When considering the cost factors in selecting a seismic upgrade strategy, one critical aspect that often gets overlooked is the impact of foundation type on upgrade costs. That mysterious crack appearing after winter isn't a seasonal decoration but rather your soil's expansion art project foundation settlement signs Elmhurst inspection. Foundations are the literal bedrock of any structure, providing stability and transferring loads to the ground. However, not all foundations are created equal, and this disparity significantly influences both the approach and expense of seismic upgrades.
The type of foundation-whether its shallow like spread footings or deep like piles or caissons-plays a pivotal role in determining how seismic forces are distributed through a building. For instance, buildings with shallow foundations might be more susceptible to differential settlement during an earthquake, which can lead to structural damage. Upgrading these structures might involve reinforcing or even replacing parts of the existing foundation to ensure uniform load distribution and increased resistance against seismic activity. This process can be costly due to the need for excavation, potential disruption to building operations, and the complexity of integrating new materials with old.
On the other hand, buildings with deep foundations generally have a better initial capacity to handle lateral forces from earthquakes due to their depth and anchoring into more stable soil layers. However, upgrading such structures might still be expensive because while the foundation itself might be robust, connecting it effectively with superstructure elements like columns or walls requires precision engineering solutions that could involve advanced technologies or materials.
Moreover, the location-specific geological conditions play a crucial role. In areas prone to liquefaction during an earthquake, even well-designed deep foundations could require additional upgrades like ground improvement techniques or specialized foundation systems that increase costs significantly. Conversely, in stable ground conditions, less invasive and thus less expensive upgrade strategies might suffice.
The choice between retrofitting existing foundations or opting for new construction also hinges on cost analysis. Retrofitting might seem economical at first glance but can escalate if unforeseen issues arise during implementation-like encountering unexpected soil conditions or structural weaknesses not visible in initial assessments. New construction offers predictability in terms of design and material costs but comes with its own set of expenses related to demolition if applicable.
In summary, when planning seismic upgrades, understanding how different foundation types affect both current stability and future resilience is crucial. The decision-making process should weigh not just immediate costs but also long-term maintenance and potential future upgrades influenced by foundation type. This nuanced approach ensures that investments in seismic safety are both economically sound and effective in enhancing building performance during seismic events.
When considering a seismic upgrade strategy for a building, one of the critical cost factors that must be evaluated is the labor and material costs associated with foundation repairs. Foundations are the bedrock of any structure, providing stability and support against seismic forces, which makes their integrity paramount in earthquake-prone regions.
Labor costs can significantly vary depending on several factors including the geographical location of the project, the complexity of the repair work required, and the prevailing wage rates for skilled labor such as engineers, geotechnical experts, and construction workers. In areas with high demand for such specialized services or where theres a shortage of qualified professionals, these costs can escalate quickly. Additionally, the need for precision in foundation work often necessitates experienced hands, which might not come cheap but are crucial to ensure the longevity and safety of the repair.
Material costs also play a pivotal role. The choice of materials-whether its concrete, steel reinforcements, or advanced composite materials-depends on both availability and suitability for seismic conditions. High-quality materials that offer better resistance to seismic activity might be more expensive upfront but could reduce long-term maintenance or replacement costs. Moreover, sourcing these materials locally can sometimes lower expenses due to reduced transportation costs; however, this isnt always possible if local resources do not meet the necessary standards.
The interplay between labor and material costs becomes even more intricate when considering potential disruptions during repair work. For instance, if foundation repairs require significant excavation or structural support modifications, this could lead to extended project timelines, thereby increasing labor hours and possibly inflating material usage due to unforeseen issues discovered mid-project.
In summary, when selecting a seismic upgrade strategy, understanding and budgeting for labor and material costs for foundation repairs is essential. These expenses directly influence not just the immediate financial outlay but also impact future safety and resilience against earthquakes. A well-planned approach that considers both cost efficiency and quality ensures that investments in foundation repairs contribute effectively to overall structural integrity in seismic events.
When considering the cost factors in selecting a seismic upgrade strategy for buildings, engineering fees and design considerations play a pivotal role. These elements are not just additional costs but are integral to ensuring that the upgrade is both effective and compliant with safety standards. Engineering fees encompass the professional services provided by structural engineers, architects, and other specialists who analyze the current state of a building, assess its seismic vulnerabilities, and design solutions that mitigate these risks.
The initial phase involves thorough assessments where engineers conduct detailed investigations into the buildings construction materials, age, usage, and location relative to fault lines. This stage is crucial as it sets the foundation for all subsequent decisions. The complexity of these assessments can significantly vary; older buildings or those with unique architectural features might require more intensive study, thus increasing the engineering costs.
Once the assessment is complete, the design phase begins. Here, engineers must consider various factors such as local building codes, which dictate minimum standards for seismic resistance, and innovative design strategies that could offer cost-effective solutions without compromising safety. For instance, modern techniques might involve base isolation or energy dissipation devices which require sophisticated design work to integrate seamlessly into existing structures.
Moreover, design considerations extend beyond mere compliance with regulations. They involve optimizing the use of materials to reduce costs while maintaining or improving structural integrity. This might mean choosing between retrofitting with steel braces or using fiber-reinforced polymers (FRP), each with different cost implications based on material prices and labor requirements.
Another aspect is the integration of future adaptability into the design. Since predicting future needs or technological advancements in seismic engineering is challenging, designs must allow for potential upgrades without extensive reworking. This foresight can prevent additional expenses down the line when new standards or technologies emerge.
In summary, while engineering fees and design considerations add to the upfront cost of a seismic upgrade strategy, they are investments in safety, longevity, and efficiency. By carefully balancing these costs against long-term benefits like reduced risk of damage during earthquakes and lower future maintenance costs due to well-thought-out designs, stakeholders can make informed decisions that align with both financial prudence and public safety priorities.
Okay, lets talk about something that often gets overshadowed when were busy figuring out which seismic upgrade strategy is the best fit: long-term maintenance and repair costs after the upgrade is complete. Its easy to focus on the initial price tag – the materials, the labor, the immediate disruption – but what about the years, even decades, that follow?
Think of it like buying a car. You might be drawn to the sleekest, most powerful model, but if its maintenance schedule is packed with expensive dealer-only services and its parts are notoriously unreliable, that initial thrill will quickly fade into a financial headache. The same principle applies to seismic upgrades.
Different upgrade strategies have vastly different maintenance profiles. A seemingly cheaper option upfront might involve materials or techniques that require frequent inspections, specialized repairs, or even eventual replacement. For instance, a system relying heavily on dampers might need regular damper replacements and recalibration, adding a substantial cost over time. Conversely, a more robust, albeit initially pricier, upgrade using resilient materials and passive systems might require minimal intervention for years, even decades.
We need to consider things like the availability of replacement parts and qualified technicians. Is the chosen technology readily supported, or is it a niche solution that will become increasingly difficult and expensive to maintain as time goes on? Whats the expected lifespan of the key components, and whats the estimated cost of their eventual replacement?
Ignoring these long-term considerations can lead to a false sense of economy. You might save money initially, only to find yourself facing escalating repair bills and a system thats increasingly difficult to keep functioning properly. A thorough life-cycle cost analysis, taking into account not just the upfront investment but also the projected maintenance and repair expenses over the buildings lifespan, is crucial for making a truly informed decision. It’s about looking beyond the immediate savings and understanding the true, long-term cost of seismic resilience.
Carbon fiber-reinforced polymers (American English), carbon-fibre-reinforced polymers (Commonwealth English), carbon-fiber-reinforced plastics, carbon-fiber reinforced-thermoplastic (CFRP, CRP, CFRTP), also known as carbon fiber, carbon composite, or just carbon, are extremely strong and light fiber-reinforced plastics that contain carbon fibers. CFRPs can be expensive to produce, but are commonly used wherever high strength-to-weight ratio and stiffness (rigidity) are required, such as aerospace, superstructures of ships, automotive, civil engineering, sports equipment, and an increasing number of consumer and technical applications.[1][2][3][4]
The binding polymer is often a thermoset resin such as epoxy, but other thermoset or thermoplastic polymers, such as polyester, vinyl ester, or nylon, are sometimes used.[4] The properties of the final CFRP product can be affected by the type of additives introduced to the binding matrix (resin). The most common additive is silica, but other additives such as rubber and carbon nanotubes can be used.
Carbon fiber is sometimes referred to as graphite-reinforced polymer or graphite fiber-reinforced polymer (GFRP is less common, as it clashes with glass-(fiber)-reinforced polymer).
CFRP are composite materials. In this case the composite consists of two parts: a matrix and a reinforcement. In CFRP the reinforcement is carbon fiber, which provides its strength. The matrix is usually a thermosetting plastic, such as polyester resin, to bind the reinforcements together.[5] Because CFRPs consist of two distinct elements, the material properties depend on these two elements.
