Tekna

Offshore Pumps 2007

Pump Theory -
API Reciprocating
Displacement Pumps.

Steve Digby
SPX Process Equipment Limited
Bran+Luebbe Operation U.K.
 SPX Process Equipment

2003 2002

WCB-Flow Products
GD Engineering
2005 Plan
Employees 2585
OFM
Oilfield Fabricating & Machine
After Market & Field Services
 Pump Theory
API Reciprocating Displacement Pumps

Topics
• Reciprocating versus Rotary Pumps
• Basic Operation of Reciprocating Pumps
• API Specifications 674 & 675
• Suction Side Installation Considerations
• Overall Cost of Ownership
 Pump Theory
API Reciprocating Displacement Pumps

• API stands for American Petroleum Institute

• API 674 and 675 are widely used as an industrial

standard for reciprocating displacement pumps.

• Mainly used in Petroleum, Chemical Processing, and

Oil&Gas Industry.

• Describes and specifies constructional design,

qualification criteria, and how pumps and documentation
shall be executed.
 Pump Theory
API Reciprocating Displacement Pumps

Reciprocating metering/dosing pumps deliver a

controlled & accurate flow to predetermined points of a
process independent of pressure.
 Pump Theory
API Reciprocating Displacement Pumps

API 675 Metering Pump With API 674 Reciprocating Triplex

Diaphragm Pumphead Pump With Diaphragm
Pumpheads
 Pump Theory
API Reciprocating Displacement Pumps

Metering Pump Equation

V=A.h.n
V = theoretical Volumetric flow of the
metering pump
A = plunger square area
h = stroke length
n = stroking speed (stroke frequency)
 Positive Displacement Pumps
Reciprocating
Definition (in accordance with API Standard 674)

There is no actual definition in the standard other than

highlighting the difference between a Power Pump & Direct
Acting Pump.
Essentially these pumps transmit a predetermined mass
flow at medium to high pressure.

Pumps are normally configured in Triplex, Quintuplex and

Septuplex designs.
 Positive Displacement Pumps
Controlled Volume
Definition (in accordance with API Standard 675)

“A controlled volume pump is a reciprocating pump in

which precise volume control is provided by varying
effective stroke length”.

• Such pumps are also known as metering, proportioning,

chemical injection, dosing, or controlled volume pump.
• These pumps deliver a controlled & accurate flow to
predetermined points of a process independent of
pressure.
 Pump Theory
API Reciprocating Displacement Pumps
Typical Deviations to API 675
API Listing
1.5 Equipment offered is referring to German and European standards i.e. DIN, EN, IEC,
ISO,....
2.2.5.1 Details of threading conform to ISO.
2.12.3 Unless proposed differently visual indication of capacity setting is shown as actual stroke
length.
2.13.1.13 Bolts are calculated and selected in accordance with German pressure vessel code
(AD-Merkblätter).
3.1.7 Motors are flanged directly to the pump. Consequently, there is no need for jackscrews.
3.3 Metering pumps are suitable for mounting directly onto prepared concrete. Base plates are
therefore optional and can be quoted at additional cost.
3.3.9 If not stated differently base plates will not be furnished with jackscrews.
3.4.3.2 If not stated differently single point terminal box for instrumentation is not included.
3.4.4.3 The gauges used for local diaphragm rupture indication have dials either 63 mm or 100
mm, depending on size of pumphead.
3.4.5 Electrical systems are not included unless expressly required and specifically quoted.
 Pump Theory
API Reciprocating Displacement Pumps
API Data Sheet – Purchaser Information
1
2 For: No. of motors required 1
3 Site Serial no. TBA
4 Remarks
5 Notes: O indicates information to be completed by Purchaser.
indicates information to be completed by manufacturer.
6 API standard 674 governs unless otherwise noted
7
OPERATING CONDITIONS (to be completed by purchaser)

8 Liquid (HC) Condensate Capacity @ PT (m³/h):

9 Pumping temperature (°C) PT: Maximum Note 2 Minimum Note
Rated
3 5,3
10 Normal 19 Maximum 58Minimum -9 Discharge pressure (bar g):
11 Density @ PT (kg/m³): 569,8 Maximum Minimum Rated Note 4
12 Vapor pressure @ PT (bar): Suction pressure ( bar g):
13 Viscosity @ PT (cP): 0,16 Maximum Minimum Rated 17,8
14 Acceleration head (m) Note 1 Differential pressure (bar g):
15 NPSH available (m): 14,7 Maximum 19,2 Minimum Rated 16,2
 Pump Theory
API Reciprocating Displacement Pumps

Installation Considerations & How to Avoid Problems

 Pump Theory
API Reciprocating Displacement Pumps
Flow Pattern of various Pumps Types

Simplex Pump
Duplex Pump
Triplex Pump
Centrifugal Pump
 Pump Theory
API Reciprocating Displacement Pumps
What we are Trying to Avoid
Suction Side Discharge Side
• Insufficent NPSHA • Insufficent Flow
• Pump Starvation • Over Pressure
• Cavitation • Pipe Hammer

General Poor Pump Operation

In almost all cases of insufficient flow rate or frequent service
calls the pump will be blamed, not the system
Only Recognised as Problems During Commissioning or
Initial Operation.
 Pump Theory
API Reciprocating Displacement Pumps
Many Installations Are Designed On Smooth Flow
Conditions & Ignore Factors Such as:-

• Reciprocating Pumps Generate a Pulsating

Flow
• ~3x Equivalent Smooth Flow.
• Line Losses Can be High.
• Crucial on Critical Applications i.e. Liquid
Gases, High Temperature, Volatile Liquids.
 Pump Theory
API Reciprocating Displacement Pumps
Flow Pattern of a Single Head Pump
100 % Capacity setting

60 % Capacity setting

Top
dead
Discharge

Center

Bottom
Bottom dead
dead Center
Center
Suction
 Pump Theory
API Reciprocating Displacement Pumps
Two Major Factors That Can Adversely Affect The
Operation of Reciprocating Pumps Buy Are Often
Overlooked are:
•Friction Losses
Higher Viscosity Applications
Pressure Required to ensure that the liquid flows continually in the
system during the maximum demanded flow volume.
Low Viscosity Application
•Mass Acceleration Losses
Pressure Required to cause the liquid to move at the beginning of
each plunger stroke

•Both Have a high impact on NPSHA .

