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Transcript of Write Up on Pumps
PUMPS…… CRITICAL ENTITIES OF A UNIT
BY : VINAY KUMAR SHARMA
A Brief Introduction of Pumps:- Page 2
PREFACE
This report is on “Pumps” and deals with various hardware specifications
and the process involved in the selection of a pump for a specific work
purpose in hydrocarbon industries. Pumps are critical entities of any
industry and are crucially linked to the layout development. Fluids, as per
their property, have a tendency to flow from higher potential to lower
potential. But when it is required to bring fluids to a higher altitude from
lower or transfer of fluid, pumps have their very indispensible role. Pumps
are devices that impart kinetic energy to fluids to bring them to higher
altitudes.
Hopeful of appreciation by pioneers of the industry, every possible
detail to the best of knowledge has been incorporated. Anything and
everything including constructive criticism and suggestions that adds value to
it is highly welcome.
A Brief Introduction of Pumps:- Page 3
CONTENTS
1. INTRODUCTION
1.1 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Pump classification. . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Selection of Pumps. . . . . . . . . . . . . . . . . . . . . . . . 6
2. CENTRIFUGAL PUMPS 9
2.1 Working Principal. . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Important Parameter. . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 System Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Constructional features. . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Criterion in Pump Design. . . . . . . . . . . . . . . . . . . . . . 45
2.6 Criterion for selection of Motor. . . . . . . . . . . . . . . . . . . 47
2.7 Sundyne Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.8 Double Suction Pump. . . . . . . . . . . . . . . . . . . . . . . 50
2.9 Axial Flow Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.10 Barrel Pump or Can Pump. . . . . . . . . . . . . . . . . . . . . . 52
2.11 Pump classification. . . . . . . . . . . . . . . . . . . . . . . . 53
A Brief Introduction of Pumps:- Page 4
3. POSITIVE DISPLACEMENT PUMP 55
3.1 Types of Positive Displacement Pump. . . . . . . . . . . . . . . 55
3.2 Difference between Centrifugal & Positive Displacement Pump 55
3.3 Advantage of Positive Displacement Pump. . . . . . . . . . . . 56
3.4 Pump Characteristic. . . . . . . . . . . . . . . . . . . . . . . . 56
3.5 When to Use PD Pumps. . . . . . . . . . . . . . . . . . . . . . 57
3.6 Plunger Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.7 Reciprocating Diaphragm type of Pump. . . . . . . . . . . . . . 59
3.8 Rotary types Pumps. . . . . . . . . . . . . . . . . . . . . . . . 60
4. PROCUREMENT/ ORDERING SYSTEM IN GAIL 71
4.1 Categorization of MR. . . . . . . . . . . . . . . . . . . . . . 71
4.2 Summary of ordering systems of Pumps unit in GAIL PATA. . . 71
4.3 Evaluation Criterion. . . . . . . . . . . . . . . . . . . . . . . . 72
4.4 Evaluation of Prices in case of Pumps. . . . . . . . . . . . . . . 72
4.5 Problem faced & Lesson learnt. . . . . . . . . . . . . . . . . . 73
4.6 Areas of Improvement. . . . . . . . . . . . . . . . . . . . . . 74
4.7 Important Documents for Review. . . . . . . . . . . . . . . . 74
A Brief Introduction of Pumps:- Page 5
CHAPTER-1
INTRODUCTION: CLASSIFICATION AND SELECTION OF PUMPS
1.1 PUMPS
A pump is a hydraulic machine which receives a flow of liquid at a certain inlet pressure,
raises this pressure to a higher value and discharges the liquid through the outlet.
The purpose of a pump is to add energy to a fluid, resulting in an increase in a fluid
pressure, not necessarily an increase of fluid speed across the Pump.
1.2 Pumps Classification
Pumps may be classified on the basis of applications they serve, the materials from
which they are constructed, the liquids they handle and their orientation in space. A
more basic system of classification could be the principle by which energy added to
the fluid.
Progressive Cavity
1.2.1 Dynamic-in which energy is continuously added to increase the fluid velocities
within the machines to values in excess of that occurring at the discharge such that
Single / Two Stage
Multistage
Horizontal
Sump Pump
Turbine Type
Barrel Pump
Vertical
Medium to large flows
Low to medium pressures
Viscosity < 200 Cst
Dynamic(Centrifugal)
Screw
Gear
Liquid Ring
Rotary
Metering
Piston / Plunger
Reciprocating
Low to medium flows
Pressure no limitation
Positive Displacement
PUMPS
Sundyne pump
A Brief Introduction of Pumps:- Page 6
subsequent velocity reduction within or beyond the pump produces a pressure
increase.
1.2.2 Positive displacement- in which energy is periodically added by application of
force to one or more movable boundaries of any desired number of enclosed, fluid
containing volumes, resulting in a direct increase in pressure up to the value
required to move the fluid through valves and ports in to the discharge line.
Displacement pumps are essentially divided in to reciprocating and rotary types,
depending upon the nature of the pressure producing members.
1.3 Selection of Pumps
Selection of right type of pump for different fluid and operating conditions
can be daunting because of the large number of options to fit various
operating conditions. Before proceeding to the actual pump selection, it is
necessary to have the complete knowledge of the location and the basic job to
be performed. The proper pump selection requires a careful study of the
hydraulic system also.
A Brief Introduction of Pumps:- Page 7
1.3.1 Major Parameter for Selection of Pumps
The following points are to be considered at the time of pump selection
i) Fluid Characteristics: A detailed study of the fluid characteristics
is usually the most important factor for the proper selection of
pumps. i.e. Chemical identity of the fluid pumped such as pH,
dissolved oxygen, corrosive or abrasive nature, Concentration,
suspended solids and temperature, etc.
ii) Absolute Viscosity: It plays an important role while selecting the
pump. It causes the liquid to resist flow, the higher the viscosity, the
greater the head loss due to friction in the pipeline and in the pump
casing as well as in the whole system. The suction head and the
available Net Positive Suction Head (NPSH) both decreases with an
increase in liquid viscosity for the same pumping rate. At the same
time, discharge and total head both increases with an increase in
liquid viscosity for the same pumping rate. In other words, the
power requirement also increases with liquid viscosity.
iii) Specific Gravity: It affects the pump life along with performance
of the pump.
iv) Temperature: The operating temperature at the pump is an
important factor affecting overall performance of the pump. While
considering temperature, the combined ambient and liquid
temperature along with the temperature rise due to evaluation of
heat from the resistance in the system shall be taken into
consideration. As per general experience, pumps can perform
efficiently with trouble-free operation over an approximate
temperature of up to 80°C.
v) Space available for pump: It helps in selecting the pump, i.e.,
horizontal or vertical. It also influences the model and size of the
pump.
A Brief Introduction of Pumps:- Page 8
vi) Self Priming Requirement: A pump where suction nozzle
elevation is above the source, there self priming capacity may be
necessary. Positive Displacement pump such as a piston pump or
a rotary screw or gear pump are used which are able to self-prime.
vii) Variable Head/Flow requirement: Centrifugal pumps and
Axial Flow pumps are most suitable pumps for variable head /
flow requirement. For high flow and high head combinations, a
multi-stage centrifugal pump can be used. Various designs of this
type of pump are available for wide range of condition. (High
temperature, cryogenic, water, hydrocarbon, and so on).
viii) Low Flow with Precise Flow Adjustment Ability: For low-flow
applications where accurate flow metering is necessary, a
proportioning pump is appropriate. This type of pump can also be
provided with variable flow capability. Certain types of gear,
plunger, and diaphragm pumps can also be used in combination
with a variable speed drive for flow rate regulation.
ix) Low Available Net Positive Suction Head: If the available net
position suction head (NPSHA) is low, specially designed
centrifugal pumps can be considered, like Sundyne Pump.
Depending upon how low the NPSHA is, either horizontal end
suction with a suction inducer or a horizontal double suction
arrangement may be applied. A vertical turbine pump may also be
used, either immersed in the process fluid (possibly in a tank or
vessel) or in a specially designed vessel (known as a suction can)
that can be installed below grade to increase the NPSHA.
A Brief Introduction of Pumps:- Page 9
CHAPTER-2
CENTRIFUGAL PUMP
A centrifugal pump is one of the simplest pieces of devices whose purpose is to convert
energy of an electric motor or engine into velocity or kinetic energy and then into
pressure of a fluid that is being pumped. The energy changes occur into two main parts
of the pump, the impeller and the volute. The impeller is the rotating part that converts
driver energy into the kinetic energy. The volute is the stationary part that converts the
kinetic energy into pressure.
Centrifugal pumps are entirely dynamic in action, that is to say they
depend upon rotational speed to generate a head which is manifest as a difference of
pressure between inlet and outlet branches. The quantity of liquid pumped and the power
involved depends upon the system of liquid contained, static pressures and pipeline etc.
to which pump is attached.
Centrifugal pumps are used for large discharge through smaller heads.