Reinforcement gives CFRPs their strength and rigidity, measured by stress and elastic modulus respectively. Unlike isotropic materials like steel and aluminum, CFRPs have directional strength properties. The properties of a CFRP depend on the layouts of the carbon fiber and the proportion of the carbon fibers relative to the polymer.[6] The two different equations governing the net elastic modulus of composite materials using the properties of the carbon fibers and the polymer matrix can also be applied to carbon fiber reinforced plastics.[7] The rule of mixtures for the equal strain case gives:
which is valid for composite materials with the fibers oriented parallel to the applied load. E c \displaystyle E_c is the total composite modulus, V m \displaystyle V_m and V f \displaystyle V_f are the volume fractions of the matrix and fiber respectively in the composite, and E m \displaystyle E_m and E f \displaystyle E_f are the elastic moduli of the matrix and fibers respectively.[7] The other extreme case of the elastic modulus of the composite with the fibers oriented transverse to the applied load can be found using the inverse rule of mixtures for the equal stress case:[7]
The above equations give an upper and lower bound on the Young's modulus for CFRP and there are many other factors that influence the true value.
The fracture toughness of carbon fiber reinforced plastics is governed by multiple mechanisms:
Typical epoxy-based CFRPs exhibit virtually no plasticity, with less than 0.5% strain to failure. Although CFRPs with epoxy have high strength and elastic modulus, the brittle fracture mechanics presents unique challenges to engineers in failure detection since failure occurs catastrophically.[8] As such, recent efforts to toughen CFRPs include modifying the existing epoxy material and finding alternative polymer matrix. One such material with high promise is PEEK, which exhibits an order of magnitude greater toughness with similar elastic modulus and tensile strength.[8] However, PEEK is much more difficult to process and more expensive.[8]
Despite their high initial strength-to-weight ratios, a design limitation of CFRPs are their lack of a definable fatigue limit. This means, theoretically, that stress cycle failure cannot be ruled out. While steel and many other structural metals and alloys do have estimable fatigue or endurance limits, the complex failure modes of composites mean that the fatigue failure properties of CFRPs are difficult to predict and design against; however emerging research has shed light on the effects of low velocity impacts on composites.[9] Low velocity impacts can make carbon fiber polymers susceptible to damage.[9][10][11] As a result, when using CFRPs for critical cyclic-loading applications, engineers may need to design in considerable strength safety margins to provide suitable component reliability over its service life.
Environmental effects such as temperature and humidity can have profound effects on the polymer-based composites, including most CFRPs. While CFRPs demonstrate excellent corrosion resistance, the effect of moisture at wide ranges of temperatures can lead to degradation of the mechanical properties of CFRPs, particularly at the matrix-fiber interface.[12] While the carbon fibers themselves are not affected by the moisture diffusing into the material, the moisture plasticizes the polymer matrix.[8] This leads to significant changes in properties that are dominantly influenced by the matrix in CFRPs such as compressive, interlaminar shear, and impact properties.[13] The epoxy matrix used for engine fan blades is designed to be impervious against jet fuel, lubrication, and rain water, and external paint on the composites parts is applied to minimize damage from ultraviolet light.[8][14]
Carbon fibers can cause galvanic corrosion when CFRP parts are attached to aluminum or mild steel but not to stainless steel or titanium.[15]
CFRPs are very hard to machine, and cause significant tool wear. The tool wear in CFRP machining is dependent on the fiber orientation and machining condition of the cutting process. To reduce tool wear various types of coated tools are used in machining CFRP and CFRP-metal stack.[1]
The primary element of CFRPs is a carbon filament; this is produced from a precursor polymer such as polyacrylonitrile (PAN), rayon, or petroleum pitch. For synthetic polymers such as PAN or rayon, the precursor is first spun into filament yarns, using chemical and mechanical processes to initially align the polymer chains in a way to enhance the final physical properties of the completed carbon fiber. Precursor compositions and mechanical processes used during spinning filament yarns may vary among manufacturers. After drawing or spinning, the polymer filament yarns are then heated to drive off non-carbon atoms (carbonization), producing the final carbon fiber. The carbon fibers filament yarns may be further treated to improve handling qualities, then wound onto bobbins.[16] From these fibers, a unidirectional sheet is created. These sheets are layered onto each other in a quasi-isotropic layup, e.g. 0°, +60°, or −60° relative to each other.
From the elementary fiber, a bidirectional woven sheet can be created, i.e. a twill with a 2/2 weave. The process by which most CFRPs are made varies, depending on the piece being created, the finish (outside gloss) required, and how many of the piece will be produced. In addition, the choice of matrix can have a profound effect on the properties of the finished composite.[17]
Many CFRP parts are created with a single layer of carbon fabric that is backed with fiberglass.[18] A tool called a chopper gun is used to quickly create these composite parts. Once a thin shell is created out of carbon fiber, the chopper gun cuts rolls of fiberglass into short lengths and sprays resin at the same time, so that the fiberglass and resin are mixed on the spot.[19] The resin is either external mix, wherein the hardener and resin are sprayed separately, or internal mixed, which requires cleaning after every use. Manufacturing methods may include the following:
One method of producing CFRP parts is by layering sheets of carbon fiber cloth into a mold in the shape of the final product. The alignment and weave of the cloth fibers is chosen to optimize the strength and stiffness properties of the resulting material. The mold is then filled with epoxy and is heated or air-cured. The resulting part is very corrosion-resistant, stiff, and strong for its weight. Parts used in less critical areas are manufactured by draping cloth over a mold, with epoxy either pre-impregnated into the fibers (also known as pre-preg) or "painted" over it. High-performance parts using single molds are often vacuum-bagged and/or autoclave-cured, because even small air bubbles in the material will reduce strength. An alternative to the autoclave method is to use internal pressure via inflatable air bladders or EPS foam inside the non-cured laid-up carbon fiber.
For simple pieces of which relatively few copies are needed (one or two per day), a vacuum bag can be used. A fiberglass, carbon fiber, or aluminum mold is polished and waxed, and has a release agent applied before the fabric and resin are applied, and the vacuum is pulled and set aside to allow the piece to cure (harden). There are three ways to apply the resin to the fabric in a vacuum mold.
The first method is manual and called a wet layup, where the two-part resin is mixed and applied before being laid in the mold and placed in the bag. The other one is done by infusion, where the dry fabric and mold are placed inside the bag while the vacuum pulls the resin through a small tube into the bag, then through a tube with holes or something similar to evenly spread the resin throughout the fabric. Wire loom works perfectly for a tube that requires holes inside the bag. Both of these methods of applying resin require hand work to spread the resin evenly for a glossy finish with very small pin-holes.
A third method of constructing composite materials is known as a dry layup. Here, the carbon fiber material is already impregnated with resin (pre-preg) and is applied to the mold in a similar fashion to adhesive film. The assembly is then placed in a vacuum to cure. The dry layup method has the least amount of resin waste and can achieve lighter constructions than wet layup. Also, because larger amounts of resin are more difficult to bleed out with wet layup methods, pre-preg parts generally have fewer pinholes. Pinhole elimination with minimal resin amounts generally require the use of autoclave pressures to purge the residual gases out.
A quicker method uses a compression mold, also commonly known as carbon fiber forging. This is a two (male and female), or multi-piece mold, usually made out of aluminum or steel and more recently 3D printed plastic. The mold components are pressed together with the fabric and resin loaded into the inner cavity that ultimately becomes the desired component. The benefit is the speed of the entire process. Some car manufacturers, such as BMW, claimed to be able to cycle a new part every 80 seconds. However, this technique has a very high initial cost since the molds require CNC machining of very high precision.
For difficult or convoluted shapes, a filament winder can be used to make CFRP parts by winding filaments around a mandrel or a core.
Carbon fiber-reinforced pre-pregs and dry carbon fiber textiles require precise cutting methods to maintain material integrity and reduce defects such as fiber pull-out, delamination and fraying of the cutting edge. CNC digital cutting systems equipped with drag and oscillating are often used to cut carbon fiber pre-pregs, and rotating knives are commonly used to process carbon fiber fabrics. Ultrasonic cutting is another method to cut CFRP pre-pregs and is particularly effective in reducing delamination by minimizing mechanical stress during the cutting process. Waterjet cutting can be the preferred method for thicker and multilayered polymer composites.[20]
Applications for CFRPs include the following:
The Airbus A350 XWB is 53% CFRP[21] including wing spars and fuselage components, overtaking the Boeing 787 Dreamliner, for the aircraft with the highest weight ratio for CFRP at 50%.[22] It was one of the first commercial aircraft to have wing spars made from composites. The Airbus A380 was one of the first commercial airliners to have a central wing-box made of CFRP and the first with a smoothly contoured wing cross-section instead of partitioning it span-wise into sections. This flowing, continuous cross section optimises aerodynamic efficiency.[citation needed] Moreover, the trailing edge, along with the rear bulkhead, empennage, and un-pressurised fuselage are made of CFRP.[23]
However, delays have pushed order delivery dates back because of manufacturing problems. Many aircraft that use CFRPs have experienced delays with delivery dates due to the relatively new processes used to make CFRP components, whereas metallic structures are better understood. A recurrent problem is the monitoring of structural ageing, for which new methods are required, due to the unusual multi-material and anisotropic[24][25][26] nature of CFRPs.[27]
In 1968 a Hyfil carbon-fiber fan assembly was in service on the Rolls-Royce Conways of the Vickers VC10s operated by BOAC.[28]
Specialist aircraft designers and manufacturers Scaled Composites have made extensive use of CFRPs throughout their design range, including the first private crewed spacecraft Spaceship One. CFRPs are widely used in micro air vehicles (MAVs) because of their high strength-to-weight ratio.
