency of the operation of the pump as it has one of the largest impacts. Large gaps in the pump with respect to the gears create headspace that weakens the efficiency of the pump as there will be internal leakage. On the other side, insufficient clearance could result in severe mechanical damage due to the parts grinding against each other and providing excessive friction which leads to overheating.
- Gear Meshing Clearances: measurements that will avoid backflow or negative wear and are aligned with accurate specifications from the gears’ manufacturers. Gears’ meshing clearances are evaluated in micrometers (µm).
- Housing-to-Gear Clearance: Used to avoid exceeding operational smoothness while maintaining functional sealing. Generally is between 0.03 mm and 0.1 mm.
- Operational Speeds: Rotations per minute that fall under the suggested marks to avoid clearance problems at high speeds.
- Material Consideration: The difference in the composition of housing and gears results in varying rates of thermal expansion and contraction during operations and must also be assessed during the operational analysis.
I’m able to optimize the flow rate and efficiency of the pump concerning its technical prerequisites by designing suitable clearances and modifying the clearances of the gears.
Importance of proper viscosity matching
To properly match the viscosity of fluids, they must be able to function effectively in hydraulic systems and pumps. Poorly matched fluid viscosity could result in reduced productivity and increased wear and tear on the equipment or total system failure.
- Operating Temperature: Fluids are chosen from those whose viscosity indices match the expected temperature fluctuations, which are usually between 10 degrees celsius and 80 degrees celsius. This ensures that film strength is maintained and fluid degradation is minimized.
- Pump Design: The viscosity range and target indices I defined are aligned with the target capacity specifications of the pumps. This is usually between 16 cSt and 36 cSt at the operating temperature. This is done to ensure the optimum flow characteristics are met.
- System Pressure: To obtain film stability in high-pressure systems, a higher viscosity value is necessary, and these should generally be above 20 cSt to reduce internal leakage and safeguard against wear.
- Startup Conditions: For startup conditions that are cold, I analyze the pour point of the fluid and its viscosity behavior at low temperatures to ensure it stays within the defined limits to avoid cavitation or stress on the device.
Adjusting the working fluid’s viscosity to these parameters ensures that I am comfortable managing risks while simultaneously system performance, thermally and mechanically loading fluid.
Frequently Asked Questions (FAQs)
Q: What is an internal gear pump, and how does it work?
A: An internal gear pump is a type of positive displacement pump that uses a unique “gear within a gear” design. It consists of an outer rotor gear that meshes with an inner idler gear. As these gears rotate, they create cavities that draw fluid in at the pump inlet, carry it around the pump casing, and expel it at the discharge side of the pump. This ingenious design allows for efficient and smooth fluid transfer.
Q: What are the main components of an internal gear pump?
A: The main components of an internal gear pump include 1. a Drive gear (outer rotor) 2. Idler gear (inner gear) 3. Pump casing 4. Crescent-shaped partition 5. Inlet and outlet ports These moving parts work together to create the pumping action.
Q: How does fluid flow through an internal gear pump?
A: Fluid flow in an internal gear pump follows this process: 1. Suction at the pump inlet creates a vacuum. 2. Fluid is drawn into the pump as the gears come out of the mesh. 3. The fluid is trapped by the gear teeth as the gears rotate against the pump casing. 4. As the gears mesh again, the fluid is forced out through the discharge side of the pump.
Q: What are the advantages of internal gear pumps?
A: Internal gear pumps have several advantages: 1. They have better suction capabilities than other gear pump designs. 2. They can handle a wide range of fluid viscosities. 3. They provide smooth, pulse-free flow. 4. They have relatively few moving parts, making them reliable and easy to maintain. 5. They can operate at various speeds and pressures.
Q: In which industries are internal gear pumps commonly used?
A: Gear pumps are commonly used in various industries, including: 1. Oil and petrochemical 2. Food and beverage 3. Pharmaceutical 4. Chemical processing 5. Paint and coatings 6. Automotive They are particularly useful for applications requiring precise fluid transfer and handling of viscous liquids.
Q: How does the Viking Pump design differ from other internal gear pumps?
A: The Viking Pump design incorporates a unique crescent-shaped partition between the idler gear and the rotor gear. This crescent helps to separate the suction side from the discharge side of the pump, improving efficiency and reducing internal slippage. The Viking design also allows for easy maintenance and part replacement.
Q: What types of fluids can internal gear pumps handle?
A: Internal gear pumps are versatile and can handle a wide range of fluids, including 1. Low to high viscosity liquids 2. Clean or mildly abrasive fluids 3. Lubricating and non-lubricating fluids 4. Temperature-sensitive materials 5. Shear-sensitive fluids This versatility makes gear pumps useful in many applications across various industries.
Q: How do internal gear pumps compare to other positive displacement pumps?
A: Compared to other positive displacement pumps, internal gear pumps have better suction capabilities and can handle a wider range of viscosities. They also provide a smoother flow with less pulsation than some other pump types. Internal gear pumps are generally more compact and have fewer moving parts than many other positive displacement pumps, making them easier to maintain and repair.