2.1 Working Principle
2.1.1 Centrifugal Force
Liquid enters the pump suction and then the eye of the impeller. When the impeller
rotates, it spins the liquid sitting in the cavities between the vanes outward and imparts
centrifugal acceleration. As the liquid leaves the eye of the impeller a low pressure area
is created at the eye allowing more liquid to enter the pump inlet.
2.1.2. Conversion of Kinetic Energy to Pressure Energy
The key idea is that the energy created by the centrifugal force is kinetic energy. The
amount of energy given to the liquid is proportional to the velocity at the edge or vane
tip of the impeller. The faster the impeller revolves or the bigger the impeller is, then the
higher will be the velocity of the liquid at the vane tip and the greater the energy
imparted to the liquid.
This kinetic energy of a liquid coming out of an impeller is harnessed by creating
a resistance to the flow. The first resistance is created by the pump volute (casing) that
catches the liquid and slows it down. In the discharge nozzle, the liquid further
decelerates and its velocity is converted to pressure according to Bernoulli’s principle.
A Brief Introduction of Pumps:- Page 10
2.2 Important Parameter of Centrifugal Pump
2.2.1 Capacity (min/nor/rated): Capacity means the flow rate with which liquid is moved or pushed by the pump to the
desired point in the process. It is commonly measured in either gallons per minute (gpm)
or cubic meters per hour (m3/hr). The capacity usually changes with the changes in
operation of the process. For example, a boiler feed pump is an application that needs a
constant pressure with varying capacities to meet a changing steam demand. The
capacity depends on a number of factors like:
Process liquid characteristics i.e. density, viscosity
Size of the pump and its inlet and outlet sections
Impeller size
Impeller rotational speed RPM
Size and shape of cavities between the vanes
Pump suction and discharge temperature and pressure conditions
For a pump with a particular impeller running at a certain speed in a liquid, the only
items on the list above that can change the amount flowing through the pump are the
pressures at the pump inlet and outlet. The effect on the flow through a pump by
changing the outlet pressures is graphed on a pump curve.
Minimum Capacity: Although a constant speed Centrifugal pump will operate over a
wide range of capacity but at low flow it will encounter following troubles:
i) Abrasive wear: Liquids containing a large amount of abrasive particles,
such as sand or ash must flow continuously through the pump. If flow
decreases, the particles can circulate inside the pump passages and quickly
erode the impeller, casing and even wear ring and shaft. Each pump has a
value of minimum continuous flow which is a characteristic of that
ii) Thermal: Inescapable energy conversion loss in the pump warms the
liquid.
iii) Hydraulic: When the flow decreases far enough, the impeller encounters
the suction or discharge recirculation or both.
iv) Mechanical: Both constant and fluctuating load in the radial and axial
directions increases as pump capacity fall. Bearing damage, shaft and
impeller breakage can occur. Its value can be obtained from the
characteristic curves provided in the vendor’s catalogue. The pump should
A Brief Introduction of Pumps:- Page 11
be selected so that the minimum flow during the service does not fall below
minimum continuous flow.
2.2.2 Pressure Pressure is usually measured in gauge that registers the difference between the pressure
in vessel and current atmospheric pressure. Therefore the gauge does not indicate the
true total gas pressure.
To obtain the true pressure or pressure above zero, it is necessary to add the current
atmospheric or barometric pressure, expressed in proper units. This sum is the absolute
pressure.
2.2.3 Pump Head
Head/ static head is the distance between two horizontal levels in a liquid. It is also the
measure of the pressure exerted by a column or body of liquid because of the weight of
the liquid. The term pump head represents the net work performed on the liquid by the
pump. It is composed of four parts. The static head (Hs), or elevation; the pressure head
(Hp) or the pressures to be overcome; the friction head (Hf) and velocity head (Hf),
which are frictions and other resistances in the piping system.
Significance of using the “head” term instead of the “pressure” term
A Brief Introduction of Pumps:- Page 12
The pressure at any point in a liquid can be thought of as being caused by a vertical
column of the liquid due to its weight. The height of this column is called the static head
and is expressed in terms of feet of liquid.
The same head term is used to measure the kinetic energy created by
the pump. In other words, head is a measurement of the height of a liquid column that
the pump could create from the kinetic energy imparted to the liquid. Imagine a pipe
shooting a jet of water straight up into the air, the height the water goes up would be the
head.
The head is not equivalent to pressure. Head is a term that has units of a length or feet
and pressure has units of force per unit area or pound per square inch. The main reason
for using head instead of pressure to measure a centrifugal pump’s energy is that the
pressure from a pump will change if the specific gravity (weight) of the liquid changes,
but the head will not change. Since any given centrifugal pump can move a lot of
different fluids, with different specific gravities, it is simpler to discuss the pump's head
and forget about the pressure. So a centrifugal pump’s performance on any Newtonian
fluid, whether it's heavy (sulfuric acid) or light (gasoline) is described by using the term
‘head’. The pump performance curves are mostly described in terms of head.
A given pump with a given impeller diameter and speed will raise a liquid to a
certain height regardless of the weight of the liquid.
i) Pressure head:- Pressure can be converted to head with following formula:-
H = Pressure/Density = P/ρg
ii) Velocity Head: - It is the head required to impart velocity to liquid. It is
eequivalent to the vertical distance through which the liquid would have to fall
to acquire the same velocity.
A Brief Introduction of Pumps:- Page 13
Velocity head = V2 / 2g
iii) Friction Head: - It is the force or pressure required to overcome friction and
is obtained at the expense of the static pressure head. Unlike velocity head,
friction head cannot be “recovered” or reconverted to static pressure head.
Thermal energy is usually wasted, therefore resulting in a head loss from the
system.
Hf= f(L/D)(V2/2Zg)
Where f is friction factor, L is length of pipe, and D is
dia. of pipe
Total dynamic head = Hs + Hp + Hv + Hf
Suction lift: Suction lift exists when the source of supply is below the center line of the
pump.
Suction head: Suction head exists when the source of supply is above the centerline of
the pump.
2.2.4 Net Positive Suction Head (NPSH)
NPSH is what the pump needs, the minimum requirement to perform its duties. NPSH
takes into consideration the suction piping and connections, the elevation and absolute
pressure of the fluid in the suction piping, the velocity of the fluid and the temperature.
Some of these factors add energy to the fluid as it moves into the pump, and others
subtract energy from the fluid. There must be sufficient energy in the fluid for the
impeller to convert this energy into pressure and flow. If the energy is inadequate we say
that the pump suffers inadequate NPSH.
The Hydraulic Institute Standards defines NPSH as the total
suction head in meters absolute, determined at the suction nozzle and corrected to datum,
less the vapor pressure of the liquid in meters absolute. Simply stated, it is an analysis of
energy conditions on the suction of a pump to determine if the liquid will vaporize at the
lowest pressure point in the pump.
The pressure, which a liquid exerts on its surroundings, is dependent upon its
temperature. This pressure, called vapor pressure, is a unique characteristic of every
fluid and increases. When the vapor pressure within the fluid reaches the pressure of the
surrounding medium, the fluid begins to vaporize or boil. The temperature at which this
vaporization occurs will decrease as the pressure of the surrounding medium decreases.
A liquid increases greatly in volume when it vaporizes. One cubic foot of
water at room temperature becomes 1700 cu. Ft. of vapor at the same temperature.
A Brief Introduction of Pumps:- Page 14
It is obvious from the above that if we are to pump a fluid effectively, we
must keep it in the liquid form. NPSH is simply a measure of the amount of suction head
to prevent this vaporization at the lowest pressure point in the pump.
Net Positive Suction Head (NPSH) is a statement of the minimum
suction conditions required to prevent cavitations in a pump.
i) NPSHA (Available):- NPSHA is a total available suction pressure - over
the vapor pressure - (expressed in feet/ meter of head). In other words, it is Net
Suction Head - vapor pressure (expressed as head). This is the energy in the
fluid at the suction connection of the pump over and above the liquid’s vapor
pressure. It is a characteristic of the system and we say that the NPSHA should
be greater than the NPSHR (NPSHA > NPSHR).
ii) NPSHR (Required):-It is the energy in the liquid required to overcome the
friction losses from the suction nozzle to the eye of the impeller without
causing vaporization. It is a characteristic of the pump and is indicated on the
pump's curve. It varies by design, size, and the operating conditions. It is
determined by a lift test, producing a negative pressure in inches of mercury
and converted into feet of required NPSH.
How to increase NPSHA?
a) INCREASE P SOURCE:
-Increase Vessel/Reactor Pressure
-Install Booster Pump Upstream Of Main Pump
Ps
H friction
NPSH (A-R)
NPSH A
NPSH R
P vap
H vap
A Brief Introduction of Pumps:- Page 15
b) INCREASE delta H:
-Increase Vessel Level
-Increase Minimum Liquid Level
-Lower Pump Installation Level
c) DECREASE SUCTION LOSSES:
-Increase Suction Pipe Size
-Reduce Suction Pipe Length
-Minimize No. Of Bends
-Use Low delta P Valves/Strainers in Suction
d). REDUCE VAPOUR PRESSURE:
-Lower Liquid Temp.
