Video of “A $19 desktop constant head tank”

Here is a link to a video from the “A $19 desktop constant head tank” post. The video shows the water being pumped from the lower tank up into the constant head tank, overflowing into the funnel and draining back into the lower tank. The outflow is bent upward to prevent water flowing out, but can be connected to tubing to provide constant flow rate over prolonged periods of time.


An index of all the demonstrations posted on this blog can be found here. Don’t forget to follow @nbkaye on twitter for updates to this blog. If you have a demonstration that you use in class that you would like to share on this blog please email me (nbkaye@clemson.edu). I also welcome comments (through the comments section or via email) on improving the demonstrations.

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A $19 desktop constant head tank

I have been planning on doing some pipe flow demonstrations in class using straws and rubber connectors. However, to do that I need a constant head tank that will drive the flow. Ideally the entire system would sit on a desktop so that no special mounting would need to be brought into the classroom. I am still working on the pipe flow demonstration but I thought that the budget desktop constant head tank design may be helpful to share.

Equipment

You will need:

  1. A small aquarium pump $8 
  2. A funnel $1
  3. 2 plastic tubs with straight sides (I used plastic shoe boxes) $4
  4. A small tube of silicone sealant $3
  5. A binder clip $1
  6. A short length of tubing to connect to the pump $1
  7. A hard plastic straw $1

20180530_140256

Figure 1: Materials needed for construction (binder clip missing).

Design

The basic idea is that there is a lower reservoir tank that feeds the upper tank via a pump. The upper tank contains a constant height weir overflow, with return to the reservoir tank, and an outlet below the overflow that will have a constant head. Provided the weir length on the overflow is large and the flow rate through the pump is substantially larger than the flow rate out of the constant head outlet then there will always be water flowing over the weir and the head over the weir will be relatively constant. In this budget design the reservoir and upper tank are plastic shoe boxes and the weir overflow is a funnel. Water is pumped using an aquarium pump from the lower to the upper tank and returns through the funnel to the lower tank. The upper tank rests on the lower so that the entire system can sit on a desk.

CH Tank

Construction

  1. Drill a hole in the center of the base of one of the shoe boxes with a diameter equal to that of the middle of the funnel neck.
  2. Drill a hole in the side of the same shoe box with a diameter a fraction smaller than the straw.
  3. Push the straw through the side hole (it should be a tight fit) and then seal around the hole with the silicone sealant on both sides
  4. Place the funnel inside the same shoe box with the neck protruding through the hole and seal around the funnel neck on both sides of the hole. The top of the funnel should be below the rim of the box so that water will flow into the funnel before it overflows out of the box.
  5. Attach the tubing to the aquarium pump and place it in the second shoe box.
  6. Attach the binder clip to the box with the funnel and use it as a mount for the tubing such that the tubing is pointed into the box but not into the funnel
  7. Place the box containing the funnel on top of the box containing the pump with the funnel outlet draining into the lower box.

Figure 2: (a) fully assembled constant head tank system. The yellow straw is the constant head outlet. (b) close up of the upper tank showing the inflow tube mounted (from the pump) through the binder clip and the funnel overflow back into the lower reservoir tank. (c) alternate view of the entire system.

Operation

  1. Block the end of the outlet straw or connect it to the test rig to be used.
  2. Fill the lower box until it is almost overflowing and the upper box until it is about to overflow into the funnel.. This is most easily done by pouring water into the upper tank and allowing it to overflow through the funnel into the lower tank.
  3. Turn on the pump. The water will be pumped into the upper box and drain through the funnel back into the lower box. The head in the upper box will remain essentially constant provided there is water overflowing into the funnel.

Comments

The $19 budget is approximate. You will use only a fraction of the $3 tube of sealant and may need to buy a box of binder clips to get the one you want. The whole thing takes about 15 minutes to assemble provided you have an electric drill with the appropriate drill bits for cutting the holes.

Video Update for “Pump performance curves”

In the initial “Pump performance curves ” post I had forgotten who I had learned it from. It turns out to have been John Cimbala and Laura Pauley from Penn State. They have kindly passed on the videos they showed at the 2007  APS-DFD meeting in Salt Lake City. The full videos are linked here, here, and here. GIFS are below. It is so simple but there is so much in it. This is one of my favorite labs we do now.

pump-performance-experiment-00_00_00-00_00_57 pump_take_home_experiment-00_00_00-00_00_27 shut-off_head_demonstration-00_00_00-00_00_23



An index of all the demonstrations posted on this blog can be found here. Don’t forget to follow @nbkaye on twitter for updates to this blog. If you have a demonstration that you use in class that you would like to share on this blog please email me (nbkaye@clemson.edu). I also welcome comments (through the comments section or via email) on improving the demonstrations.

