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OBJECTIVE
REVIEW STEPS FOR SELECTING A PUMP
A PUMP IS REQUIRED
WHEN THERE IS A NEED TO DELIVER A LIQUID FROM ONE POINT TO ANOTHER POINT WITHIN A PIPING SYSTEM, AND BY OBSERVATION P1<P2 OR IF P1>P2 BUT P1< (FRICTIONAL LOSSES + P2) FOR A GIVEN FLOW RATE A PUMP IS A PIECE OF EQUIPMENT THAT IS USED TO ADD ENERGY TO A FLUID.
STATIC DISCHARGE HEAD HEIGHT OF LIQUID ABOVE OR BELOW THE CENTERLINE OF PUMP DISCHARGE.
FRICTION HEAD SUM OF THE ENERGY LOSSES IN SUCTION AND DISCHARGE LINE. TOTAL DYNAMIC HEAD (TDH) (USED TO SIZE PUMP) DIFFERENCE BETWEEN PUMPING SYSTEMS DISCHARGE AND SUCTION HEADS.
hf = f LV^2/(D*2g)
Fittings hf = KV^2/(2g) where: hf = frictional head loss, ft. f = pipe friction factor, dimensionless (see crane manual) K = fittings friction factor, dimensionless (see crane manual) L = pipe length, ft. D = pipe diameter, ft. V = fluid velocity, ft./sec. g = acceleration of gravity, 32.17 ft./sec.
EXAMPLE PROBLEM
Given: Oil S.G. = 0.87 Pipe = 4" sch. 40 30 psig Flowrate = 250 gpm
15 35
10
15 800 psig
Pump
Determine TDH
Calculate - Total Dynamic Head TDH = hd - hs hs = hss + hps - hfs hss = 35 hps = 30 (2.31) = 79.66
.87
hfs = 5.31 from crane manual (fluid flow & friction loses) (takes into account piping length & diameter, fitting) hs = 35 + 79.66 - 5.31 = 109.35
hfs = 2.65 from Crane Manual (fluid flow & friction losses) hd = 0 + 2124.14 + 2.65 = 2126.79 TDH = 2126.79 - 109.35 = 2017.44
EXXON COMPANY, U.S.A. PRODUCTION DEPARTMENT TECHNOLOGY SECTION FACILITY ENGINEERING PROGRAMS VERSION 3.7.1
KINETIC PUMP REQUIREMENTS Date: Project Name: Total Dynamic Head Calculation Tag Number: INPUT PARAMETERS Flow Rate (gpm) ..: Pump Efficiency Factor (fraction): Motor Efficiency Factor (fraction)...: Atmospheric Pressure (psia).: Liquid Vapor Pressure (psia): Specific Gravity (water = one):
***FROM SUCTION SOURCE TO PUMP INLET*** Suction Source Operating Pressure (psig)...: Height of Fluid Above Pump Reference (ft)...: Frictional Losses (psi).: ***FROM PUMP OUTLET TO DISCHARGE POINT*** Discharge Point Operating Pressure (psig)...: Discharge Point Above Pump Reference (ft)...: Frictional Losses (psi)..: Flow Control Valve Losses (psi) : RESULTS Suction Head, feet Discharge Head, feet . Total Dynamic Head, feet
RECIPROCAL
PLUNGER (DUPLEX, TRIPLES, QUINTUPLEX)
CENTRIFUGAL PUMPS
CENTRIFUGAL PUMPS CONSIST OF A ROTATING IMPELLER AND A STATIONARY HOUSING. THE FLUID CONTAINED IN THE PUMP CASING IS FORCED OUT OF THE HOUSING THROUGH THE DISCHARGE OUTLET; THE CREATED VACUUM PULLS IN MORE FLUID THROUGH THE SUCTION INLET. THE IMPELLER IS ROTATED BY A SHAFT.
CENTRIFUGAL PUMPS
THE FLUID MOVES IN THE DIRECTION OF ROTATION AND RADIALLY OUTWARD THROUGH THE VOLUTE (A CURVE THAT WINDS AROUND AND CONSTANTLY RECEDES FROM A CENTER POINT) AND TO THE DISCHARGE OUTLET.