-Minimize Heat Pick-up in Suction Line
How to decrease NPSHR?
a) Select pump at lower speeds
b) Use double suction impellers
c) Modify pump geometry
d) Use inducer
2.2.5 Cavitations
It is the formation and subsequent collapse of vapor filled cavities (such as bubbles,
vapor filled pockets etc) in a liquid due to dynamic action. Inadequate NPSHA
establishes favorable conditions for cavitation in the pump. If the pressure in the eye of
the impeller falls below the vapor pressure of the fluid, then bubble formation begins. As
bubbles flow from low pressure to higher, they implode against metal surfaces with high
energy. These micro-hammer-like impacts erode the material, creating cavities – thus
“cavitation”.
2.2.6 Vapor pressure
The vapor pressure of a liquid is the absolute pressure at which the liquid vaporizes or
converts into a gas at a specific temperature. The vapor pressure of a liquid increases
with its temperature. For this reason the temperature should be specified for a declared
vapor pressure.
Thoma’s cavitation factor:- The thoma cavitation factor is used to indicate the onset of
cavitation. It is defined as:
σ = (Ha – Hs – Hv)/ Hmano = NPSH / Hmano
Ha = atmospheric pressure expressed in meters
Hv = vapor pressure in meters.
A Brief Introduction of Pumps:- Page 16
Hs = Total suction head.
Hmano = Manometric Head = Head imparted by the impeller to
Liquid – loss of head in the pump.
How does vapor pressure effect pump performance? When cavitation occurs in a pump, its efficiency is reduced. It can also cause sudden
surges in flow and pressure at the discharge nozzle. The calculation of the NPSHR (the
pump’s minimum required energy) and the NPSHA (the system’s available energy), is
based on an understanding of the liquid’s absolute vapor pressure. The effects of
cavitation are noise and vibration. If the pump operates under cavitating conditions for
enough time, the following can occur:
Pitting marks on the impeller blades and on the internal volute casing wall of the
pump.
Premature bearing failure.
Shaft breakage and other fatigue failures in the pump.
Premature mechanical seal failure.
These problems can be caused by:
A reduction of pressure at the suction nozzle.
An increase of the temperature of the pumped liquid.
An increase in the velocity or flow of the fluid.
Separation and reduction of the flow due to a change in the viscosity of the liquid.
Undesirable flow conditions caused by obstructions or sharp elbows in the suction
piping.
The pump is inadequate for the system.
2.2.7 Brake Horse Power (BHP)
The work performed by a pump is a function of the total head and the weight of the
liquid pumped in a given time period.
Pump input or brake horsepower (BHP) is the actual horsepower delivered to the pump
shaft.
Pump output or hydraulic or water horsepower (WHP) is the liquid horsepower
delivered by the pump.
2.2.8 Efficiency
The ratio of power output of the pump to the power input to the pump is called
efficiency of the pump.
Ƞ= WKW/ 366.9× BKW
A Brief Introduction of Pumps:- Page 17
2.2.9 Best Efficiency Point (BEP)
Best Efficiency Point (BEP) is the capacity at maximum impeller diameter at which the
efficiency is highest. All points to the right or left of BEP have a lower efficiency.
Significance of BEP
BEP as a measure of optimum energy conversion
When sizing and selecting centrifugal pumps for a given application the pump efficiency
at design should be taken into consideration. The efficiency of centrifugal pumps is
stated as a percentage and represents a unit of measure describing the change of
centrifugal force (expressed as the velocity of the fluid) into pressure energy. The B.E.P.
(best efficiency point) is the area on the curve where the change of velocity energy into
pressure energy at a given gallon per minute is optimum; in essence, the point where the
pump is most efficient.
BEP as a measure of mechanically stable operation
The impeller is subject to non-symmetrical forces when operating to the right or left of
the BEP. These forces manifest themselves in many mechanically unstable conditions
like vibration, excessive hydraulic thrust, temperature rise, and erosion and separation
cavitation. Thus the operation of a centrifugal pump should not be outside the furthest
left or right efficiency curves published by the manufacturer. Performance in these areas
induces premature bearing and mechanical seal failures due to shaft deflection, and an
increase in temperature of the process fluid in the pump casing causing seizure of close
tolerance parts and cavitation.
BEP as an important parameter in calculations
BEP is an important parameter in that many parametric calculations such as specific
speed, suction specific speed, hydrodynamic size, viscosity correction, head rise to
shutoff, etc. are based on capacity at BEP. Many users prefer that pumps operate within
80% to 110% of BEP for optimum performance.
2.2.10 Pump specific speed
Pump specific speed is a dimensionless quantity which is similar for geometrically
similar pumps and is defined as
A Brief Introduction of Pumps:- Page 18
Ns = NQ1/2
/ H3/4
Specific speed is calculated at best efficiency point (BEP) with the maximum impeller
diameter.
Specific speed as a measure of the shape or class of the impellers
The specific speed determines the general shape or class of the impellers. As the specific
speed increases, the ratio of the impeller outlet diameter, D2, to the inlet or eye diameter,
D1, decreases. This ratio becomes 1.0 for a true axial flow impeller. Radial flow
impellers develop head principally through centrifugal force. Radial impellers are
generally low flow high head designs. Pumps of higher specific speeds develop head
partly by centrifugal force and partly by axial force. A higher specific speed indicates a
pump design with head generation more by axial forces and less by centrifugal forces.
An axial flow or propeller pump with a specific speed of 10,000 or greater generates its
head exclusively through axial forces. Axial flow impellers are high flow low head
designs.
Specific speed identifies the approximate acceptable ratio of the impeller eye diameter
(D1) to the impeller maximum diameter (D2) in designing a good impeller.
Ns: 500 to 5000; D1/D2 > 1.5 - radial flow pump
Ns: 5000 to 10000; D1/D2 < 1.5 - mixed flow pump
Ns: 10000 to 15000; D1/D2 = 1 - axial flow pump
Specific speed is also used in designing a new pump by size- factoring a smaller pump
of the same specific speed. The performance and construction of the smaller pump are
used to predict the performance and model the construction of the new pump.
Pump Suction Specific Speed:-
Pump suction specific speed provides an assessment of pumps susceptibility to internal
recirculation. It is mathematically defined as:-
S = NQ1/2
/ NPSHR3/4
Suction specific speed is also calculated at BEP with maximum impeller diameter.
Also
(Thoma’s cavitation factor) = (Ns/ S)3/4
2.2.11 Priming of a centrifugal pump
The operation of filling the suction pipe, casing of the pump and a portion of the delivery
pipe completely from outside source with the liquid to be raised, before starting the
pump, to remove any air gas or vapor from the parts of the pump is called priming of
centrifugal pump. If the pump is not primed before starting, air pockets inside the
A Brief Introduction of Pumps:- Page 19
impeller may give rise to vortices and cause discontinuity of flow. Further dry running of
the pump may result in rubbing and seizing of the wear rings and cause severe damage.
2.3 System Curves
Ordinarily a centrifugal pump is worked under its maximum efficiency conditions.
However the pump is run at conditions different from the design condition, it performs
differently. Therefore to predict the behavior of the pump under varying conditions of
speeds, heads, discharges or powers tests are usually conducted. The results obtained
from these tests are plotted in form of characteristic curves. These curves generate useful
information about the performance of a pump in its installation.
The following four types of characteristic curves are usually prepared for
centrifugal pumps:
1. Main characteristic curves
2. Operating characteristic curves
3. Constant efficiency or Muschel curves
4. Constant head or constant discharge curves
2.3.1 Main characteristic curves
The main characteristic curve is obtained as follows:
The pump is run at a constant speed and the discharge is varied over the
desired range.
Measurements are taken for manometric head and shaft power for each
discharge.
Calculations are made for pump efficiency.
The curves are plotted between Q and Hmano; Q and P; and Q and ƞ for that
speed.
The same procedure is repeated by running the pump at another speed.
The family of curves is obtained as shown in the fig.1
Fig. 1
2.3.2 Operating characteristic curves
A Brief Introduction of Pumps:- Page 20
When a centrifugal pump operates at the design speed the maximum efficiency occurs.
Evidently from optimum performance, the pump needs to be operated at the design
speed and the discharge is varied, as in the case of main characteristic curves. The
operating characteristics are shown in the fig.2 below. The design discharge and head are
obtained from the corresponding curve where the efficiency is maximum.
Fig.2
2.3.3. Constant efficiency or Muschel curve:
The constant efficiency curve also called as iso- efficiency curve, depicts the
performance of a pump over its entire range of operation. The curves are obtained from
main characteristic curves as follows:
For a given efficiency, the values of discharge are obtained from fig.1. these
points are projected on the head v/s discharge curve of fig1.
Similarly for other values of efficiency and speed, the points are obtained and
projected.
The points corresponding to one efficiency are joined.
The constant efficiency curve helps to locate the regions where the pump would operate
with maximum efficiency.