Pump efficiency calculations

Just a quick note on an extension of the pump performance curves demonstration that was suggested by Ed Maurer of SCU. The initial demonstration had students calculate the head rise – flow rate relationship for a cheap aquarium pump. Ed extended this with the addition of an inline power meter (such as the Kill A Watt meter). Simply record the power consumed (P in watts) for each flow rate (Q) and pump head rise (Ep=height over which water is pumped plus tubing and exit head loss) . The efficiency can then be calculated as

η=γQEp/P.

You can then plot the pump efficiency against flow rate on the same plot as the head rise vs flow rate. When Ed Maurer did this he reported very low efficiency peaking around 20%. This is not terribly surprising as they are cheap pumps (typically only cost around $20).


An index of all the demonstrations posted on this blog can be found here. Don’t forget to follow @nbkaye on twitter for updates to this blog. If you have a demonstration that you use in class that you would like to share on this blog please email me (nbkaye@clemson.edu). I also welcome comments (through the comments section or via email) on improving the demonstrations.

Pump performance curves

I sometimes use this as an in class demonstration and sometimes as a lab test toward the end of the semester. It is good for illustrating experimental method and measurement uncertainty while demonstrating pump performance characteristics. I first saw a version of this demonstration at an APS DFD meeting about 8 years ago though I am having trouble recalling who presented it.

Equipment

  1. Bucket
  2. Stopwatch
  3. Tape measure
  4. Measuring cup
  5. Aquarium pump
  6. Extension cord
  7. Tube connected to the outlet of the aquarium pump

Photo Apr 14, 10 44 42 AM

Demonstration

  1. Fill the bucket with enough water to fully cover the pump, attach the tube to the pump outlet and place the pump in the bucket.
  2. Hold the tube vertically above the pump and turn it on (typically there is no on – off switch so plugging it in turns it on). The water should rise up the tube and then stop. Measure the head difference between the top of the water in the tube and the top of the water in the bucket. This is the shut off head.
  3. Lower the tube outlet until water starts to flow. Holding the outlet steady measure the distance from the bucket water surface to the outlet and the time taken to fill the measuring cup. Calculate the flow rate.
  4. Repeat step 3 until you have 6 to 8 different head – flow rate data pairs ranging from the shut off head to negligible elevation difference.
  5. Write up the head flow rate pairs on the board and plot the data by hand with elevation on the vertical axis and flow rate on the horizontal axis.

Analysis The data plotted should show an increase in flow rate with decreasing elevation like a typical pump performance curve. However, the data needs to be corrected to account for head loss in the tubing.

Draw a sketch of the pump – bucket – tube system with a control volume around the whole system.

pumps

Write down the work energy equation from the water surface and the tube outlet.

Z1 + u12/2g + p1/g + EP= Z2 + u22/2g + p2/ g +  hl

All the terms on the left hand side are zero except the pump head EP while the pressure at the outlet is p2=0. Using the Darcy–Weisbach equation for the head loss then Eis given by

EP= h+ (u22/2g)(1+ fL/D)

where f is the friction factor, L is the tube length, and D is the tube diameter. The exit velocity can be calculated based on the flow rate u2=Q/A=4Q/πD2. The main problem here is that the friction factor f varies with the Reynolds number and, therefore, the flow rate. Therefore, you need to calculate the friction factor and exit velocity for each data point. This can be given to the class as an in class exercise. Once the actual EP values have been calculated they can be plotted on the same graph. Some aquariums pumps actually come with a pump performance curve that can be compared to the measured data. In that case you can print the manufacturer curve on an overhead transparency. My experience with this is that cheap pumps rarely behave exactly as given in the manufacturer curve.

The demonstration presents a great opportunity to discuss experimental error. The first major source of error is the head measurement because it is hard to hold the tube steady, the water level in the bucket drops while you are filling the measuring cup, and you need to keep the tape measure vertical (though small angles away from the vertical will not make much difference). The second major error is in the measurement of the time taken to fill the measuring cup. Even if you use a 4 cup measure, it still fills in a few seconds for the larger flow rates. Therefore, a small error in timing of say half a second can lead to 10-20% error in the flow rate calculation. Both of these errors can be reduced by making multiple measurements at each height. It is also possible to estimate the individual errors and use them to place error bars on the pump performance curve data.

An index of all the demonstrations posted on this blog can be found here. Don’t forget to follow @nbkaye on twitter for updates to this blog. If you have a demonstration that you use in class that you would like to share on this blog please email me (nbkaye@clemson.edu). I also welcome comments (through the comments section or via email) on improving the demonstrations.