unibloc engineering manual

7/27/2019 Unibloc Engineering Manual

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UNIBLOC

-PD

PUMP ENGINEERING MANUAL

1701 Spinks Drive SEMarietta, GA 30067-8925 USA

(770) 218-8900 fax (770) 218-8442www.flowtechdiv.com [email protected]

TECHNICAL MANUAL NO. MANUAL3G.DOC


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INTRODUCTION

The UNIBLOC line of positive displacement pumps are manufactured by TEKNOFLOW Inc./Flowtech Div.

located in Marietta, GA USA. The pumps have been designed mainly for the sanitary industries, but are

suitable for many industrial applications as well.

The information enclosed in this engineering manual will give fundamental information to properly select a

UNIBLOC pump. It has also been produced in an effort to educate anyone who may be involved in with the

selection and use of a positive displacement pump. If for any reason the information presented is not clear or

additional assistance is needed please contact Flowtech or one of our distributors.

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CONTENTS

Page

1. Fluid Flow Fundamentals......................................................... 4

2. Fluid Flow in a System ............................................................ 6

3. Rotary Lobe Pump Fundamentals............................................ 12

4. Shaft Seals................................................................................ 15

5. Safety Equipment ..................................................................... 17

6. Motor and Drive Fundamentals ............................................... 20

7. LABTOPIntegrated Pump Systems........................................ 21

8. UNIBLOC

Performance Data ................................................. 22

9. Pump Selection Procedure ....................................................... 23

10. Pipe Friction Loss Chart .......................................................... 25

11. Pump Performance Charts........................................................ 26

12.UNIBLOC

Dimensions........................................................... 48

13. Chemical Resistance Information ............................................ 56

14. Pump Application Data Sheet .................................................. 57

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1. FLUID FLOW FUNDAMENTALS

The following properties and concepts are useful when analyzing a fluid that is going to be handled

with a UNIBLOCpump.

DENSITY is mass per unit volume and changes inversely with temperature, i.e. density decreases as

temperature increases.

SI units: Density (kg/ m3) = mass (kg) / volume (m

3)

Standard units: Density (lbs./ ft3) = mass (lbs.) / volume (ft

3)

SPECIFIC GRAVITY, S.G., is the ratio of a fluids density to the density of water.

SI units: S.G. = Fluid Density (kg/ m3) / 1000 (kg/ m

3)

Standard units: S.G. = Fluid Density (lbs./ ft3) / 62.4 (lbs./ ft

3)

TEMPERATURE is a measure of a fluids internal energy.

SI units:0C

Standard units:0F

ABSOLUTE VISCOSITY is a measure of the fluids resistance to a shear force.

It is determined by measuring the force needed to rotate a spindle suspended in the

fluid. It decreases as temperature increases.

SI units: kg/ms

Standard units: cPs

KINEMATIC VISCOSITY is a measure of the time it takes a fluid to travel, by

the force of gravity, through a vertical tube over a certain distance.

SI units: Kinematic Viscosity (m2/s) = Absolute Viscosity (kg/ms) /

Density (kg/ m3)

Standard units: Kinematic Viscosity (ft/s) = Absolute Viscosity (cPs) / Density

(lbs./ ft3)

STATIC HEAD is the pressure at a point in a fluid at rest.

FRICTION HEAD is the loss in pressure or energy due to friction.

PRESSURE HEAD is pressure (psig or bar) expressed as head (ft. or meters).

DISCHARGE HEAD is the pressure at a pumps outlet.

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TOTAL HEAD is the pressure difference between a pumps inlet and outlet.

SUCTION HEAD is the inlet pressure of a pump when above atmospheric.

SUCTION LIFT is the inlet pressure of a pump when below atmospheric.

FLUID TYPES

Newtonian Fluids exhibit no change in viscosity as the shear rate,

velocity, changes. They include such fluids as water, mineral oil, and

syrups.

Non-Newtonian Fluids include several types whose viscosities vary as the shear rate, velocity, changes.

Plastic Fluids require an initial force, or yield point, at which they will

begin to flow.

Pseudo Plastic Fluids decrease rapidly in viscosity as the shear rate,

velocity, increases. Their viscosity is independent of time.

Thixotropic Fluids decrease in viscosity, with a constant shear rate,

over a period of time. They may also have a yield point and show

pseudo-plastic characteristics. They include paints, inks, gels, lotions,

and shampoo.