CHANGE PUMP SPEED CHANGING IMPELLER DIAMETER GPM2 = GPM1 ((D2/D1) x (N2/N1)) TDH2 = TDH1 ((D2/D1) x (N2/N1))^2 BHp2 = BHp1 ((D2/D1) x (N2/N1))^3
------------Basis of Curve-----------Speed 1780 rpm Diameter 12.56 in No. of impellers 1 Viscosity 0.75 cp Suction Press 10.0 psig Rating Point Input Data Required for All Cases: Suction Pressure 10 psig Specific Gravity 0.88 Viscosity 0.75 cp Impeller Diameter 13.5 in Speed 1780 rpm Number of stages 1 Data Dependent on Calc Mode: Flow 570.0 US gpm --orDischarge Press - psig -orSystem Resistance Curve: Flow - US gpm Pressure - psig | | | | | | | | | | | | | | | | Calculated Performance Calculated Mode: At given Flow
Flow 570.0 US gpm Head 192.0 ft Disch Press 83.3 psig Power 32.4 hp Percent BEP flow 82.7 % Effeciency 75.0 % NPSH Reqd 5.0 ft Ns, Sp Speed 949 Nss, Suct Sp Sp 11653
PEGASYS
SUCTION PIPING
Flooded
Suction/Vapor Free Minimal Turbulence Head Loss < 1 ft/100 equivalent feet No Vapor Traps/Constant Slope Short and Direct/Free of Turns Long Radius bends Straight pipe ahead of pump Eccentric (FSU) reducers
DISCHARGE PIPING
Velocity ~ 7 fps Head Loss ~ 1 #/100 equivalent feet Recycle/Bypass Line Straight pipe downstream of pump Concentric reducers Backpressure valve (if required) Relief Valve Check Valve Block Valve
RECIPROCATING PUMPS Reciprocating pumps consist of piston or plunger moving back and forth within a fixed volume cylinder. As the piston or plunger moves backward, the reduced cylinder pressure opens the suction valve. As the piston or plunger moves forward, the increased cylinder pressure opens the discharge valve. The alternating or reciprocating action results in flow and pressure variation in the pump suction, within the pump, and in the pump discharge. The flow is thus said to be pulsating.
RECIPROCATING PUMPS
RECIPROCATING PUMPS SERVE IN A LARGE NUMBER OF APPLICATIONS. THEY ARE LOW SPEED MACHINES COMPARED TO CENTRIFUGALS; HOWEVER, RECIPROCATING PUMPS DO HAVE SIGNIFICANTLY HIGHER EFFICIENCIES, GENERALLY 85 TO 95 PERCENT. THIS MEANS LOWER HORSEPOWER REQUIREMENTS. RECIPROCATING PUMPS ARE BEST SUITEDFOR HIGH PRESSURE, LOW VOLUME APPLICATIONS
PD PUMP CALCULATION
Quintuplex Pump - (5) Plungers Plunger diameter = 3.75 Speed = 276 rpm Maximum load (F) = 10,000 lbs. Stroke = 4.25 V.E. = 90%
Capacity = Speed x Displacement x V.E. Displacement = (# of plungers) x stroke x (plunger area) Displacement = (5) x (4.25/12) x ((3.14/4)x(3.75/12)^2) Displacement = 0.1358 cuft/rev x 7.48 gal/cuft Displacement = 1.0159 gal/rev Capacity = 276 rev/min x 1.0159 gal/rev x 0.90 Capacity = 252.3 gal/min x 34.28 Capacity = 8650 BPD Maximum discharge pressure (Pmax) = load/area Pmax = 10000 lbs./11.044 sq inch Pmax = 905 psi
