BAPCO MODERNIZATION PROGRAM SPECIFICATIONS

(BMPS)

PROJECT SPECIFICATION No.

BMPS-G1
PUMPS AND DRIVERS – GENERAL SPECIFICATION
The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

I. GENERAL DESCRIPTION OF BMPS-G1

This specification covers the requirements for the design and installation of pumps and pump drivers for
refinery services.

II. CONFLICTS AND DEVIATIONS

It is Contractor’s (and Supplier’s / Subcontractor’s) responsibility to obtain all applicable specifications,
codes and standards, and to ensure compliance with the requirements contained therein. The word
‘should’ shall be replaced by ‘shall’ wherever it appears in these documents.

It shall be the Contractor’s (and Supplier’s / Subcontractor’s) responsibility to bring all conflicts and
deviations to the Owner’s attention in a timely manner and request a ruling interpretation or a resolution
in writing. The Contractor (and Supplier / Subcontractor) is not at liberty to assume which instruction
would govern. Refer Project Specification No. BMPS-A2 (Specifications, Codes and Standards) for
guidelines to manage conflicts and deviations.

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 The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

TABLE OF CONTENTS

1. SCOPE 6

2. DEFINITIONS 6

3. REGULATIONS, CODES AND SPECIFICATIONS 7

3.1 International Standards ...................................................................................................................... 7

3.2 Owner Documents.............................................................................................................................. 8

4. GENERAL 10

4.1 Pump Type ....................................................................................................................................... 10

4.2 Design Conditions ............................................................................................................................ 11

4.3 Limits of Operation ........................................................................................................................... 11

4.4 Economics ........................................................................................................................................ 11

4.5 Equipment Noise Limitations ............................................................................................................ 11

4.6 Mechanical Seals and Flushing Systems......................................................................................... 12

4.7 Pump Couplings ............................................................................................................................... 12

4.8 Quench Connections to Mechanical Seals ...................................................................................... 12

4.8.1 Quench Steam ................................................................................................................................. 12

4.8.2 Quench (flush) Water/Condensate ................................................................................................... 12

4.9 Pump Location ................................................................................................................................. 13

4.10 Overhead Clearance for Maintenance ............................................................................................. 13

4.11 Nozzle Orientation ............................................................................................................................ 13

4.12 Bearing Lubrication .......................................................................................................................... 13

4.13 Parts Interchangeability .................................................................................................................... 13

5. CENTRIFUGAL PUMPS 14

5.1 API 610 Horizontal Pumps ............................................................................................................... 14

5.2 API 610 Vertical Inline Pumps (excluding high speed special purpose, e.g. Sundyne) .................. 14

5.3 Non-API 610 Pumps......................................................................................................................... 15

5.4 High-speed Sundyne Pumps ........................................................................................................... 15

5.4.1 Capacity ........................................................................................................................................... 15

5.4.2 Low Flow Protection ......................................................................................................................... 15

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 The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

5.4.3 Materials ........................................................................................................................................... 15

5.4.4 High Suction Pressure Application ................................................................................................... 16

5.5 Vertical Cantilever Pumps ................................................................................................................ 16

5.6 Other Vertical Pumps ....................................................................................................................... 16

5.7 Sealless Pumps................................................................................................................................ 16

5.8 Sump Pumps .................................................................................................................................... 16

5.9 Oily Water Separator Service ........................................................................................................... 17

5.10 Cooling Tower Sump and Basin Design .......................................................................................... 17

5.11 Ebullating Pumps ............................................................................................................................. 17

5.11.1 General ............................................................................................................................................. 17

5.11.2 Material of Construction ................................................................................................................... 19

5.11.3 Auxiliaries ......................................................................................................................................... 19

5.12 Materials ........................................................................................................................................... 20

5.13 Vents and Drains .............................................................................................................................. 20

5.14 Minimum Flow Bypass ..................................................................................................................... 21

5.15 Pump Warm-up ................................................................................................................................ 21

5.16 Suction and Discharge Piping Design .............................................................................................. 22

5.17 Pressurized Lubricating System ....................................................................................................... 22

5.18 Centrifugal Pump Data Sheets ......................................................................................................... 22

6. POSITIVE DISPLACEMENT PUMPS 22

6.1 Rotary Pumps................................................................................................................................... 22

6.2 Controlled Volume (Proportioning) Pumps ...................................................................................... 23

6.3 Reciprocating Pumps ....................................................................................................................... 23

7. SPECIAL REQUIREMENTS FOR FIRE WATER PUMPS 23

7.1 Pump Design .................................................................................................................................... 23

7.2 System Pressures ............................................................................................................................ 23

7.3 Pump Type ....................................................................................................................................... 23

7.4 Suction Line Sizing ........................................................................................................................... 24

7.5 Relief Valve ...................................................................................................................................... 24

7.6 Low Flow Protection ......................................................................................................................... 24

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 The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

8. PUMP DRIVERS AND DRIVE GEARS 24

8.1 Electric Motors .................................................................................................................................. 24

8.2 Steam Turbines ................................................................................................................................ 25

8.2.1 Economics ........................................................................................................................................ 25

8.2.2 Exhaust Relief Valve ........................................................................................................................ 25

8.2.3 Non-condensing Turbines ................................................................................................................ 25

8.2.4 Automatic Start Turbines .................................................................................................................. 26

8.3 Special Requirements for Fire Water Pump Drivers and Installations ............................................. 26

8.4 Gear Units ........................................................................................................................................ 27

9. SPARE ROTORS 27

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The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

1. SCOPE
This Specification covers the requirements for the design and installation of pumps and pump drivers
for refinery services.

