Pumps Overview

Baljit S BaggaPumps an Overview

PUMPS an OverviewPUMPS an Overview• Types, Applications & Hydraulic Calculations

• Rotodynamic Pumps Single Stage Centrifugal Pumps Multistage Centrifugal Pumps

• Positive Displacement Pumps Reciprocating Pumps Rotary Pumps


PUMPS an OverviewPUMPS an Overview

• What is a Pump?• How many different types of Pumps?• Application of Pumps in Industry• Pump Terminology & Definitions• Pumps in Hydrocarbon, Oil & Gas Industry • Difference between Pump and compressor• What is the closest & dearest Pump to you?• Pump Technology Advancements (3 phase pumping)• Sub-sea Multiphase pumping


MACHINERY APPLICATIONMACHINERY APPLICATION

An overview of the Machinery used in Exploration and Production Activities

• General concepts

• Fluid machinery fundamentals

• Pumps

• Compressors

• Drivers


DRIVER

TR

AN

SM

ISS

ION

DRIVEN UNIT

GAS TURBINE

ELECTRIC MOTOR

DIESEL ENGINE

GAS ENGINE

Steam Turbine, Hydraulic turbine

Compressed Air

GENERATOR

PUMP

COMPRESSOR

BASEPLATEENCLOSURELUBRICATIONCOOLINGVENTILATIONAIR INTAKE ETC

GEARBOXCLUTCHFLUID COUPLINGFLEXIBLE COUPLINGS

MACHINERY PACKAGE


MAIN CLASSES OF FLUID MACHINEMAIN CLASSES OF FLUID MACHINE

Fluid machines fall into two main classes: Turbomachines:

Centrifugal Axial

Displacement Machines: Reciprocating Rotary


Turbomachinery Working PrincipleTurbomachinery Working Principle

• Rotor adds kinetic energy to fluid

• Kinetic energy converted to pressure energy

Bernouilli’s equation:p + ½ V2 = constantp = pressure = densityV = velocity


Turbomachine RotorsTurbomachine Rotors

Centrifugal Rotor Axial Rotor


TURBOMACHINE STATORS: DIFFUSERSTURBOMACHINE STATORS: DIFFUSERS

VANED DIFFUSERSCROLL DIFFUSER


Turbomachine Performance CurveTurbomachine Performance Curve

Flow

Pres

sure

Increasing Speed, Diameter, Density


Displacement Machines: Displacement Machines: ReciprocatingReciprocating

CRANKCROSSHEAD PISTON SUCTION VALVE

DISCHARGE VALVE


Displacement Machines: RotaryDisplacement Machines: Rotary

THREE LOBE PUMP


Displacement Machine: Performance Displacement Machine: Performance CurveCurve

FLOW

PR

ES

SU

RE


System Resistance CurveSystem Resistance Curve

Machine

Reservoir

Pressure = Pr

Process resistance curve

Flow

Pre

ssu

re d

rop

Pr


Machine and System: Operating Machine and System: Operating PointPoint

Flow

Pre

ssur

e


Machines in Parallel and SeriesMachines in Parallel and Series

Machines in Series

Flow

Pre

ssur

e

Machines in Parallel

Flow

Pre

ssur

e



• What is a Pump? – “A machine used for the purpose of transferring quantities of fluids (and /or gases) from one place to other” Pump generates head.

• Pump Types – Rotodynamic and Positive Displacement Centrifugal - Reciprocating Volute Piston Diffuser Plunger (API610 - 18 Types Diaphragm

classified as Rotary Pumps Overhung (OH1-6) Screw (single, twin screw) Between Bearings (BB1-5) Gear type Vertical Shafts (VS1-7) Vane type Lobe type

• Application of Pumps in Industry (more than 120 + applications, e.g. in steel, paper, brewery, water, transport, aviation, automobile, power plants industries)

• Pump Terminology & Definitions (Hydraulic Institute Publications, International codes & standards have 28000 + terms and 14000+ definitions)



• Pumps in Hydrocarbon, Oil & Gas Industry• Pumps have a wide application in the industry• Pumps are employed at the very core of E&P business

- crude oil treating and transport

- water treating and injection

- condensate handling

• Pumps are also employed for ancillary and utility applications, e.g.

