Moving Fluids

Concept and Theory

Graco, Inc.
P.O. Box 1441
Minneapolis, MN 55440-1441 ©1995 Graco Inc. Form No. 321-037 12/95 Rev 2 SL Training 11/14
Understanding Your Customer’s Situation

Characteristics of the Fluid to Be Moved

The more you know about the fluid your customer plans to move, the better you will be able to
recommend the appropriate equipment and accessories. Most of this information is available
from the material manufacturer, either from a material safety data sheet (MSDS), a material
technical data sheet, or by calling the manufacturer. Some of the fluid characteristics you may
need include:

 Viscosity  Solids content

 Grease hardness (NLGI number)  Formulation (solvent-borne, water-
 Specific gravity* borne)
 Surface tension*  Moisture sensitivity
 Shear rate  Curing method
 Corrosiveness  Specific heat*
 Abrasiveness

*This information may or may not be available. If it is not available, it will seldom impact system
design.
Characteristics of the Application

Depending on the application, you will gather different pieces of information from your customer.
For example, in an airless spray application, the customer will probably be able to provide you
with typical flow rates and pressures they are currently experiencing. In an extrusion application,
the customer may tell you the average bead rate and size. You will then need to convert that
information into data that you can use to select equipment. Some of the application
characteristics you will need include:

 Fluid flow rate (volume)

 Pressure at dispense point or applicator
 Available power source
 Temperature

Customer Priorities

Along with characteristics of the fluid and the application, you need to consider the customer’s
priori- ties. For example, some customers may be concerned about the initial cost of the system,
while other customers may be willing to spend more initially to keep maintenance and repair
costs down in the future. Some priorities you should discuss with your customer include:

 Initial budget
 Maintenance capabilities
 Portability requirements
 Production requirements
 Material conservation
Progress Check
Directions: After answering the following questions, compare your answers with
those provided in the answer key following this progress check. If you respond to
any items incorrectly, return to the text and review the appropriate topics.

1. Which of the following fluid characteristics you may want to consider before
recommending fluid handling equipment and accessories?
a. Viscosity
b. Shear rate
c. Corrosiveness
d. Fluid flow rate
e. Solids content
f. Temperature
g. Moisture sensitivity
h. Specific heat
2. List the characteristics of your customer’s application you should consider before
recommending fluid handling equipment and accessories.
______________________________________________________________________
______________________________________________________________________
3. Which of the following are potential priorities should you discuss with your customer
before recommending fluid handling equipment and accessories?
a. Initial budget
b. Available power source
c. Pressure at dispense point of applicator
d. Maintenance capabilities
e. Portability requirements
f. Fluid formulation, whether solvent-borne or water-borne
g. Production requirements
h. Material conservation
Answers to Progress Check

1. A, B, C, E, G, H. Before recommending fluid handling equipment and accessories, you

should know as much as possible about the fluid your customer plans to move. Some of
the fluid characteristics to consider are viscosity, shear rate, corrosiveness,
abrasiveness, solids content, formulation, moisture sensitivity, curing method, and
specific heat.
2. Characteristics of your customer’s application you should consider before
recommending fluid handling equipment and accessories include: fluid flow rate
(volume), pressure at dispense point or applicator, available power source, and
temperature.
3. A, D, E, G, H. Before recommending fluid handling equipment and accessories, you
should discuss with your customers their potential priorities, among which may be their
initial budget, maintenance capabilities, portability requirements, production
requirements, and material conservation.
Getting the Fluid into the System

Pressure Pots

After completing this subsection, you will be able to:

 Describe how a pressure pot works

 Match each component of a pressure pot with its function
 Differentiate between single regulated and dual regulated pressure pots
 Recognize situations for which a pressure pot would be an appropriate solution

How Pressure Pots Work

A pressure pot is a pressurized vessel. For every one pound or air pressure applied to the
pressure pot, one pound of fluid pressure is generated (or produced). The pressure created
within the tank causes the fluid to flow out of the tank through a hose to the system or the intake
of a pump.
 Figure 3 illustrates a pressure pot and its key components, including:

 Fluid outlets
 Pressure relief valve
 Bleeder valve
 Clamps
 Tank
 Regulator
Bleeder valve

Air inlet

Fluid outlet
Regulator

Clamps

Pressure relief
valve
ASME tank

Bottom fluid
outlet

05623
Figure 3 A pressure pot and its key components
Pressure pots have both a top and bottom fluid outlet. The bottom fluid outlet is often used as a
feed supply for highly viscous materials, texture materials, and plural component materials. The
bottom outlet is also used for completely emptying a tank.