The overall goal of pump sizing, selection and specification is to maximize profitability while providing
safe, reliable equipment which satisfies operating requirements and local environmental constraints.

The intention of this Specification, therefore, is to consider the following factors in determining
maximum profitability:

— Safety and environmental needs (including noise)

— Initial cost

— Installation and commissioning expense

— Energy consumption

— Reliability

— On-stream availability of plant (often the overwhelming economic factor)

— Ease of operability

— First-time startup in critical services

— Maintenance expense

— Operating flexibility

As there will be some degree of conflict between these factors, operating input and engineering
judgment on relative priorities will always be necessary.

2. DEFINITIONS
Within this Specification the following definitions shall apply:

OWNER The Bahrain Petroleum Company B.S.C. (Closed).

The terms “Purchaser”, “Company” and “Owner” are interchangeable.

CONTRACTOR Company / Organisation responsible for detail engineering design,

procurement, construction and pre-commissioning of the facilities.

SUPPLIER Company/ Organisation supplying equipment, materials or service.

The terms “Vendor and “Supplier” are interchangeable.

SUBCONTRACTOR Company / Organisation contracted and managed by the Contractor.

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The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

3. REGULATIONS, CODES AND SPECIFICATIONS

3.1 International Standards

The equipment covered in this specification shall comply with the latest applicable revision of the
following Codes, Standards, Regulations and Specifications referred to therein.

American Petroleum Institute (API)

STD 610 Centrifugal Pumps for General Refinery Service

STD 611 General Purpose Steam Turbines for Refinery Service

STD 612 Special Purpose Steam Turbines for Refinery Service

STD 613 Special Purpose Gear Units for Refinery Service

STD 617 Centrifugal Compressors for General Refinery Service

STD 674 Positive Displacement Pumps – Reciprocating

STD 675 Positive Displacement Pumps – Controlled Volume

STD 676 Positive Displacement Pumps – Rotary

STD 677 General Purpose Gear Units for Refinery Service

STD 682 Pumps – Shaft Sealing Systems for Centrifugal and Rotary Pumps

STD 685 Sealless Centrifugal Pumps

American Society of Mechanical Engineers (ASME)

B73.1 Specification for Horizontal End Suction Centrifugal Pumps for

Chemical Process

B73.2 Specification for Vertical In-Line Centrifugal Pumps for Chemical

Process

Engineering Equipment and Materials Users' Association (EEMUA)

Publication 107 Recommendations for the Protection of Diesel Engines for Use in
Zone 2 Hazardous Area

Hydraulic Institute (HI)

5.1-5.6 Sealless Centrifugal Pump Standards

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The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

National Fire Protection Association (NFPA)

STD 20 Installation of Centrifugal Fire Pumps

3.2 Owner Documents

The primary reference project specifications (BMPS) and standard forms / drawings are listed below.
The complete list of Owner Documents is provided in BMPS-A2.

SPECIFICATIONS

BMPS-A1 Basic Engineering Design Data

BMPS-A2 Specifications, Codes and Standards

BMPS-A3 Design Philosophy

BMPS-A4 Refinery Layout and Spacing

BMPS-A20 Noise Limitations

BMPS-A21 Noise Limitations for Equipment

BMPS-B1 General Welding Requirements

BMPS-B5 Coating of External Surfaces and Colour Coding

BMPS-B9 Positive Alloy Material Identification

BMPS-B11 Shop Inspection Requirements, FATs and SATs

BMPS-G2 Centrifugal Pumps for General Refinery Service

BMPS-G3 Centrifugal Pumps (non-API Pumps)

BMPS-G4 Vertical Centrifugal Pumps (Inline, Sump, Barrel, and Turbine)

BMPS-G5 Reciprocating Pumps

BMPS-G6 Controlled Volume Positive Displacement (Metering) Pumps

BMPS-G7 Rotary Pumps

BMPS-G8 Oil Mist Lubrication System

BMPS-G9 Shaft Sealing Systems for Centrifugal and Rotary Pumps

BMPS-J6 Instrumentation for Package Units

BMPS-J11 Relief Valves

BMPS-J15 Machine Condition Monitoring (MCM) System

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The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

BMPS-K5 General Purpose Steam Turbines

BMPS-K6 Special Purpose Steam Turbines

BMPS-K8 General Purpose Pressure Lubrication Systems

BMPS-K9 Lubrication, Shaft Sealing and Control Oil Systems for Special
Purpose Applications

BMPS-K12 Acoustic Enclosures for Machines

BMPS-L1 Refinery Piping

BMPS-L2 Piping Line Classes

BMPS-P3 Electrical Requirements for Package Units

BMPS-P18 HV Induction Motors

BMPS-P19 LV Induction Motors

BMPS-S5 Loss Prevention Basis of Design, Fire Protection and Safety Systems

BMPS-S12 Guidelines for preparation of Spare Parts and Interchangeability Lists

(SPILs)

BMPS-S13 Guidelines for preparation of Lubrication Schedule for Machinery

191807-D-001-0 LC-Fining Reactor Recycle Pumps

191807-D-VFD-001-0 LC-Fining Reactor Recycle Pump Variable Frequency Drive

191807-D-002-0 Seal Oil Injection Pump Package

STANDARD FORMS AND DRAWINGS

BMPS-G-50301 Centrifugal Pump – Data sheet

BMPS-G-50302 Mechanical Seal – Data sheet

BMPS-G-50303 Reciprocating Pump – Data sheet

BMPS-G-50304 Proportioning Pump – Data sheet

BMPS-G-50305 Rotary Pump – Data sheet

BMPS-G-50306 Mechanical Seal - Vendor Drawing and Data Requirements

BMPS-G-50307 Inspection Checklist for Mechanical Seal

BMPS-G-50308 Centrifugal Pumps - Vendor Drawings and Data Requirements

BMPS-G-50309 Inspection Checklist for Centrifugal Pumps

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The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