- chemical injection

- fuel transfer

- lube oil circulation

- Cooling medium circulation

- fire water, - drinking water

- domestic sewage

• Pumps employed for special applications, e.g. downhole ESP, PCP and beam pumps. (ESP- electro-submersible pump, PCP-progressive cavity pump)


Pumps in Upstream OperationsPumps in Upstream Operations *


ObjectivesObjectives

Brief overview of pump hydraulics and terminology

• Review selection of the two main types of pumps and their drivers:

Roto-dynamic (centrifugal pumps)

Positive displacement (reciprocating, rotary)

• Discuss Centrifugal pump relationship of

“head” and pump fluid’s “pressure increase”• Review cavitation that can damage a pump

• Match a pump curve to the “system” curve

Brief overview of pump hydraulics and terminology

• Review selection of the two main types of pumps and their drivers:

Roto-dynamic (centrifugal pumps)

Positive displacement (reciprocating, rotary)

• Discuss Centrifugal pump relationship of

“head” and pump fluid’s “pressure increase”• Review cavitation that can damage a pump

• Match a pump curve to the “system” curve


Simplified Pump hydraulic sketchSimplified Pump hydraulic sketch

FE

Pipe Fric lossSuction & Dis

Static Gain CV loss

Static Loss

Eqipment Loss

Strainer Loss

Flow Element

(FE) Loss

Valve Loss

Psuction

Low Liq Level

Pdestination

Rated = 200 gpm @ Head = 300 ft

T/L Elev

Pump C/L

Grade

Hi Liq Level


Pump HardwarePump Hardware

Pump HardwarePump Hardware

Volute CasingVolute CasingDiffuserDiffuserSuction nozzleSuction nozzleDischarge NozzleDischarge NozzleImpellersImpellersVanesVanesShroudShroudWear ringsWear ringsBearingsBearingsStuffing boxStuffing boxShaft SealsShaft SealsCouplingCouplingDriverDriverBaseplateBaseplate


Pressure profile inside pumpPressure profile inside pump

Pressure profileinside pump


Bottom line - How Do I Select a Bottom line - How Do I Select a Pump?Pump?

• What are the Issues?– Flow– Required head– Upstream and downstream losses– NPSHA vs. NPSHR

– Installation (series or parallel)– Controls– Other issues?

• Pump selection guide – General Range

- Further details in later slides


General Ranges of Application for Different Pump Types General Ranges of Application for Different Pump Types


NPSHANPSHA


TopicsTopics

• Pump Purpose• Pump Types and Major Components• Fundamentals of Pumps• Pump System Calculations• Pump Installations• Pump Selections• Summary• Class Problem


Purpose of PumpsPurpose of Pumps

10 m

200 kPa 1000 kPa

200 m3/hr

500 m3/hr

Purpose


TopicsTopics

• Pump Purpose

• Pump types and

Major Components of

Centrifugal and Reciprocating Pumps

• Fundamentals of Pumps• Pump System Calculations• Installation Issues and Surveillance• Pump Selections• Summary• Class Problem


Centrifugal PumpsCentrifugal Pumps

Multi Stage Centrifugal PumpMulti Stage Centrifugal Pump

RasGas Sulfinol Circulation Pump

Pump Types



Eelectric motor driven Centrifugal pump.

Pump Types



Low pressure separator feeds deep well vertical turbine pump

Head above pump intake prevents cavitation

Vertical PumpVertical Pump

Pump Types


Vertical Pump InstallationVertical Pump Installation

Right angle drive

Pump Types


Multiphase PumpsMultiphase Pumps

Two subsea multiphase pumps being prepared for installation

Two subsea multiphase pumps being prepared for installation

Pump Types



Single Stage Centrifugal PumpSingle Stage Centrifugal Pump

Pump Components


Basic Types of ImpellersBasic Types of Impellers

Pump Components


Horizontal Single Stage Pump - Major Horizontal Single Stage Pump - Major ComponentsComponents

• Horizontal, single stage, overhung• Bearings support shaft (cantilevered)• Stuffing box holds seal(s) or packing

GPSA Fig 12-6a

Pump Components


Horizontal Multi-Stage Pump - Major ComponentsHorizontal Multi-Stage Pump - Major Components

• Horizontal, multi-stage, opposed impellers (thrust balancing)

• Axially split case• Mechanical seals

GPSA Fig 12-6c

Pump Components


Reciprocating PumpsReciprocating Pumps

ENERGY Pushing

Also called Plunger PumpsAlso called Plunger Pumps

Pump Components


Reciprocating PumpsReciprocating Pumps

LaBarge TEGCirculation Pump

Pump Components


TopicsTopics

• Pump Purpose• Pump types and Major Components

• Fundamentals of Pumps• Pump System Calculations• Driver Choices• Installation Issues and Surveillance• Pump Selections• Summary• Class Problem


Pumps Increase Liquid EnergyPumps Increase Liquid Energy

Pushing

Whirling

Energy

Energy

Fundamentals



Pushing

Whirling

Energy

Energy

Fundamentals


Head and PressureHead and Pressure

HEAD

Head is independent of diameter

The pressure at the bottom of each cylinder is the same

10 ft 4.3

Afor water SG = 1.0so PA = 4.3 psig

100 ft

B

43.