The pressure relief valve automatically relieves air pressure inside the pressure pot to prevent
over-pressurization. This over-pressurization may result from a failure in the supply source or
regulator, or from temperature variations.

The bleeder valve allows you to manually relieve pressure inside the pot before removing the
lid.

Clamps help maintain a tight seal between the tank and tank cover.

Both ASME (American Society of Mechanical Engineers) approved and non-ASME approved
tanks are available. ASME approved tanks are designed to avoid ruptures and come in 2, 5, 10,
and 15 U.S. gallons (8, 19, 38, and 57 liters) sizes. Less expensive, non-ASME approved tanks
are designed for non-corrosive, lower pressure applications and come in a 2 U.S. gallons (8
liters) size.

The regulator controls pressure within the tank.

Types of Pressure Pots

In a single regulated pressure pots the air pressure regulator controls the outbound fluid
pressure only. Single regulated pressure pots may be used:

 With plural components materials as the catalyst supply

 When pumping to a proportioner
 In spray applications along with an existing booth regulator

In dual regulated pressure pots, one air pressure regulator controls fluid pressure and one air
pressure regulator controls atomizing air to a spray gun. Dual regulated pressure pots are
commonly used when the air source is a distance from the pressure pot, to allow control of both
air and fluid pressure right at the pot.

05624 05625

Figure 4 Single regulated pressure pot (left) and dual regulated pressure pot (right)
When to Select a Pressure Pot

Pressure pots are an excellent solution for a number of applications, including:

When long term cost is a concern. Pressure pots require little repair maintenance, resulting in
lower long term expense.

In low volume applications. Pressure pots are commonly found in low volume applications
such as feeding one or two spray guns in an air spray application. Low volume may be better
described by the amount of fluid used in an 8-hour day. Pressure pots would be appropriate for
applications that require refilling every two or three days.

In multiple color applications. For small quantities, a pail is set right inside the pot for easy
clean up.

With moisture-sensitive or oxygen-sensitive materials. The self-contained environment of a

pressure pot may be a better selection for moisture sensitive materials such as isocyanate.

For degas/isolation applications. A pressure pot can be used as a vacuum tank when the
customer needs all the air pulled out of the material for precision mixing.

As a low pressure feed supply. In applications where the fluid pressure must be very low,
pressure can often be controlled more accurately with a pressure pot than with a pump and fluid
regulator.

For fine finish applications. A pressure pot can provide pulse-free fluid delivery when a
pulsating reciprocating pump is not acceptable.

Pressure pots are also a good solution in applications where portability is not a priority and
when agitation is required in a small, sealed system.
Progress Check
Directions: After answering the following questions, compare your answers with
those provided in the answer key following this progress check. If you respond to
any items incorrectly, return to the text and review the appropriate topics.

1. Describe how a pressure pot works.

______________________________________________________________________
______________________________________________________________________
______________________________________________________________________

For items 2 through 6, match the pressure pot component with its description:

Component

a. Bottom fluid outlet

b. Pressure relief valve
c. Bleeder valve
d. Clamps
e. Regulator

Description

2. Automatically relieves pressure inside the pressure pot to prevent over-pressurization.

3. Help maintain a tight seal between the tank and the lid.
4. Allows you to manually relieve pressure inside the pot before removing the lid.
5. Controls pressure within the tank.
6. Often used as a feed supply for highly viscous materials, texture materials, and plural
component materials.
7. What does the air pressure regulator in a single regulated pressure pot control?
______________________________________________________________________
8. Dual regulated pressure pots have two air pressure regulators. What does each of these
regulators control?
______________________________________________________________________
______________________________________________________________________
9. Select the applications for which a pressure pot would be a good solution:
a. When long term cost is a concern
b. In high volume applications
c. In multiple color applications using small quantities of color
d. With moisture – or oxygen-sensitive materials
e. For degas/isolation applications
f. As a high pressure feed supply
g. For fine finish applications when a pulsating reciprocating pump is not acceptable
h. Where portability is not a priority
Answers to Progress Check