________________________ __________ ________ _________ __________ _________ _________ _________ _________ ________ EXXON M ECHANI CAL DESI GN PROGRAM PDPUM P, Ver s i on 1. 1 ROTATI NG EQUI PM ENT ________________________ __________ ________ _________ __________ _________ _________ _________ _________ ________ Pr ogr am : For m ul a Sour c e( s ) : Des c r i pt i on: Rec i pr oc at i ng Pum ps API 14E, Gas o Des i gn I nf o, Pum p M odul e, Gr eer Cat al og Cal c ul at es hy dr aul i c and power r equi r em ent s f or a PD pum p, i nc l udi ng ac c el er at i on head. Cal c ul at es pul s at i on dam pener s i z i ng. ________________________ __________ ________ _________ __________ _________ _________ _________ _________ ________ Pr oj ec t Nam e: I t em Des c r i pt i on/ Ser v i c e: Cas e Des c r i pt i on: Pr epar ed by : Dat e: ? ? ? ? ? 24- Sep- 02
Tag:
Rev i s i on:
Chec k ed/ Appr ov ed by : __________ ________ _________ __________ _________ _________ _________ _________ ________ ________________________ __________ ________ _________ __________ _________ _________ _________ _________ ________ I NPUTS --------Ty pe of Pum p ( T f or Tr i pl ex , Q f or Qui nt upl ex ) : St r ok e, i nc hes : Ex x on M ax RPM ===> Pl unger Di am et er , i nc hes : Vol um et r i c Ef f i c enc y , % : Pum p RPM : Per c ent of m ax RPM ===> Gal l ons per Rev ol ut i on ===> Rat e, BPD ===> M ax di s c har ge Pr es s ur e, ps i g: Pl unger Load r equi r ed, l bs ===> Suc t i on Pr es s ur e, ps i g: M ec hani c al Ef f i c enc y , % Hor s epower r equi r ed ===> Hor s epower at : 90 Suc t i on Pi pi ng I D, i Li qui d Vel oc i t y , f t / Suc t i on Pi pi ng Lengt Li qui d Fac t or : Em pi r i c al Cons t ant f Ac c el er at i on Head, f Ac c Head w/ 100% VE: nc hes : s ec - - - > h ( ac t ual ) , Q 4. 25 340 3. 750 90 276 81% 1. 0160 8, 657 905 9, 995 30 84 % VE, & 800 4. 026 6. 36 ft: 40 2 ps i g ===>> 153 135 ( <- - Ty pi c al l y 87% t o 82% , = 8657 BPD r at e) 85% i s nor m al <- - Ty pi c al l y 95 t o 90 per c ent OUTPUTS --------COM M ENTS ---------
or pum p t y pe - - - > 0. 040 t ===> 43. 6 Suc t i on Vel oc i t y - - > 7. 07 Ac c Head, f t ===> 48. 5 Pul s at i on Dam pener s i z i ng: Pul s at i on al l owed i n s y s t em , %: 2 % <- M i ni m um Pul s at i on Dam pener Si z e, gal l ons ===> 0. 9 Suc t i on St abi l i z er , gal l ons ===> 10. 2 <- ____ ________________________ __________ ________ _________ __________ _________ _________
Vel oc i t y s houl d be l es s t han: 1. 5 f t / s ec per 14E 2 f t / s ec per Ex x on s pec <- - 1. 5 f or wat er , gl y c ol , am i ne 2. 0 f or m os t hy dr oc ar bons 2. 5 f or c om pr es s i bl e f l ui ds 1. 4 f or i nc om pr es s i bl e f l ui ds <- -
SUCTION PIPING
Flooded
Suction/Vapor Free Minimal Turbulence Velocity ~ 2 fps Head Loss < 1 ft/100 equivalent feet No Vapor Traps/Constant Slope Short and Direct/Free of Turns Long Radius bends Straight pipe ahead of pump Eccentric (FSU) reducers Pulsation dampener
DISCHARGE PIPING
Velocity ~ 7 fps Head Loss ~ 1 #/100 equivalent feet Recycle/Bypass Line Straight pipe downstream of pump Concentric reducers Pulsation dampener Relief Valve Check Valve Block Valve
NPSH
CAVITATION CAVITATION IS VAPORIZATION WITHIN A PUMP. IT CAN REDUCE A PUMPS PERFORMANCE AND MAY DAMAGE THE PUMP.