Pressure = h * SG * 0.43 Head = P * 2.31 / SG

PB = 43. psig

*

Fundamentals


Head and PressureHead and Pressure

HEAD

Head is independent of diameter

The pressure at the bottom of each cylinder is the same

10 m 98

A100 m

B

980

for water SG = 1.0so PA = 98 kPa PB = 980 kPa

Pressure = h * SG * 9.81 Head = P / (SG * 9.81)

Fundamentals


Head and Pressure Head and Pressure are related byare related by DENSITYDENSITY(or specific gravity in this example)(or specific gravity in this example)

30 ft

11

30 ft

13

30 ft

7

Water sp gr = 1.030 ft headPressure = h * SG * 0.43(30)(1.000)(.43) = 13 psig

Water sp gr = 1.030 ft headPressure = h * SG * 0.43(30)(1.000)(.43) = 13 psig

API 30 crude sp gr = .87630 ft head Pressure = h * SG * 0.43(30)(0.876)(.43) = 11 psig

API 30 crude sp gr = .87630 ft head Pressure = h * SG * 0.43(30)(0.876)(.43) = 11 psig

Propane liquid sp gr = 0.5530 ft head Pressure = h * SG * 0.43(30)(0.550)(.43) = 7 psig

Propane liquid sp gr = 0.5530 ft head Pressure = h * SG * 0.43(30)(0.550)(.43) = 7 psig

Fundamentals


Head and Pressure Head and Pressure are related byare related by DENSITY DENSITY(or specific gravity in this example)(or specific gravity in this example)

10 m

98

Water sp gr = 1.0 10 m head Pressure = h * SG * 9.81(10)(1.000)(9.8) = 98 kPa

10 m

86

10 m

54

API 30 crude sp gr = .87610 m head Pressure = h * SG * 9.81(10)(0.876)(9.8) = 86 kPa

Propane liquid sp gr = 0.5510 m headPressure = h * SG * 9.81(10)(0.550)(9.8) = 54 kPa

Fundamentals


TopicsTopics

• Pump Purpose• Pump types and Major Components• Fundamentals of Pumps

• Pump System Calculations

• Installation Issues and Surveillance• Pump Selections• Summary• Class Problem


Total Dynamic Head = System Total Dynamic Head = System CurveCurve

00-15185-004.ai

h1

P1

HS = P1 + h1 - LP1

h2

P2

ControlValve

HD = P2 + h2 + LP2 + LCV

Friction

Losses, LP1

Friction

Los

ses,

LP

2HT = HD - HS

HT = (P2 - P1) + (h2 - h1) + LP1 + LP2 + LCV

HT = P1,2 + h1,2 + LOSSES(pressure units must be converted to head units)

HT = HD - HS

HT = (P2 - P1) + (h2 - h1) + LP1 + LP2 + LCV

HT = P1,2 + h1,2 + LOSSES(pressure units must be converted to head units)

h1,2

*

System Calculations


Suction and Discharge Curves give System Suction and Discharge Curves give System CurveCurve

Suction head diminishes with rate due to friction loss (Lp1)

Discharge head increases with rate due to friction and control valve loss (Lp2+Lcv)

Total dynamic head for the system is the difference

*

PUMPH

System Calculations


Pump and System CurvePump and System Curve

A centrifugal pump always operates at the intersection of the pump curve & the system curve.

GPSA page 12-7 #6(control valve should absorb 30% of the friction head loss for good control)

