Steve Digby Pump Etheori

Tekna
Offshore Pumps 2007

Pump Theory -
API Reciprocating
Displacement Pumps.
Steve Digby
SPX Process Equipment Limited
Bran+Luebbe Operation U.K.
SPX Process Equipment
WCB-Flow Products
2003 2002
GD GD GD GD Engineering Engineering Engineering Engineering
OFM OFM OFM OFM
Oilfield Fabricating & Machine
After Market & Field Services
2005 Plan
Employees 2585
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 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
Reciprocating metering/dosing pumps deliver a
controlled & accurate flow to predetermined points of a
process independent of pressure.
Pump Theory
API 675 Metering Pump With
Diaphragm Pumphead
API 674 Reciprocating Triplex
Pump With Diaphragm
Pumpheads
Pump Theory
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 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-Merkbltter).
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.
Typical Deviations to API 675
Pump Theory
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 (m/h):
9 Pumping temperature (C) PT: Maximum Note 2 Minimum Note 3 Rated 5,3
10 Minimum -9 Discharge pressure (bar g):
11 Density @ PT (kg/m): 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
Normal 19 Maximum 58
API Data Sheet Purchaser Information
Pump Theory
Installation Considerations & How to Avoid Problems
Pump Theory
Flow Pattern of various Pumps Types
Simplex Pump
Duplex Pump
Triplex Pump
Centrifugal Pump
Pump Theory
Suction Side
Insufficent NPSHA
Pump Starvation
Cavitation
What we are Trying to Avoid
Discharge Side
Insufficent Flow
Over Pressure
Pipe Hammer
In almost all cases of insufficient flow rate or frequent service
calls the pump will be blamed, not the system
General Poor Pump Operation
Only Recognised as Problems During Commissioning or
Initial Operation.
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
Many Installations Are Designed On Smooth Flow
Conditions & Ignore Factors Such as:-
Pump Theory
Bottom
dead
Center
100 % Capacity setting
60 % Capacity setting
S
u
c
t
i
o
n
D
i
s
c
h
a
r
g
e
Bottom
dead
Center
Top
dead
Center
Flow Pattern of a Single Head Pump
Two Major Factors That Can Adversely Affect The
Operation of Reciprocating Pumps Buy Are Often
Overlooked are:
Pump Theory
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
Plunger or Piston Diameter.
Stroke Length
Internal Pipe Diameter & Overall Length.
Pump Speed.
Pump Configuration (Single or Multi Head)
Factors Affecting Mass Acceleration Pressure
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
Net positive suction head (NSPH) is the total inlet
pressure, stated in meters head minus the vapor
pressure of the liquid in meters
Net Positive Suction Head
What is a System ?
(in terms of the issue NPSH)
A system is normally composed of:
a pump
a vessel from which the pump takes the liquid (suction vessel)
piping between pump and suction vessel including valves,
elbows, strainers, etc.
Suction
vessel
Pump
p
(abs)
or H
abs
H
st
(Static
head)
L
(Length of suction piping)
d
(pipe inside diameter)
Pump Theory
Pump Theory
Mass Acceleration Forces
Simplex Pump
Duplex Pump
Triplex Pump
Centrifugal Pump
Net Positive Suction Head Available
NPSHA is a property of the system & determined
by the purchaser!
Pump Theory
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)
Head in
suction vessel
(above liquid
level)
Head of
vapor
pressure
Head of
friction
losses
Head of
mass
acceleration
losses
NPSHA
Static
head
NPSHR
NPSH margin
Total head
The NPSH concept
Pump Theory
How can NPSHA be calculated ?
NPSHA = H +H
st
- H
vp
- H
fr
- H
ma
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
Pump Theory
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
Pump Theory
Plunger Sealings
Non Return Valves
Pump Theory
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
Considerations to Maximise The NPSHA of the System
Pump Theory
Pulsation Dampeners
Pump Theory
Pulsation Dampener Affect
0 180
360
Overall Cost of Ownership
Pump Theory
Process Fluid : Methanol
Flowrate : 12m3/hr
298,500 313,000
Total costs after 3 years
operation
148,500 63,000
Inc 1 set of plungers
Maintenance costs after
3 years operation
40,500 18,000
Annual maintenance
costs
50 h x 150 = 7,500 10 h x 150 = 1,500
- labour costs
6 x 2,000 = 12,000 6 x 2,000 =12,000
- pump valves
None 3 x 1,000 = 3,000
- diaphragms
12 x 1,000 = 12,000 3 x 500 = 1,500
- plunger packing
6 x 3,000 = 18,000 None
Annual Spare Use
- plungers
150,000 250,000
Investment Cost
Triplex Triplex
Pump Type
Packed Plunger Pump Diaphragm Pump
Comments
Packing Friction
Necessary
Needs to be contained
~5% Lower
Not Required
None
Energy costs
Lubrication of Plunger
Packing Leakage
Comparison of the investment and maintenance costs of a hydraulically
actuated diaphragm pump compared to a packed plunger pump
Process Pressure : 160 bar
Operating Hours : 8000/year
Thank you - Questions
Pump Theory

Steve Digby Pump Etheori

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Tekna

Offshore Pumps 2007

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