2.3.4. Constant head and constant discharge curves
The performance a variable speed pump for which the speed constantly varies can be
determined by these curves. When the pump has a variable speed, the plots between Q
and N, and Hmano and N may be obtained.
A Brief Introduction of Pumps:- Page 21
2.4 CONSTRUCTIONAL FEATURES
General Components of Centrifugal Pumps
A centrifugal pump has two main components:
I. A rotating component comprised of an impeller and a shaft
II. A stationary component comprised of a casing, casing cover, and bearings.
Various parts of a centrifugal pump are briefly described below:
2.4.1 Impellers:
Impellers are the components of pump which impart dynamic energy to the fluid, which
gets converted to pressure energy. This may be classified on the basis of
(a)Mechanical design of impellers
According to this impellers may be classified as:
(i) Completely open
It consists of vanes attached to a central hub for mounting on the shaft without any form
of sidewall or shroud. The disadvantage of the impeller is its structural weakness and it’s
A Brief Introduction of Pumps:- Page 22
more sensitiveness to wear. Due to more wear the efficiency deteriorates rapidly. One
advantage of open impeller is that they are better suited for handling stringy materials.
Also they are better suited for handling liquids containing suspended matter as the
possibility of clogging is not there. They are used in small inexpensive pumps.
Fig: Open impeller Fig: Semi- open impeller
(ii) Semi open
It incorporates a single shroud usually at the back of the impeller. This shroud may or
may not have pump out vanes which are vanes located at the back of impeller shroud.
This function is to reduce the pressure at the back hub of the impeller and prevent
foreign matter from lodging in the back of the impeller and interfering with
proper operation of the pump and stuffing box
(iii) Closed
It is almost universally used in pumps handling clear liquids, incorporates shrouds or
enclosing side walls that totally enclose impeller water ways from suction eye to the
periphery. Although this design prevents the liquid slippage that occurs between an open
or semi-open impeller and its side plates a running joint must be provided between the
impeller and casing to separate the discharge and suction chambers of the pump. This
running joint is usually formed by a relatively short cylindrical surface on the impeller
shroud that rotates within slightly larger cylindrical surface.
Fig: Closed impeller (single suction) Fig: Closed impeller (double suction)
(b)Based on suction type
Single and double suction impellers:
A Brief Introduction of Pumps:- Page 23
In single suction impellers the liquid enters the suction eye on one side only. A double
suction impeller is in effect two single suction impellers arranged back to back in a
single casing, the liquid enters simultaneously from both sides, while the two casing
suction passage ways are connected to a common suction passage and a single suction
nozzle. For the general service axially split casing design, a double suction impeller is
favoured because it is theoretically in axial hydraulic balance and because the greater
suction area of a double suction impeller permits the pump to operate with less absolute
head or its better NPSH characteristics.
2.4.1 i) Axial thrust
Axial thrust in single stage pump
Axial hydraulic thrust on an impeller is the sum of the unbalanced forces acting in an
axial direction. The ordinary single suction impeller with the shaft passing through the
impeller eye is subjected to axial thrust because a portion of the front wall is exposed to
suction pressure and thus relatively more backwall surface is exposed to discharge
pressure. If the discharge chamber pressure was uniform over the entire impeller surface,
the axial force acting toward the suction would be equal to the product of the net
pressure generated by the impeller and the unbalanced annular area. Generally speaking,
axial thrust toward the impeller suction is about 20 to 30% less than the product of the
pressure and the unbalanced area.
Theoretically, a double-suction impeller is in hydraulic axial balance, with the
pressure on one side equal to and counterbalancing the pressure on the other. In practice,
this balance may not be achieved for the following reasons:
1. The suction passages to the two suction eyes may not provide equal or uniform
flows to the two sides.
2. Unequal leakage through the two leakage joints can upset the balance.
3. External conditions, such as an elbow located too close to the pump suction
nozzle, may cause unequal flow to the two suction eyes.
Combined, these factors can create axial unbalance. To compensate for this, all
centrifugal pumps, even those with double suction impellers, incorporate thrust bearings.
2.4.1 ii) Axial thrust in multistage pumps
Most multistage pumps are built with single suction impellers in order to simplify the
design of inter stage connections. Two arrangements are possible for the single suction
impellers:
1. Several single suction impellers mounted on one shaft, each having its suction inlet
facing in the same direction and its stage following one another in ascending order of
pressure. The axial thrust is then balanced by following hydraulic balancing devices;
a. Balancing drums
A Brief Introduction of Pumps:- Page 24
b. Balancing disks
c. Combination balancing disk and drum
2. An even number of single suction impeller may be used, one half facing in one
direction and the other half facing in opposite direction. With this arrangement, axial
thrust on the first half is compensated by the thrust in the opposite direction on the
other half. This mounting of single suction impellers back to back is called opposed
impellers.
Impeller Axial Thrust Diagram
Rotor Assembly Axial Thrust With Balancing Disc & Drum
A Brief Introduction of Pumps:- Page 25
2.4.2 Shaft and Shaft Sleeves
i) Shaft
The basic function of a centrifugal pump shaft is to transmit the torque
encountered in starting and during operation while supporting the impeller and
other rotating parts. It must do this job with a deflection less than the minimum
clearance between rotating and stationary parts.
Loads involved- (1) Torque
(2) Weight of the parts
(3) Both radial and axial hydraulic forces
In designing a shaft, the maximum allowable deflection, the span or overhang and the
location of the loads all have to be considered, as does the critical speed of the resulting
design.
Critical speed: Any object made of elastic material has a natural period of vibration.
When a pump rotor or shaft rotates at any speed corresponding to its natural frequency,
minor unbalances will be magnified. These speeds are called the critical speeds.
Rigid and Flexible shaft:
A rigid shaft means one with an operating speed lower than its first critical speed.
A flexible shaft means one with an operating speed higher than its first critical speed.
It is possible to operate centrifugal pump shaft above their critical speed for the
following two reasons-
1) Very little time is required to attain full speed from rest.
2) The pumped liquid in the stuffing box packing and the internal leakage joints
act as a restraining force on the vibration.
ii) Shaft sleeves:
Pump shaft are usually protected from erosion, corrosion and wear at stuffing boxes,
leakage joints, internal bearings and in the waterways by renewable sleeves.
The most common shaft sleeve function is that of protecting the shaft from
wear at a stuffing box.
A Brief Introduction of Pumps:- Page 26
Fig: Shaft and Shaft sleeve
Material for stuffing box sleeve: Stuffing box shaft sleeves are surrounded in the
stuffing box packing , the sleeve must be smooth so that it can turn without generation
too much friction and heat. Thus the sleeve materials must be capable of taking very fine
finish, preferably a polish; therefore cast iron is not suitable for shaft sleeve. Hard
bronze is suitable for pumps handling clear water. Hardened chrome or other stainless
steels for pumps subjected to grit. Etc;
2.4.4 Bearings
The function of bearings in centrifugal pump is to keep the shaft in correct alignment
with the stationary parts under the action of radial and transverse loads. Bearing that give
radial positioning to the rotor are known as line bearings and those locate the rotor
axially are called thrust bearings. In most application the thrust bearings serve actually
both as thrust and radial bearings.
In horizontal pump with bearings on each end, the bearings are usually
designated by their location as inboard and outboard. Inboard bearings are located
between the casing and the coupling. Pumps with overhang impeller have both bearings
on the same side of casing so that the bearing nearest the impeller is called inboard and
the one farthest away outboard. In a pump provided with bearings at both ends, the thrust
bearing is usually placed at outboard end and the line bearing at the outboard end.
2.4.5 Wear rings
Wear rings are used on close clearance areas of casings and impellers where they form
leakage joints between suction and discharge pressure. They act as replaceable wear
surfaces and are respectively called impeller and casing wear rings. In case of open
impellers, they are provided only on casing and are called wear plates. Since wear rings
are close clearance parts, they have galling/seizing tendencies. Therefore minimum wear
ring clearances are insisted upon even though this may mean lower efficiencies.
A Brief Introduction of Pumps:- Page 27
Fig: Wear rings
2.4.6 Casing
The casing is an airtight chamber surrounding the pump impeller. It is the part that
contains the pump components and is used for converting the velocity energy to pressure
energy. It contains suction and discharge arrangements, supporting for bearings and
facilitates to house the rotor assembly.
The essential purposes of the casings are:
I. To guide the water to and from the impeller, and
II. To partially convert the kinetic energy into pressure energy.
a) Solid and split casings
Solid casing implies a design in which the discharge waterways leading to the discharge
nozzle are all contained in one casing, or fabricated piece. The casing must have one side
open so that the impeller may be introduced into it.