System Calculations


Characteristic Pump CurveCharacteristic Pump Curve

Pump Head

Efficiency

NPSHR

Hor

sep

ower

Hor

sep

ower

Eff

icie

ncy 50

40

30

20

60

70

80

10

0

350

300

250

200

150

200200100100 300300 40040000

151525253535

55

Horsepower

PumpHead, ftPump

Head, ft

Closed valve pressure

Pump Flow, gpmPump Flow, gpm

NPSHR

30

25

20

15

System Calculations


Characteristic Pump CurveCharacteristic Pump Curve

Pump Head

Efficiency

NPSHR

kWkWEff

icie

ncy 50

40

30

20

60

70

80

10

0

100

80

60

40

20

50502525 7575 10010000

101015152020

55

Horsepower

PumpHead, m

PumpHead, m

m3/hrm3/hr

Closed valve pressure

NPSHR

10

8

6

4

System Calculations


Performance CurvesPerformance Curves

Pump curves show:• Head vs. capacity

– For a range of impeller diameters– At design speed only

• Horsepower– For a range of impeller diameters– At design specific gravity

• NPSH required vs. flow rate• Efficiency map

– Best-efficiency point (BEP)– Efficiency decreases as

• Flow rate increases or decreases

• Impeller diameter is reducedSystem Calculations


Typical Performance CurveTypical Performance Curve

Closed valve head or “shut-off” head

BEP

*

System Calculations


Pump PowerPump Power

Hydraulic PowerEfficiency

Brake Power =

Hydraulic Power (hp) = Q(gpm) x H (ft) x SG

3960

Hydraulic Power (kW) = Q(m3/hr) x H (m) x SG

368

Power required for the fluid

Brake Power (bhp) =Q(gpm) x P (psi)

1714 x Eff

Brake Power (kW) =Q(m3/hr) x P (kPa)

37.5 x Eff

Power required at the pump shaft

*

System Calculations


Net Positive Suction Head Net Positive Suction Head RequiredRequired

NPSHR

Temperature

Pre

ssur

e

NPSHR = Head loss (in meters or feet) of pumped fluid from the suction flange to the impeller eye or suction valve

Head loss (in meters or feet) of pumped fluid from the suction flange to the impeller eye or suction valve

P {

System Calculations


Net Positive Suction Head Net Positive Suction Head AvailableAvailable

h1

P1

Suction Head, HS = P1 + h1 - LP1

NPSHA = HS - PVP

= P1 + h1 - LP1 - PVP

(pressure units must be converted to head units)

Suction Head, HS = P1 + h1 - LP1

NPSHA = HS - PVP

= P1 + h1 - LP1 - PVP


NPSHA must be greater than NPSHR to avoid cavitation


NPSH Available for Reciprocating NPSH Available for Reciprocating PumpsPumps

h1

P1

Suction Pressure, HS = P1 + h1 - LP1 - Laccel

NPSHA = HS - PVP

= P1 + h1 - LP1 - Laccel - PVP


Suction Pressure, HS = P1 + h1 - LP1 - Laccel

NPSHA = HS - PVP

= P1 + h1 - LP1 - Laccel - PVP


NPSHA must be greater than NPSHR to avoid cavitation

Additional head loss due to accelerating flow

System Calculations


Net Positive Suction HeadNet Positive Suction Head

• NPSHA =

– (Total suction head) - (flowing liquid vapor pressure)

– Converted to head units, in absolute pressure

• NPSHR =

– Head required by pump manufacturer

• If NPSHA > NPSHR no vaporization

• if NPSHA < NPSHR vaporization and CAVITATION

Acceleration and velocity effects should be considered in rigorous analyses.


Net Positive Suction HeadNet Positive Suction Head

NPSH & CAVITATION• NPSH as the total suction head in feet absolute, determined

at the suction nozzle and corrected to datum, less the vapor pressure of the liquid in feet absolute. – NPSHA is defined as static head + surface pressure head - the

vapor pressure of your product - loss in the piping, valves and fittings

– This is the minimum head required to stop the pump from caviating.

• Cavitation means that cavities are forming in the liquid that we are pumping. This causes.– loss in capacity. – loss of pump head (pressure) – Efficiency Loss. – Noise, Vibration, and damage to pump components.


Cavitation in an ImpellerCavitation in an Impeller

Note: Cavitation can also damage plungers and valves in reciprocating pumps

LIQUID

Vaporbubblesform

Bubbles collapse violently as pressure increases:DAMAGE TO SHROUDSAND VANES

*

Produces a “Rattling stones”

sound

NPSHA < NPSHR

Temperature

Pre

ssur

e

System Calculations


CavitationCavitation

• Occurs when NPSHA < NPSHR

• Bubbles of vapor form in suction passages• Bubbles collapse violently when they reach a

point of higher pressure• Results:

– Pitting of impeller, sometimes severe– Noise, sound of “rattling stones”

• Damage– Greater with single component liquids, e.g. water– Multi-component liquids do not re-condense so

suddenly. However, head/flow capacity loss will result.

