LOW FLOW / HIGH HEAD

Centrifugal Pump Options

Calgary Pump Symposium
November 18,2005
Presented by
Frank Korkowski & Larry Glassburn
 A LONG
TIME AGO IN
A REFINERY FAR
FAR AWAY. . . A GALACTIC
WAR RAGES BETWEEN PUMP
MANUFACTURERS AND THE EVIL
EMPIRE OF PROCESS ENGINEERS.
FROM THIS PRESENTATION YOU WILL LEARN
THE SECRETS OF THE “ DARK SIDE ” OF LOW
FLOW / HIGH HEAD PUMPS AND LEARN HOW
TO USE THE FORCE TO . . . . “CHOOSE WISELY”
8000
RPM
25,000
RPM
3600
RPM
 Presentation
• Why do we need “low flow,high head”
LF / HH pumps?
• Centrifugal Pump Fundamentals
• Types of low flow / high head pumps
• Considerations and factors that impact
your pump selection choices
• Summary
1. Why & How we got to LF/HH Pumps
• In the beginning, processes were pretty basic, low
pressure…no LF/HH demand, 1 and 2-stage OH
pumps were sufficient
• 1930’s More efficient and improved chemical
reactions required higher process pressures and
temperatures…LF/HH demand is born, multistage
pumps and PD pumps were employed
• 1960’s Partial Emission (Barske) pumps with a
Gearbox for higher impeller speeds to 25,000 rpm
and Pitot Tube pumps were introduced.
• 1980’s Various types of Barske wheels and
increased number of stages were introduced
• 2000’s (so far) VFD’s to increase impeller
rotational speed…..
Classification of Pumps
H yd rau lic In stitu te A P I-610
O H1; O H2
OH3
O v e rh u n g 1 - a n d 2 - s ta g e OH4
Im p e lle r OH5
OH6
R o to d y n a m ic
(C en trifu g al) B e tw e e n 1 - a n d 2 - s ta g e BB1
B e a rin g s BB2
M u ltis ta g e BB3
BB4
V e rtic a lly BB5
Supended
K in e tic
R e g e n e ra tiv e O v e rh u n g P e rip h e ra l
T u rb in e B e tw e e n S id e C h a n n e l
B e a rin g s

S p e c ia l E ffe c t R o ta tin g C a s in g (p ito t)

Pum ps
D irect A ctin g S im p lex, D u p lex, etc
R e c ip ro c a tin g P o w er F ram e A P I-6 7 4

P o s itiv e C o n tro lle d V o lu m e D iap h rag m A P I-6 7 5

D is p la c m e n t
G ear
R o ta ry S crew A P I-6 7 6
V an e
Lobe
Reciprocating Pumps
2. Centrifugal Pump Fundamentals

• Head vs. Tip Speed, Torque vs. HP

• Affinity Laws
• Specific Speed—ns
• Suction Specific Speed—S
• NPSH
Head vs. Tip Speed … Torque vs. Hp
Theoretical head is defined by the formula:
Where: HT = Theoretical Head (Ft.)
HT = U2
g U = Impeller Tip Speed (ft./sec.)
g = Acceleration = 32.3 ft./sec2.

Tip speed (U) is found by the formula:

DN Where: D = Impeller Diameter (in.)

U =
229 N = Speed (RPM)
Constant
Speed
Q2/Q1 = D2/D1
D=Impeller
Diameter

H2/H1 = (D2/D1)2

BHP2/BHP1 = (D2/D1)3
Constant
Impeller
Diameter
Q2/Q1 = N2/N1 Q = capacity
N = speed

H2/H1 = (N2/N1)2 H = head

BHP=brake
horse power

BHP2/BHP1 = (N2/N1)3
Specific Speed ns

Nx Q
ns = 3/4
H
Where: Q = Flow (gpm) @ BEP
N = Speed (RPM)
H = Head (per stage)
Impeller Design vs. Specific Speed

D2/D1 > 2 D2/D1 = 1.5-2. D2/D1 < 1.5 D2/D1 = 1.

(D2 = Vane O.D. D1 = Vane I.D.)

Pump Specific Speed ns
• Dimensionless number based on the affinity
laws used to select the impeller geometry for
maximum efficiency.
• ns between 200 and 1000 = Barske
• ns between 1000 and 5000 = Francis vane
• ns between 5000 and 15000 = axial flow
pump (inducer)
ns vs. Impeller Design, Curve Shape
 Curve Characteristics vs. ns

600 ns 1000 to 1500 ns

Typical Partial Emission Typical Multistage
Open/Semi Open Impellers Closed Impellers
Curve Characteristics vs. ns

4000 ns 10,000 ns
Typical Mixed Flow Typical
Axial Flow Machine
Efficiency vs. ns by Pump Types
Suction Specific Speed S

N × Q
S =
(NPSH R ) 3/4

Where: Q = Flow (gpm) @ BEP

“per eye”
N = Speed (RPM)
NPSHR = Net Positive Suction Head
“required” by the pump
NPSH

• Net Positive Suction Head is the

amount of energy available in the fluid
at the pump suction flange.
• Successful pump operation results
when the suction fluid has sufficient
energy to push liquid into the pump
faster than the pump can pump it away.
What Does NPSH Have To Do With
Pump Maintenance?