A split casing is made of two or more parts fastened together. Axially split
casing is a casing divided by a plane through the shaft centerline or axis. Since both the
suction and discharge nozzles are usually in the same half of the casing, the other half
may be removed for inspection of the interior without disturbing the bearing or the
piping. Radial split casing is a casing split in a plane perpendicular to the axis of
rotation or shaft centerline.
b) Volute Casing
In this type of casing the area of flow gradually increases from the impeller outlet to the
delivery pipe so as to reduce the velocity of flow. Thus the increase of pressure occurs in
volute casing.
c) Single and Double volute casing
In a single volute casing design, uniform or near uniform pressure act on the impeller
when the pump is operated at design capacity (which coincides with the best efficiency).
At other capacities, the pressure around the impeller is not uniform and there is a
resultant radial reaction (F).
A Brief Introduction of Pumps:- Page 28
F= KD2W2H(S.G) / 10.21(104) in metric units
Where K – Radial thrust factor (depends on % of design capacity
and pump specific speed.)
D2 – Impeller diameter
W2 – Impeller width
H – Pump total head
This unbalanced radial thrust increase as capacity decrease from that design flow. Thus a
high head pump with a large impeller diameter will have a much greater radial reaction
force at partial capacity then a low head pump with a small impeller diameter. Radial
thrust is least in the region of Best Efficiency point (discussed later.)
Because of the increasing application of pumps which must operate at reduced
capacities, it has become desirable to design standard units to accommodate such
conditions. One solution is to use heavier shafts and bearings. Expect for low head
pumps in which only a small additional load is involved, the solution is not economical.
The only practical answer is a casing design that develops a much smaller radial
reaction force at reduced capacities. One of these is the double volute casing design, also
called twin volute or dual volute design.
This design consists of two 180 degree volutes. A pressure unbalance exists at
partial capacity through each 180 degree arc, the two forces are approximately equal and
opposite. Thus little if any radial forces act on the shaft and bearings.
Fig: A double volute casing pump
d) Vortex Casing
If a circular chamber is provided between the impellers and the volute chambers, the
casing is known as vortex casing. The circular chamber is known as vortex or whirlpool
chamber. The efficiency of a volute pump fitted with a vortex chamber is more than that
of a simple volute pump.
2.4.8 Seal Chamber and Stuffing Box
Seal chamber and Stuffing box both refer to a chamber, either integral with or separate
from the pump case housing that forms the region between the shaft and casing where
sealing media are installed. When the sealing is achieved by means of a mechanical seal,
the chamber is commonly referred to as a Seal Chamber.
A Brief Introduction of Pumps:- Page 29
When the sealing is achieved by means of packing, the chamber is
referred to as a Stuffing Box. Both the seal chamber and the stuffing box have the
primary function of protecting the pump against leakage at the point where the shaft
passes out through the pump pressure casing. When the pressure at the bottom of the
chamber is below atmospheric, it prevents air leakage into the pump. When the pressure
is above atmospheric, the chambers prevent liquid leakage out of the pump. The seal
chambers and stuffing boxes are also provided with cooling or heating arrangement for
proper temperature control.
2.4.9 Mechanical Seal or Packing
Packing or seal are required to prevent the process fluid from leaking to atmosphere and
to prevent loss of pressure energy. Packing are now used for only water services. For all
hydrocarbon services mechanical seal may be used in single, tandem or double
configurations. Single pusher type seal are most commonly used. Tandem seal are used
for hazardous fluids where leakage to atmosphere cannot be allowed.
Advantages of mechanical seals:- 1. Greater sealing capability
2. Lower leakage
3. Tolerance of liquids
4. No adjustment- self compensation for wear, therefore do not require adjustment.
Fig: Gland packing Fig: Mechanical seal
A Brief Introduction of Pumps:- Page 30
Fig: Tandem seal
i) Principle (Mechanical seals)
The sliding seal interface is affected between the flat, polished mating faces of
two rings, one connected and sealed to pump’s rotor, the other to its casing. One
of the ring is flexibly mounted to accommodate manufacturing tolerances, axial
movement of pumps rotor and wear of the seal faces.
Lubricants are used to lower the coefficient of friction and remove the heat
generated.
For mechanical seal to function, the forces tending to close its faces must exceed
those tending to open the faces. This net closing force gives rise to what is
termed as face loading has a upper limit beyond which the lubricating film
between the faces break down.
ii) Seal material
Depends upon the type of fluid to be handled and on operating conditions.
Most commonly used material is carbon and silicon carbide.
iii) Mechanical seal classification
A Brief Introduction of Pumps:- Page 31
By design:- Unbalance, Balance, rotating seal ring face seal, stationary face ring
seal, single spring seal.
By installation:- Single, Double, Internally mounted, Back to back mounted,
Face to face mounted, Tandem seal.
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2.4.12 Couplings
A coupling is used wherever there is a need to connect a prime mover to a piece of
driven machinery. The principal purpose of a coupling is to transmit rotary motion and
torque from one piece of equipment to another. Couplings may perform other secondary
functions, such as accommodating misalignment between shafts, compensating for axial
shaft movement, and helping to isolate vibration, heat, and electrical eddy currents from
one shaft to another.
Centrifugal pumps are connected to their drivers through couplings of one
sort or another, except for close-coupled units, in which the impeller is mounted on an
extension of the shaft of the driver.
Classification:- i) Rigid Couplings:- Rigid couplings are used to connect machines where it is desired
to maintain shafts in precise alignment. They are also used where the rotor of one
machine is used to support and position the other rotor in a drive train. Because a rigid
coupling cannot accommodate misalignment between shafts, precise alignment of
machinery is necessary when one is used.
ii) Flexible Couplings:- Flexible couplings accomplish the primary purpose of any
coupling; that is, to transmit a driving torque between prime mover and driven machine.
In addition, they perform a second important function: they accommodate unavoidable
misalignment between shafts. A proliferation of designs exists for flexible couplings,
which may be classified into two types: mechanically flexible and materially flexible.
A. Mechanically flexible coupling:- Mechanically flexible couplings compensate for
misalignment between two connected shafts by means of clearances incorporated in the
design of the coupling.
B. Material flexible coupling:- These couplings rely on flexing of the coupling
element to compensate for shaft misalignment. The flexing element may be of any
suitable material (metal, elastomer, or plastic) that has sufficient resistance to fatigue
failure to provide acceptable life. Material flexible shaft couplings can be divided into
two basic groups: elastomeric and non-elastomeric.
Elastomeric couplings use either rubber or polymer elements to achieve flexibility.
These elements can either be in shear or in compression. Tire and rubber sleeve designs
are elastomer in shear couplings; jaw and pin and bushing designs are elastomer in
compression couplings.
Non-elastomeric couplings use metallic elements to obtain flexibility. These can be one
of two types: lubricated or non- lubricated.
Lubricated designs accommodate misalignment by the sliding action of their
components, hence the need for lubrication. The non-lubricated designs accommodate
A Brief Introduction of Pumps:- Page 43
misalignment through flexing. Gear, grid and chain couplings are examples of non-
elastomeric, lubricated couplings. Disc and diaphragm couplings are non-elastomeric
and non- lubricated
Fig: Elastomer coupling (flexible type coupling)
2.4.13 Suction and Discharge Nozzle
The suction and discharge nozzles are part of the casings itself. They commonly have the
following configurations.
1. End suction/Top discharge - The suction nozzle is located at the end of, and
concentric to, the shaft while the discharge nozzle is located at the top of the case
perpendicular to the shaft. This pump is always of an overhung type and typically
has lower NPSHR because the liquid feeds directly into the impeller eye.
Top Discharge
End Suction
A Brief Introduction of Pumps:- Page 44
2. Top suction /Top discharge nozzle -The suction and discharge nozzles are
located at the top of the case perpendicular to the shaft. This pump can either be
an overhung type or between-bearing type but is always a radially split case pump.
Top Suction Top Discharge
3. Side suction / Side discharge nozzles - The suction and discharge nozzles are
located at the sides of the case perpendicular to the shaft. This pump can have
either an axially or radially split case type.
Side Suction
Side Discharge
A Brief Introduction of Pumps:- Page 45
2.5 CRITERIA IN PUMP DESIGN
Following points are taken into consideration, according to American Petroleum
Institute (API) standards, while selecting a pump:
2.5.1 BASIC DESIGN CONDITIONS
1) Pumps shall be designed & constructed for a minimum service life of 20 yrs.
& at least 3 yrs. of uninterrupted operation.
2) Pumps shall be capable of operation at the normal & rated operating points &
any other anticipated operating conditions.
3) Pumps shall be capable of at least 5% head increase at rated conditions by
replacement of impeller.
4) Pumps shall be capable of operating at least upto the maximum continuous
speed (equals 105% of rated speed).
5) Pumps that have stable head/ flow rate curves are preferred for all applications.
6) Pumps shall have a preferred operating region of 70% to 120% of best
efficiency flow rate of the pump.
7) The best efficiency point for the pump should be between the rated point & the
normal point.
8) For pumps with heads greater than 200m & more than 225kw the radial
clearance between the diffuser vane & the impeller shall be at least 30% of the
maximum impeller blade tip radius for diffuser design & at least 6% for volute
design.