BMPS-G-50310 Reciprocating Pumps – Vendor Drawing and Data Requirements

BMPS-G-50311 Inspection Checklist for Reciprocating Pumps

BMPS-G-50312 Rotary Pumps – Vendor Drawing and Data Requirements

BMPS-G-50313 Inspection Checklist for Rotary Pumps

BMPS-G-50314 Proportioning Pumps – Vendor Drawing and Data Requirements

BMPS-G-50315 Inspection Checklist for Proportioning Pumps

BMPS-K-50403 General Purpose Steam Turbine - Data Sheet

BMPS-K-50404 Special Purpose Steam Turbine - Data Sheet

BMPS-K-50412 General Purpose Steam Turbines - Vendor Drawings and Data

Requirements

BMPS-K-50413 Inspection Checklist for General Purpose Steam Turbines

BMPS-K-50414 Special Purpose Steam Turbines - Vendor Drawings and Data

Requirements

BMPS-K-50415 Inspection Checklist for Special Purpose Steam Turbines

BMPS-SD-G-10289 Pump Case Vent and Drain Connections

BMPS-SF-A-612 Material Selection Basis

BMPS-SF-B-255 Lubricant Schedule for Machinery

GD-G1368-0 Standard Pump Base Plate

4. GENERAL

4.1 Pump Type

i. The type of pump to be used for any given service shall be determined by design and economic
considerations.

ii. Centrifugal pumps are preferred, unless uneconomical or unsuitable for the service. For low-
flow, high-head services requiring reciprocating or multistage centrifugal pumps, single-stage,
high-speed centrifugal (Sundyne) pumps should be considered as an alternative (refer to
§5.4).

iii. Rotary pumps are preferred for high-viscosity services (above 3000 SSU (660Cs)) or for small
capacity, non-corrosive, clean-lubricating services such as fuel oil or hydraulic systems.

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The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

4.2 Design Conditions

i. Pumps shall be specified to handle design process flow based on process design data
supplied. Refer to §3.2 for the applicable data sheets.

ii. Total developed head shall be based on lowest suction pressure, highest discharge pressure
and fully fouled equipment.

iii. Where pumps are required to cope with more than one design condition, e.g. dual duty of plant
startup with cold stock, the Contractor shall check feasibility of operation and shall include
sufficient information on the data sheets to ensure adequate driver size.

iv. No overcapacity shall be specified, however, pumps shall be capable of delivering at least
110% of design flow rate on the same curve as the operating point.

v. For cases where process surges are encountered, such as column bottom service, 10% extra
flow capacity shall be specified together with an appropriate increase in friction head loss. The
associated equipment and lines shall be sized for the design flow rate.

vi. For criteria applicable to design and selection of pumps, refer to BMPS-A3 (Design
Philosophy).

4.3 Limits of Operation

i. All pumps shall be suitable for operating at the specified operating conditions and at off-design
conditions occurring at plant startup, shutdown, process upset, power outage and re-
acceleration (as applicable).

ii. The Contractor shall determine appropriate limits of operation for each pump and include these
limits on equipment data sheets. The data shall indicate any trace amounts of H 2S, chlorides
and other corrosive constituents that could occur during normal operation and at off-design
conditions (such as plant steam-out), which would have to be taken into account in pump and
mechanical seal material selection (refer to §5.12).

4.4 Economics

Pump efficiency shall be taken into account in pump selection.

4.5 Equipment Noise Limitations

Equipment noise limitations shall be determined in accordance with BMPS-A21 (Noise Limitations for
Equipment).

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 The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

4.6 Mechanical Seals and Flushing Systems

i. Mechanical shaft seals and flushing systems shall be utilized for all services where practical,
except in fire water service, in which packed pumps are required. The seal and flushing
systems design shall be in accordance with API 682 and the requirements of specification
BMPS-G9 (Shaft Sealing Systems for Centrifugal and Rotary Pumps).

ii. Data for pump mechanical seals (for centrifugal and rotary pumps) shall be entered on
standard form BMPS-G-50302 (Mechanical Seal – Data Sheet).

4.7 Pump Couplings

Couplings shall incorporate non-sparking features for all hydrocarbon handling services. Furthermore
the coupling shall be all metallic flexible disc type.

4.8 Quench Connections to Mechanical Seals

The seal Supplier should be consulted on all seal quench proposals, but in general the following shall
apply.

4.8.1 Quench Steam

In general it is recommended that steam quench be used for flammable and combustible liquids
whenever the following conditions exist:

i. The seal chamber temperature is less than 38°C (100°F) below the auto ignition temperature
of the pumped fluid.

ii. The pour point of the pumped fluid is less than 38°C (100°F).

The steam quench connection shall include a pressure reducing valve to minimize steam leakage to
atmosphere, a suitably located steam trap to ensure uninterrupted steam supply, isolating valves and
a drain connection.

As an alternative, low pressure nitrogen quench can also be used in place of a steam quench with
Owner’s approval.

4.8.2 Quench (flush) Water/Condensate

A piped-up clean water flush shall be installed at the quench connection when it is necessary to dilute
(e.g. corrosive fluid), or flush away, crystallizing product leakage (e.g. salt water, caustic).

To avoid housekeeping problems on the baseplate, the seal drain should be piped up a suitable drain
connection.