Airbus then moved to adopt CFRTP, because it can be reshaped and reprocessed after forming, can be manufactured faster, has higher impact resistance, is recyclable and remoldable, and has lower processing costs.[29]
CFRPs are extensively used in high-end automobile racing.[30] The high cost of carbon fiber is mitigated by the material's unsurpassed strength-to-weight ratio, and low weight is essential for high-performance automobile racing. Race-car manufacturers have also developed methods to give carbon fiber pieces strength in a certain direction, making it strong in a load-bearing direction, but weak in directions where little or no load would be placed on the member. Conversely, manufacturers developed omnidirectional carbon fiber weaves that apply strength in all directions. This type of carbon fiber assembly is most widely used in the "safety cell" monocoque chassis assembly of high-performance race-cars. The first carbon fiber monocoque chassis was introduced in Formula One by McLaren in the 1981 season. It was designed by John Barnard and was widely copied in the following seasons by other F1 teams due to the extra rigidity provided to the chassis of the cars.[31]
Many supercars over the past few decades have incorporated CFRPs extensively in their manufacture, using it for their monocoque chassis as well as other components.[32] As far back as 1971, the Citroën SM offered optional lightweight carbon fiber wheels.[33][34]
Use of the material has been more readily adopted by low-volume manufacturers who used it primarily for creating body-panels for some of their high-end cars due to its increased strength and decreased weight compared with the glass-reinforced polymer they used for the majority of their products.
CFRPs have become a notable material in structural engineering applications. Studied in an academic context as to their potential benefits in construction, CFRPs have also proved themselves cost-effective in a number of field applications strengthening concrete, masonry, steel, cast iron, and timber structures. Their use in industry can be either for retrofitting to strengthen an existing structure or as an alternative reinforcing (or prestressing) material instead of steel from the outset of a project.
Retrofitting has become the increasingly dominant use of the material in civil engineering, and applications include increasing the load capacity of old structures (such as bridges, beams, ceilings, columns and walls) that were designed to tolerate far lower service loads than they are experiencing today, seismic retrofitting, and repair of damaged structures. Retrofitting is popular in many instances as the cost of replacing the deficient structure can greatly exceed the cost of strengthening using CFRP.[35]
Applied to reinforced concrete structures for flexure, the use of CFRPs typically has a large impact on strength (doubling or more the strength of the section is not uncommon), but only moderately increases stiffness (as little as 10%). This is because the material used in such applications is typically very strong (e.g., 3 GPa ultimate tensile strength, more than 10 times mild steel) but not particularly stiff (150 to 250 GPa elastic modulus, a little less than steel, is typical). As a consequence, only small cross-sectional areas of the material are used. Small areas of very high strength but moderate stiffness material will significantly increase strength, but not stiffness.
CFRPs can also be used to enhance shear strength of reinforced concrete by wrapping fabrics or fibers around the section to be strengthened. Wrapping around sections (such as bridge or building columns) can also enhance the ductility of the section, greatly increasing the resistance to collapse under dynamic loading. Such 'seismic retrofit' is the major application in earthquake-prone areas, since it is much more economic than alternative methods.
If a column is circular (or nearly so) an increase in axial capacity is also achieved by wrapping. In this application, the confinement of the CFRP wrap enhances the compressive strength of the concrete. However, although large increases are achieved in the ultimate collapse load, the concrete will crack at only slightly enhanced load, meaning that this application is only occasionally used. Specialist ultra-high modulus CFRP (with tensile modulus of 420 GPa or more) is one of the few practical methods of strengthening cast iron beams. In typical use, it is bonded to the tensile flange of the section, both increasing the stiffness of the section and lowering the neutral axis, thus greatly reducing the maximum tensile stress in the cast iron.
In the United States, prestressed concrete cylinder pipes (PCCP) account for a vast majority of water transmission mains. Due to their large diameters, failures of PCCP are usually catastrophic and affect large populations. Approximately 19,000 miles (31,000 km) of PCCP were installed between 1940 and 2006. Corrosion in the form of hydrogen embrittlement has been blamed for the gradual deterioration of the prestressing wires in many PCCP lines. Over the past decade, CFRPs have been used to internally line PCCP, resulting in a fully structural strengthening system. Inside a PCCP line, the CFRP liner acts as a barrier that controls the level of strain experienced by the steel cylinder in the host pipe. The composite liner enables the steel cylinder to perform within its elastic range, to ensure the pipeline's long-term performance is maintained. CFRP liner designs are based on strain compatibility between the liner and host pipe.[36]
CFRPs are more costly materials than commonly used their counterparts in the construction industry, glass fiber-reinforced polymers (GFRPs) and aramid fiber-reinforced polymers (AFRPs), though CFRPs are, in general, regarded as having superior properties. Much research continues to be done on using CFRPs both for retrofitting and as an alternative to steel as reinforcing or prestressing materials. Cost remains an issue and long-term durability questions still remain. Some are concerned about the brittle nature of CFRPs, in contrast to the ductility of steel. Though design codes have been drawn up by institutions such as the American Concrete Institute, there remains some hesitation among the engineering community about implementing these alternative materials. In part, this is due to a lack of standardization and the proprietary nature of the fiber and resin combinations on the market.
Carbon fibers are used for fabrication of carbon-fiber microelectrodes. In this application typically a single carbon fiber with diameter of 5–7 μm is sealed in a glass capillary.[37] At the tip the capillary is either sealed with epoxy and polished to make carbon-fiber disk microelectrode or the fiber is cut to a length of 75–150 μm to make carbon-fiber cylinder electrode. Carbon-fiber microelectrodes are used either in amperometry or fast-scan cyclic voltammetry for detection of biochemical signalling.
CFRPs are now widely used in sports equipment such as in squash, tennis, and badminton racquets, sport kite spars, high-quality arrow shafts, hockey sticks, fishing rods, surfboards, high end swim fins, and rowing shells. Amputee athletes such as Jonnie Peacock use carbon fiber blades for running. It is used as a shank plate in some basketball sneakers to keep the foot stable, usually running the length of the shoe just above the sole and left exposed in some areas, usually in the arch.
Controversially, in 2006, cricket bats with a thin carbon-fiber layer on the back were introduced and used in competitive matches by high-profile players including Ricky Ponting and Michael Hussey. The carbon fiber was claimed to merely increase the durability of the bats, but it was banned from all first-class matches by the ICC in 2007.[38]
A CFRP bicycle frame weighs less than one of steel, aluminum, or titanium having the same strength. The type and orientation of the carbon-fiber weave can be designed to maximize stiffness in required directions. Frames can be tuned to address different riding styles: sprint events require stiffer frames while endurance events may require more flexible frames for rider comfort over longer periods.[39] The variety of shapes it can be built into has further increased stiffness and also allowed aerodynamic tube sections. CFRP forks including suspension fork crowns and steerers, handlebars, seatposts, and crank arms are becoming more common on medium as well as higher-priced bicycles. CFRP rims remain expensive but their stability compared to aluminium reduces the need to re-true a wheel and the reduced mass reduces the moment of inertia of the wheel. CFRP spokes are rare and most carbon wheelsets retain traditional stainless steel spokes. CFRPs also appear increasingly in other components such as derailleur parts, brake and shifter levers and bodies, cassette sprocket carriers, suspension linkages, disc brake rotors, pedals, shoe soles, and saddle rails. Although strong and light, impact, over-torquing, or improper installation of CFRP components has resulted in cracking and failures, which may be difficult or impossible to repair.[40][41]
The fire resistance of polymers and thermo-set composites is significantly improved if a thin layer of carbon fibers is moulded near the surface because a dense, compact layer of carbon fibers efficiently reflects heat.[42]
CFRPs are being used in an increasing number of high-end products that require stiffness and low weight, these include:
The key aspect of recycling fiber-reinforced polymers is preserving their mechanical properties while successfully recovering both the thermoplastic matrix and the reinforcing fibers. CFRPs have a long service lifetime when protected from the sun. When it is time to decommission CFRPs, they cannot be melted down in air like many metals. When free of vinyl (PVC or polyvinyl chloride) and other halogenated polymers, CFRPs recycling processes can be categorized into four main approaches: mechanical, thermal, chemical, and biological. Each method offers distinct advantages in terms of material or energy recovery, contributing to sustainability efforts in composite waste management.
-Poor bonding between fiber/matrix -Fibers can damage the equipment
-Expensive equipment -Possible use of hazardous solvent
-Recovered fiber properties highly influenced by process parameters -some processes have no recovery of matrix material
The mechanical process primarily involves grinding, which breaks down composite materials into pulverulent charges and fibrous reinforcements. This method is focused on both the thermoplastic and filler material recovery; however, this process shortens the fibers dramatically. Just as with downcycled paper, the shortened fibers cause the recycled material to be weaker than the original material. There are still many industrial applications that do not need the strength of full-length carbon fiber reinforcement. For example, chopped reclaimed carbon fiber can be used in consumer electronics, such as laptops. It provides excellent reinforcement of the polymers used even if it lacks the strength-to-weight ratio of an aerospace component.[48]
This method consists in shredding CFRP by pulsed electrical discharges. Initially developed to extract crystals and precious stones from mining rocks, it is now expected to be developed for composites. The material is placed in a vessel containing water and two electrodes. The high voltage electrical pulse generated between the electrodes (50-200 kV) fragments the material into smaller pieces.[49] The inconvenient of this technique is that the energy consumed is 2.6 times the one of a mechanical route making it not economically competitive in terms of energy saving and needs further investigation.