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Dilatent Fluids increase in viscosity as shear rate increases and is

independent of time. They include clays, oxides, and crystalline

materials.

2. FLUID FLOW IN A SYSTEM

As a fluid moves through a system of tanks, pipes, equipment, valves, and fittings the energy in the

system is conserved, but changes form. The types of energy are described below.

KINETIC ENERGY is due to the motion of a fluid.

= 1/2 x mass x velocity2

POTENTIAL ENERGY is due to the height of a fluid.

=height x mass x accel. of gravity

PRESSURE ENERGY is internal energy of a fluid which could do work.

MECHANICAL ENERGY is put into the fluid by a pump.

FRICTIONAL LOSSES represents the energy

lost due to friction as the liquid moves through

straight piping, elbows, reductions, valves,

strainers, heat exchangers and other equipment.


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

system.

PA The starting pressure may be constant atmospheric pressure if the system is open or if it is

closed, the pressure inside the supply vessel.

A At the beginning point there is pressure energy, PA, and potential energy due to the elevation of

the supply vessel above the pump.

A-B Moving from A to B the potential energy changes to pressure energy.

B-C Potential energy is further changed to pressure energy. However, some of the pressure energy is

lost due to friction.

C-D Additional pressure energy is lost due to pump frictional losses. Then mechanical energy is

added by the pump and pressure energy rises quickly.

D-E As the fluid moves to a higher elevation the pressure energy is reduced in the form of frictional

losses and the remainder changes to potential energy.


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E-F The remaining pressure energy is changed to potential energy. An analysis of the fluids energy

at the inlet must be performed to insure that the fluid is able to enter the pump and to also do so with

enough energy to prevent cavitations. The energy available in the fluid in a system is determined by

subtracting the fluids vapor pressure from the pressure at the inlet. This Net Inlet Pressure Available

(NIPA) may be converted to head to give Net Positive Suction Head Available (NPSHA). The

NPSHA must be higher than the Net Positive Suction Head Required (NPSHR).

The NPSHR is different for each pump size and is also dependent on each pumps components and the

operating conditions of the system. It can only be determined by testing a pump. If the NPSHA is less

than the NPSHR the fluid will not enter the pump. If it is high enough to allow fluid into the pump, but

less than the fluids vapor pressure then cavitations will occur, resulting in noisy pump operation,

vibration, deterioration of the fluid, pump damage, and damage to other system components. The

following graphs illustrate under what typical conditions the NPSH values may change. The shade

area indicates the safe operating range.

INLET

PRESSURE

FLUID

VAPOR

PRESSURE

NIPRNIPA

When viscosity is increased the NPSHR and NPSHA is reduced, as

well as the safe operating area.

Increasing the pump size decreases the NPSHR and increases the safe

operating area.

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Reducing the inlet pipe length, fittings, valves, and elbows and

increasing the inlet pipe diameter reduces friction losses and increases

the NPSHA, as well as the safe operating area.

Increasing the inlet pressure by elevating the feed vessel or pressurizing

it increases the NPSHA and the safe operating area.

Reducing the pump speed decreases the output capacity and moves the

running point to a larger safe operating range.


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The illustration above shows an optimized system in which the inlet pressure required has been

reduced. The short, large diameter inlet pipe reduces friction from point B to C, which is very

important when highly viscous fluids are being pumped. In such cases a pump with a rectangular inlet,

which increases the inlet area, is also crucial to proper pump operation.


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The system shown above illustrates the ability of the UNIBLOCpumps to lift liquids. The surface of

the liquid in the supply tank at left is located below the pump inlet and thus there is no energy to push

the liquid into the pump. Furthermore, an analysis of the total pressure loss from the tank to the pump

inlet will yield a negative Net Inlet Pressure Available (NIPA). As a result, a vacuum greater than the

negative NIPA must be created in the supply line (B-C) in order to lift the liquid and fill the pump.

Priming the pump in this manner may be accomplished by pressurizing the tank such that the negative

NIPA is reduced or a positive NIPA is created. The pump may also be run dry to create this vacuum.

The standard Class C rotors, or special low clearance rotors (i.e. polymer rotors), and specific shaft

seals must be used in this case. The priming ability can be improved if the pump has some fluid in it.