% clearance, P = 100(R2 – R1)/R1
R2 – Radius of volute
R1 – Maximum impeller blade tip radius
9) Cooling system if specified by the purchaser is used. To avoid condensation,
the minimum temperature at the cooling water inlet to bearing housing should
be above the ambient air temperature.
10) Spares & all replacement parts of the pump & all furnished auxiliaries
shall as a minimum meet the criteria of the API codes.
2.5.2 WEAR RINGS AND RUNNING CLEARANCES
1. Mating wear surfaces of hardenable materials shall have difference in Brinell
hardness no. of at least 50 unless both the stationary & the rotating wear
surfaces have Brinell hardness no. of at least 400.
2. Renewable wear rings if used shall be held in place by a press fit with locking
pins, screws or by tack welding.
A Brief Introduction of Pumps:- Page 46
3. The diameter of hole in a wear for radial pin shall not be more than 1/3 the
width of the wear ring.
4. Running clearances shall be sufficient to assure freedom from seizure under all
specified operating conditions.
5. For materials with low galling tendencies the clearance shall be used within
the range 010 – 037 inches & for materials with high galling tendencies
operating at above 200 C, 125 um shall be added to the above diametric
clearances.
6. For non-metallic wear rings materials with very low galling tendencies
clearances less than above should be used.
2.5.3 MECHANICAL SHAFT SEALS
1. Seal cartridge shall be removable without disturbing the driver.
2. Seal chamber face runout should not exceed 5 um/mm of seal chamber box.
3. Seal chamber & seal gland shall have provisions for for only those connections
required by the seal flush plan.
4. Provision shall be made to ensure complete venting of the seal chamber.
5. If specified jackets shall be provided on seal chambers for heating.
2.5.4 BEARINGS & BEARING HOUSINGS
1. Each shaft shall be supported by 2 radial bearing & 1 double acting axial bearing.
2. Thrust bearings shall be sized for continuous operation under all specified
conditions including maximum differential pressure.
3. Rolling element bearings shall be mounted directly on the shaft & shall be
retained on the shaft with an interference fit.
4. Bearing housings shall be arranged so that bearings can be replaced without
disturbing pump drives or mountings.
5. Sufficient cooling, including an allowance for fouling shall be provided to
maintain oil & bearing temperature.
6. Bearing housing for rolling element bearing shall be designed to prevent
contamination by moisture, dust & other foreign matter.
7. Shielded or sealed bearings shall not be used.
2.5.5 LUBRICATION
For lubrication of bearing & bearing housings following points shall be taken into
consideration:
1. Unless otherwise specified, bearings & bearing housing shall be designed for oil
lubrication.
A Brief Introduction of Pumps:- Page 47
2. The operation & maintenance manual shall describe how the lubrication system
circulates oil.
3. If specified, provision shall be made for either pure oil or purge oil lubrication.
4. If specified, rolling element bearing shall be grease lubricated.
2.5.6 MATERIAL
Material for pump elements is selected on the basis of following points:
1. The purchaser shall specify the material class for pump parts.
2. The material specification of all components shall be clearly stated in the
vendor’s proposal.
3. The vendor shall specify the optional test & inspection procedures that are
necessary to ensure that materials are satisfactory for the service.
4. Pump casing parts of double casing pumps that are to handle flammable or
hazardous liquids shall be of carbon steel or alloy steel.
5. The purchaser shall specify any erosive or corrosive agents present in the process
fluids & in site environment.
6. The purchaser shall specify the amount of wet H2S that may be present.
2.6 Criterion for selection of motor
The power of the motor should be taken as the greatest of the following three values:
1. At the rated point
2. At the end of curve
3. At the minimum continuous flow
After selecting the largest value it should be multiplied by suitable safety factor
depending on its value. The safety factor is to be chosen as follows:
1. 1.25 for P less than 22KW
2. 1,15 for 22KW < P < 55KW
3. 1.1for P greater than 55KW
A Brief Introduction of Pumps:- Page 48
FORMAT FOR PUMP DATASHEET
1
GENERAL
2
Project: Job No.:
3
Owner: Site:
4
Purchaser: Max./Min.
Ambient C:
Unit: Unit No:
5
Item No.: Service:
6
No. Reqd.: Working Standby Parallel Operation Required: Yes No 7
Applicable to Proposal Purchase As Built 8
Scope option & Information specified by purchaser Information Reqd. from & option left to vendor. Vendor to cross the selected option. 9
Driver: Working Standby Driver Supplied & Mounted By: Pump Mfr. Other 10
OPERATING CONDITIONS
11
Liquid Handled Capacity (m3/hr): Min/Nor/Rated:
12
Pumping Temp. ( C): Normal Max. Discharge Pressure (kg/cm²,A):
13
Specific Gravity at P.T./15 C: Suction Pressure: Nor./ Max. (kg/cm²,A):
14
Vapour Pressure at P.T. (kg/cm²,A): Diff. Pressure (kg/cm²) @ Rated Capacity:
15
Viscosity at P.T. (cP/cst): Corr./Eros. By: Diff. Head (m) @ Rated Capacity:
16
Solids in suspension Yes No Size: % NPSH Available (m):
17
MANUFACTURERS SPECIFICATIONS
18
Pump Manufacturer: Model No.:
19
CONSTRUCTION PERFORMANCE
20
Casing Mounting: Centerline Foot Inline Proposal Curve No.
21
Casing Split: Axial Radial Visc. Corr. Factor: C CQ CH
22
Type: Single Volute Double Volute Diffuser NPSH Reqd. (Water) (m): F/L Speed (rpm):
23
Casing Connection: Vent Drain Gauge No. of stages: Efficiency (%):
24
Nozzles Size ANSI Rating Facing Position Rated BKW(0% Tol.): kW Max.BKW rtd. Imp.: kW
25
Suction BKW @ MCF( =1.0): kW Rec. Driver Rating: (kW) kW
26
Discharge Max.head rtd imp.(m): Cap@ BEP(m3/hr):
27
Imp. (mm) Max: Rated: Min: Type: MCF (m3/hr):Stable Thermal
28
Brg.: Type/No. Radial: Thrust: Lub: M.A.W.P @ 15 C/P.T./Design Temp.(kg/cm²,G):
29
Cplg.:Make/Type: Fleximetl w spacer Nonspark Guard Yes No Hydrostatic Test pressure (kg/cm²,G):
30
Driver Half cplg. mounted by: Pump Mfr. Others Rotation facing coupling end: CW CCW 31
Packing Type: Size: No. of rings: Seal flush/ Quench plan: Material :
32
Mech. Seal: Make Model::
API Code : Ext. seal flush fluid: LPM: @ kg/cm²G/ C
33
Base Plate Drain Rim Type : Yes No Fdn. Bolts: Yes No Seal Barrier fluid: LPM: @ kg/cm²G/ C
34
Throat Bush: Yes No No Matl.: Bal. Device: Yes No Ext. quench fluid: LPM: @ kg/cm²G/ C
35
Materials (API-610 Matl. Class): MOC ASTM Grades C.W. Plan : LPM: @ kg/cm²G/ C
36
I - Cast Iron Casing Weight(kg): Pump+Base+Coupling: Driver:
37
B - Bronze Impeller AUXILIARY PIPING INTERFACE CONNECTIONS 38 B - Bronze Impeller
(All interface conn.shall be termntd.with a f/l. block valve) 39
S - Carbon Steel Inner Case parts (All interface conn.shall be termntd.with a flng. block valves)
40
C - 11-13% Chr. Stl. Sleeve Packed Size Rating(ANSI) Facing 41
h - Hardened Sleeve Seal Lantern Ring Inlet/Outlet
42
f - Faced Casing ring H-BHN Ext. Seal flush fluid Inlet/Outlet
43
K -SS 304 Impeller ring 50(min) Seal Quench fluid Inlet
44
L -SS 316 Shaft Seal pot vent/ drain
45
X Throttle Bush Casing vent/ drain
46
Y Throat Bush C.W Inlet/ Outlet
47
Z Balance Drum Base plate drain (only flanged)
48
Driver suitable for Pump starting with open Disc. Valve condition. Casing steam jacket
49
INSPECTION & TESTS (EACH PUMP) SHOP INSPECTION & TESTS (EACH PUMP) 50
Witness Observe Witness Observe
51
Shop Test / Inspection NPSH As Reqd. Per Spec. Mandatory 52
Material Certificates Dismantle Insp. & Re-assembly after Test 53
Hydrostatic Unitisation/Dimensional Check 54
Performance/Sound Level Check for direction of rotation of pump & driver.
55
Applicable Specification: API Std. 610, Edition, alongwith EIL Std. Spec.No. 6-41-
56
REMARKS:- 1) Max. allowable casing working pressure shall not be less than kg/cm²G @ C.
57
2) Down Stream Design Pressure is kg/cm²g.
58
3) Accessories and Instrumentation shall be as per EIL approved vendors only.
59
4) Unitization of Pump and Driver shall be done in pump manufacturer's shop.