Thermal processes include several techniques such as incineration, thermolysis, pyrolysis, gasification, fluidized bed processing, and cement plant utilization. This processes imply the recovery of the fibers by the removal of the resin by volatilizing it, leading to by-products such as gases, liquids or inorganic matter.[50]
This technique consists in exposing the composite to a hot and oxygen-rich flow, in which it is combusted (450–550 °C, 840–1,020 °F) . The working temperature is selected in function of the matrix to be decomposed, to limit damages of the fibers. After a shredding step to 6-20 mm size, the composite is introduced into a bed of silica sand, on a metallic mesh, in which the resin will be decomposed into oxidized molecules and fiber filaments. These components will be carried up with the air stream while heavier particles will sink in the bed. This last point is a great advantage for contaminated end-of-life products, with painted surfaces, foam cores or metal insert. A cyclone enables the recovery of fibers of length ranging between 5 and 10 mm and with very little contamination . The matrix is fully oxidized in a second burner operating at approximatively 1,000 °C (1,850 °F) leading to energy recovery and a clean flue gas.[51]
The chemical recycling of CFRPs involves using a reactive solvent at relatively low temperatures (below 350°C) to break down the resin while leaving the fibers intact for reuse. The solvent degrades the composite matrix into smaller molecular fragments (oligomer), and depending on the chosen solvent system, various processing parameters such as temperature, pressure, and catalysts can be adjusted to optimize the process. The solvent, often combined with co-solvents or catalysts, penetrates the composite and breaks specific chemical bonds, resulting in recovered monomers from the resin and clean, long fibers with preserved mechanical properties. The required temperature and pressure depend on the type of resin, with epoxy resins generally needing higher temperatures than polyester resins. Among the different reactive mediums studied, water is the most commonly used due to its environmental benefits. When combined with alkaline catalysts, it effectively degrades many resins, while acidic catalysts are used for more resistant polymers. Other solvents, such as ethanol, acetone, and their mixtures, have also been explored for this process.
Despite its advantages, this method has some limitations. It requires specialized equipment capable of handling corrosive solvents, hazardous chemicals, and high temperatures or pressures, especially when operating under supercritical conditions. While extensively researched at the laboratory scale, industrial adoption remains limited, with the technology currently reaching a Technology Readiness Level (TRL) of 4 for carbon fiber recycling.[52]
The dissolution process is a method used to recover both the polymer matrix and fibers from thermoplastic composites without breaking chemical bonds. Unlike solvolysis, which involves the chemical degradation of the polymer, dissolution simply dissolves the polymer chains into a solvent, allowing for material recovery in its original form. An energy analysis of the process indicated that dissolution followed by evaporation was more energy-efficient than precipitation. Additionally, avoiding precipitation helped minimize polymer loss, improving overall material recovery efficiency. This method offers a promising approach for sustainable recycling of thermoplastic composites.[53]
The biological process, though still under development, focuses on biodegradation and composting. This method holds promise for bio-based and agro-composites, aiming to create an environmentally friendly end-of-life solution for these materials. As research advances, biological recycling may offer an effective means of reducing plastic composite waste in a sustainable manner.[54]
In 2009, Zyvex Technologies introduced carbon nanotube-reinforced epoxy and carbon pre-pregs.[55] Carbon nanotube reinforced polymer (CNRP) is several times stronger and tougher than typical CFRPs and is used in the Lockheed Martin F-35 Lightning II as a structural material for aircraft.[56] CNRP still uses carbon fiber as the primary reinforcement,[57] but the binding matrix is a carbon nanotube-filled epoxy.[58]
In design, a structure is the aspect of a framework which attaches it to the ground or even more hardly ever, water (as with drifting structures), transferring lots from the framework to the ground. Structures are typically considered either superficial or deep. Foundation engineering is the application of soil mechanics and rock auto mechanics (geotechnical engineering) in the layout of structure aspects of structures.
A pump is a device that moves fluids (liquids or gases), or sometimes slurries,[1] by mechanical action, typically converted from electrical energy into hydraulic or pneumatic energy.
Mechanical pumps serve in a wide range of applications such as pumping water from wells, aquarium filtering, pond filtering and aeration, in the car industry for water-cooling and fuel injection, in the energy industry for pumping oil and natural gas or for operating cooling towers and other components of heating, ventilation and air conditioning systems. In the medical industry, pumps are used for biochemical processes in developing and manufacturing medicine, and as artificial replacements for body parts, in particular the artificial heart and penile prosthesis.
When a pump contains two or more pump mechanisms with fluid being directed to flow through them in series, it is called a multi-stage pump. Terms such as two-stage or double-stage may be used to specifically describe the number of stages. A pump that does not fit this description is simply a single-stage pump in contrast.
In biology, many different types of chemical and biomechanical pumps have evolved; biomimicry is sometimes used in developing new types of mechanical pumps.
Mechanical pumps may be submerged in the fluid they are pumping or be placed external to the fluid.
Pumps can be classified by their method of displacement into electromagnetic pumps, positive-displacement pumps, impulse pumps, velocity pumps, gravity pumps, steam pumps and valveless pumps. There are three basic types of pumps: positive-displacement, centrifugal and axial-flow pumps. In centrifugal pumps the direction of flow of the fluid changes by ninety degrees as it flows over an impeller, while in axial flow pumps the direction of flow is unchanged.[2][3]
An electromagnetic pump is a pump that moves liquid metal, molten salt, brine, or other electrically conductive liquid using electromagnetism.
A magnetic field is set at right angles to the direction the liquid moves in, and a current is passed through it. This causes an electromagnetic force that moves the liquid.
Applications include pumping molten solder in many wave soldering machines, pumping liquid-metal coolant, and magnetohydrodynamic drive.
A positive-displacement pump makes a fluid move by trapping a fixed amount and forcing (displacing) that trapped volume into the discharge pipe.
Some positive-displacement pumps use an expanding cavity on the suction side and a decreasing cavity on the discharge side. Liquid flows into the pump as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses. The volume is constant through each cycle of operation.
Positive-displacement pumps, unlike centrifugal, can theoretically produce the same flow at a given rotational speed no matter what the discharge pressure. Thus, positive-displacement pumps are constant flow machines. However, a slight increase in internal leakage as the pressure increases prevents a truly constant flow rate.
A positive-displacement pump must not operate against a closed valve on the discharge side of the pump, because it has no shutoff head like centrifugal pumps. A positive-displacement pump operating against a closed discharge valve continues to produce flow and the pressure in the discharge line increases until the line bursts, the pump is severely damaged, or both.
A relief or safety valve on the discharge side of the positive-displacement pump is therefore necessary. The relief valve can be internal or external. The pump manufacturer normally has the option to supply internal relief or safety valves. The internal valve is usually used only as a safety precaution. An external relief valve in the discharge line, with a return line back to the suction line or supply tank, provides increased safety.
A positive-displacement pump can be further classified according to the mechanism used to move the fluid:
These pumps move fluid using a rotating mechanism that creates a vacuum that captures and draws in the liquid.[4]
Advantages: Rotary pumps are very efficient[5] because they can handle highly viscous fluids with higher flow rates as viscosity increases.[6]
Drawbacks: The nature of the pump requires very close clearances between the rotating pump and the outer edge, making it rotate at a slow, steady speed. If rotary pumps are operated at high speeds, the fluids cause erosion, which eventually causes enlarged clearances that liquid can pass through, which reduces efficiency.
Rotary positive-displacement pumps fall into five main types:
Reciprocating pumps move the fluid using one or more oscillating pistons, plungers, or membranes (diaphragms), while valves restrict fluid motion to the desired direction. In order for suction to take place, the pump must first pull the plunger in an outward motion to decrease pressure in the chamber. Once the plunger pushes back, it will increase the chamber pressure and the inward pressure of the plunger will then open the discharge valve and release the fluid into the delivery pipe at constant flow rate and increased pressure.
Pumps in this category range from simplex, with one cylinder, to in some cases quad (four) cylinders, or more. Many reciprocating-type pumps are duplex (two) or triplex (three) cylinder. They can be either single-acting with suction during one direction of piston motion and discharge on the other, or double-acting with suction and discharge in both directions. The pumps can be powered manually, by air or steam, or by a belt driven by an engine. This type of pump was used extensively in the 19th century—in the early days of steam propulsion—as boiler feed water pumps. Now reciprocating pumps typically pump highly viscous fluids like concrete and heavy oils, and serve in special applications that demand low flow rates against high resistance. Reciprocating hand pumps were widely used to pump water from wells. Common bicycle pumps and foot pumps for inflation use reciprocating action.