This creates a film of liquid between the rotors and the housing, filling the clearances and making the

pump more efficient. The chart at left shows how the pumps ability to create a low pressure at the

inlet improves the more liquid it initially has inside the housing.

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3. ROTARY LOBE FUNDAMENTALS

The UNIBLOC

pump is a rotary lobe pump that moves fluid by creating a low pressure cavity at the inlet

side which draws fluid into the pump. The lobes, or rotors, then close the cavity as they turn in the housing.

As the rotors mesh at the outlet port the fluid is squeezed out of the pump.

The UNIBLOC

pump delivers a constant volume over time, with very small pulsations. Other types

of positive displacement pumps, however, have great variations in the discharge flow which result in

pulsations with large amplitudes as found with peristaltic pumps or high frequency pulsations as is

common with gear or multi-lobe pumps.

UNIBLOC-PD PERISTALTIC

PUMPS

GEARPUMPS

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The shape of the rotors in

the UNIBLOC

pump has

been designed to maximize

its efficiency. The long arc

shape of the rotors makes a

long seal as it sweeps

around the rotor housingcavity minimizing slip.

SLIP, or backflow,in a

rotary lobe pump is a

condition in which liquid

moves backwards from the

high pressure, outlet, side of

the pump to the low

pressure, inlet, side. To prevent galling and wear, the rotors have been designed such that they do not

touch each other, the housing, or the cover. A thin space is thus created through which fluid may

move. This movement of fluid is called slip and is an indication of the efficiency of a pump. A pump

with a higher rate of slip will have less output.

The slip rate increases very quickly as the clearances increases.

It is proportional to the clearance cubed (C3).

Slip decreases quickly as the fluid viscosity increases.

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Slip increases as pressure increases.


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The energy level (temperature) of the liquid that remains inside

the pump increases as slip increases.

The fluid that squeezes through these thin spaces is subject to high shear stress and may damage the

product if it is sensitive to such a stress. However, such degradation of the product can be minimized o

or eliminated with the proper pump size and speed.

The UNIBLOC

pumps may also be used to meter low viscosity liquids if conditions are suitable. At

low pressures and high speed the percentage of slip is low compared to the actual amount that exits the

pump. Therefore, at a constant speed the pump will deliver a constant capacity which can be

determined by measuring the number of revolutions the pump shaft turns. The system should dedesigned so that its pressure is also constant, as shown below.

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4. SHAFT SEAL OPTIONS

SINGLE MECHANICAL SEAL

Available for all pump sizes. Operating speed up to 1500 rpm.Maximum viscosity 5,000-100,000 cPs. Available seal materials

are stainless steel, carbon, and silicone carbide. Sanitary, high

speed, high pressure, can run dry for very short periods, long life.

FLUSHED SINGLE MECHANICAL SEALAvailable for all pump sizes, except the 200, 250, and 275 . Operating

speed up to 1500 rpm. Maximum viscosity 5,000-100,000 cPs.

Available seal materials are stainless steel, carbon, and silicone carbide.Sanitary, high speed, high pressure, can run dry, long life.

DOUBLE MECHANICAL SEALAvailable for all pump sizes, except the 200, 250 and 275.

Operating speed up to 1500 rpm. Maximum viscosity 5,000-

100,000 cPs. Available seal materials are stainless steel, carbon,

and silicone carbide. Sanitary, high speed, high pressure, can run

dry, long life.

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SINGLE O-RING SEALAvailable for all pump sizes. Operating speed up to 300 rpm.

Maximum viscosity 500,000-1,000,000 cPs depending on the

product type. Inexpensive, low speed, moderate pressure, easy toreplace, works well with sticky liquids, can not run dry.

DOUBLE O-RING SEALAvailable for all pump sizes, except 200, 250, and 275. Operating

speed up to 300 rpm. Maximum viscosity 500,000-1,000,000 cPsdepending on the product type. Inexpensive, low speed, moderate

pressure, easy to replace, works well with sticky liquids, can run dry

for short periods.

DOUBLE O-LIPTM

SEALAvailable for all pump sizes, except 200, 250, and 275. Operating

speed up to 500 rpm. Maximum viscosity 100,000-1,000,000 cPs

depending on the product type. Moderate speed, moderate

pressure, very durable, easy to replace, works well with sticky

liquids, can run dry, long life.