*

System Calculations


Surveillance - Eliminating CavitationSurveillance - Eliminating Cavitation

1. Increase NPSHA

– Elevate the supply vessel or lower the pump (increase elevation differential)

– Shorten the suction piping or increase diameter (reduce suction friction losses)

– Reduce fluid temperature (reduce PV)

– Use a booster pump

System Calculations


Surveillance - Eliminating CavitationSurveillance - Eliminating Cavitation

2. Reduce NPSHR

– Increase throttling in the discharge line, this action will reduce rate and increase suction pressure

– Use an oversized pump or double-suction pump– Use an impeller with a larger eye

System Calculations


Impeller Diameter ChangesImpeller Diameter Changes

• Increase head/capacity • Decrease head

– To reduce power consumption– To reduce maximum discharge

pressure

Why Change Impellers?

Affinity Laws:

These relationships are approximate.Use manufactures performance curve when possible

1

212 D

DQQ

2

1

212 D

DHH

3

1

212 D

DBHPBHP

*

System Calculations


Characteristics of Pumps in SeriesCharacteristics of Pumps in Series

• At any given capacity (flow rate) Q,HT = H1 + H2 + ... + Hn

• New operating point where be where the system curve intersects the total head curve.

Figure 15System Calculations


Characteristics of Parallel PumpsCharacteristics of Parallel Pumps

Figure 17

• New operating point where the system curve intersects the total head curve.

• Note: Two pumps in parallel do not have twice the capacity of a single pump!!

System Calculations


Water Injection PumpWater Injection Pump

Pulsation Dampeners

Discharge Relief

Valve

SuctionDischarge

Electric Motor

System Calculations


Head and Flow RateHead and Flow Rate

Basic Pump Performance at Constant Speed

Capacity

Hea

d

CENTRIFUGAL

CapacityCapacity

Hea

dH

ead

POSITIVE DISPLACEMENT

System Calculations


Typical Plunger Pump Typical Plunger Pump PerformancePerformance


TopicsTopics• Pump Purpose• Pump Types and Major Components• Fundamentals of Pumps• Pump System Calculations• Driver Choices

• Installation Issues and Surveillance– Control Systems– Viscosity Effects– Surveillance

• Pump Selections• Summary• Class problem


Common Control SystemsCommon Control Systems

Control SystemsSingle Centrifugal Pumps• Throttle discharge flow

– Most common

• Variable speed– Requires a variable speed driver !– Remember, that pump curves are generally for one

operating speed

• Recirculation control– use with caution for centrifugal pumps– possible high power consumption, increased fluid temp

• Suction throttling should never be used– Could cause cavitation

Control SystemsSingle Centrifugal Pumps• Throttle discharge flow

– Most common

• Variable speed– Requires a variable speed driver !– Remember, that pump curves are generally for one

operating speed

• Recirculation control– use with caution for centrifugal pumps– possible high power consumption, increased fluid temp

• Suction throttling should never be used– Could cause cavitation

*

Control System


Common Control Systems (cont’d)Common Control Systems (cont’d)

• Centrifugal pumps must be protected against low-flow condition– Below minimum flow, pump may overheat, cavitation and seal

damage can occur.

• Minimum flow is normally 25 to 30% of flow at BEP (Best Efficiency Point)

*

Control System


Centrifugal Pump Protection Against Low-Centrifugal Pump Protection Against Low-FlowFlow

Figure 18

Control System


Caution - Pumps in SeriesCaution - Pumps in Series

• System design pressure must be suitable for the shutoff pressure of both pumps combined

• Extra controls and a safety valve may be required

• System design pressure must be suitable for the shutoff pressure of both pumps combined

• Extra controls and a safety valve may be required

Figure 16Control System


Caution - Pumps In ParallelCaution - Pumps In Parallel

• Parallel operation can result in unbalanced flow, with less than minimum flow in one pump

• This can occur if curves are flat, and– Pump speeds are

different– Impellers are not

identical

• Parallel operation can result in unbalanced flow, with less than minimum flow in one pump

• This can occur if curves are flat, and– Pump speeds are

different– Impellers are not

identical

*

Control System


Controls - Pumps in ParallelControls - Pumps in Parallel

If natural flow balancing cannot be guaranteed:

Figure 20

Figure 19

or separate minimum flow recycle controls

Use separate flow controllers,

Control System


Protecting Reciprocating PumpsProtecting Reciprocating Pumps

PT

Pressure sensor detects high pressure from closed block valve and opens a bypass to keep pressure within acceptable limits

Control System


Viscosity Effects On Pump Viscosity Effects On Pump PerformancePerformance

• Lower efficiency• Reduced head• Reduced capacity

Viscosity EffectsViscosity EffectsHigher viscosity results in:

} More Driver Power Required

Centrifugals Reciprocating

Water, Alcohol Always preferred Seldom used

Crude Oil, TEG Always preferred Seldom used

Heavy Crude Oil Head capacity begins to deteriorate Seldom used

Crankcase Oils Significant performance fall-off Sometimes used

First Cul Molasses Seldom used Generally preferred

Asphalt Never used Always used

*

Viscosity


Surveillance Considerations – PumpsSurveillance Considerations – Pumps

Surveillance

• Vibration on plunger pumps– Vibration monitors for shut down device– Leak detection sensors on hydrocarbon fluids

(Piper Alpha disaster on a plunger pump)

• Vibration monitors on critical centrifugal pumps– Detect impeller wear, trash, or severe cavitation– Alarm for call out to check pump

Surveillance


Surveillance Considerations – Pump SealsSurveillance Considerations – Pump Seals

• Packing used on water– Periodic adjustment required

• Mechanical seals on high pressure or flammable fluids– Trash or debris ruins seal face, use strainers or

filters

– Use flush line to eliminate leakage mess at seal

– Use flush line to recover hazardous leakage, such as H2S

Surveillance


TopicsTopics

• Pump Purpose• Pump Types and Major Components• Fundamentals of Pumps• Pump System Calculations• Driver Choices• Installation Issues and Surveillance

• Pump Selections• Summary• Class Problem


How Do I Select a Pump?How Do I Select a Pump?

• What are the Issues?– Flow– Required head– Upstream and downstream losses– NPSHA vs. NPSHR

– Installation ( series or parallel )– Controls– Other?

• Pump selection guide

Selection


Pump Selection GuidePump Selection Guide

Selection


TopicsTopics

• Pump purpose• Pump types and major components• Fundamentals of pumps• Pump System calculations• Driver choices• Installation Issues and Surveillance• Pump selections

• Summary• Class problem


SUMMARY: PUMPSSUMMARY: PUMPS

• Pump performance is determined by flow and head (P)

• Head relates to pressure based on the density of the fluid

• Sufficient NPSHA prevents cavitation

• Pump curve required for centrifugal pump application

• Pumps can be centrifugal or reciprocating

• Pump performance is determined by flow and head (P)

• Head relates to pressure based on the density of the fluid

• Sufficient NPSHA prevents cavitation

• Pump curve required for centrifugal pump application

• Pumps can be centrifugal or reciprocating

Summary


Centrifugal Pump CharacteristicsCentrifugal Pump Characteristics

• Main pump type in upstream operations

• Initial cost is less than for plunger pumps for most applications.

• Require less space than plunger pumps

• Lower operating costs than plunger pumps

• May be directly connected to electric motors or turbines (or the speed reducers)

• Have no reciprocating parts or valves and thus have a non-pulsating discharge

• Main pump type in upstream operations

• Initial cost is less than for plunger pumps for most applications.

• Require less space than plunger pumps

• Lower operating costs than plunger pumps

• May be directly connected to electric motors or turbines (or the speed reducers)

• Have no reciprocating parts or valves and thus have a non-pulsating discharge

*

Selection


Reciprocating Pump Reciprocating Pump CharacteristicsCharacteristics

• Can achieve high discharge pressures• Can offer precise flow control• Small to medium capacity• High volumetric efficiency• Pulsating discharge• Higher costs• Higher maintenance

• Can achieve high discharge pressures• Can offer precise flow control• Small to medium capacity• High volumetric efficiency• Pulsating discharge• Higher costs• Higher maintenance

*

Selection


Pump ReferencesPump References

SUBJECT: PLAYING WITH A FEW PUMP TERMS • In any discussion of centrifugal pumps you will find

that there are several terms that are interrelated:

• Head , Capacity, Horsepower & Efficiency

• TDH = the total discharge head measured in feet / meter

• GPM = gallons per minute / liters per second.

• HP = horsepower required (or KW).

• Efficiency - defined as horsepower (water horsepower) out of the pump divided by the horsepower (brake horsepower) into the pump.

These numbers are shown on pump print and Nameplate.


Pump ReferencesPump References

• APIs – 610 (Centrifugal Pumps), 674 (Reciprocating)

• APIs – 675 (C.V. Metering), 676 (Rotary Pumps)

• Upstream Machinery GPs • - GP 10-01-01 Centrifugal Pumps for Petrochem O&G Ind.

