Types of Pumps

The types of pumps most often encountered in a refinery or chemical plant can be classified as either kinetic or positive displacement pumps
z

Kinetic Pumps In a kinetic pump energy is added continuously to increase the fluid's velocity within the pump to values in excess of those in the discharge pipe. Passageways within the pump then reduce the velocity until it matches that in the discharge pipe. Bernoulli's law states that as the velocity head of the fluid is reduced, the pressure head must increase. Therefore, in a kinetic pump the kinetic energy or velocity energy of the fluid is increased and then converted to potential or pressure energy. Most of the pumps used in ExxonMobil chemical plants are centrifugal pumps, in which the kinetic energy is imparted to the fluid by a rotating impeller, which generates centrifugal force.

Positive Displacement Pumps In a positive displacement pump the volume containing the liquid is decreased until the resulting liquid pressure is equal to the pressure in the discharge system. That is, the liquid is compressed mechanically, causing a direct increase in potential energy. Most positive displacement pumps are reciprocating pumps, where the displacement is accomplished by linear motion of a piston in a cylinder. Rotary pumps are another common type of positive displacement pump. In these pumps displacement is caused by circular motion.

Slide 6.2

Centrifugal Pumps
This type of pump is used almost exclusively in refineries and chemical plants. Centrifugal pumps have few moving parts and therefore tend to have greater reliability and lower maintenance costs than positive displacement pumps. A centrifugal pump generally has a spare unless the plant can run without it.

Design Considerations: Pressure rise is dependent on density, because velocity is converted to static head in feet of fluid. Head developed is determined by speed (RPM), impeller diameter, and number of impellers (stages). Multistage pumps can develop head up to 6000 ft (1800m), about 1300 - 2500 psi (90-175 kg/cm2) for hydrocarbons. Minimum capacity without recirculation is usually limited to 15 - 20 gpm (4 m3/h) Centrifugal pumps lose efficiency as viscosity increases.

Slide 6.3

Special Types of Centrifugal Pumps Integral Gear Driven Sundyne

Speed increasing gear box integral with pump. Single stage design up to 2100 psig (148 kg/cm2g) discharge pressure, 1000 psig suction pressure (70 kg/cm2g), and 650F (343C). Multistage design up to 3750 psig (265 kg/cm2g) discharge pressure, 1000 psig suction pressure (70 kg/cm2g), and 500F (260C). High heads achieved by operating impellers at speeds to 25000 rpm. Such operating speeds result in high NPSHR. Low cost pump for high pressure applications. Caution: Pump must be operated very stable to avoid damage. Pressure surges can damage pump. Consider providing warehouse spare in addition to installed spare.

Slide 6.4

Special Types of Centrifugal Pumps Vertical In-Line

Bolts directly into piping like a valve. Small footprint. Single sealing chamber. Choice of horizontal or vertical pump usually based on economic and space considerations. Design up to 500 psig (35 kg/cm2g) discharge pressure, 300 psig (21 kg/cm2g) suction pressure, and 600F (315C). May not be suitable for large motors.

3.49
Slide 6.5

Special Types of Centrifugal Pumps Canned

Casing buried, with first impeller below grade. Used for tight NPSHA services and in high head services where the large number of stages required does not allow horizontal orientation of the pump. Generally avoid since installation requires excavation. Design up to 1300 psig (91 kg/cm2g) discharge pressure, 300 psig (21 kg/cm2g) suction pressure, and 500F (260C).

3.54
Slide 6.6

Reciprocating Pumps
Reciprocating pumps are often used in to handle viscous fluids and in sludge and slurry service. Compared to centrifugal pumps, reciprocating pumps:

z z z

are more efficient are poorer at handling liquids containing solids that erode valves and seals have higher maintenance costs and lower availability because of pulsating flows and the large number of moving parts

Design Considerations: Its performance curve is constant capacity, variable head. It produces a pulsating flow. Pulsations are minimized by use of multiple plungers (duplex, triplex, etc). Pressure rise is independent of fluid density, so these pumps are used where a wide range of fluids must be handled. Reciprocating pumps are used for low capacities and high heads. They need safety valve protection.