1. A pressure pot is a pressurized vessel. For every one pound of air pressure applied to
the pressure pot, one pound of fluid pressure is generated (or produced). The pressure
created within the tank causes the fluid to flow out of the tank through a hose to the
system or intake of a pump.
2. B. The pressure relief valve automatically relieves pressure inside the pressure to
prevent over-pressurization.
3. D. Clamps help maintain a tight seal between the tank and the lid.
4. C. The bleeder valve allows you to manually relieve pressure inside the pot before
removing the lid.
5. E. The regulator controls pressure within the tank.
6. A. The bottom fluid outlet is often used as a feed supply for highly viscous materials,
texture materials, and plural component materials.
7. The air pressure regulator in a single regulated pressure pot controls the outbound fluid
pressure only.
8. In dual regulated pressure pots, one air pressure regulator controls fluid pressure and
one air pressure regulator controls atomizing air to the spray gun.
9. A, C, D, E, G, H. Pressure pots are an excellent solution for a number of applications,
including: when long term cost is a concern, in low volume applications, in multiple color
applications using small quantities of color, with moisture- or oxygen-sensitive materials,
for degas/isolation applications, as a low pressure feed supply, for some fine finish
applications, where portability is not a priority, when agitation is required in a small,
sealed system.
Pump Feed Issues
Loading a Piston Pump

No matter what feed method we use, our purpose is to load the pump. In this section, we will
assume that our goal is to load a reciprocating piston pump. To load a reciprocating piston
pump you need a positive supply of fluid to the pump inlet, also known as positive fluid
pressure. Positive fluid pressure is a condition in which the pressure on the outside of the pump
inlet is greater than the internal pressure of the pump during upstroke. That positive fluid
pressure forces material into the pump intake.

04538
Figure 5 A positive supply of fluid (positive fluid pressure) is required to load a
reciprocating piston pump

A pump’s fluid output is determined by how fast the positive fluid pressure can force the fluid
into the pump cavity. The pump cavity must be 100 percent full during every cycle. If the pump
cavity is not 100 percent full, the restriction will cause a condition called cavitation. Cavitation is
when the pump creates a vacuum (negative pressure) on the fluid. At this point, the pump draws
a gas instead of a liquid, or creates a void if the fluid is viscous. When a void develops in the
pump cavity, the result is pump diving and inconsistent pressure and flow. The way to avoid
cavitation is to make sure you have positive fluid pressure at the pump inlet.
Suction Lift Loss

To ensure that you have positive fluid pressure entering the pump, you need to understand the
concept of suction lift loss. Total suction lift loss takes into consideration both frictional pressure
loss (due to restriction caused by pipe, hose, or tubing) and vertical pressure loss (due to the
weight of the fluid).A simple formula will help you calculate total suction lift loss and determine
whether you have a positive or negative pressure situation. It is critical to evaluate suction lift
loss when siphon feeding a pump.

Formula

Step One Frictional pressure loss

+ Vertical pressure loss
= Total suction lift loss

Step Two Atmospheric pressure available

- Total suction lift loss
Pressure (result can be positive or negative)

Example

Your customer wants to siphon feed a fluid from a 55-gallon (200 liter) drum. The lift distance is
3 feet (1 meter). Atmospheric pressure available to load the pump is 12 psi (.083 MPa, .83 bar).
Frictional pressure loss is 9 psi (.062 MPa, .62 bar) and vertical pressure loss is 1.32 psi (.009
MPa, .09 bar).