• - GP 10-01-02 Centrifugal Pumps (ANSI)

• - GP 10-01-04 Centrifugal Pumps for Non-HC Gen. Plant Services

• - GP 10-01-05 Centrifugal Pumps Subm. Motor for LNG Services

• - GP 10-02-04 Centrifugal Fire Pumps (NFPA)

• - GP 10-02-05 P.D. Pumps (Rotary - Multiphase Twin Rotor)

• - GP 10-02-06 Upstream P.D. Pumps (Reciprocating)


TopicsTopics

• Pump Purpose• Pump Types and Major Components• Fundamentals of Pumps• Pump System Calculations• Driver Choices• Pump Installations• Pump Selections• Summary

• Class Problem


SimplifiedSimplified Pump hydraulic sketchPump hydraulic sketch

FE

Pipe Fric lossSuction & Dis

Static Gain CV loss

Static Loss

Eqipment Loss

Strainer Loss

Flow Element

(FE) Loss

Valve Loss

Psuction

Low Liq Level

Pdestination

Rated = 200 gpm @ Head = 300 ft

T/L Elev

Pump C/L

Grade

Hi Liq Level


Hydraulics TrainingHydraulics Training

KEY CALCULATION PARAMETERS

• Liquid Physical properties

• Cavitation and NPSH

• Friction loss

• Flow meter and control valve loss

• Equipment loss

• Elevation change (final/intermediate elevation)

• Exit Conditions


Pump ProblemPump Problem

• To provide good control of the oil export process, a discharge control valve should be added to the flow path. The head loss of the discharge control valve should be approximately 30% of the frictional head loss of the export flowline.

• Determine the system head, the required pump discharge pressure when the control valve is added to the existing flowline and calculate the required BHP for the oil export pump. Do the calculations for Ramp-up, Design, and Abandonment.

• To provide good control of the oil export process, a discharge control valve should be added to the flow path. The head loss of the discharge control valve should be approximately 30% of the frictional head loss of the export flowline.

• Determine the system head, the required pump discharge pressure when the control valve is added to the existing flowline and calculate the required BHP for the oil export pump. Do the calculations for Ramp-up, Design, and Abandonment.


Pump Problem SolutionPump Problem Solution

English units

SI units

Step1: Determine the total head for the system

23.0 PCV LL

SG

lengthflowlinegradfrictionLP

31.22

SG

lengthflowlinegradfrictionLP

81.92

CVPD LLhPH 222 111 PS LhPH HT = HD - HS



English units

SI units

Step 1(cont’d): Determine the total head for the system 212 3.1

31.2P

suctiondeliverysDT Lhh

SG

PPHHH

212 3.181.9 P

suctiondeliverySDT Lhh

SG

PPHHH

*

English units Flowrate(gpm)

Suction P(psia)

Discharge P(psia)

System Head(ft-lbf/lbm)

Power (Hp)

Ramp-Up 1196 15 219Design 4823 15 2047Abandonment 613 15 118

SI units Flowrate(m3/min)

Suction P(kPa)

Discharge P(kPa)

System Head(m)

Power (kW)

Ramp-Up 4.5 103 66Design 18.3 103 677Abandonment 2.3 103 37



Step 2: Determine the pump differential pressure

English units

SI units SGmHkPaP Tpump 81.9)()(

SGftHpsiP Tpump 433.0)(

*



Step 3: Determine the pump discharge pressure

English units SI unitspsiaPP pumpedisch 15arg kPaPP pumpedisch 4.103arg

*


Suction P(psia)

Discharge P(psia)


Power (Hp)

Ramp-Up 1196 15 63 219Design 4823 15 724 2047Abandonment 613 15 27 118


Suction P(kPa)

Discharge P(kPa)

System Head(m)

Power (kW)

Ramp-Up 4.5 103 430 66Design 18.3 103 5435 677Abandonment 2.3 103 195 37



Step 4: Determine the pump brake power, assuming pump eff.= 75%English units SI units

75.01715

)()(

psiaPgpmV

BHP

75.060

)()min(3

kPaPmVBP

*


Suction P(psia)

Discharge P(psia)


Power (Hp)

Ramp-Up 1196 15 63 219 73Design 4823 15 724 2047 2773Abandonment 613 15 27 118 20


Suction P(kPa)

Discharge P(kPa)

System Head(m)

Power (kW)

Ramp-Up 4.5 103 430 66 54Design 18.3 103 5435 677 2247Abandonment 2.3 103 195 37 15



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• API 610 Centrifugal Pumps Types, Classification and Designations

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API Standard 610 / ISO 13709 - The pumps described in this International Standard are classified and designated as shown in Table 1 — Pump classification type identification and Pump type Orientation Type code (18 types)

Overhung (6 types)OH1 - Foot-mounted OH1OH2 - Horizontal Centreline Flexibly coupled supported OH2OH3 - Vertical in-line with bearing bracket OH3OH4 - Rigidly coupled Vertical in-line OH4OH5 - Vertical in-line OH5OH6 - Overhung Close-coupled High-speed integrally geared OH6