TO UNDERSTAND THE OCCURRENCE OF CAVITATION IT IS IMPORTANT TO REMEMBER THAT A LIQUID WILL VAPORIZE AT A COMPARATIVELY LOW TEMPERATURE IF ITS PRESSURE IS REDUCED SIGNIFICANTLY. WATER, FOR INSTANCE, WILL VAPORIZE AT 100 DEG F IF IT IS EXPOSED TO A VACUUM OF 28 INCHES OF MERCURY. THE PRESSURE AT WHICH A LIQUID WILL VAPORIZE IS CALLED ITS VAPOR PRESSURE.
EACH PUMP DESIGN HAS A REQUIRED NET POSITIVE SUCTION HEAD (NPSH). THE REQUIRED NPSH IS DEFINED AS THE REDUCTION IN TOTAL HEAD AS THE LIQUID ENTERS THE PUMP. THIS NUMBER IS SPECIFIED BY THE MANUFACTURER.
THE AVAILABLE NPSH IS THE DIFFERENCE BETWEEN THE TOTAL SUCTION HEAD AND THE VAPOR PRESSURE OF THE LIQUID.
WHEN THE AVAILABLE NPSH IS EQUAL TO OR GREATER THAN THE REQUIRED NPSH, THE PUMP WILL NOT CAVITATE. (NPSHA>NPSHR)
hss
pump
NPSHA > NPSHR > 16 feet (to prevent cavitation) NPSHA = hpsa + hss - hfs -hvpa Solve for hss hss = 16 + hvpa +hfs - hpsa hss = 16 + 47.9 + 4.86 - 47.9 = 20.86 feet
PROPERTIES OF WATER
Temperature Degrees F. 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 212 220 230 Specific Gravity 1.001 1.001 1.000 0.999 0.998 0.996 0.994 0.992 0.990 0.987 0.985 0.982 0.979 0.975 0.972 0.968 0.965 0.961 0.959 0.957 0.953 Vapor Pressure Feet of Water, Absolute 0.3 0.4 0.6 0.8 1.2 1.6 2.2 3.0 4.0 5.2 6.8 8.8 11.2 14.2 17.9 22.3 27.6 34.0 35.4 41.5 50.4
EXXON COMPANY, U.S.A. PRODUCTION DEPARTMENT TECHNOLOGY SECTION FACILITY ENGINEERING PROGRAMS VERSION 3.7.1
KINETIC PUMP REQUIREMENTS Date: Project Name: NPSHA Calculation Tag Number: INPUT PARAMETERS Flow Rate (gpm) ..: Pump Efficiency Factor (fraction): Motor Efficiency Factor (fraction)...: Atmospheric Pressure (psia).: Liquid Vapor Pressure (psia): Specific Gravity (water = one): ***FROM SUCTION SOURCE TO PUMP INLET*** Suction Source Operating Pressure (psig)...: Height of Fluid Above Pump Reference (ft)...: Frictional Losses (psi).: ***FROM PUMP OUTLET TO DISCHARGE POINT*** Discharge Point Operating Pressure (psig)...: Discharge Point Above Pump Reference (ft)...: Frictional Losses (psi)..: Flow Control Valve Losses (psi) : RESULTS Suction Head, feet Discharge Head, feet . Total Dynamic Head, feet NPSHA, feet
CALCULATING HORSEPOWER
FORMULAS
CENTRIFUGAL PUMP BHP = (GPM x TDH x S.G.)/(3960 x e) RECIPROCAL PUMP BHP = (GPM x DELTAP)/(1714 x e)
e = 0.5
e = 0.9
SAMPLE CALCULATION
CENTRIFUGAL PUMP BHP = (250 x 2017.45 x 0.87)/(3960 x 0.5) BHP = 221.6 hp RECIPROCAL PUMP BHP = (250 x 759.8)/(1714 x 0.9) BHP = 123.1 hp
EXXON COMPANY, U.S.A. PRODUCTION DEPARTMENT TECHNOLOGY SECTION FACILITY ENGINEERING PROGRAMS VERSION 3.7.1 KINETIC PUMP REQUIREMENTS Date: Project Name: Brake Horsepower Calculation Tag Number: INPUT PARAMETERS Flow Rate (gpm) ..: Pump Efficiency Factor (fraction): Motor Efficiency Factor (fraction)...: Atmospheric Pressure (psia).: Liquid Vapor Pressure (psia): Specific Gravity (water = one):