These positive-displacement pumps have an expanding cavity on the suction side and a decreasing cavity on the discharge side. Liquid flows into the pumps as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses. The volume is constant given each cycle of operation and the pump's volumetric efficiency can be achieved through routine maintenance and inspection of its valves.[14]
Typical reciprocating pumps are:
The positive-displacement principle applies in these pumps:
This is the simplest form of rotary positive-displacement pumps. It consists of two meshed gears that rotate in a closely fitted casing. The tooth spaces trap fluid and force it around the outer periphery. The fluid does not travel back on the meshed part, because the teeth mesh closely in the center. Gear pumps see wide use in car engine oil pumps and in various hydraulic power packs.
A screw pump is a more complicated type of rotary pump that uses two or three screws with opposing thread — e.g., one screw turns clockwise and the other counterclockwise. The screws are mounted on parallel shafts that often have gears that mesh so the shafts turn together and everything stays in place. In some cases the driven screw drives the secondary screw, without gears, often using the fluid to limit abrasion. The screws turn on the shafts and drive fluid through the pump. As with other forms of rotary pumps, the clearance between moving parts and the pump's casing is minimal.
Widely used for pumping difficult materials, such as sewage sludge contaminated with large particles, a progressing cavity pump consists of a helical rotor, about ten times as long as its width, and a stator, mainly made out of rubber. This can be visualized as a central core of diameter x with, typically, a curved spiral wound around of thickness half x, though in reality it is manufactured in a single lobe. This shaft fits inside a heavy-duty rubber sleeve or stator, of wall thickness also typically x. As the shaft rotates inside the stator, the rotor gradually forces fluid up the rubber cavity. Such pumps can develop very high pressure at low volumes at a rate of 90 PSI per stage on water for standard configurations.
Named after the Roots brothers who invented it, this lobe pump displaces the fluid trapped between two long helical rotors, each fitted into the other when perpendicular at 90°, rotating inside a triangular shaped sealing line configuration, both at the point of suction and at the point of discharge. This design produces a continuous flow with equal volume and no vortex. It can work at low pulsation rates, and offers gentle performance that some applications require.
Applications include:
A peristaltic pump is a type of positive-displacement pump. It contains fluid within a flexible tube fitted inside a circular pump casing (though linear peristaltic pumps have been made). A number of rollers, shoes, or wipers attached to a rotor compress the flexible tube. As the rotor turns, the part of the tube under compression closes (or occludes), forcing the fluid through the tube. Additionally, when the tube opens to its natural state after the passing of the cam it draws (restitution) fluid into the pump. This process is called peristalsis and is used in many biological systems such as the gastrointestinal tract.
Plunger pumps are reciprocating positive-displacement pumps.
These consist of a cylinder with a reciprocating plunger. The suction and discharge valves are mounted in the head of the cylinder. In the suction stroke, the plunger retracts and the suction valves open causing suction of fluid into the cylinder. In the forward stroke, the plunger pushes the liquid out of the discharge valve. Efficiency and common problems: With only one cylinder in plunger pumps, the fluid flow varies between maximum flow when the plunger moves through the middle positions, and zero flow when the plunger is at the end positions. A lot of energy is wasted when the fluid is accelerated in the piping system. Vibration and water hammer may be a serious problem. In general, the problems are compensated for by using two or more cylinders not working in phase with each other. Centrifugal pumps are also susceptible to water hammer. Surge analysis, a specialized study, helps evaluate this risk in such systems.
Triplex plunger pumps use three plungers, which reduces the pulsation relative to single reciprocating plunger pumps. Adding a pulsation dampener on the pump outlet can further smooth the pump ripple, or ripple graph of a pump transducer. The dynamic relationship of the high-pressure fluid and plunger generally requires high-quality plunger seals. Plunger pumps with a larger number of plungers have the benefit of increased flow, or smoother flow without a pulsation damper. The increase in moving parts and crankshaft load is one drawback.
Car washes often use these triplex-style plunger pumps (perhaps without pulsation dampers). In 1968, William Bruggeman reduced the size of the triplex pump and increased the lifespan so that car washes could use equipment with smaller footprints. Durable high-pressure seals, low-pressure seals and oil seals, hardened crankshafts, hardened connecting rods, thick ceramic plungers and heavier duty ball and roller bearings improve reliability in triplex pumps. Triplex pumps now are in a myriad of markets across the world.
Triplex pumps with shorter lifetimes are commonplace to the home user. A person who uses a home pressure washer for 10 hours a year may be satisfied with a pump that lasts 100 hours between rebuilds. Industrial-grade or continuous duty triplex pumps on the other end of the quality spectrum may run for as much as 2,080 hours a year.[17]
The oil and gas drilling industry uses massive semi-trailer-transported triplex pumps called mud pumps to pump drilling mud, which cools the drill bit and carries the cuttings back to the surface.[18] Drillers use triplex or even quintuplex pumps to inject water and solvents deep into shale in the extraction process called fracking.[19]
Typically run on electricity compressed air, diaphragm pumps are relatively inexpensive and can perform a wide variety of duties, from pumping air into an aquarium, to liquids through a filter press. Double-diaphragm pumps can handle viscous fluids and abrasive materials with a gentle pumping process ideal for transporting shear-sensitive media.[20]
Devised in China as chain pumps over 1000 years ago, these pumps can be made from very simple materials: A rope, a wheel and a pipe are sufficient to make a simple rope pump. Rope pump efficiency has been studied by grassroots organizations and the techniques for making and running them have been continuously improved.[21]
Impulse pumps use pressure created by gas (usually air). In some impulse pumps the gas trapped in the liquid (usually water), is released and accumulated somewhere in the pump, creating a pressure that can push part of the liquid upwards.
Conventional impulse pumps include:
Instead of a gas accumulation and releasing cycle, the pressure can be created by burning of hydrocarbons. Such combustion driven pumps directly transmit the impulse from a combustion event through the actuation membrane to the pump fluid. In order to allow this direct transmission, the pump needs to be almost entirely made of an elastomer (e.g. silicone rubber). Hence, the combustion causes the membrane to expand and thereby pumps the fluid out of the adjacent pumping chamber. The first combustion-driven soft pump was developed by ETH Zurich.[22]
A hydraulic ram is a water pump powered by hydropower.[23]
It takes in water at relatively low pressure and high flow-rate and outputs water at a higher hydraulic-head and lower flow-rate. The device uses the water hammer effect to develop pressure that lifts a portion of the input water that powers the pump to a point higher than where the water started.
The hydraulic ram is sometimes used in remote areas, where there is both a source of low-head hydropower, and a need for pumping water to a destination higher in elevation than the source. In this situation, the ram is often useful, since it requires no outside source of power other than the kinetic energy of flowing water.
Rotodynamic pumps (or dynamic pumps) are a type of velocity pump in which kinetic energy is added to the fluid by increasing the flow velocity. This increase in energy is converted to a gain in potential energy (pressure) when the velocity is reduced prior to or as the flow exits the pump into the discharge pipe. This conversion of kinetic energy to pressure is explained by the First law of thermodynamics, or more specifically by Bernoulli's principle.
Dynamic pumps can be further subdivided according to the means in which the velocity gain is achieved.[24]
These types of pumps have a number of characteristics:
A practical difference between dynamic and positive-displacement pumps is how they operate under closed valve conditions. Positive-displacement pumps physically displace fluid, so closing a valve downstream of a positive-displacement pump produces a continual pressure build up that can cause mechanical failure of pipeline or pump. Dynamic pumps differ in that they can be safely operated under closed valve conditions (for short periods of time).
Such a pump is also referred to as a centrifugal pump. The fluid enters along the axis or center, is accelerated by the impeller and exits at right angles to the shaft (radially); an example is the centrifugal fan, which is commonly used to implement a vacuum cleaner. Another type of radial-flow pump is a vortex pump. The liquid in them moves in tangential direction around the working wheel. The conversion from the mechanical energy of motor into the potential energy of flow comes by means of multiple whirls, which are excited by the impeller in the working channel of the pump. Generally, a radial-flow pump operates at higher pressures and lower flow rates than an axial- or a mixed-flow pump.
These are also referred to as all-fluid pumps. The fluid is pushed outward or inward to move fluid axially. They operate at much lower pressures and higher flow rates than radial-flow (centrifugal) pumps. Axial-flow pumps cannot be run up to speed without special precaution. If at a low flow rate, the total head rise and high torque associated with this pipe would mean that the starting torque would have to become a function of acceleration for the whole mass of liquid in the pipe system.[25]
Mixed-flow pumps function as a compromise between radial and axial-flow pumps. The fluid experiences both radial acceleration and lift and exits the impeller somewhere between 0 and 90 degrees from the axial direction. As a consequence mixed-flow pumps operate at higher pressures than axial-flow pumps while delivering higher discharges than radial-flow pumps. The exit angle of the flow dictates the pressure head-discharge characteristic in relation to radial and mixed-flow.