Between Bearings (5 types)BB1 - Axially split BB1BB2 - 1- and 2-stage Radially split BB2BB3 - Axially split BB3BB4 - Single casing BB4BB5 - Between-bearings Multistage Radially split Double casing BB5

Vertical Shafts (7 types)VS1 - Diffuser VS1VS2 - Discharge through Volute VS2VS3 - Column Axial flow VS3VS4 - Line shaft VS4VS5 - Single casing Separate discharge Cantilever VS5VS6 - Diffuser VS6VS7 - Centrifugal pumps Vertically suspended Double casing Volute VS7



API Standard 610 / ISO 13709

4.2 Pump designations – and illustrations of the Overhung (6 types) of pumps

4.2.1 Pump type OH1 - Foot-mounted single-stage overhung pumps shall be designated pump type OH1. (This type does not meet all the requirements of this International Standard, see Table 2.) Figure 1 — Pump type OH1

4.2.2 Pump type OH2 - Centreline-mounted single-stage overhung pumps shall be designated pump type OH2. They have a single bearing housing to absorb all forces imposed upon the pump shaft and maintain rotor position during operation. The pumps are mounted on a baseplate and are flexibly coupled to their drivers. Figure 2 — Pump type OH2

4.2.3 Pump type OH3 - Vertical in-line single-stage overhung pumps with separate bearing brackets shall be designated pump type OH3. They have a bearing housing integral with the pump to absorb all pump loads. The driver is mounted on a support integral to the pump. The pumps and their drivers are flexibly coupled. Figure 3 — Pump type OH3

4.2.4 Pump type OH4 - Rigidly coupled vertical in-line single-stage overhung pumps shall be designated pump type OH4. Rigidly coupled pumps have their shaft rigidly coupled to the driver shaft. (This type does not meet all the requirements of this International Standard, see Table 2.) Figure 4 — Pump type OH4

4.2.5 Pump type OH5 - Close-coupled vertical in-line single-stage overhung pumps shall be designated pump type OH5. Close coupled pumps have their impellers mounted directly on the driver shaft. (This type does not meet all the requirements of this International Standard, see Table 2.) Figure 5 — Pump type OH5

4.2.6 Pump type OH6 - High-speed integral gear-driven single-stage overhung pumps shall be designated pump type OH6. These pumps have a speed increasing gearbox integral with the pump. The impeller is mounted directly to the gearbox output shaft. There is no coupling between the gearbox and pump; however, the gearbox is flexibly coupled to its driver. The pumps may be oriented vertically or horizontally. Figure 6 — Pump type OH6




4.2 Pump designations – and illustrations of the BB (5 types) of pumps

Between Bearings (5 types)

4.2.7 Pump type BB1 - Axially split one- and two-stage between-bearings pumps shall be designated pump type BB1.Fig 7

4.2.8 Pump type BB2 - Radially split one & two-stage between-bearings pumps shall be designated pump type BB2. Fig 8

4.2.9 Pump type BB3 - Axially split multistage between-bearings pumps shall be designated pump type BB3. Figure 9.

4.2.10 Pump type BB4 - Single-casing radially split multistage between-bearings pumps shall be designated pump type BB4. These pumps are also called ring-section pumps, segmental-ring pumps or tie-rod pumps. These pumps have a potential leakage path between each segment. (This type does not meet all the requirements of this Int. Std., see Table 2.) Fig.10

4.2.11 Pump type BB5 - Double-casing radially split multistage BB pumps (barrel pumps) shall be designated pump type BB5. Figure 11




4.2 Pump designations – and illustrations of Vertical Shaft (7 types) pumps

4.2.12 Pump type VS1 - Wet pit, vertically suspended, single-casing diffuser pumps with discharge through the column designated type VS1. Fig.12

4.2.13 Pump type VS2 - Wet pit, vertically suspended single-casing volute pumps with discharge through the column designated type VS2. Fig.13

4.2.14 Pump type VS3 - Wet pit, vertically suspended, single-casing axial-flow pumps with discharge through the column designated type VS3. Fig.14

4.2.15 Pump type VS4 - Vertically suspended, single-casing volute line-shaft driven sump pumps designated pump type VS4. Fig.15

4.2.16 Pump type VS5 - Vertically suspended cantilever sump pumps shall be designated pump type VS5. Fig. 16.

4.2.17 Pump type VS6 - Double-casing diffuser vertically suspended pumps shall be designated pump type VS6. Fig. 17.

4.2.18 Pump type VS7 - Double-casing volute vertically suspended pumps shall be designated pump type VS7. Fig. 18



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