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BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

Where there is a concern about the contaminated quench flush water entering the drain, a dual seal
with an unpressurized water buffer fluid may be used.

4.9 Pump Location

Pumps shall be located in accordance with BMPS-A4 (Refinery Layout and Spacing).

4.10 Overhead Clearance for Maintenance

The Contractor shall provide, in his design, overhead clearance for maintenance of vertical pumps.

4.11 Nozzle Orientation

Pumps with top suction and discharge nozzles are preferred when the piping is all overhead.

4.12 Bearing Lubrication

The preferred method of lubrication for pump and motor driver antifriction bearings, where practical, is
by pure oil mist. Pure oil mist systems shall be in accordance with BMPS-G8 (Oil Mist Lubrication
System).

In case pressurized oil system is required, it shall be provided in accordance with BMPS-K8 (General
Purpose Pressure Lubrication Systems) or BMPS-K9 (Lubrication, Shaft Sealing and Control Oil
Systems for Special Purpose Applications), as applicable.

Supplier shall advise on required lubricating oil by completing the form in project specification BMPS-
S13 (Guidelines for preparation of Lubrication Schedule for Machinery).

Supplier shall also advise on flushing oil, chemical required to remove preservation or prepare the
equipment for commissioning. Fluid for seal system shall also be included.

4.13 Parts Interchangeability

i. In order to minimize the spare parts inventory, the number of Suppliers of a given type of
equipment shall be minimized.

ii. The Contractor shall provide the Owner with an interchangeability list of all major components
and wearing parts for the equipment, within a specified time following the purchase order
placement. Refer to §3.2 for the applicable Vendor Drawings and Data Requirements. Project
specification BMPS-S12 [Guidelines for Preparation of Spare Parts and Interchangeability
Lists (SPILs)] shall be used. The SPILs shall be provided within 2 months from shipment date.
As per Owner policy, the Contractor shall ensure that 2 years spare parts are available before
start-up.

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The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

iii. In addition to the above and as an obligation to the Owner, the mechanical seal Supplier shall
be required to provide a consolidated SPIL directly to the Owner, which covers all the
mechanical seals supplied across the Project (BMP). This SPIL shall be provided at least 2
months before scheduled start-up date.

iv. In cases where a large number of pumps are to be purchased, the Owner may require the
Contractor to obtain this information from the Supplier prior to purchase.

5. CENTRIFUGAL PUMPS

5.1 API 610 Horizontal Pumps

Heavy-duty horizontal centrifugal pumps, in accordance with ‘API 610’ latest edition as modified by
BMPS-G2 (Centrifugal Pumps for General Refinery Service), are preferred for all continuous-duty
refinery processes, hydrocarbon or toxic services and other critical services such as boiler feed water,
off-plot charge pumps, etc.

5.2 API 610 Vertical Inline Pumps (excluding high speed special purpose, e.g.
Sundyne)

While vertical inline pumps can be cheaper to install and sometimes more reliable, they are also subject
to seal problems, difficulties in removing the driver for pump maintenance, etc., and are not always
acceptable.

Therefore, vertical inline pumps, in accordance with ‘API 610’ as modified by BMPS-G2 (Centrifugal
Pumps for General refinery Service), may only be used in services listed in §5.1, providing they show
specific advantages in economics, installation or maintenance and providing the following conditions
are met:

a) Driver rating does not exceed 75 kW (100 BHP).

b) Pump is not coupled with an axially-split rigid coupling. Pumps with flexible spacer coupling
are preferred.

c) Seal flush is arranged to prevent vapor from accumulating in the seal chamber.

d) Mechanical seal can be replaced without removing the driver.

e) Pump is electric motor driven (turbine driven pumps shall be horizontal type, unless otherwise
approved by the Purchaser).

f) Pumping temperature not higher than 177°C (350°F).

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 The Bahrain Petroleum Company B.S.C. (Closed) Pumps & Drivers

BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

5.3 Non-API 610 Pumps

i. Pumps that do not fully comply with ‘API 610’ are permitted in non-hydrocarbon, non-toxic,
non-critical services, where significant savings over ‘API 610’ design can be demonstrated,
and evidence of satisfactory service under similar conditions can be confirmed.

ii. These pumps shall be manufactured in accordance with ASME B73.1 or B73.2 and with the
following project specifications, as applicable:

 BMPS-G3 [Centrifugal Pumps (non-API Pumps)]

 BMPS-G4 [Vertical Centrifugal Pumps (Inline, Sump, Barrel, and Turbine)].

iii. Moreover the design shall comply with the requirements of API standards for service life,
materials, shaft stiffness, mechanical seals, bearings, and auxiliary piping. The use of non-API
610 pumps is subject to the Owner’s approval.

5.4 High-speed Sundyne Pumps

High-speed, single-stage Sundyne centrifugal pumps for low-flow, high-head service may be used for
applications outside the range of conventional centrifugal pumps. High-speed pumps other than those
manufactured by Sundstrand are subject to the Owner’s approval.

5.4.1 Capacity

When selecting Sundyne pumps, care should be exercised to ensure that the operating capacity point
is well away from the sharp “break” or “knee”, typical of a Sundyne pump curve. Use of a flow restriction
orifice on the pump outlet, in accordance with the pump Supplier’s recommendation, may aid in
ensuring that the flow does not exceed the “break”.

5.4.2 Low Flow Protection

Sundyne pumps are sensitive to low flow and require special attention to protect against low flow
problems. The following features shall be incorporated in the design:

a) Minimum flow protection, such as a flow control valve. Either feature shall recirculate pumped
fluid from upstream of the discharge check valve, back to a tank or vessel.

b) System control valves shall be located within 1.5 m (5 ft.) from Sundyne pumps. If this is not
practicable, the pump Supplier shall be consulted for a mutually agreeable minimum.