FLUSHED DOUBLE O-LIPTM

SEAL

Available for all pump sizes, except 200, 250, and 275. Operatingspeed up to 500 rpm. Maximum viscosity 100,000-1,000,000 cPs

depending on the product type. Moderate speed, moderate pressure,

very durable, easy to replace, works well with sticky liquids, can run

dry for long periods, long life.


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FLUSHED SEALS

Seals provided with flush housings must be fitted with flushing systems that will cool and lubricate them,

otherwise the seals will NOT OPERATE CORRECTLY. The flushing system also provides a barrier of

protection between the environment and the pumped media. The o-ring and double o-lip seals may be

filled with a lubricating grease that is approved for contact with the pumped media instead of using the

following flushing systems. The piping arrangements and system components are recommended forsatisfactory operation of the seals and to insure containment of the pumped liquid.

FLUSHOUTLET

CONTROL VALVE(i.e diaphragm valve)

VERTICAL PUMP PORTS

(recommended piping arrangement)

HORIZONTAL PUMP PORTS(recommended piping arrangement)

PRESSUREGAUGE

SHUT OFFVALVE

FLUSHINLET

CHECKVALVE

CONTROL VALVE

(i.e diaphragm valve)SHUT OFF

VALVE

CHECKVALVE

FLUSHINLET

PRESSUREGAUGE

FLUSHOUTLET

FLUSHOUTLET

SHUT OFFVALVE

FLUSHINLET

FLUSHOUTLET

PRESSUREGAUGE

CHECKVALVE


FLUSHINLET

SHUT OFFVALVE

CHECKVALVE

PRESSUREGAUGE


The illustrations at left show

alternative methods of arranging the

flushing system and its components.

Although not ideal, they are

adequate for less critical pump

applications.

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5. SAFETY EQUIPMENT

RELIEF VALVE

Positive displacement pumps can develop pressures in

excess of safe operating parameters if a restriction or

blockage occurs in the discharge line. An external bypass

line with a relief valve, as shown at left, is highly

recommended.

If such an arrangement is not practical a cover with a relief valve,

shown at left, is available for all pump sizes except the 200, 250, and

275. Its bypass flow capacity, however, is much smaller than an

external line and therefore the fluid that re-circulates through the relief

valve will heat up very quickly. Also, once the valve openingpressure is reached the bypass and system pressures will increase more

rapidly than if an external line is used.

RELIEFVALVE

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PRESSURE SENSING DEVICES

Dial pressure and/or vacuum gauges installed at the inlet and outlet of the pump will provide a quick visual

indication of the status of the system. A pressure switch at the pump outlet is connected to the pumps

electric motor and will stop the motor in case the system pressure exceeds the set point of the switch.

Pressure transducers can be coupled to a variable frequency drive which can modulate the speed of the motor

and the pump thereby controlling the system pressure.

STRAINERS

Depending on their size, particles in a product can damage a pump. Open systems may also be at risk for the

introduction of foreign objects. A properly selected strainer mounted on the pumps inlet side will eliminate

any materials that could interfere with safe operation. Caution must be used, however, since the strainers

can fill with debris restricting or blocking flow to the pump.

ISOLATION VALVES

Shut off valves mounted on the inlet and outlet sides of the pump will isolate it from the system. The pump

can then be serviced or removed without having to empty the system.

CHECK VALVES

Check valves should be used to prevent backflow since the pumps, when stopped, will allow some liquid and

air to flow through it.

CHECKVALVE

CHECKVALVE

SHUT OFF VALVE

FLOW FLOW

STRAINER

PRESSURE RELIEF VALVE

PRESSURE GAUGE

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6. MOTOR AND DRIVE FUNDAMENTALS

The following section has been provided to give some brief guidelines when selecting a motor to drive

the UNIBLOC

pumps. When making a motor selection the environment in which it will be operating

must be analyzed as its use may be restricted by government codes. The pumps typically operate

below the base speeds of most motors and therefore require a speed reducer in conjunction with the

motor. There are many types of arrangements to drive the pumps, but a direct drive type, shown below,

is most recommended.

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

damage to the pump.

Drives may be divided into two groups, constant speed and variable speed.