Step One 9.0 psi (.062 MPa, .62 bar) frictional pressure loss
+ 1.32 psi (.009 MPa, .09 bar) vertical pressure loss
= 10.32 psi (.071 MPa, .71 bar) total suction lift loss

Step Two 12.0 psi (.083 MPa, .83 bar) atmospheric pressure available
- 10.32 psi (.071 MPa, .71 bar) total suction lift loss
= 1.7 psi (.012 MPa, .12 bar) positive pressure

Since 1.7 psi (.012 MPa, .12 bar) positive pressure is available, siphon feed is an acceptable
feed method for your customer.
Vapor Pressure

Vapor pressure is the pressure required to keep a fluid in a liquid state before it turns to gas.
Since gases cannot be pumped by Graco equipment, vapor pressure is a concern when
pumping volatile liquids or fast evaporating solvents. If the pressure available to prime the pump
drops below the vapor pressure of the liquid, the pump will draw a gas instead of the liquid. This
will result in cavitation, or a total inability to pump the liquid.

In theory, to determine if you can pump a liquid you must first add your vertical pressure loss
and frictional pressure loss to determine total pressure loss. Then, subtract total pressure loss
from the atmospheric pressure that is available to load the pump. If the result is less than the
vapor pressure of the liquid, you cannot prime the pump.

Example

Your customer wants to siphon feed a fluid from a 55-gallon (200-liter) drum. The lift distance is
3 feet (1 meter). Atmospheric pressure available to load the pump is 12 psi (.083 MPa, .83 bar).
The vapor pressure of the fluid is 6 psi (.041 MPa, .41 bar). Frictional pressure loss is 7 psi
(.048 MPa, .48 bar) and vertical pressure loss is 1.4 psi (.009 MPa, .09 bar).

Step One 7.0 psi (.048 MPa, .48 bar) frictional pressure loss
+ 1.4 psi (.009 MPa, .09 bar) vertical pressure loss
= 8.4 psi (.057 MPa, .57 bar) total pressure loss

Step Two 12.0 psi (.083 MPa, .83 bar) atmospheric pressure
- 8.4 psi (.057 MPa, .57 bar) total pressure loss
= 3.6 psi (.026 MPa, .26 bar) available pressure

Step Three 3.6 psi (.026 MPa, .26 bar) available pressure
- 6.0 psi (.041 MPa, .41 bar) vapor pressure of liquid
= -2.4 psi (-.015 MPa, -.15 bar)

Since the available pressure is less than the vapor pressure of the liquid, you cannot siphon
feed this fluid in this application. You will have to feed the pump by a method with less pressure
loss between the fluid container and the pump.

Vapor Pressure Recommendation

To prevent potential priming and loading problems due to vapor pressure loss, Graco
recommends that siphon feed be used only when available pressure exceeds vapor pressure by
5 psi (.034 MPa, .34 bar) or more. If vapor pressure is not known, available pressure should be
equal to or greater than 8 psi (.06 MPa, .6 bar) after subtracting vertical and frictional pressure
loss.
Pressure Differential: A Warning

The term pressure differential is an important one as you go through the process of selecting a
feed method. The pressure differential tells you the total pressure available to get a fluid into a
pump. Without that information, you may recommend the wrong feed method. Because it is
easy to underestimate all the factors that go into determining total pressure loss in a system and
because customer situations may change, make sure you check and double-check all your
information and calculations before selecting a feed method.

Example

Imagine that you have a long water hose from the fluid container to the inlet of the pump and 40
psi (.276 MPa, 2.76 bar) pressure available to feed the pump. As you move through the hose
the pressure drop is 50 psi (.34 MPa, 3.4 bar). By the time you get to the end of the hose, the
result is -10 psi (-.068 MPa, -.68 bar).

This example illustrates that, if your inlet hose is too long, the pressure drop through the hose
will result in negative pressure at the pump inlet and you risk pump cavitation. A solution to this
problem would be to use a shorter hose, a larger diameter hose, or to use a feed pump.

The most common factors that adversely affect feed pressure loss include: high viscosity
materials and a suction hose that is either too long and/or has too small an inside diameter.