5.4.3 Materials

i. Material for higher speed Sundyne pumps (greater than 3000 rpm) shall be carefully reviewed.
Sundyne pumps develop very high localized velocities. Performance depends upon

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BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

maintaining close clearances. In general, materials for Sundyne pumps shall be at least one
grade above that which is required in slower speed, standard pump designs (refer to §5.12 of
this Specification). Unless otherwise approved by the Owner, Sundyne pumps shall not be
used in abrasive or slurry services.

ii. Sundyne pumps in even mildly corrosive service shall have Type 316 stainless steel diffuser
parts.

5.4.4 High Suction Pressure Application

For applications in which the suction pressure exceeds 1380 kPa (ga) (200 psig), Sundyne’s “Model
LMV-311” shall be provided with a pre-lubrication kit for the gearbox and thrust bearing lubrication.

5.5 Vertical Cantilever Pumps

Vertical cantilever type pumps with shaft support bearings outside the pumped liquid are preferred for
abrasive, sludge and slurry services, provided the cantilever shaft length does not exceed 3m (10 ft.).

5.6 Other Vertical Pumps

Other types of vertical pumps may be used where the above preferred design is unable to meet NPSH
requirements, or their use is dictated by the applications, e.g. vertical can pumps, vertical sump pumps,
multistage vertical turbine pumps, etc. BMPS-G2 (Centrifugal Pumps for General Refinery Service)
and BMPS-G4 [Vertical Centrifugal Pumps (Inline, Sump, Barrel, and Turbine)] shall apply where
applicable.

5.7 Sealless Pumps

i. Sealless pumps, such as magnetic drive or canned motor types, may be used in hazardous
services where no leakage of pumped product is acceptable under any conditions, and where
the pumped fluid is clean and lubricating. The pumps shall be fully instrumented to protect
against dry running, excess temperature rise, bearing wear and the failure of the containment.
Selection of sealless pumps is subject to the Owner’s approval.

ii. For services with vapor pressure greater than 100 kPa (abs) (14.7 psia), such as LPG, the
Contractor shall jointly review with the pump Supplier the adequacy of the recirculation line
and external cooling line installation to prevent liquid flashing and dry running.

iii. The pump construction shall conform to the requirements of ‘API 685’.

5.8 Sump Pumps

i. Vertical centrifugal (line-shaft or submersible) sump pumps with bearings lubricated by the
pumped liquid are not acceptable for process services, unless otherwise agreed by the Owner.
They are acceptable for sump services only when handling non-gritty liquids, such as sanitary

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BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

sewage sumps. For other sump services, self-priming horizontal centrifugal pumps,
progressive cavity pumps, vertical cantilever-shaft or vertical submersible pumps are
preferred.

ii. Where vertical pumps with bearings lubricated by the pumped fluid are supplied, they shall be
fitted with low flow shutdown devices.

5.9 Oily Water Separator Service

i. For pumps in oily water separator service, consideration shall be given to selecting pump types
that minimize emulsification of the oily water mix. Slow speed pumps with large internal flow
passages, such as the Hidrostal screw centrifugal pump or progressive cavity pumps, should
be reviewed for suitability.

ii. Where progressive cavity pumps are selected, the Contractor shall indicate on the data sheets
if the presence of aromatics is anticipated, in order to allow correct selection of pump materials.

5.10 Cooling Tower Sump and Basin Design

i. Sump and basin design for large cooling tower pumps above 700 m 3/h (3100 US gpm) shall
be in accordance with Hydraulic Institute Standards. Sump and basin model flow studies shall
be carried out for all applications in which pump rated capacity exceeds 4500 m 3/h (20,000
US gpm).

ii. In all cases, the Contractor shall review technical acceptability of final sump and intake design
with the equipment Supplier. The intake design and submergence shall be in accordance with
Hydraulic Institute Standard guidelines for avoidance of vortex formation.

5.11 Ebullating Pumps

5.11.1 General

i. Ebullating Pump is a very special pump employed in no. 1 Residue Hydrocracker Unit
(1RHCU) of Bapco Refinery and operates as recirculating pumps of the Ebullated Bed
Reactor. The operating conditions of the pump (the same of the reactor) are very critical for
what concerns temperature and pressure which can reach respectively around 900°F (480°C)
and 3,200 psig (220 barg).

ii. The Contractor shall utilize Licensor specifications for the design, sizing, procurement and
installation of these pumps in 1RHCU.

iii. The Ebullating pumps are available on the market, internal type, with the impeller and inlet
diffuser inside the reactor bottom, and external type where pump is connected to reactor
bottom by means welded process piping.

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BMPS BMPS-G1
Bapco Modernization Program Specifications Revision 0, October 2015

iv. The pump impeller and diffuser shall be capable of passing liquid containing catalyst solids up
to 1/32 inches (0.8 mm) in diameter by 5/32 inches (4 mm) in length.

v. The unit shall be suitable for forward and reverse rotation operation.

vi. Considering the above operating conditions and that the pump is un-spared, its design must
be highly reliable.

vii. The pump type is similar to a vertical pump and mainly consists of three assembled sections:

a) Hydraulic side, in contact with the process fluid, composed by pump casing, the inlet
diffuser and a single impeller mounted directly on electric motor shaft.

b) The driver consists of an electric motor open winding type, rotor and stator are installed
inside a forged alloy steel pressure retaining housing, completely filled with seal oil.

c) The third section, flanged to the opposite end of the pump casing, consists of an oil-
water heat exchanger.