Constant speed drives are most functional when achieving an exact flow is not critical. They can not

compensate for changes in system conditions. If the design capacity of the system is an absoluteminimum then the next higher motor speed should be selected. In such a case, the pumps output

capacity will increase, but so will the system pressure drop and required power. The system should be

reevaluated to insure that the pump will operate within its design parameters and that the motor can

supply the additional power. Constant speed drives with belts offer some flexibility to change

operating speeds by changing the size of the pulley or sheave.

Variable speed drives are used when the pumps output capacity must be exact. They are able to

compensate for system changes. Mechanical variable speed drives use belt or friction disc technology

to vary the speed of the motor. Hydraulic drives provide high torque capabilities over broad speed

ranges. Pneumatic motors provide a low cost variable speed alternative, but have speed adjustment

limitations. However, they are particularly useful when explosion proof requirements must be met.Electronic variable speed drives vary the frequency supplied to the AC motor to change its speed.

They can provide a very wide and accurate range of operating speeds. However, attention must be

paid to torque requirements since the motor supplied torque changes with speed. An AC motor

produces the largest torque at its base frequency, normally 60 or 50 Hz. As frequency, or speed,

decreases, its output torque and power decreases linearly. At low speeds the motor may require

additional cooling or a motor with a higher power rating may have to be used. When the speed goes

above the base frequency, power remains constant, but torque decreases slowly.

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7. LABTOPINTEGRATED PUMP SYSTEMS

Flowtech provides a program of complete pump and drive packages for laboratory scale applications to

small scale manufacturing. They are compact, plug in the wall, ready to use units incorporating

variable speed control, gearmotor, and the Flowtech UNIBLOC

pumps. Capacity ranges from 0.05

GPM (0.2 LPM) to 50 GPM (189 LPM) are available. These small units have become especially

popular in many laboratories. They are able to perform at pressures exceeding 45 psig (3 bar) and as aresult have replaced many peristaltic pumps. The integrated pump systems may be operated at the unit

with a NEMA 4 keypad or from another location by using the speed controllers remote functions.

These units provide flexibility in any scale up program and once their capacity has been exceeded, the

largerUNIBLOC

pumps can then be incorporated. Please contact Flowtech for more information.

22

L A B T O P R2

Capacity to 6.2 gpm (24 lpm)

L A B TO P R2

L A B TO P

L A B T O P R2

3 5 0

3 0 0

Capacity to 18 gpm (68 lpm)

B T O P R23 0 0

3 5 0

L A B TO PL A

L A B T O P R4 0 0

4 5 0

1

Capacity to 50 gpm (189 lpm)


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8. PUMP PERFORMANCE DATA

The data contained in the capacity charts is representative of tests that have been performed on

many pumps over several years. Due to variations in system conditions and normal manufacture some

deviation may occur. For this reason, all UNIBLOC

pumps are factory tested to insure that each

pump will meet or exceed the application parameters. A test certificate is sent with each pump that

leaves the factory. The following table should be used as a first estimate of the pump model needed.

The capacity listed is the highest that a particular size is able to produce. However, the charts must be

consulted to verify that a pump model will be able to safely accommodate a certain viscosity, pressure,

speed, and capacity.

UNIBLOC

MODEL

STAND.

CONN.

SIZE

CAPACITY

gallons/100 rev.

(liters/100 rev.)

MAX.

SPEED

(rpm)

MAX.

OPERATING

PRESSURE

psig (bar)

250 3/4 1.1 (4.2) 1000 100 (6.9)

275 1 1.4 (5.3) 1000 80 (5.5)

300 1 2.8 (10.6) 1000 200 (13.8)

350 1.5 4.0 (15.1) 1000 175 (12.1)

400 1.5 8.1 (30.7) 900 250 (17.2)

450 2 10.9 (41.3) 900 175 (12.1)

500 2.5 22.1 (83.6) 800 300 (20.7)

550 3 28.5 (108) 800 210 (14.5)

575 4 36.1 (137) 700 150 (10.3)

600 4 or 6 52.2 (198) 600 300 (20.7)650 6 79.6 (301) 500 275 (19.0)

675 8 107 (405) 400 175 (12.1)

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9. PUMP SELECTION PROCEDUE

In making an initial selection, the following liquid and system parameters must be determined. The

information may then be used to select the proper pump size using the charts in Section 8.