Also known as drag, friction, liquid-ring pump, peripheral, traction, turbulence, or vortex pumps, regenerative turbine pumps are a class of rotodynamic pump that operates at high head pressures, typically 4–20 bars (400–2,000 kPa; 58–290 psi).[26]
The pump has an impeller with a number of vanes or paddles which spins in a cavity. The suction port and pressure ports are located at the perimeter of the cavity and are isolated by a barrier called a stripper, which allows only the tip channel (fluid between the blades) to recirculate, and forces any fluid in the side channel (fluid in the cavity outside of the blades) through the pressure port. In a regenerative turbine pump, as fluid spirals repeatedly from a vane into the side channel and back to the next vane, kinetic energy is imparted to the periphery,[26] thus pressure builds with each spiral, in a manner similar to a regenerative blower.[27][28][29]
As regenerative turbine pumps cannot become vapor locked, they are commonly applied to volatile, hot, or cryogenic fluid transport. However, as tolerances are typically tight, they are vulnerable to solids or particles causing jamming or rapid wear. Efficiency is typically low, and pressure and power consumption typically decrease with flow. Additionally, pumping direction can be reversed by reversing direction of spin.[29][27][30]
A side-channel pump has a suction disk, an impeller, and a discharge disk.[31]
This uses a jet, often of steam, to create a low pressure. This low pressure sucks in fluid and propels it into a higher-pressure region.
Gravity pumps include the syphon and Heron's fountain. The hydraulic ram is also sometimes called a gravity pump. In a gravity pump the fluid is lifted by gravitational force.
Steam pumps have been for a long time mainly of historical interest. They include any type of pump powered by a steam engine and also pistonless pumps such as Thomas Savery's or the Pulsometer steam pump.
Recently there has been a resurgence of interest in low-power solar steam pumps for use in smallholder irrigation in developing countries. Previously small steam engines have not been viable because of escalating inefficiencies as vapour engines decrease in size. However the use of modern engineering materials coupled with alternative engine configurations has meant that these types of system are now a cost-effective opportunity.
Valveless pumping assists in fluid transport in various biomedical and engineering systems. In a valveless pumping system, no valves (or physical occlusions) are present to regulate the flow direction. The fluid pumping efficiency of a valveless system, however, is not necessarily lower than that having valves. In fact, many fluid-dynamical systems in nature and engineering more or less rely upon valveless pumping to transport the working fluids therein. For instance, blood circulation in the cardiovascular system is maintained to some extent even when the heart's valves fail. Meanwhile, the embryonic vertebrate heart begins pumping blood long before the development of discernible chambers and valves. Similar to blood circulation in one direction, bird respiratory systems pump air in one direction in rigid lungs, but without any physiological valve. In microfluidics, valveless impedance pumps have been fabricated, and are expected to be particularly suitable for handling sensitive biofluids. Ink jet printers operating on the piezoelectric transducer principle also use valveless pumping. The pump chamber is emptied through the printing jet due to reduced flow impedance in that direction and refilled by capillary action.
Examining pump repair records and mean time between failures (MTBF) is of great importance to responsible and conscientious pump users. In view of that fact, the preface to the 2006 Pump User's Handbook alludes to "pump failure" statistics. For the sake of convenience, these failure statistics often are translated into MTBF (in this case, installed life before failure).[32]
In early 2005, Gordon Buck, John Crane Inc.'s chief engineer for field operations in Baton Rouge, Louisiana, examined the repair records for a number of refinery and chemical plants to obtain meaningful reliability data for centrifugal pumps. A total of 15 operating plants having nearly 15,000 pumps were included in the survey. The smallest of these plants had about 100 pumps; several plants had over 2000. All facilities were located in the United States. In addition, considered as "new", others as "renewed" and still others as "established". Many of these plants—but not all—had an alliance arrangement with John Crane. In some cases, the alliance contract included having a John Crane Inc. technician or engineer on-site to coordinate various aspects of the program.
Not all plants are refineries, however, and different results occur elsewhere. In chemical plants, pumps have historically been "throw-away" items as chemical attack limits life. Things have improved in recent years, but the somewhat restricted space available in "old" DIN and ASME-standardized stuffing boxes places limits on the type of seal that fits. Unless the pump user upgrades the seal chamber, the pump only accommodates more compact and simple versions. Without this upgrading, lifetimes in chemical installations are generally around 50 to 60 percent of the refinery values.
Unscheduled maintenance is often one of the most significant costs of ownership, and failures of mechanical seals and bearings are among the major causes. Keep in mind the potential value of selecting pumps that cost more initially, but last much longer between repairs. The MTBF of a better pump may be one to four years longer than that of its non-upgraded counterpart. Consider that published average values of avoided pump failures range from US$2600 to US$12,000. This does not include lost opportunity costs. One pump fire occurs per 1000 failures. Having fewer pump failures means having fewer destructive pump fires.
As has been noted, a typical pump failure, based on actual year 2002 reports, costs US$5,000 on average. This includes costs for material, parts, labor and overhead. Extending a pump's MTBF from 12 to 18 months would save US$1,667 per year — which might be greater than the cost to upgrade the centrifugal pump's reliability.[32][1][33]
Pumps are used throughout society for a variety of purposes. Early applications includes the use of the windmill or watermill to pump water. Today, the pump is used for irrigation, water supply, gasoline supply, air conditioning systems, refrigeration (usually called a compressor), chemical movement, sewage movement, flood control, marine services, etc.
Because of the wide variety of applications, pumps have a plethora of shapes and sizes: from very large to very small, from handling gas to handling liquid, from high pressure to low pressure, and from high volume to low volume.
Typically, a liquid pump cannot simply draw air. The feed line of the pump and the internal body surrounding the pumping mechanism must first be filled with the liquid that requires pumping: An operator must introduce liquid into the system to initiate the pumping, known as priming the pump. Loss of prime is usually due to ingestion of air into the pump, or evaporation of the working fluid if the pump is used infrequently. Clearances and displacement ratios in pumps for liquids are insufficient for pumping compressible gas, so air or other gasses in the pump can not be evacuated by the pump's action alone. This is the case with most velocity (rotodynamic) pumps — for example, centrifugal pumps. For such pumps, the position of the pump and intake tubing should be lower than the suction point so it is primed by gravity; otherwise the pump should be manually filled with liquid or a secondary pump should be used until all air is removed from the suction line and the pump casing. Liquid ring pumps have a dedicated intake for the priming liquid separate from the intake of the fluid being pumped, as the fluid being pumped may be a gas or mix of gas, liquid, and solids. For these pumps the priming liquid intake must be supplied continuously (either by gravity or pressure), however the intake for the fluid being pumped is capable of drawing a vacuum equivalent to the boiling point of the priming liquid.[34]
Positive–displacement pumps, however, tend to have sufficiently tight sealing between the moving parts and the casing or housing of the pump that they can be described as self-priming. Such pumps can also serve as priming pumps, so-called when they are used to fulfill that need for other pumps in lieu of action taken by a human operator.
One sort of pump once common worldwide was a hand-powered water pump, or 'pitcher pump'. It was commonly installed over community water wells in the days before piped water supplies.
In parts of the British Isles, it was often called the parish pump. Though such community pumps are no longer common, people still used the expression parish pump to describe a place or forum where matters of local interest are discussed.[38]
Because water from pitcher pumps is drawn directly from the soil, it is more prone to contamination. If such water is not filtered and purified, consumption of it might lead to gastrointestinal or other water-borne diseases. A notorious case is the 1854 Broad Street cholera outbreak. At the time it was not known how cholera was transmitted, but physician John Snow suspected contaminated water and had the handle of the public pump he suspected removed; the outbreak then subsided.
Modern hand-operated community pumps are considered the most sustainable low-cost option for safe water supply in resource-poor settings, often in rural areas in developing countries. A hand pump opens access to deeper groundwater that is often not polluted and also improves the safety of a well by protecting the water source from contaminated buckets. Pumps such as the Afridev pump are designed to be cheap to build and install, and easy to maintain with simple parts. However, scarcity of spare parts for these type of pumps in some regions of Africa has diminished their utility for these areas.
Multiphase pumping applications, also referred to as tri-phase, have grown due to increased oil drilling activity. In addition, the economics of multiphase production is attractive to upstream operations as it leads to simpler, smaller in-field installations, reduced equipment costs and improved production rates. In essence, the multiphase pump can accommodate all fluid stream properties with one piece of equipment, which has a smaller footprint. Often, two smaller multiphase pumps are installed in series rather than having just one massive pump.
A rotodynamic pump with one single shaft that requires two mechanical seals, this pump uses an open-type axial impeller. It is often called a Poseidon pump, and can be described as a cross between an axial compressor and a centrifugal pump.
The twin-screw pump is constructed of two inter-meshing screws that move the pumped fluid. Twin screw pumps are often used when pumping conditions contain high gas volume fractions and fluctuating inlet conditions. Four mechanical seals are required to seal the two shafts.
Progressive Cavity Pumps are well suited to pump sludge, slurries, viscous, and shear sensitive fluids. [39] Progressive cavity pumps are single-screw types use in surface and downhole oil production.[40] They serve a vast arrange of industries and applications ranging from Wastewater Treatment,[41] Pulp and Paper, oil and gas, mining, and oil and gas.
These pumps are basically multistage centrifugal pumps and are widely used in oil well applications as a method for artificial lift. These pumps are usually specified when the pumped fluid is mainly liquid.