•Only the higher of the two values is considered.
•On reciprocating pumps this is generally Mass Acceleration.
 Pump Theory
API Reciprocating Displacement Pumps

Factors Affecting Mass Acceleration Pressure

• Plunger or Piston Diameter.
• Stroke Length
• Internal Pipe Diameter & Overall Length.
• Pump Speed.
• Pump Configuration (Single or Multi Head)

Example.
Single Head Pump 20mm Dia Plunger x 20 mm Stroke Length
Operating Speed 100 Strokes/Min Fitted To 8mm NB Pipe
Mass Acceleration Pressure = 0.84 m/m
Pipe Length = 10m
∆P = 8.4m or 0.84 Bar
 Pump Theory
API Reciprocating Displacement Pumps

Net Positive Suction Head

Net positive suction head (NSPH) is the total inlet

pressure, stated in meters head minus the vapor
pressure of the liquid in meters
 Pump Theory
API Reciprocating Displacement Pumps
What is a System ?
(in terms of the issue “NPSH”)
A system is normally composed of:
p(abs) • a pump
Suction • a vessel from which the pump takes the liquid (suction vessel)
vessel or Habs
• piping between pump and suction vessel including valves,
elbows, strainers, etc.
L
(Length of suction piping)

Hst Pump

(Static
head)

d
(pipe inside diameter)
 Pump Theory
API Reciprocating Displacement Pumps
Mass Acceleration Forces

Simplex Pump
Duplex Pump
Triplex Pump
Centrifugal Pump
 Pump Theory
API Reciprocating Displacement Pumps
Net Positive Suction Head Available
NPSHA is a property of the system & determined
by the purchaser!

Net Positive Suction Head Required

NPSHR is a property of the pump and is the minimum
pressure required, measured at the suction flange, to
prevent cavitation.

For satisfactory pump operation NPSHA should always

exceed NPSHR by a minimum of *1 -2 m
*(varies for different pump types and suppliers)
 Pump Theory
API Reciprocating Displacement Pumps
Total head
The NPSH concept
Head of
vapor
pressure Head of
friction
losses
Head in Head of
suction vessel mass
(above liquid acceleration
level) losses

NPSHA
Static NPSHR
head

NPSH margin
 Pump Theory
API Reciprocating Displacement Pumps

How can NPSHA be calculated ?

The calculation is no more than determining the
difference between
• positive heads
i.e. absolute head in suction vessel plus static head
and
• negative heads (losses)
i.e. head due to vapor pressure, friction and mass
acceleration

NPSHA = H +Hst - Hvp - ΣHfr - Hma

 Pump Theory
API Reciprocating Displacement Pumps
Inadequate NPSHA Will Cause Cavitation Leading To:
• Erratic Performance
• Reduced Flow
• Erosion in The Plunger Packing Area and Non Return
Valves
• A Lot of Noise!!!
• Cost
Non Return Valves

Plunger Sealings
 Pump Theory
API Reciprocating Displacement Pumps

Considerations to Maximise The NPSHA of the System

• Minimise the pipe length
• Maximise the bore diameter
• Minimise no of bend, tees and valves etc.
• Use of Pulsation Dampening Devices
• Increase Pressure (Booster Pump, Nitrogen
Blanket, Static Head etc).
• Use of a multi head pump.
• Adequate Pipe Supporting
 Pump Theory
API Reciprocating Displacement Pumps

Pulsation Dampeners
 Pump Theory
API Reciprocating Displacement Pumps
Pulsation Dampener Affect

0 180 360
 Pump Theory
API Reciprocating Displacement Pumps

Overall Cost of Ownership

Comparison of the investment and maintenance costs of a hydraulically
actuated diaphragm pump compared to a packed plunger pump

Process Fluid : Methanol Process Pressure : 160 bar

Flowrate : 12m3/hr Operating Hours : 8000/year

Diaphragm Pump Packed Plunger Pump

Pump Type Triplex Triplex

Investment Cost 250,000 150,000

Annual Spare Use

- plungers None 6 x 3,000 = 18,000

- plunger packing 3 x 500 = 1,500 12 x 1,000 = 12,000

- diaphragms 3 x 1,000 = 3,000 None

- pump valves 6 x 2,000 =12,000 6 x 2,000 = 12,000

- labour costs 10 h x 150 = 1,500 50 h x 150 = 7,500

Annual maintenance 18,000 40,500

costs
Maintenance costs after 63,000 148,500
3 years operation Inc 1 set of plungers

Total costs after 3 years 313,000 298,500

operation

Comments
Energy costs ~5% Lower Packing Friction
Lubrication of Plunger Not Required Necessary
None Needs to be contained
Packing Leakage
 Pump Theory
API Reciprocating Displacement Pumps

Thank you - Questions