Pressure boosting
pump

Feed pump

05626
Figure 6 A shorter suction hose, a larger diameter suction hose, or a feed pump
(illustrated here) can help increase fluid pressure at the pump inlet.
Progress Check
Directions: After answering the following questions, compare your answers with
those provided in the answer key following this progress check. If you respond to
any items incorrectly, return to the text and review the appropriate topics.

1. Describe positive fluid pressure.

______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
2. Explain the term cavitation.
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
3. Your customer wants to siphon feed a fluid from a 55-gallon (200 liter) drum. The lift
distance is 3 feet (1 meter). Frictional pressure loss is 9 psi (.062 MPa, .62 bar) and
vertical pressure loss is 1.32 psi (.009 MPa, .09 bar). Atmospheric pressure available to
load the pump is 12 psi (.083 MPa, .83 bar). Use this suction lift loss formula provided to
calculate whether this is a positive or negative pressure situation.
a. Positive pressure
b. Negative pressure

Step 1
Frictional pressure loss
+ Vertical pressure loss
= Total suction lift loss

Step 2
Atmospheric pressure available
- Total suction lift loss
= Pressure (result can be positive or negative)

4. Define vapor pressure and give an example of the types of fluids for which it is a
concern.
 ______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
5. Why is pressure differential important when selecting a feed method?
______________________________________________________________________
______________________________________________________________________
Answers to Progress Check

1. To load a reciprocating piston pump you need a positive supply of fluid to the pump inlet,
also known as positive fluid pressure. Positive fluid pressure is a condition in which the
pressure on the outside of the pump inlet is greater than the internal pressure of the
pump during upstroke. That positive fluid pressure forces material into the pump intake.
2. A pump cavity must be 100 percent full during every cycle. If the pump cavity is not 100
percent full, a restriction will cause a condition called cavitation. Cavitation is when the
pump creates a vacuum (negative pressure) on the fluid. At this point, the pump draws a
gas instead of a liquid, or creates a void if the fluid is viscous. When a void develops in
the pump cavity, the result is inconsistent pressure and flow.
3. A. The application described is a positive pressure situation. Calculations are:
Step 1
9 psi (.062 MPa, .62 bar) frictional pressure loss
+ 1.32 psi (.009 MPa, .09 bar) vertical pressure loss
= 10.32 psi (.071 MPa, .71 bar) total suction lift loss

Step 2
12 psi (.083 MPa, .83 bar) atmospheric pressure available
- 10.32 psi (.071 MPa, .71 bar) total suction lift loss
= 1.7 psi (.012 MPa, .12 bar) positive pressure
4. Vapor pressure is the pressure required to keep a fluid in a liquid state before it turns
into a gas. Since gases cannot be pumped, vapor pressure is a concern when pumping
volatile liquids or fast evaporating solvents.
5. The pressure differential tells you the total pressure available to get a fluid into a pump.
Without that information, you may recommend the wrong feed method. Because it is
easy to underestimate all the factors that go into determining total pressure loss in a
system and because customer situations may change, make sure you check and double
check all your information and calculations before selecting a feed method.
Siphon Feed

Customers often request siphon feeding because it is a relatively simple and low-cost pump
feed method. In siphon feeding, atmospheric pressure pushes the fluid through a hose from the
fluid container into the pump.

Head
Pressure

05627
Figure 7 Two types of siphon feed systems: siphon feed with benefit of head pressure
(left) and standard (right)

Siphon feeding is a good solution for moving fluids of up to 5,000 cp that flow easily. Siphon
feeding works well when pumping from a closed head drum, when agitation requirements
dictate large blades that do not allow the pump to be in the container, and when your customer
prefers a wall mount.

It is important to remember that a long siphon hose or a small diameter siphon hose can make it
more difficult to feed a pump, due to greater pressure loss. When considering siphon feeding,
be sure to evaluate vertical pressure loss, vapor pressure loss, and especially frictional pressure
loss.
Gravity Feed

Gravity feeding is another popular feed method. In gravity feeding, the only pressure being
applied is atmospheric pressure and the weight of the fluid. Typically, the fluid flows through the
bottom of the container to the pump intake, which is below the fluid level.

05628
Figure 8 Gravity feed system inside containment barrier

Gravity feeding works well with fluids that flow easily and have viscosities of up to 5,000 cp.
Gravity feeding is common in permanent tank installations and bulk tote tank installations.