• Inducer, impeller, cover , diffuser and pump

case can suffer metal loss via “cavitation”
• Prevent Cavitation
by:
¾ Increase NPSHA
(of the system)
¾ Decrease NPSHR
(of the pump)
 NPSHA
• NPSHA = ABSOLUTE PRESSURE HEAD
(Barometric Pressure +/- Fluid Vapor
Pressure converted to head)
- VAPOR PRESSURE HEAD (Temp. at
Suction Flange)
- LINE LOSSES (Frictional Loss)
+/- STATIC HEAD (Difference in Elevation
from the Liquid Level to Pump Centerline)
+ VELOCITY HEAD (Small, Often Negligible)

• Consistent Units of Feet or Meters

• Pump suction gage improves accuracy
How To Increase NPSHA

• Increase Suction Vessel Pressure

• Decrease Vapor Pressure
(Decrease Suction Temperature)
• Decrease Line Losses
• Increase Static Head
How To Decrease NPSHR
• Add Inducers

Typical S =
18,000 to
23,000

• Operate unit near BEP

• Select lower speed unit
 What Does NPSH Have To Do With
Pump Maintenance?

• Inducer, impeller, cover , diffuser and pump

case can suffer metal loss via “cavitation”

• Resulting high speed rotor unbalance can

lead to higher vibration and possible bearing
failure.
• Seal problems
3. Types of Low Flow/
High Head Pumps
• Hydraulic Envelope
• Sectional Views
• Methods for Handling Axial Thrust
• Ways to Handle Radial Loads
 Hydraulic Envelope
Low Flow/High Head

• Product options are available

• Over-lap of product performance envelopes does
occur—you do have choices
• Understand your system requirements
• Gather details and discuss with the pump supplier
Single Stage
3600 RPM
Two stage
3600 RPM

Pitot
 Single Stage
Medium Speed
Gearbox

Single Stage
Medium Speed
VFD
 Pitot
3600-5000 RPM
 Multi-stage
Between Bearings
3600 RPM
 Single Stage
Integral High Speed
Gearbox
Multi-stage Barske
3600 RPM
 Two Stage Barske
Integral High Speed
Gearbox
Three Stage Barske
Integral High Speed
Gearbox
Low Flow, High Head Pumps
A Barske – single stage @ 3600 rpm

B Pitot @ 3600 – 5000 RPM

or
Barske – two stage @ 3600 RPM

Barske – Single stage or two stage

C
• Gearbox @ 6000 – 17000 RPM
• VFD @ 8000 RPM

D Pitot @ 3600 – 5000 RPM

E Multi-stage barrel @ 3600 RPM

Barske – single stage

F
Gearbox @ 9000 – 25,000 RPM

Barske– multi-stage (barrel) @ 3600 RPM

G
Barske – two stage
H Gearbox @ 9000 – 25,000 RPM

Barske – Three-Stage
I Gearbox @ 9000 –25,000 RPM
Single-stage Barske
Two-stage Barske
Multi-stage Horizontal and
Vertical Options
Gearbox Driven Multi-stage
Pump with Barske Impellers
Pitot Pump Sectional
 Pitot Principles of Operation

Centrifugal Rotor Cover Pick-Up Tube

Generates 50% of Head Generates 50% of Head

Discharge
Rotor Assembly

Mechanical Seal on Suction Side Suction

 Methods for Handling Axial Thrust

• Pump-out vanes
• Balance holes
• Wear rings
• Balance Drum
• Back-to-back Impellers
• Special Bearing Arrangements
Multi-radial-blade Impellers

Blades

Shroud

Hydraulic
Balance Holes
 Closed Impeller

LABYRINTH STEPS (wear ring)

Methods for Handling Radial Loads

• Volute Designs (circular vs. constant

velocity)
• Diffusers
Radial Load Trends
Principles of Developing Head in Diffuser Pumps

IMPELLER CONICAL
DIFFUSER
PUMP CASING

A C
B
DIFFUSER
THROAT

VELOCITY
PRESSURE

A B C A B C
KMC Bearings
Flexure Pivot™ Radial and Thrust
4. Considerations & Factors
for Your Pump Selection Choices
• Footprint
• NPSH
• Pump / System Interaction
• Life Cycle Cost
Efficiency Operational Flexibility MTBPM
Maintenance Practices Equipment Desirability
Service Support Personal Preference
Price & Delivery ISO 13709 (API 610) Compliance
• Equipment Field Experience
 ISO 13709 (API 610) Compliance

• Classifications OH3, OH4, OH5, OH6

• Pressure Containment
• Temperature Limits
• Mechanical Seal Designs
• Hydrocarbon Applications
• Handling Solids
• Pump Bearing Housing
5. Summary
• Do your homework to understand the
process system requirements
• Select a pump type to fit your system for
normal and any upset conditions
• Evaluate the true benefit of any pump’s
“special features”
• Evaluate Life Cycle Cost

Bottom Line… Choose Wisely

Questions and Answers