Slide 6.7

Centrifugal Pumps Design

z

When designing a system utilizing a centrifugal pump, keep in mind that centrifugal pump performance changes with operating conditions, as illustrated by the pump curves on this screen. This is a typical centrifugal pump curve at a constant speed (rotational velocity). As the flow rate through the pump increases, the generated head decreases. The efficiency curve reaches a maximum, hopefully near the design point. The brake horsepower curve increases continuously with flow rate.

Slide 6.8

Centrifugal Pumps Impeller Change

If the pump speed is changed (i.e. variable speed drive or larger impeller), the head and flow rate will also change.

IMPELLER CHANGE
450 400 350 300
11 IMPELLER

1000 900 800 700 600

11 IMPELLER 10 IMPELLER

10 IMPELLER

HEAD

250 200 150 100 50 0 0

500 400 300 200

100 200 400 600 800 1000 1200 1400 1600 1800

FLOW

Slide 6.9

POWER

Centrifugal Pumps Design

This curve shows how a control valve affects flow through a pumped system. The control valve pressure drop decreases the flow rate through the system. When the control valve opens fully, the flow rate increases from the "operating flow rate" to the "maximum flow rate" the point where the system pressure drop equals the pump discharge pressure.

Slide 6.10

Problem-Pump Curves
z

z z z

The plant needs to pump 1000 m3/hr (as read in the computer) of 0.8 s.g. water. How much head will the pump put up? How much pressure does the pump put up? What is the power requirement? At start-up, the pump will pump 1000 m3/hr of cold water. How much pressure will the pump put up?

IMPELLER CHANGE
450 400 350 300 1000 900 800 700 600 500 400 300 200 0 100 200 400 600 800 1000 1200 1400 1600 1800

250 200 150 100 50 0

FLOW

Slide 6.11

POWER

HEAD

Pump Affinity Laws

z

Relationships called "Pump affinity laws show the effect of changing speed or impeller diameter on pump performance. Pump affinity laws are useful when looking at a new service for an existing pump. FLOW Q (Peripheral Speed) {Q2=Q1(N2/N1) or Q2=Q1 (D2/D1)} HEAD H ~ (Peripheral Speed) 2 {H2=H1 (N2/N1) 2 or H2=H1 (D2/D1) 2}

**important**

**important**

POWER HP ~ (Peripheral Speed) 3 {HP2=HP1 (N2/N1)3 or HP2=HP1 (D2/D1) 3 Where D=impeller diameter and N=impeller RPM

**important**

Slide 6.12

Centrifugal Pump Design Factors

There are five major factors that affect the design of centrifugal pumps: Fluid properties Pump differential pressure Net positive suction head Pump casing design pressure Driver and utility requirements These factors are described in the following pages.

Slide 6.13

Fluid Properties & Differential Pressure

The fluid properties most important to pump design are fluid density and viscosity:
z

For a fixed speed pump and a fixed capacity, the pump will develop the same head regardless of the density. However, pressure rise is directly related to the fluid density. The performance of centrifugal pumps deteriorate with increased viscosity.

Differential pressure is the difference between the discharge and suction pressures and is a measure of the amount of energy that the pump must supply.

Slide 6.14

Cavitation & NPSH

z z

Cavitation refers to the formation and subsequent implosion of vapor bubbles. Cavitation occurs when the static pressure of the liquid falls to or below the vapor pressure in a moving liquid system. The vapor bubbles formed in the cavitation are subsequently imploded by increasing static pressure. Cavitation commonly occurs in and around the impeller of a centrifugal pump.

For satisfactory pump operation the liquid must flow without vaporizing from the pump inlet to a point within the impeller eye where the vanes begin to impart energy to the liquid. The force tending to suppress cavitation is the margin by which the local static pressure of the liquid exceeds the liquid vapor pressure at that temperature. When converted to terms of head of liquid, this pressure margin is termed the net positive suction head, or NPSH. To avoid cavitation, the available net positive suction head (NPSH) must be greater than that required by the pump. Slide 6.15

Calculating and Approximating NPSH

z

NPSH is calculated by the following equation:

NPSH = h p hvpa + hst his

Where: hp hvpa hst his = = = = Pressure in suction vessel vapor phase. Vapor pressure of the liquid. Height of liquid above pump suction. All suction line pressure losses.