When designing a gravity feed system, be sure to size fluid hose or pipe and fittings carefully.
Remember that a restricted pump inlet can cause cavitation.
Submersion Feed

In a submersion feed system, as illustrated in Figure 9, the pump is completely submerged

below the fluid level.

Container for
remote air
exhaust

05629
Figure 9 Submersion feed system

Submersion feeding is used with fluids that range in viscosity from 5,000 to 20,000 cp like
maintenance fluids and water waste products, and in de-watering applications. Materials that
are too viscous will not load properly.

Diaphragm pumps are the most common type of pump used in submersion feed systems.
Immersion Feed

In immersion feed systems, an extension helps immerse the pump foot valve in the fluid. Bung
and cover mounted pumps are commonly used in immersion feeding.

Immersion Feed

Air motor

2” Bung opening

Displacement
pump

05630
Figure 10 Immersion feed system

Immersion feeding can be used to load fluids that flow easily, such as paints, oils, and block
fillers with viscosities between 5,000 and 20,000 cp. Immersion feeding is commonly used to
pump materials from the original shipping container, where the pump can be set into the 2-inch
bung opening.

Since the flow path to the pump inlet is short and offers little resistance to flow, immersion
feeding is a very efficient method for feeding a pump. Be sure the outside of the pump housing,
as well as the usual wetted parts, are compatible with the material being pumped.
Follower plates are used in immersion feed systems with highly viscous materials (15,000 to
50,000 cp), such as greases in the lubrication industry. The heavy plate floats on the surface of
the material to be pumped. Positive fluid pressure results from the pressure differential
(atmospheric pressure on top of the plate and a vacuum under the plate).

The follower plate must seal around the exterior surface of the pump tube and the inner surface
of the container to be effective. The plate prevents the fluid from channeling. An example of
channeling is when a knife cuts through a product like mayonnaise and creates an air pocket.
(In grease applications, the channels collapse and form air pockets. The air pockets are drawn
into the pump, causing cavitation.) The plate also helps isolates the material from contaminants.

Follower plate

05631
Figure 11 Follower plates are used in immersion feed systems with highly viscous
materials
 Pressure Feed

Pressure feeding uses one pump, or another pressure feed source, to feed another pump.
Pressure feeding is common with fluids of medium to heavy viscosity, ranging from 5,000 to
15,000 cp. An example of a typical pressure feed application is a 5:1 ratio pump feeding a
proportioner, similar to the system illustrated in Figure 12.

Proportioning pump
Supply pumps

05632
Figure 12 Typical pressure feed system: 5:1 ratio pump feeding a proportioner

When designing a pressure feed system, it is important to keep in mind the 25 percent pressure
feed rule. This rule says that the feed supply pressure should not exceed 25 percent of the
output fluid pressure of the piston pump being fed. You need enough pressure to supply the
proper volume to the pump. The goal is to load the pump 100 percent on the upstroke.

(Important! The 25 percent pressure feed rule does not apply to diaphragm pumps or Glutton
pumps. These pumps can be damaged with that amount of feed pressure.)
Figure 13 illustrates an example where the output pressure of a proportioning pump cylinder is
2000 psi (13.8 MPa, 138 bar). 25 percent of 2000 psi (13.8 MPa, 138 bar) is 500 psi (3.45 MPa,
34.5 bar). If pressure in the pump being fed is more than 500 psi (3.45 MPa, 34.5 bar), the
pump’s foot valve will not operate properly and can cause an off- ratio situation in a plural
component application. The excess pressure can also cause unusual wear on the pump
packings. If the pressure in the pump being fed is significantly less than 500 psi (3.45 MPa, 34.5
bar), again the application can become off ratio due to insufficient loading of material. (Note that
this is only if the supply pressure becomes negative.)