A Brief Introduction of Pumps:- Page 49
2.7 SUNDYNE PUMPS:
It is a centrifugal vertical type of Pump(API OH 6) ,they are able to achieve high heads
with very low NPSH(a) using their conical diffuser and straight vaned impellers by
running at relatively high speeds. Unlike most centrifugal pumps, it operates at impeller
speedup to 23400 RPM.
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2.8 Double Suction Pumps
DOUBLE SUCTION, SPLIT CASE, HORIZONTAL CENTRIFUGAL PUMP
Higher flows moderate head
Used when low NPSHA
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2.9 Axial Flow Pump
Applications
- Pumping from a pit
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2.10 Barrel or Can Pump
Applications
Barrel Pump is used when no NPSHA
Submersible pump is used in Tank
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2.11 Multistage Pump
A Brief Introduction of Pumps:- Page 54
Applications
High head applications (Around 400 m & above)
SINGLE STAGE:
In this type of pump head is developed by a single impeller.
MULTISTAGE PUMP:
In this type of pump head is developed by the use of two or more impeller operating in
series each taking suction from the discharge of the preceding impeller
Approx 150 m head can be achieved per impeller
A Brief Introduction of Pumps:- Page 55
CHAPTER-3
POSITIVE DISPLACEMENT PUMP
Positive displacement- in which energy is periodically added by application of
force to one or more movable boundaries of any desired number of enclosed,
fluid containing volumes, resulting in a direct increase in pressure up to the value
required to move the fluid through valves and ports in to the discharge line.
Displacement pumps are essentially divided in to reciprocating and rotary types,
depending upon the nature of the pressure producing members.
3.1 Types of the Positive Displacement Pumps.
A. RECIPROCATING:
PISTON
PLUNGER
DIAPHRAGM
B. ROTARY:
TWIN SCREW
SINGLE SCREW (PROGRESSIVE CAVITY)
GEAR
VANE
LOBE (TWO, THREE LOBES)
3.2 Difference between Centrifugal Pump & Positive Displacement
Pump
A Brief Introduction of Pumps:- Page 56
3.3 Advantages of PD pumps over centrifugal Pumps
1. Flow is independent of pressure. You can change the flow without upsetting the
pump's efficiency.
2. The pump can handle high viscosity fluids efficiently.
3. The pump is self priming
4. You can get the desirable high head low flow combination that is need in many
high pressure applications.
5. They give you a non-shearing act that will not degrade sensitive
petrochemicals and polymers.
3.4 Pump Characteristic for PD Pumps
Positive displacement pumps deliver a definite volume of
Liquid for each cycle of pump operation. Therefore, the only
factor that effects flow rate in an ideal positive displacement
pump is the speed at which it operates. The flow resistance
of the system in which the pump is operating will not effect
the flow rate through the pump.
The dashed line shows actual positive displacement pump performance. This line
reflects the fact that as the discharge pressure of the pump increases, some amount of
liquid will leak from the discharge of the pump back to the pump suction, reducing the
effective flow rate of the pump. The rate at which liquid leaks from the pump
discharge to its suction is called slippage.
Some commonly used terms
Slip: Leakage flow within a rotary positive displacement pump from the discharge
back to the suction caused by the clearances needed between the rotating and
stationary parts.
Pulsation: The variation of pressure in line due to flow variations caused by piston,
plunger or diaphragm which are creating a pumping action.
A Brief Introduction of Pumps:- Page 57
Self priming: The ability for a pump to draw liquid into itself and start pumping
liquid by evacuating the air or vapour. PD pumps are inherently self priming.
3.5 When to use Positive Displacement Pumps
RECIPROCATING PUMP:
A Brief Introduction of Pumps:- Page 58
3.6 PLUNGER PUMPS
Power end is similar to that of Piston Pumps. The difference lies in the fluid end,
where the plunger runs through the packing like a piston rod.
A Brief Introduction of Pumps:- Page 59
3.7 Reciprocating Diaphragm type Pump:
Diaphragm Pumps are displacement pumps with flexible membranes clamped at their
peripheries in sealing arrangement with a stationary housing. The central portion moves
in a reciprocating manner through mechanical means such as crank or eccentric cam or
by fluid means such as compressed air or liquid under alternating pressure. .
A Brief Introduction of Pumps:- Page 60
3.8 ROTARY TYPES PUMPS
3.8.1 Main Features of Rotary Positive Displacement Pump
Positive Displacement
Slow and medium speed
Self Priming
Fairly constant discharge
Less vibration
Weight per unit flow is lower when compared to Reciprocating Type Pumps
Because of less number of parts in contact with each other, lower friction
(hydraulic and mechanically), higher efficiency.
Rotary pumps are often employed in systems where small flows at relatively high
pressures are required. Rotary Pumps are used in the lubricating and control
systems of turbine sets, large pumps and compressors, hydraulic systems.
An advantage of all Rotary Pump types is that they can be directly coupled to the
drives, which make the unit compact.
A Brief Introduction of Pumps:- Page 61
3.8.2 Screw Pumps
Screw Pumps are operating on the principle of progressively moving a fluid between sets
of counter-rotating screws. Screw Pumps have been traditionally chosen to pump viscous
fluids and impart minimum shear forces on the fluid with relatively low discharge
pressures.
Screws Pumps do not have drawbacks like speed limitations and discharge pulsations
and are characterized by uniform discharge high pressures, high speed, quiet operations
and high efficiency.
Screw Pumps are more expensive than gear and rigid vanes pumps of the same
performance because of manufacturing of specially profiled screws involve complicated
techniques.
Working of Twin Screw Pump:
Liquid is trapped at the outer end of each pair of screws. As the first space between the
screw threads rotates away from the opposite screw, a one-turn, spiral-shaped quantity of
liquid is enclosed when the end of the screw again meshes with the opposite screw. As the
screw continues to rotate, the entrapped spiral turns of liquid slide along the cylinder toward
the center discharge space while the next slug is being entrapped. Each screw functions
similarly, and each pair of screws discharges an equal quantity of liquid in opposed streams
toward the center, thus eliminating hydraulic thrust. The removal of liquid from the suction
end by the screws produces a reduction in pressure, which draws liquid through the suction
line.
A Brief Introduction of Pumps:- Page 62
3.8.3 Working of Triple screw pump
The three-screw, high-pitch, screw pump, has many of the same elements as the two-screw,
low-pitch, screw pump, and their operations are similar. Three screws, oppositely threaded
on each end, are employed. They rotate in a triple cylinder, the two outer bores of which
overlap the center bore. The pitch of the screws is much higher than in the low pitch screw
pump; therefore, the center screw, or power rotor, is used to drive the two outer idler rotors
directly without external timing gears. Pedestal bearings at the base support the weight of
the rotors and maintain their axial position. The liquid being pumped enters the suction
opening, flows through passages around the rotor housing, and through the screws from
each end, in opposed streams, toward the center discharge. This eliminates unbalanced
hydraulic thrust. The screw pump is used for pumping viscous fluids, usually lubricating,
hydraulic, or fuel oil.
Twin v/s Triple screw pumps
Twin screw Pumps
Very effective with Viscous
fluids
Dry running is also permitted
as rotating elements operate
without contact.
Entrant gas or air can also be
pumped without interrupting
the flow
Four mechanical seals are
required
Large size, More expensive
Triple Screw pump.
Handles only clean
lubricating fluids
Must not run Dry as the
screws are in close contact
If the liquid being handled
congeals at low temp, then
heat the pump casing
sufficiently otherwise the
pump element would adhere
to each other.
One or maximum two seals
are required.
Compact in size and less
expensive.
3.8.4 GEAR PUMPS
Gear Pump traps the liquid between the gear teeth on the suction side and carry it around to the
discharge side from where it forced out into the discharge pipe.
A Brief Introduction of Pumps:- Page 63
Advantage Disadvantage
Two moving parts
One stuffing box
Positive suction, non-pulsating
discharge
Ideal for high viscosity liquids
Constant and even discharge
regardless of varying pressure
conditions
Low NPSH required
Easy to maintain
Low speeds usually required
Medium pressure
One bearing runs in pumped
product
Overhung load on shaft
bearing
Working of Gear Pump
3.8.4 .i) External Gear Pump
A Brief Introduction of Pumps:- Page 64
Advantage Disadvantage
High speed
Medium pressure
No overhung bearing loads
Relatively quiet
Design lens itself to use of a wide
variety of materials
Four bushings in liquid area
Four stuffing boxes
No solids allowed
Applications
Industrial and mobile applications
Fuel and lubrication
Metering
Mixing and blending (double pump)
Hydraulic applications
OEM configurations
Precise metering applications
Low-volume transfers
Light or medium duty
3.8.4.ii) Internal gear pump
A Brief Introduction of Pumps:- Page 65
Advantage Disadvantage
Two moving parts
One stuffing box
Positive suction, non-
pulsating discharge
Ideal for high viscosity
liquids
Constant and even
discharge regardless of
varying pressure conditions
Low NPSH required
Easy to maintain
Low speeds usually required
Medium pressure
One bearing runs in pumped
product
Overhung load on shaft
bearing
working of Internal Gear Pump:
Internal Gear V/s External Gear
Ideal for High Viscosity Low to medium viscosity
Use less of space Use of more space
One stuffing box Four stuffing Box
Overhung load of the shaft Load is divided with between bearing design
A Brief Introduction of Pumps:- Page 66
3.8.5 VANES PUMP
Liquid is drawn into and discharged from an axial hole in the rotor, which is
divided into suction and discharge chambers by tight fitting end covers.