NPSH is a characteristic individual to each pump and is determined by vendor testing. The approximate NPSH required for a given flow and head is presented in Figure 4B of DP Section X-A. Pump specification must include the available NPSH. Apply a 10% safety factor on the calculated NPSH. If the available NPSH is less than the required NPSH, consider increasing the elevation of the suction drum. If the available NPSH is greater than 25 ft (7.6m), specify NPSH = 25 ft (7.6m).

Slide 6.16

NPSH Cheat Sheet

z z z z z z z z z z z z

Assume pump is 2 (0.6m) above grade, unless large pump, which will be more. 1 psi (0.07 kg/cm2) (min) for permanent suction strainer. Dont use permanent strainer if solids are not expected. 10% safety margin normally, 25% for sulfolone, 5 psi (0.35 kg/cm2) for BFW (boiler feed water) Use 32D + 200 suction line equivalent length if no isometrics available. Fluid usually at bubble point. Can be lower for Stripper bottoms. Account for acceleration in reciprocating pumps. See specialist if cost to meet NPSH too high. Do not specify greater than 25 (7.6m). Design suction line straight into pump (~5) (during detailed design) Never allow suction line elevation to go above (or even close) to vessel tangent line (no vapor pockets) (during model review) Use vessel tangent line if possible instead of LLL. Late Breaking News: DP X-D recommends extra 3 (1m) NPSH margin when selecting pump
Slide 6.17

Driver and Utility Requirements

Normally, electric motor drives are used except for pumps that must operate during a power failure. The following design information is helpful when developing specifications for electric motor pumps.
z

Pump brake kW is defined by: Minimum driver size: To determine operating load (kWH):

Pump BkW =

Q (m3 / hr ) P (bar ) 36 Pump Efficiency

Minimum Driver Size = PumpBkW 1.1

Operating Load =
z

Pump BkW Motor Efficiency

To determine pump connected load (kWH):

Pump Connected Load =

MotorSize (kW ) Motor Efficiency at full load

Slide 6.18

Motor Sizing (located in DP XXX-G)

Slide 6.19

Design Pressure for Centrifugal Pumps

z

Casing design pressure for centrifugal pumps is the maximum suction pressure plus the maximum differential pressure. The maximum differential for new pumps is limited by GP 10-1-1 to 1.2 times the head at rated capacity. In addition, centrifugal pumps should be capable of at least a 5% head increase by replacing the impeller (API 610). The result is a recommended maximum differential of 1.26 (1.2 x 1.05 = 1.26) times the rated differential pressure of the pump. The maximum suction pressure is usually set by having the PR valve blowing and having a high liquid level in the suction vessel. Variable speed pumps, which can operate continuously at 105% of rated speed, should be designed for at least 1.39 (1.2 x 1.05 x (1.05)2=1.39) times the rated differential pressure of the pump. If the pump can operate with more than one fluid, consider the fluids with the highest and lowest specific gravity, since these will result in the highest and lowest differential pressures.

Slide 6.20

Design Pressure for Other Equipment

z

Equipment between the pump discharge and a control valve should have a maximum operating pressure equal to the maximum suction pressure plus maximum pump shutoff differential pressure. (max-max) Equipment between the pump discharge and a block valve should also have a maximum operating pressure of maximum suction pressure plus maximum pump shutoff differential pressure if closing the valve has the direct result of raising the suction pressure to maximum. If however, closing the block valve does not raise suction pressure to maximum, the maximum operating pressure should be the higher of Normal pump suction pressure plus maximum pump shutoff differential pressure (normal-max) Maximum pump suction pressure plus normal pump differential pressure (max-normal)

Design pump suction piping design pressure for parallel pumps at least 75% of discharge design pressure. (0.75=1/1.33, so is good for short term overpressure)