***FROM SUCTION SOURCE TO PUMP INLET*** Suction Source Operating Pressure (psig)...: Height of Fluid Above Pump Reference (ft)...: Frictional Losses (psi).: ***FROM PUMP OUTLET TO DISCHARGE POINT*** Discharge Point Operating Pressure (psig)...: Discharge Point Above Pump Reference (ft)...: Frictional Losses (psi)..: Flow Control Valve Losses (psi) : RESULTS Suction Head, feet Discharge Head, feet . Total Dynamic Head, feet NPSHA, feet Brake Horsepower
EXXON COMPANY, U.S.A. PRODUCTION DEPARTMENT TECHNOLOGY SECTION FACILITY ENGINEERING PROGRAMS VERSION 3.7.1 POSITIVE DISPLACEMENT PUMP REQUIREMENTS Date: Project Name: Brake Horsepower Calculation Tag Number: INPUT PARAMETERS Flow Rate (gpm) ..: Pump Efficiency Factor (fraction): Motor Efficiency Factor (fraction)...: Atmospheric Pressure (psia).: Liquid Vapor Pressure (psia): Specific Gravity (water = one): ***FROM SUCTION SOURCE TO PUMP INLET*** Suction Source Operating Pressure (psig)...: Height of Fluid Above Pump Reference (ft)...: Frictional Losses (psi).: ***FROM PUMP OUTLET TO DISCHARGE POINT*** Discharge Point Operating Pressure (psig)...: Discharge Point Above Pump Reference (ft)...: Frictional Losses (psi)..: RESULTS Suction Head, feet Discharge Head, feet . Total Dynamic Head, feet Brake Horsepower
ELECTRIC MOTORS
STANDARD RATINGS The following are standard motor ratings for voltage, horsepower, and speed. Other ratings may be available upon special request. Voltage Rating Voltage 460 or 575 2300 4000 or 4600 6600 13200 Horsepower Ratings 1/2 7-1/2 3/4 10 1 15 1-1/2 20 2 25 3 30 5 40
Typical Horsepower 1/2 to 600 200 to 4000 200 to 7000 1000 to 12000 3500 to 25000
Pump Information General - What is the make / model / serial # of the pump frame? - How fast is the pump operating (rpm)? - What is the operating speed of the pump? (current, min. / max. operating speed)
Positive Displacement Pump (Plunger) - How many plungers are installed in pump? - What is the diameter of the plungers? - What is the pump stroke? - What is the pumps net positive suction head required (NPSHR)? - What type of pump valves are being used - What are the sizes of the pulsation dampeners - What type of packing is used in the fluid end - What type of lubrication system is being used on the power end?
Centrifugal Pump - Where are the pump curves for this pump? - How many stages is this pump? - What is the pumps impeller size? - What is the maximum and minimum impeller sizes for this pump? - What is the pumps net positive suction head required (NPSHR)? - What seal plan is being utilized? - What type seal flush is being utilized?
Pumping Process - What is the facilitys / pumps throughput forecast over the next 5-7 years? - How much is the facilitys / pumps throughput now? - How many pumps are designated as full-time operating units? - What type of driver is on each pump? (e.g. engine, motor, gas turbine) - What is the driver rated BHP? - How many pumps are designated as back-up units? - Are the pumps in series are parallel? - What are the flow rates of each pump? - What is the specific gravity and viscosity of the fluid being pumped? - What are the suction and discharge pressures of the fluid being pumped? - What are the current suction temperatures of the fluid being pumped? - How do the suction temperatures fluctuate (from summer to winter)? - How is the pumps volume controlled? Recycle valve, backpressure valve, on/off, variable speed control, etc.? - If fluid is being recycled, how much? - Where does the recycle line feed back into the suction system ? Upstream of the pump suction, upstream separator, etc.? - What is the systems net positive suction head available (NPSHA)?