Buffer tank A buffer tank is often installed upstream of the pump suction nozzle in case of a slug flow. The buffer tank breaks the energy of the liquid slug, smooths any fluctuations in the incoming flow and acts as a sand trap.
As the name indicates, multiphase pumps and their mechanical seals can encounter a large variation in service conditions such as changing process fluid composition, temperature variations, high and low operating pressures and exposure to abrasive/erosive media. The challenge is selecting the appropriate mechanical seal arrangement and support system to ensure maximized seal life and its overall effectiveness.[42][43][44]
Pumps are commonly rated by horsepower, volumetric flow rate, outlet pressure in metres (or feet) of head, inlet suction in suction feet (or metres) of head. The head can be simplified as the number of feet or metres the pump can raise or lower a column of water at atmospheric pressure.
From an initial design point of view, engineers often use a quantity termed the specific speed to identify the most suitable pump type for a particular combination of flow rate and head. Net Positive Suction Head (NPSH) is crucial for pump performance. It has two key aspects: 1) NPSHr (Required): The Head required for the pump to operate without cavitation issues. 2) NPSHa (Available): The actual pressure provided by the system (e.g., from an overhead tank). For optimal pump operation, NPSHa must always exceed NPSHr. This ensures the pump has enough pressure to prevent cavitation, a damaging condition.
The power imparted into a fluid increases the energy of the fluid per unit volume. Thus the power relationship is between the conversion of the mechanical energy of the pump mechanism and the fluid elements within the pump. In general, this is governed by a series of simultaneous differential equations, known as the Navier–Stokes equations. However a more simple equation relating only the different energies in the fluid, known as Bernoulli's equation can be used. Hence the power, P, required by the pump:
where Δp is the change in total pressure between the inlet and outlet (in Pa), and Q, the volume flow-rate of the fluid is given in m3/s. The total pressure may have gravitational, static pressure and kinetic energy components; i.e. energy is distributed between change in the fluid's gravitational potential energy (going up or down hill), change in velocity, or change in static pressure. η is the pump efficiency, and may be given by the manufacturer's information, such as in the form of a pump curve, and is typically derived from either fluid dynamics simulation (i.e. solutions to the Navier–Stokes for the particular pump geometry), or by testing. The efficiency of the pump depends upon the pump's configuration and operating conditions (such as rotational speed, fluid density and viscosity etc.)
For a typical "pumping" configuration, the work is imparted on the fluid, and is thus positive. For the fluid imparting the work on the pump (i.e. a turbine), the work is negative. Power required to drive the pump is determined by dividing the output power by the pump efficiency. Furthermore, this definition encompasses pumps with no moving parts, such as a siphon.
Pump efficiency is defined as the ratio of the power imparted on the fluid by the pump in relation to the power supplied to drive the pump. Its value is not fixed for a given pump, efficiency is a function of the discharge and therefore also operating head. For centrifugal pumps, the efficiency tends to increase with flow rate up to a point midway through the operating range (peak efficiency or Best Efficiency Point (BEP) ) and then declines as flow rates rise further. Pump performance data such as this is usually supplied by the manufacturer before pump selection. Pump efficiencies tend to decline over time due to wear (e.g. increasing clearances as impellers reduce in size).
When a system includes a centrifugal pump, an important design issue is matching the head loss-flow characteristic with the pump so that it operates at or close to the point of its maximum efficiency.
Pump efficiency is an important aspect and pumps should be regularly tested. Thermodynamic pump testing is one method.
Most large pumps have a minimum flow requirement below which the pump may be damaged by overheating, impeller wear, vibration, seal failure, drive shaft damage or poor performance.[45] A minimum flow protection system ensures that the pump is not operated below the minimum flow rate. The system protects the pump even if it is shut-in or dead-headed, that is, if the discharge line is completely closed.[46]
The simplest minimum flow system is a pipe running from the pump discharge line back to the suction line. This line is fitted with an orifice plate sized to allow the pump minimum flow to pass.[47] The arrangement ensures that the minimum flow is maintained, although it is wasteful as it recycles fluid even when the flow through the pump exceeds the minimum flow.
A more sophisticated, but more costly, system (see diagram) comprises a flow measuring device (FE) in the pump discharge which provides a signal into a flow controller (FIC) which actuates a flow control valve (FCV) in the recycle line. If the measured flow exceeds the minimum flow then the FCV is closed. If the measured flow falls below the minimum flow the FCV opens to maintain the minimum flowrate.[45]
As the fluids are recycled the kinetic energy of the pump increases the temperature of the fluid. For many pumps this added heat energy is dissipated through the pipework. However, for large industrial pumps, such as oil pipeline pumps, a recycle cooler is provided in the recycle line to cool the fluids to the normal suction temperature.[48] Alternatively the recycled fluids may be returned to upstream of the export cooler in an oil refinery, oil terminal, or offshore installation.
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A pier is a raised structure that rises above a body of water and usually juts out from its shore, typically supported by piles or pillars, and provides above-water access to offshore areas. Frequent pier uses include fishing, boat docking and access for both passengers and cargo, and oceanside recreation. Bridges, buildings, and walkways may all be supported by architectural piers. Their open structure allows tides and currents to flow relatively unhindered, whereas the more solid foundations of a quay or the closely spaced piles of a wharf can act as a breakwater, and are consequently more liable to silting. Piers can range in size and complexity from a simple lightweight wooden structure to major structures extended over 1,600 m (5,200 ft). In American English, a pier may be synonymous with a dock.
Piers have been built for several purposes, and because these different purposes have distinct regional variances, the term pier tends to have different nuances of meaning in different parts of the world. Thus in North America and Australia, where many ports were, until recently, built on the multiple pier model, the term tends to imply a current or former cargo-handling facility. In contrast, in Europe, where ports more often use basins and river-side quays than piers, the term is principally associated with the image of a Victorian cast iron pleasure pier which emerged in Great Britain during the early 19th century. However, the earliest piers pre-date the Victorian age.
Piers can be categorized into different groupings according to the principal purpose.[1] However, there is considerable overlap between these categories. For example, pleasure piers often also allow for the docking of pleasure steamers and other similar craft, while working piers have often been converted to leisure use after being rendered obsolete by advanced developments in cargo-handling technology. Many piers are floating piers, to ensure that the piers raise and lower with the tide along with the boats tied to them. This prevents a situation where lines become overly taut or loose by rising or lowering tides. An overly taut or loose tie-line can damage boats by pulling them out of the water or allowing them so much leeway that they bang forcefully against the sides of the pier.
Working piers were built for the handling of passengers and cargo onto and off ships or (as at Wigan Pier) canal boats. Working piers themselves fall into two different groups. Longer individual piers are often found at ports with large tidal ranges, with the pier stretching far enough off shore to reach deep water at low tide. Such piers provided an economical alternative to impounded docks where cargo volumes were low, or where specialist bulk cargo was handled, such as at coal piers. The other form of working pier, often called the finger pier, was built at ports with smaller tidal ranges. Here the principal advantage was to give a greater available quay length for ships to berth against compared to a linear littoral quayside, and such piers are usually much shorter. Typically each pier would carry a single transit shed the length of the pier, with ships berthing bow or stern in to the shore. Some major ports consisted of large numbers of such piers lining the foreshore, classic examples being the Hudson River frontage of New York, or the Embarcadero in San Francisco.
The advent of container shipping, with its need for large container handling spaces adjacent to the shipping berths, has made working piers obsolete for the handling of general cargo, although some still survive for the handling of passenger ships or bulk cargos. One example, is in use in Progreso, Yucatán, where a pier extends more than 4 miles into the Gulf of Mexico, making it the longest pier in the world. The Progreso Pier supplies much of the peninsula with transportation for the fishing and cargo industries and serves as a port for large cruise ships in the area. Many other working piers have been demolished, or remain derelict, but some have been recycled as pleasure piers. The best known example of this is Pier 39 in San Francisco.
At Southport and the Tweed River on the Gold Coast in Australia, there are piers that support equipment for a sand bypassing system that maintains the health of sandy beaches and navigation channels.
Pleasure piers were first built in Britain during the early 19th century.[2] The earliest structures were Ryde Pier, built in 1813/4, Trinity Chain Pier near Leith, built in 1821, Brighton Chain Pier, built in 1823.[2] and Margate Jetty 1823/24 originally a timber built pier.