Slide 6.21

Summary of DP Downstream of Centrifugal Pump

z z z

z z

Pump: Max-Max (maximum suction P, maximum pump P) All equipment up to control valve: Max-Max Downstream of control valve: If closing block valve causes maximum suction pressure: Max-Max If not: z Normal Max (Normal suction P, maximum pump P) z Max Normal (Maximum suction P, normal pump P). When calculating suction pressure during a block in case, assume 30 minutes of liquid accumulation. Late Breaking News: Use electronic governor to limit turbine speed variation in revamps: Calculate pressure at maximum speed setpoint Use 1.005 instead of 1.05 for turbine speed variation (1.2 x 1.05 x (1.005)2=1.273) Also use actual pump curve, so 1.2 factor (head rise at shutoff) may change and 1.05 (factor for maximum impeller) may be eliminated.

Slide 6.22

Design Pressure & Temperatures Downstream of Pumps

14 psig Normal Control Valve 69 psig Max. When SV Blowing 414 psig Normal 232oF Normal 407 psig Normal 149oF Normal

Pump P =400 psig

Exch A

Exch B

Pump Discharge Press = 14 + 1.26(400) = 518 psig * or 69 + 400 = 469 psig * Pump Casing Design Press = 69 + 1.26(400) = 573 psig Pump Suction Design Press = ________ or ___ psig if parallel pumps, __% of discharge, why? Design Pressure of Exch. A = 518 psig Design Pressure of Exch. B = ___ psig Design Temperature of Exch. A = 232 + 50 = 282oF Design Temperature of Exch. B = ___ + __ = ___oF (Exch. A bypassed) why not 232? * This assumes that blocking the outlet of the pump does not result in the suction SV blowing
Slide 6.23

Mechanical Seals
z z

A seal is required to prevent process fluid from leaking past the pump shaft Mechanical seals have many advantages over packed stuffing boxes. Typical stuffing box and mechanical seal configurations are shown below. A single mechanical seal is sufficient for many pump shaft sealing services. Sometimes two mechanical seals are required, with some sealant injected between the seals. When two seals are constructed in a single assembly with some common parts, the combination is termed a double mechanical seal. When the two seals are separated and oriented in the same direction, they are termed tandem mechanical seals.

CONVENTIONAL PACKING

SINGLE MECHANICAL SEAL

Slide 6.24

Mechanical Seals Details

z

Items to consider Can the pumped fluid be used as flushing fluid? z Boiling point, solids, pressure, pour point, and lubricating value all must be considered If not, are there restrictions on the fluid? z Will it dilute the pumped fluid? z Will it contaminate the pumped fluid? If seal leaks, what are the consequences? This determines type of seal required
FLUSH IN HERE

PROCESS FLUID SECONDARY SEAL FACE PRIMARY SEAL FACE

Slide 6.25

Flushing Mechanical Seals

z

Mechanical seals must be flushed to maintain sealage. Mechanical seals are usually flushed with some of the process fluid; i.e., they are "self flushed". When the process fluid is too dirty for self-flushing, however, an external liquid is employed. Recently a new technology which flushes the seals with gas has been used for difficult services. See DP X-G for additional information on flushing systems

Slide 6.26

Sealless Pumps
z

Most pump leaks and fires are caused by seal failures. Sealless pumps are becoming popular because of their environmental and safety advantages, although they are somewhat less efficient and more expensive than other types of pumps. Their use is expected to grow, especially for handling toxic material and for sites from environmentally sensitive areas. Three basic types of sealless pumps are available: Magnetically driven pumps The drive shaft is connected to the pump impeller through magnetic couplings located at the inner wall of a metal container. Canned pumps A electric motor sheathed in metal serves as the impeller shaft, with the stator located outside the metal can. Sealless diaphragm pumps These are reciprocating machines with a flex diaphram to cause pumping action due to check valves on the inlet or outlet.

Slide 6.27

Pump Hints
Remember: pumps produce head, not pressure Lower fluid density will reduce pressure Size pump differential pressure for minimum density fluid Size motor for maximum density fluid Check downstream equipment design pressure based on maximum density fluid z Always use ACTUAL fluid rate, not standard z Account for extra flows Constant low flow recycles Warm-up lines Seal flush using pump discharge fluid
z

Slide 6.28