- differential pressure between the

the pump inlet and discharge- liquid viscosity

- liquid temperature

- capacity

Once this initial selection is made,

other liquid characteristics such

as whether it is Newtonian or

nonNewtonian and whether it is

shear or speed sensitive may be

necessary to make the final

selection with a Flowtechrepresentative.

To illustrate the proper use of the

charts, the following parameters

will be used.

Differential Pressure: 40 psig

Viscosity: 10 cPs

Capacity: 20 GPM

The chart shown at right, found in

Section 7, is used to find the pumpoperating speed and the required

horsepower. Beginning with

viscosity at point 1, find the

intersection with the applications

differential pressure at point 2. A

line drawn parallel to the charts

pressure gives the viscosity

adjusted pressure line 3-3. This line intersects the capacity at point 4. A straight line down from this

point will intersect the speed axis at point 5, which gives an operating speed of 770 rpm. The same line

intersects the Fluid Power graph at point 6, or 0.5 hp. It also intersects the Viscosity Power graph at

point 7, or 1.4 hp. Their sum is 1.9 hp and is the minimum power at the pumps drive shaft required tooperate under these conditions.

3

7

6

5

4

2

1

3

The power requirement can also be expressed as torque, which is defined as the moment of forces

required to turn a pumps drive shaft.

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Torque = F (force) x L (length)

The torque is calculated using the following formulas.

T (in-lbs.) = hp x 5250 rpm x 12

T (Nm) = 0.746 x hp x 9550 rpm

This torque must not exceed the torque limit of the pump shaft

shown in the table below. If it does, then a larger pump must be

selected.

UNIBLOC MODEL

MAX. PUMP DRIVE SHAFT TORQUE

AT MAX. DESIGN PRESSUREin-lbs. (Nm)

250 212 (24)

275 212 (24)

300 841 (95)

350 743 (84)

400 2,753 (311)

450 2,700 (305)

500 13,135 (1484)

550 12,612 (1425)575 10,170 (1149)

600 33,633 (3800)

650 30,438 (3439)

675 22,074 (2494)


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10. PIPE FRICTION LOSS CHART

PIPELE

NGTH

(feet)

304050

100

200

20

15

105

Example:

1.Given

20cps

2.Move

uptopipesize/ty

pe(3")

3.Lefttocapacity

(100gp

m)

4.Downto

pipelength(200

ft.)

5.Rightto

givepressuredro

p(5psi)

50,00

0

PRESSUREDROP

(psi)

200

100

70

50

40

30

20

50

10

1 75432

10

V IS

COSITY

(cps)

1,000

500

100

10,000

5,000

100,000

50

500

400

300

200

100

1

CAPACIT

Y(gpm)

30

20

10

5

PIPESIZE/T

YPE

SANIT

ARY

2"

1.5"

1"

SCHED

ULE

40

8"

6"

4"

3"

2

4

3

5

1

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GG

D

E

M

F

E

K

M

L

M

C

D

J F

K

L

500

A

B

C

575

575

55

0

H

J

450

400

UNIBLOC

MODEL

300

350

B

250

275

200

H

UN

IBLOC

MODEL

200-0

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675

MODEL

650

600

UNIBLOC

50


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1

500

575

1

550

1

UNIBLOC

MODEL 1

350

45

01

400

1

300

1

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UNIBLOC

MODEL

675

2 1

650

2

600

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575

1

300

550

500

450

400

350

1 1111

UNIBLOC

MODEL 1

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67

5

65

0

60

0

UNIB

LOC

MODEL 122

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MODEL

UNIB

LOC

575

550

500

450

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2 1

675

650

UNIBLOC

MODEL 2

600

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13. CHEMICAL RESISTANCE INFORMATION

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14. PUMP APPLICATION DATA SHEET

PREPARED

FOR

Fluid Name

or Type

Product

Temp.

Fluid Viscosity(cps)

CleaningTemp.

Environment

Temperature

Type of

Cleanser

Max. Particle

Size

Seal Type

Required

%

Solids

Seal Material

Required

Operating

Capacity

Horizontal or

Vertical Ports

Inlet

PressureOutlet

Pressure

Supply Pipe

Length

Supply Pipe

Size

Discharge Pipe

Length

Discharge Pipe

Size

Other Fluid

Characteristics

A C

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