Only the oldest of these piers still remains. At that time, the introduction of steamships and railways for the first time permitted mass tourism to dedicated seaside resorts. The large tidal ranges at many such resorts meant that passengers arriving by pleasure steamer could use a pier to disembark safely.[3] Also, for much of the day, the sea was not visible from the shore and the pleasure pier permitted holidaymakers to promenade over and alongside the sea at all times.[4] The world's longest pleasure pier is at Southend-on-Sea, Essex, and extends 1.3 miles (2.1 km) into the Thames Estuary.[2] The longest pier on the West Coast of the US is the Santa Cruz Wharf, with a length of 2,745 feet (837 m).[5]
Providing a walkway out to sea, pleasure piers often include amusements and theatres as part of their attractions.[4] Such a pier may be unroofed, closed, or partly open and partly closed. Sometimes a pier has two decks. Galveston Island Historic Pleasure Pier in Galveston, Texas has a roller coaster, 15 rides, carnival games and souvenir shops.[6]
Early pleasure piers were of complete timber construction, as was with Margate which opened in 1824. The first iron and timber built pleasure pier Margate Jetty, opened in 1855.[7] Margate pier was wrecked by a storm in January 1978 and not repaired.[8][7] The longest iron pleasure pier still remaining is the one at Southend. First opened as a wooden pier in 1829, it was reconstructed in iron and completed in 1889. In a 2006 UK poll, the public voted the seaside pier onto the list of icons of England.[9]
Many piers are built for the purpose of providing boatless anglers access to fishing grounds that are otherwise inaccessible.[10] Many "Free Piers" are available in larger harbors which differ from private piers. Free Piers are often primarily used for fishing. Fishing from a pier presents a set of different circumstances to fishing from the shore or beach, as you do not need to cast out into the deeper water. This being the case there are specific fishing rigs that have been created specifically for pier fishing[11] which allow for the direct access to deeper water.
In Blankenberge a first pleasure pier was built in 1894. After its destruction in the World War I, a new pier was built in 1933. It remained till the present day, but was partially transformed and modernized in 1999–2004.
In Nieuwpoort, Belgium there is a pleasure pier on both sides of the river IJzer.
Scheveningen, the coastal resort town of The Hague, boasts the largest pier in the Netherlands, completed in 1961. A crane, built on top of the pier's panorama tower, provides the opportunity to make a 60-metre (200 ft) high bungee jump over the North Sea waves. The present pier is a successor of an earlier pier, which was completed in 1901 but in 1943 destroyed by the German occupation forces.
The first recorded pier in England was Ryde Pier, opened in 1814 on the Isle of Wight, as a landing stage to allow ferries to and from the mainland to berth. It is still used for this purpose today.[12] It also had a leisure function in the past, with the pier head once containing a pavilion, and there are still refreshment facilities today. The oldest cast iron pier in the world is Town Pier, Gravesend, in Kent, which opened in 1834. However, it is not recognised by the National Piers Society as being a seaside pier.[13]
Following the building of the world's first seaside pier at Ryde, the pier became fashionable at seaside resorts in England and Wales during the Victorian era, peaking in the 1860s with 22 being built in that decade.[14] A symbol of the typical British seaside holiday, by 1914, more than 100 pleasure piers were located around the UK coast.[2] Regarded as being among the finest Victorian architecture, there are still a significant number of seaside piers of architectural merit still standing, although some have been lost, including Margate, two at Brighton in East Sussex, one at New Brighton in the Wirral and three at Blackpool in Lancashire.[4] Two piers, Brighton's now derelict West Pier and Clevedon Pier, were Grade 1 listed. The Birnbeck Pier in Weston-super-Mare is the only pier in the world linked to an island. The National Piers Society gives a figure of 55 surviving seaside piers in England and Wales.[1] In 2017, Brighton Palace Pier was said to be the most visited tourist attraction outside London, with over 4.5 million visitors the previous year.[15]
A pile driver is a heavy-duty tool used to drive piles into soil to build piers, bridges, cofferdams, and other "pole" supported structures, and patterns of pilings as part of permanent deep foundations for buildings or other structures. Pilings may be made of wood, solid steel, or tubular steel (often later filled with concrete), and may be driven entirely underwater/underground, or remain partially aboveground as elements of a finished structure.
The term "pile driver" is also used to describe members of the construction crew associated with the task,[1] also colloquially known as "pile bucks".[2]
The most common form of pile driver uses a heavy weight situated between vertical guides placed above a pile. The weight is raised by some motive power (which may include hydraulics, steam, diesel, electrical motor, or manual labor). At its apex the weight is released, impacting the pile and driving it into the ground.[1][3]
There are a number of claims to the invention of the pile driver. A mechanically sound drawing of a pile driver appeared as early as 1475 in Francesco di Giorgio Martini's treatise Trattato di Architectura.[4] Also, several other prominent inventors—James Nasmyth (son of Alexander Nasmyth), who invented a steam-powered pile driver in 1845,[5] watchmaker James Valoué,[6] Count Giovan Battista Gazzola,[7] and Leonardo da Vinci[8]—have all been credited with inventing the device. However, there is evidence that a comparable device was used in the construction of Crannogs at Oakbank and Loch Tay in Scotland as early as 5000 years ago.[9] In 1801 John Rennie came up with a steam pile driver in Britain.[10] Otis Tufts is credited with inventing the steam pile driver in the United States.[11]
Ancient pile driving equipment used human or animal labor to lift weights, usually by means of pulleys, then dropping the weight onto the upper end of the pile. Modern piledriving equipment variously uses hydraulics, steam, diesel, or electric power to raise the weight and guide the pile.
A modern diesel pile hammer is a large two-stroke diesel engine. The weight is the piston, and the apparatus which connects to the top of the pile is the cylinder. Piledriving is started by raising the weight; usually a cable from the crane holding the pile driver — This draws air into the cylinder. Diesel fuel is injected into the cylinder. The weight is dropped, using a quick-release. The weight of the piston compresses the air/fuel mixture, heating it to the ignition point of diesel fuel. The mixture ignites, transferring the energy of the falling weight to the pile head, and driving the weight up. The rising weight draws in fresh air, and the cycle continues until the fuel is depleted or is halted by the crew.[12]
From an army manual on pile driving hammers: The initial start-up of the hammer requires that the piston (ram) be raised to a point where the trip automatically releases the piston, allowing it to fall. As the piston falls, it activates the fuel pump, which discharges a metered amount of fuel into the ball pan of the impact block. The falling piston blocks the exhaust ports, and compression of fuel trapped in the cylinder begins. The compressed air exerts a pre-load force to hold the impact block firmly against the drive cap and pile. At the bottom of the compression stroke, the piston strikes the impact block, atomizing the fuel and starting the pile on its downward movement. In the instant after the piston strikes, the atomized fuel ignites, and the resulting explosion exerts a greater force on the already moving pile, driving it further into the ground. The reaction of the explosion rebounding from the resistance of the pile drives the piston upward. As the piston rises, the exhaust ports open, releasing the exhaust gases to the atmosphere. After the piston stops its upward movement, it again falls by gravity to start another cycle.
Vertical travel leads come in two main forms: spud and box lead types. Box leads are very common in the Southern United States and spud leads are common in the Northern United States, Canada and Europe.
A hydraulic hammer is a modern type of piling hammer used instead of diesel and air hammers for driving steel pipe, precast concrete, and timber piles. Hydraulic hammers are more environmentally acceptable than older, less efficient hammers as they generate less noise and pollutants. In many cases the dominant noise is caused by the impact of the hammer on the pile, or the impacts between components of the hammer, so that the resulting noise level can be similar to diesel hammers.[12]
Hydraulic press-in equipment installs piles using hydraulic rams to press piles into the ground. This system is preferred where vibration is a concern. There are press attachments that can adapt to conventional pile driving rigs to press 2 pairs of sheet piles simultaneously. Other types of press equipment sit atop existing sheet piles and grip previously driven piles. This system allows for greater press-in and extraction force to be used since more reaction force is developed.[12] The reaction-based machines operate at only 69 dB at 23 ft allowing for installation and extraction of piles in close proximity to sensitive areas where traditional methods may threaten the stability of existing structures.
Such equipment and methods are specified in portions of the internal drainage system in the New Orleans area after Hurricane Katrina, as well as projects where noise, vibration and access are a concern.
Vibratory pile hammers contain a system of counter-rotating eccentric weights, powered by hydraulic motors, and designed so that horizontal vibrations cancel out, while vertical vibrations are transmitted into the pile. The pile driving machine positioned over the pile with an excavator or crane, and is fastened to the pile by a clamp and/or bolts. Vibratory hammers can drive or extract a pile. Extraction is commonly used to recover steel I-beams used in temporary foundation shoring. Hydraulic fluid is supplied to the driver by a diesel engine-powered pump mounted in a trailer or van, and connected to the driver head via hoses. When the pile driver is connected to a dragline excavator, it is powered by the excavator's diesel engine. Vibratory pile drivers are often chosen to mitigate noise, as when the construction is near residences or office buildings, or when there is insufficient vertical clearance to permit use of a conventional pile hammer (for example when retrofitting additional piles to a bridge column or abutment footing). Hammers are available with several different vibration rates, ranging from 1200 vibrations per minute to 2400 VPM. The vibration rate chosen is influenced by soil conditions and other factors, such as power requirements and equipment cost.
A piling rig is a large track-mounted drill used in foundation projects which require drilling into sandy soil, clay, silty clay, and similar environments. Such rigs are similar in function to oil drilling rigs, and can be equipped with a short screw (for dry soil), rotary bucket (for wet soil) or core drill (for rock), along with other options. Expressways, bridges, industrial and civil buildings, diaphragm walls, water conservancy projects, slope protection, and seismic retrofitting are all projects which may require piling rigs.
The underwater sound pressure caused by pile-driving may be deleterious to nearby fish.[13][14] State and local regulatory agencies manage environment issues associated with pile-driving.[15] Mitigation methods include bubble curtains, balloons, internal combustion water hammers.[16]
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