The three sections of the ebullating pump are flanged and assembled together by using
“Superbolts” type and Grayloc gaskets.

viii. The pump is equipped with a magnetic speed pickup which provides a signal for speed readout
and provision for checking rotation.

ix. The temperature probe monitors the temperature of the oil circulating internally, as the oil
returns to the heat exchanger.

x. A Thermal analysis shall be carried out for the pump, in particular for the casing and the motor
housing. The scope of Thermal analysis is to establish the followings:

a) Operating temperature profile of the pump case and motor housing.

b) Heat flow from the hot pumped product into the motor.

c) Operating temperature gradient across the gasket joint.

xi. The thermal analysis shall content:

a) Finite Element Model (FEM)

 Boundary conditions

 Temperature dependent material properties

 Nodes and thermal gradient paths

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b) Summary of result

 Temperature gradient

 Heat flow

c) Finite Element Plots

 Elements and boundary conditions

 Reactor Recycle Pump operating temperature

 Thermal flux

 Seal ring operating temperature

d) Convection coefficient calculations.

5.11.2 Material of Construction

The materials normally used for these pumps are the following:

 Pump casing: A-182 GR. F347

 Impeller: ASTM A-351 GR.CF3M Tungsten carbide hardened face

 Inlet diffuser: ASTM A-351 GR.CF3M Tungsten carbide hardened face

 Motor housing: A-182 GR. F347.

5.11.3 Auxiliaries

i. The following main auxiliary packages shall be integral parts necessary for the good operation
of the Ebullating pump:

a) Seal oil injection system

b) Oil dryer packaged skid

c) VFD system

ii. The oil injection system shall operate to comply mainly with the following pump requirements:

a) Lubrication of the pump bearings.

b) Cooling of the motor

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c) Seal barrier to avoid migration of the process fluid into the pump

iii. The oil injection system shall consist mainly of one skid with (2x100%) API 675 automatic
controlled volume pumps complete of filters (2x100%) 5 micron filtration degree, and suction
and discharge pulsation dampeners. All material and piping in contact with the oil shall be in
SS AISI 316. The high pressure oil piping shall be provided with double block valves.

iv. The main purpose of the Oil Dryer Package, is to remove the water, particulate and other light
volatiles from seal oil in order to obtain an oil clean, dielectric (it will be in contact with the
winding of the pump electric motor) and without impurity.

v. The Oil Dryer Package shall consist mainly of one skid with a vacuum chamber, internally
provided with dispersion system consisting of inert elements followed by a dispersing tray to
increase the surface of the oil exposed to vacuum. The unit is maintained under vacuum by
two vacuum pumps working in series. Once the oil is degasified and dehydrated (an
hygrometer will check that the oil does not contain water), it is removed from the vacuum
chamber by the discharge pump and sent to the outlet through the final filter which removes
solid particles below to 5 microns in size.

vi. The oil purifier shall be equipped with a full flow by-pass valve which allows, closing the unit
outlet valve, to recirculate the oil for multiple passes inside the vacuum chamber of the system.

vii. The VFD system will allow the pump to operate at different speed in accordance with process
requirements.

5.12 Materials

i. The Contractor shall specify materials for the component parts of centrifugal pumps in
accordance with the requirements of API 610.

ii. The Contractor shall obtain the Owner’s approval for use of other materials which, in his
experience, would provide better service under process design conditions.

iii. In selecting the pump and mechanical seal materials, the Contractor shall take into account
the limits of operation specified in §4.3 of this Specification.

Selected case and impeller materials shall be shown on BMPS-SF-A-612 (Material Selection
Basis).

5.13 Vents and Drains

i. Vents, drains and auxiliary piping shall meet the requirements of BMPS-L1 (Refinery Piping)
and BMPS-L2 (Piping Line Classes) and shall conform to the drawing BMPS-SD-G-10289
(Pump Case Vent and Drain Connections).

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ii. Vents are required on all pumps or adjacent piping, unless the system is self-venting. The
design of the vents shall conform with the following:

a) Vents from pumps handling hydrocarbon stocks above 175°C (350°F), or with vapor
pressures in excess of 100 kPa (abs) (14.7 psia) at operating temperature, or liquids
containing H2S, shall be run in closed piping to the relief system or another closed
system, as approved by the Owner.

b) Pumps taking suction at pressures lower than atmospheric shall be vented to a line or
vessel under a pressure as low as, or lower than, pump suction. All LPG pumps shall
be vented both to the relief system and back to the vessel.

c) A vent with a manual isolating valve shall be installed on all vertical pumps to allow
release of vapor or gas from the mechanical seal chamber prior to startup.

iii. A casing drain and stuffing box drain shall be provided on all pumps.

5.14 Minimum Flow Bypass

i. Boiler feed pumps shall be provided with automatically-operated, modulating-type minimum

flow bypasses.

ii. Self-contained, automatic, modulating-type valves, such as Yarway/Keystone ARC valve or

equivalent, are preferred. The final selection of the valve is subject to the Owner’s approval.

iii. Valve sizing shall be based upon the greatest between 110% of minimum continuous stable
flow, or 110% of the minimum continuous thermal flow, as defined in ‘API 610’.

iv. The Contractor shall verify with the valve Supplier that the bypass backpressure is sufficient
to prevent erosion/cavitation damage due to flashing across the bypass valve.