500
psi
2000
psi

05633
Figure 13 Illustration of 25 percent pressure feed rule, which says that the feed supply
pressure should not exceed 25 percent of the output fluid pressure of the piston pump
being fed

There are some situations for which the 25 percent rule may not be appropriate. One example
of a situation where it may not be appropriate is when a ram system is used to move a very
viscous material. (Ram systems are described later in this module). With heavier viscosity
materials, rather than using the 25 percent rule, you may need to use the viscosity of the
material and the down force of the ram to calculate the output pressure of your proportioning
pump. Or, you could use a higher or lower pressure to create a pressure balance within the
system to compensate for different viscosities.
Variations of Pressure Feed

Inductor systems and ram systems are variations of a standard pressure feed system.

An inductor system (illustrated in Figure 14) consists of a pump, motor, inductor plate,
pneumatic elevator, and stand. The atmospheric pressure on the inductor plate, along with the
weight of the plate and the pump, help load and prime the pump.

Inductors are commonly used to move viscous industrial fluids, from 20,000 to 100,000 cp, that
flow slowly. You will find inductors used to move food products (like mayonnaise) and greases
in low temperature applications. Inductor systems commonly pump materials from their original
shipping containers.

05634
Figure 14 An inductor system is a type of pressure feed system used to move viscous
industrial fluids
A ram system (illustrated in Figure 15) consists of a pump, motor, ram plate, hydraulic or
pneumatic ram, and stand. The atmospheric pressure on the ram plate, the weight of the plate
and pump, and the down force from one or more ram cylinders prime and load the pump. One-,
two-, and four-post ram configurations are commonly available.

Rams can move viscous industrial fluids that do not flow easily, from 100,000 to 6,000,000 cp.
(For fluids of more than 3,000,000 cp, you should always call Graco Technical Assistance at 1-
800-543-0339 before making a feed method recommendation.) One-part silicones are moved
with rams. Very heavy greases that need to be pumped in cold weather may also require a ram
system to prevent cavitation.

Heated ram plates (also known as platens) are used to pump certain types of materials that
must be heated to reduce the viscosity so they can flow and be pumped at the available
pressure. Heated ram plates may also be used to melt a material from a solid to a liquid.

Pneumatic rams provide the additional pressure often required due to heavier viscosities. An
example of this might be when a high-viscosity silicone from a 55-gallon drum is used to fill
tubes for caulking guns.

Hydraulic rams develop higher down pressure than pneumatic rams and are used when
additional power is required to load the pump. Hydraulic rams are commonly used with
extremely viscous materials such as butyls with viscosities over 3,000,000 cp.

05635 05636
Figure 15 A ram system is a type of pressure feed system used to move very viscous
industrial fluids. Pictured here are a one-post ram (left) and a two-post ram (right).
Use the following chart as a quick reference to help you narrow your choice of feed methods
based on the viscosity of the fluid that your customer wants to move:

Feed Methods and Viscosity Summary Chart

Feed Method Approximate Viscosity Range
Siphon up to 5,000 cp
Gravity up to 5,000 cp
Submersion up to 20,000 cp
Immersion 5,000 to 20,000 cp
Follower Plates 15,000 to 50,000 cp
Pressure 5,000 to 150,000 cp
Inductors 20,000 to 100,000 cp
Rams 100,000 to 6,000,000 cp

Figure 16 Ranges provided in this chart are for Newtonian-type fluids. Non-Newtonian
fluids may react differently
 Bulk Unloading Systems

Bulk unloading systems offer customers cost savings and efficiency. Due to lower cost of
materials purchased in bulk and higher container disposal costs, the numbers of customers
using these systems continually rises. Bulk unloading systems move greases, food products,
sealants and adhesives, and inks. Automotive assembly plants, printing plants, and large
commercial packaging plants all use the bulk systems.

An example of a bulk unloading system is a “Bag in a Box Evacuation System” (BES), illustrated
in Figure 17. The systems also use Uni-drums and funnel-bottomed tote tanks. Since tote tanks
are reusable, the customer’s container disposal costs are reduced.