As the rotor rotates in the direction indicated, space between the vanes grows in
volume, the result being that the liquid is drawn in from suction chamber through
radial holes.
As the vanes run along the volume of space is decreased and the liquid is
discharged into discharge chamber.
Working of Vane Pumps:
SLIDIDNG VANE PUMP . SWINGING VANE PUMP
A Brief Introduction of Pumps:- Page 67
Advantages Disadvantages
Medium capacity
Medium speed
Thin liquids
Sometimes preferred for
solvents, LPG
Can run dry for short
periods
Can have one seal or
stuffing box
Develops good vacuum
Can have two stuffing boxes
Medium pressure
Complex housing
Not suitable for high
viscosity
Not good with abrasives
Applications
Aerosol/Propellants
Aviation Service - Fuel Transfer, Deicing
Auto Industry - Fuels, Lubes, Refrigeration Coolants
Barge Unloading
Bulk Transfer of LPG and NH3
Chemical Process Industry
LPG Cylinder Filling
Ethanol/Alcohol Refining
Fertilizer Production - CO Transfer
Lubrication Blending - Solvents, Oils
Mobile Transport - Chemicals, Fuels, LPG, NH3
Petroleum Industry - Crude Oils and Hydrocarbons
Power Generation - Fuels, Lubrication
Pulp and Paper
Railroad Transfer - Fuels, Lube Oils, Coolant
Refrigeration - Freons, Ammonia
Rubber and Plastic
Solvent Distribution
A Brief Introduction of Pumps:- Page 68
3.8.6 Lobe pump
Advantage Disadvantage
Pass medium solids
High acceptance
Little galling possibility
Timing gears
More space required
May require factory service to repair
Two seals
Working of lobe Pumps:
Applications: Food processing.
Beverages.
Dairy Produce.
Personal Hygiene Products.
Pharmaceutical.
Biotechnology.
Chemical.
Industrial.
Medium and heavy duty cycles.
A Brief Introduction of Pumps:- Page 69
3.8.7 PROGRESSIVE CAVITY PUMP
It is used for pumping difficult materials such as sewage sludge contaminated with
large particles or highly viscous liquid containing solid particle, this pump
consists of a helical shaped rotor, about ten times as long as its width.
This can be visualized as a central core of diameter , with typically a curved spiral
wound around . This shaft fits inside a heavy duty rubber sleeve. As the shaft
rotates, fluid is gradually forced up the rubber sleeve. Such pumps can develop
very high pressure at quite low volumes.
1>Rotor,2>Stator,3>Drive train with joint,4>Shaft Seal,
5> Suction / Discharge housing, 6>lantern (housing) with flanged
drive
3.9 Selection between Reciprocating Pumps
A Brief Introduction of Pumps:- Page 70
3.9.1 Depending on solid particles in the fluid for rotary Pumps
3.9.2 Depending on the flow requirement for rotary pumps
A Brief Introduction of Pumps:- Page 71
CHAPTER-4
PROCUREMENT/ORDERING SYSTEM IN GAIL PATA
4.1 Categorizations of Material Requisition
The following considerations were made for categorizations of MR (Material
Requisition):
1. SINGLE STAGE CENTRIFUGAL PUMP
2. MULTISTAGE CENTRIFUGAL PUMP
3. SUNDYNE PUMP
4. RECIPROCATING PUMP
5. VERTICAL PUMP
6. MEETING THE BIDDERS CRITERIA FOR NPSHA
7. COSTING OF MR SHOULD BE LESS THAN 10 CR (POA CASE)
4.2 Summary of Ordering system of Pump for Cracker Unit of GAIL PATA
MR No.
MR Description
MR QTY.
PO QTY.
Bids Recd. Date
TBA Relsd.
Price Bids
Opening
Sch. Date
of Order
Act. Date
of Order
5580 CENTRIFUGAL HORIZONTAL PUMP
65 63 21 JUL 12 AUG 25 AUG 22 JUL 02 SEP
5570 PUMP CENTRIFUGAL HORIZINTAL
5 5 01 SEP 19 SEP 26 SEP 20 JUL 19 OCT
5560 PUMP CETRIFUGAL PUMP
10 10 05 SEP 07 OCT 25 OCT 17 JUL 09 NOV
5620 PUMP CENTRIFUGAL PUMP
18 18 8 NOV 07 DEC 14 DEC 30 NOV 20 DEC
5550 VERTICAL PUMP 16 14 9 NOV 21 NOV 19 DEC 25 OCT 22 DEC
5590 RECIPROCATING PUMP
8 8 27 DEC 06 FEB 17 FEB 13 AUG 04 MAR
5552 PROGRESSIVE CAVITY PUMP
2 2 31 OCT 5 JAN 18 JAN 15 NOV 28 JAN
A Brief Introduction of Pumps:- Page 72
4.3 Evaluation Criterion:
1. The offered Model of Pump by bidder should meet Pump datasheet parameter.
2. The NPSHA should normally be at least 0.6m above the NPSHR of offered
model.
3. By Analyzing the Pump Characteristic Curves, i.e.
Pump Curve shall meet the rated condition of Pump Datasheet
BEP should be between the rated point and the normal point
The head capacity characteristic curve should continuously rise as flow is
reduced to shutoff (or zero flow).
Operating Point should be between MCF and 120% of BEP
Do not select the pump at max. Impeller dia. (5% head rise should be
possible)
4. By reviewing the Performance Track Record of offered model.
5. Power loading
4.4 EVALUATION OF PRICES IN CASE OF PUMPS
TOTAL EVALUATED COST = A+ B + C
A Total Capital cost of Package/ item comprising:
Basic quoted price of equipment including
Commissioning, special tools & tackles and
Mandatory Spare
Freight
Taxes & duties i.e Excise Duty + Educational
Cess (10.3%), Sales Tax (CST with
concessional Form i.e. 2% / VAT), Service Tax
(applicable on freight & services @10.3%)
A Brief Introduction of Pumps:- Page 73
B Differential Operating Cost, i.e.
B= N(OP) * (BKWE – BKWR) * CF * 8000*DF
WHERE,
N(OP) = NO. OF OPERATING UNITS
BKWE = GUARANTEE SHAFT POWER(KW) FOR
PUMP QUOTED BY BIDDER UNDER
EVALUATION.
BKWR = LOWEST QUOTED (GUARANTEE) PUMP
BKW (AMONGST THE TECHNICALLY
ACCEPTABLE BIDDERS)
CF = COST OF ENERGY i.e. 3.84 RUPEES PER KWH
8000 = NUMBER OF OPERATING HOURS PER YEAR
DF = DISCOUNTING FACTOR TO ARRIVE AT NET
PRESENT VALUE(NPV) BASED ON NO. OF
OPERATING YEARS (i.e. ∑ N=2 TO N = K+1 [ 1 / {1
+(X/100)}]N = 2.915)
X = PERCENTAGE RATE OF INTEREST = SBI BASE
RATE ON THE DATE OF PRICE OPENING + 5% =
10% + 5% = 15%
NOTE:- Power loading applicable for Centrifugal Pump
only.
C Cost of Supervision of Erection , Testing &
Commissioning (i.e. no. of pumps X no. of Mandays X
per diem rate)
4.5 Problems faced & Lessons learnt
1. Changes in data sheets by Process after floating of enquiry.
2. Revised MR issued rather than amendments showing key changes.
3. Though limited enquiry was issued as per EIL MSL, PTR requirement
was there and many vendors didn’t submit along with offer.
4. Though zero deviation tendering TQ’s were issued.
5. Cost estimate data bank not accurate always.
6. Type of pump changed by Licensor based on our feedback regarding
Charcoal particle presence in fluid (type of pump changed from screw
to progressive cavity).
A Brief Introduction of Pumps:- Page 74
7. Seal related issues (packing / dual 53A & 53B)
8. Limited source for supply of Vertical pumps - Landed in single vendor
case.
4.6 Areas for improvement
1. Pre tendering / Pre Bid must
2. Data bank for various types of models offered to be available with RED
rather than seeking PTR for each MR
3. Costing data bank to be strengthened
4. MR to be concise rather than bulky
5. Only addendum covering changes in MR clauses to be issued rather
than revision of entire MR
6. TBA format needs revision.
7. MR should preferably specify end – top arrangement for ease of piping
4.7 Important Documents for review
1. Pump General arrangement drawing
2. Pump Cross sectional drawing
3. Pump Datasheets and Characteristic curves.
4. Utility Data
5. Pump Motor data or Turbine datasheet with P&IDs.