5.15 Pump Warm-up

i. For protection from thermal shock, automatic-start spare pumps handling fluids above 150°C
(300°F) shall be kept warm (e.g. by arranging a bypass around the discharge check valve with
a restriction orifice to prevent reverse rotation).

ii. All large single and multistage pumps handling fluids above 200°C (390°F), with complex
casing shapes, such that the possibility of formation of stagnant fluid areas makes them
unsuitable for warm-up by discharge bypass alone, shall be provided with a warm-up piping
system designed in consultation with the pump Supplier.

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5.16 Suction and Discharge Piping Design

i. Suction and discharge piping shall be designed in accordance with the latest edition of the
‘Hydraulic Institute Standards for Centrifugal, Rotary and Reciprocating Pumps’ and BMPS-
L1 (Refinery Piping) and BMPS-L2 (Piping Line Classes).

ii. Suction lines shall not permit vapor accumulation, nor result in unequal flow to the inlet eye of
double suction pump impellers.

The length of straight pipe upstream of the pump suction nozzle shall be in accordance with
pump Supplier’s recommendation. The use of flow straighteners is subject to the Owner’s
approval.

iii. Suction lines to vertical pumps should take suction from above the bottom of any vessel.

5.17 Pressurized Lubricating System

Pressurized lube systems in accordance with BMPS-K8 (General Purpose Pressure Lubrication
Systems) or BMPS-K9 (Lubrication, Shaft Sealing and Control Oil Systems for Special Purpose
Applications), as applicable, shall be supplied when serving critical pump trains (pump, driver, gear
increaser, hydraulic turbine, etc.) whose energy density (see Table 10, bullet c) of API 610) is 4.0×106
kW/min (5.4×106 hp/min) or higher, or are in critical services, such as high pressure reactor feed, boiler
feed water or cooling tower circulation, or when recommended by the pump or driver Supplier.

5.18 Centrifugal Pump Data Sheets

Data for API and non-API centrifugal pumps shall be entered on standard form BMPS-G-50301
(Centrifugal Pump – Data Sheet).

6. POSITIVE DISPLACEMENT PUMPS

6.1 Rotary Pumps

i. Rotary Pumps shall be in accordance with ‘API 676’ and BMPS-G7 (Rotary Pumps).

ii. External bearings and timing gears are required in process services. Internal bearings are
acceptable for lube-oil services and hydraulic systems only.

iii. Data for rotary pumps shall be entered on standard form BMPS-G-50305 (Rotary Pump – Data
Sheet).

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6.2 Controlled Volume (Proportioning) Pumps

i. Controlled volume (proportioning), pumps shall be in accordance with ‘API 675’ and BMPS-
G6 [Controlled Volume Positive Displacement (Metering) Pumps].

ii. Diaphragm-type pumps are preferred, gear-type may also be employed. Packed plunger type
is prohibited in services which are toxic, have odor problems, present corrosion hazards or
other personnel hazards.

iii. Data for controlled volume pumps shall be entered on standard form BMPS-G-50304
(Proportioning Pump – Data Sheet).

6.3 Reciprocating Pumps

i. Reciprocating pumps shall be in accordance with ‘API 674’ and BMPS-G5 (Reciprocating
Pumps).

ii. Data for reciprocating pumps shall be entered on standard form BMPS-G-50303
(Reciprocating Pump – Data Sheet).

7. SPECIAL REQUIREMENTS FOR FIRE WATER PUMPS

7.1 Pump Design

Fire water pumps shall be supplied in accordance with ‘NFPA 20’ and ‘API 610’ as modified by BMPS-
G2 (Centrifugal Pumps for General Refinery Service)’. Fire water pump selection and installation
design shall also comply with the requirements of BMPS-S5 (Loss Prevention Basis of Design, Fire
Protection and Safety Systems).

7.2 System Pressures

The suction and discharge pressures specified on the pump data sheet will be those required at the
terminal points of the pump package. The Contractor shall make allowance for internal losses from
pipework, strainers, changes in elevation, etc., when determining pump pressures and head.

7.3 Pump Type

i. Horizontal centrifugal pumps shall be used, provided the pressure available at the pump
suction is at least atmospheric below 100% rated capacity conditions.

ii. The NPSH available shall exceed the NPSH required by at least 1m (3 ft) at all points on the
pump curve from minimum continuous flow to 150% of the rated capacity.

iii. Multiple pumps with the same characteristics are preferred.

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7.4 Suction Line Sizing

Suction piping components shall be sized for at least 150% of total connected pump rated capacity,
but not less than that specified in ‘NFPA 20’.

7.5 Relief Valve

i. An external relief valve shall be provided in the discharge line of all firewater pumps, whether
driven by constant- or variable-speed drives. The set pressure shall be chosen to protect the
downstream pipework and to protect the operation and integrity of all firewater appliances in
the system.

ii. The sizing and location of relief valves shall comply with ‘NFPA 20’ and shall accommodate
pump shut-in pressures, determined with maximum suction pressure coincident with maximum
speed (trip speed if appropriate).

iii. Relief valves shall be in accordance with BMPS-J11 (Relief Valves).

7.6 Low Flow Protection

i. Low flow relief or leak-off valves will be provided by the Owner downstream of each pump to
maintain the minimum continuous stable flow (as defined in ‘API 610’) with no flow into the
firewater system.

ii. The capacity of the relief or leak-off system shall take into account any permanent internal
flows, such as for diesel engine cooling, and shall be specified by the Contractor, in
consultation with the pump Supplier.

8. PUMP DRIVERS AND DRIVE GEARS

8.1 Electric Motors

i. Motor drivers and electrical items shall conform to BMPS-P3 (Electrical Requirements for
Package Units). All electric motors shall be supplied in accordance with the following project
specifications, as applicable:

 BMPS-P18 (HV Induction Motors)

 BMPS-P19 (LV Induction Motors).

ii. Motors shall meet the noise limitations of BMPS-A21 (Noise Limitations for Equipment).