While bulk unloading systems are popular with many customers, you need to be aware of a few
issues related to these systems:

 For viscous materials, you will need a self-priming pump

 You need large supply hoses, especially when gravity feeding
 With greases, you may need to manually fill and prime the hose and stand

“Bag in a Box Evacuation System”

Pump elevator

Fluid outlet

Pumps

Bin
Control box

Inductor plate

Material being pumped

SST frame

05637
Figure 17 An example of a bulk unloading system
Progress Check
Directions: After answering the following questions, compare your answers with
those provided in the answer key following this progress check. If you respond to
any items incorrectly, return to the text and review the appropriate topics.

For items 1 through 5, match the feed method with its description.

Feed Method

a. Siphon feed
b. Gravity feed
c. Submersion feed
d. Immersion feed
e. Pressure feed

Description

1. With this feed method, the only pressure being applied is atmospheric pressure and the
weight of the fluid. This feed method works well with fluids that flow easily and have
viscosities of up to 5,000 cp. It is common in permanent tank installations and bulk tote
tank installations.
2. This feed method uses one pump, or another pressure feed source, to feed another
pump. It is common with fluids of medium to heavy viscosity, ranging from 5,000 to
150,000 cp.
3. This feed method is used with fluids that range in viscosity from 5,000 to 20,000 cp, like
maintenance fluids and water waste products. Materials that are too viscous will not load
well with this feed method. Diaphragm pumps are the most common type of pumps and
with this feed method.
4. This feed method is used to load fluids that flow easily, such as paints, oils, and block
fillers with viscosities between 5,000 and 20,000 cp. It is commonly used to pump
materials from the original shipping container. Bung and cover mounted pumps are
typical with this feed method.
5. With this feed method, atmospheric pressure pushes the fluid from the top of the fluid
container through a hose, into the pump. It is a good method for moving fluids of up to
5,000 cp that flow easily. This feed method works well when pumping from a closed
head drum, when agitation requirements dictate large blades that do not allow the pump
to be in the container, and when your customer prefers a wall mount.
6. For what types of material or application would you recommend a follower plate to a
customer using immersion feeding?
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7. State the 25 percent pressure feed rule.
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8. An inductor system and a ram system are both variations of a standard pressure feed
system. For what types of materials or applications would you recommend an inductor
system? For what types of materials or applications would you recommend a ram
system?
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9. Complete the missing information in this chart:

Feed Methods and Viscosity Summary Chart

Feed Method Approximate Viscosity Range
Siphon up to 5,000 cp
Gravity
Submersion
Immersion 5,000 to 20,000 cp
Follower Plates
Pressure
Inductors
Rams 100,000 to 6,000,000 cp

10. Explain the advantages of bulk unloading systems and give several examples of
materials or applications for which they are appropriate.
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Answers to Progress Check

1. B. Gravity feed
2. E. Pressure feed
3. C. Submersion feed
4. D. Immersion feed
5. A. Siphon feed
6. Follower plates are used in immersion feed systems with highly viscous materials
(15,000 to 50,000 cp), such as greases in the lubrication industry
7. The 25 percent pressure feed rule says that the feed supply pressure should not exceed
25 percent of the output fluid pressure of the piston pump being fed.
8. You might recommend an inductor system to move viscous industrial fluids, from 20,000
to 100,000 cp, that flows slowly. Inductors can move food products (like mayonnaise)
and greases in low temperature applications. You might recommend a ram system to
move industrial fluids with viscosities from 100,000 to 6,000,000 cp. Ram systems can
move one-part silicones and very heavy greases that need to be pumped in cold
weather.
9.
Feed Methods and Viscosity Summary Chart
Feed Method Approximate Viscosity Range
Siphon up to 5,000 cp
Gravity up to 5,000 cp
Submersion up to 20,000 cp
Immersion 5,000 to 20,000 cp
Follower Plates 15,000 to 50,000 cp
Pressure 5,000 to 150,000 cp
Inductors 20,000 to 100,000 cp
Rams 100,000 to 6,000,000 cp
10. Bulk unloading systems offer customers cost savings and efficiency. Due to lower cost of
materials purchased in bulk and higher container disposal costs, the numbers of
customers using these systems continually rises. Bulk unloading systems move greases,
food products, sealants and adhesives, and inks. Automotive assembly plants, printing,
plants, and large commercial packaging plants all use these systems.