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8.2 Steam Turbines

i. Turbine drivers shall meet the requirements of ‘API 611’ as modified by BMPS-K5 (General
Purpose Steam Turbines) or ‘API 612’ as modified by BMPS-K6 (Special Purpose Steam
Turbines).

ii. Standard form BMPS-K-50403 (General Purpose Steam Turbine – Data Sheet) shall be used
in specifying general purpose steam turbine requirements.

iii. Standard form BMPS-K-50404 (Special Purpose Steam Turbine – Data Sheet) shall be used
in specifying special purpose steam turbine requirements.

iv. Turbines shall meet the noise limitations of BMPS-A21 (Noise Limitations for Equipment).

8.2.1 Economics

In selecting continuously operating turbines, due consideration shall be given to the economics of
steam usage considering the specific steam consumption of the turbine.

8.2.2 Exhaust Relief Valve

i. Relief valves shall be installed on the exhaust piping of turbines to provide full flow relief when
the inlet steam pressure is greater or equal to 1000 kPa (ga) (150 psig), or when the turbine
is on automatic or remote start.

ii. Turbines with steam inlet pressure below 1000 kPa (ga) (150 psig) shall have exhaust casing
rated for steam inlet pressure in accordance with BMPS-K5 (General Purpose Steam Turbine).

8.2.3 Non-condensing Turbines

i. All non-condensing turbines shall be suitable for exhausting to a low pressure steam system
and fitted with an atmospheric exhaust when they are to be automatically started. Startup shall
be with exhaust to atmosphere and subsequently switch to exhaust into the steam system.

ii. Unless otherwise specified, non-condensing standby turbines, suitable for atmospheric
exhaust and provided with automatic startup shall be used in the following services:

a) Any turbine whose only purpose is to protect equipment during an emergency shutdown
following a power failure.

b) Where the turbine is so remote from the available exhaust system as to render the
recovery of the exhaust economically unjustified. In this case the exhaust shall be fitted
with a suitable noise attenuation device, which shall meet the requirements of BMPS-
K12 (Acoustic Enclosures for Machines).

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8.2.4 Automatic Start Turbines

i. Control valves for automatic start of turbines shall be located in the steam line immediately
ahead of the turbine.

ii. Single-stage, high back-pressure turbines shall be vented to the low pressure header when
turbine is not operating, to prevent damage to shaft packing while stopped. Vent system shall
include a control valve actuated by the automatic starting circuit, and check valves in the
exhaust and vent lines. It is not necessary or desirable to keep any pressure in the turbine
casing, or to keep it hot.

iii. Multi-stage turbines should be manually started.

8.3 Special Requirements for Fire Water Pump Drivers and Installations

Drivers and driver installations shall follow the requirements of ‘NFPA 20’ and BMPS-S5 (Loss
Prevention Basis of Design, Fire Protection and Safety Systems) except as noted in §8.4. Internal
combustion engine drivers for fire pumps shall meet the following requirements:

i. A satisfactory engine jacket water temperature shall be maintained by a closed-loop radiator

cooling system, designed for operation at full load at the maximum ambient dry-bulb
temperature for the respective location.

ii. Engine lubrication shall be by a full-flow pressure system with wet sump, strainer, pump,
piping, oil cooler and full-flow type oil filter. The pump shall be driven from the engine
crankshaft.

iii. The pump unit shall be directly connected to the driver by a spacer-type flexible coupling. The
Owner’s approval is required for the use of gear drivers on all horizontal centrifugal pumps.
Right-angle gear drivers will be permitted for the vertical turbine pumps driven by diesel
engines or steam turbines. Right-angle gearboxes shall have an AGMA service factor SF = 2,
based on maximum driver rating.

iv. Engines specified for installation in a hazardous area shall be provided with the protection
equipment, preferably in accordance with ‘EEMUA Publication 107’ or as mutually agreed
between the Supplier and the Contractor.

v. An engine governor shall be provided in accordance with NFPA 20 to prevent excessive speed
should the pump lose suction.

vi. All engine controls shall be provided with suitable stamped or engraved stainless steel
nameplates identifying each control. Engines shall be provided with local readouts of cooling
water temperature, oil pressure, fuel pressure, tachometer and engine hour meter.

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vii. Each firewater pump package shall be provided with a local control panel located on the
package and suitably protected against vibration.

8.4 Gear Units

i. Gears (not integral with the pump such as Sundyne) shall be in accordance with the
requirements of Table 1.

TABLE 1: Pitch Line Velocity Limitations for Pump Gears

Driver Power (kW)

Pitch Line Velocity (m/s)
less than 750 750 and above

less than 25.4 API 677 API 677

25.4 and above API 677 API 613

a) General Purpose Gears shall comply with ‘API 677’.

b) Special Purpose Gears shall comply with ‘API 613’.

ii. Service factor for gear reducers on crank-driven power pumps, e.g. high pressure condensate
injection pumps, shall be two or greater.

iii. All gear units shall be provided with an air purge. Normally, instrument air will be available and
satisfactory for this purpose. The air connection shall have a Fischer-Porter rotameter “Model
10A3135H”, or the Owner’s approved equivalent, to control and indicate flow.

9. SPARE ROTORS
For machinery over 750 kW (1000 BHP) and others as designated by the Owner, the Contractor shall
obtain proposals for spare rotors and review them with the Owner prior to placement of orders for the
machine.

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