East Asia Manila Inc. Ss QUPMENTENGNEERS HANDBOOK 2.1 PUMPS GENERAL 2.1 PUMPS GENERAL 2.1.1 Classification of Dynamic Pumps Pumps 1 ----! DISPLACEMENT | u DYNAMIC CENTRIFUGAL mann H soc res MIXED Flow, |_[ SINGLESUCTION NONPRIMING ~) | SEMI-OPEN MULTISTAGE L_ CLOSED PSINGLE STAGES r ‘SELF-PRIMING oo H JET (EDUCTOR) yess urT SPECIAL EFFECT Cd HYDRAULIC RAM L ELECTROMAGNETIC Figure 2.1-1 Classification of Dynamic PumpsCHAPTER 2 PUMPS 2.1.2 Classi ation of Displacement Pumps. GS East Asia Manila Inc PUMPS ROTARY SINGLE ROTOR MULTIPLE ROTOR| ‘SCREW PERISTALIC E rose DismAceNENT PISTON, r sniex sreaMe-DOuBkE ACTING -simniex SINGLE ACTING DUPLEX rower —[ H DOUBLE ACTING TRIPLEX [oraranacon LH c CIRCUMFERENTIAL PISTON SCREW Figure 2.1-2 Classification of Displacement PumpsGS East Asia Manila Inc. ROTATING EQUVENTENGNEERSHANOEOOK 2.1 PUMPS GENERAL 2.1.3 Pump Selection Criteria Selecting pumps at the very least, the designer must: * Define and understand the system application, and perform a hydraulic or fluid system analysis. This activity is normally done by Process Engineering Group. + Determine the basic pump and driver type for the application * Determine the pump size and its design operating point * Decide on pump design considerations to maximize the system’s energy efficiency. Additional items to consider for a complete system understanding are: * Whether the system will be operated continuously or in an intermittent mode +The system’s flow type (e.g., constant or variable volume) + Aneed to provide continuity of service or redundancy for any equipment (N+1) + Aneed for future capacity or expansion of the system 2.1.3.1 Centrifugal Pumps This is the most common type of pump used in the process plant. Centrifugal pumps are sub- divided into number of types according to application. See Figure 2.1-1 for centrifugal pump types. Approximately 80% of all pumping application can be met with centrifugal pumps. Operating Conditions: * Flow: 4.5 to 22712.5 m’/hr (20 - 100,000 GPM) ‘* Temperature: from Cryogenic to 454 C (850 F) * Discharge Pressure: Atm to 422 kg/cm’g (6,000 psig) Advantages: * Cost: Compared to other alternatives, centrifugal pumps usually are lowest in initial cost and in operating cost. * Simplest: Few moving parts leads to relatively low maintenance costs. * Controls: Capacity control is simple and direct by throttling the discharge head developed bu the pump. Variable motor speed can be used, the advantage is the energy savings. Motor speed control for slurry pumps is the preferable method because it avoids control valve erosion. * Fluids: Slimes and slurries can de design for if necessary. Limitations: * Viscocity: Pumping of high viscosity fluids (above 3,000 SSU) is prohibitive with centrifugal pumps.GS East Asia Manila Inc 10__ CHAPTER 2 PUMPS OTATINGLQUPMUNT ENGINEER HANOBOOK ‘* Capacity: Low capacity, high head services are difficult to satisfy. ‘Efficiency: Centrifugal pumps are generally less efficient than other types of pumps. Efficiency are normally 60-75% but in small capacities it maybe as low as 20%. High speed Sundyne pumps operate at low efficiencies, but have the ability to produce high head requirements with single stage 2.1.3.2. Reciprocating Pumps Reciprocating pumps are positive displacement pumps. It produces pressure by the motion of a piston in a cylinder. Types of reciprocating pumps are shown in Figure 2.1-2. Reciprocating pumps find greatest application in low flow, high head services. Advantages: ‘© Fluids: Since horsepower is a function of discharge pressure and volumetric flow rate, a wide range of fluids with various specific gravities maybe handled. Limitations: © Cost: Both initial and maintenance cost are higher than any other type of pumps © Control: Discharge pressure and flow pulsation makes control difficult ‘+ Space: Space requirements are large. 2.1.3.3 Rotary Pumps Rotary pumps are also positive displacement pumps. Types of rotary pumps are shown in Figure 2.1-2. These types of pumps should be considered for high viscosity applications and when continuous flow against varying heads is required. Advantages: © Viscosity: for high viscosity applications ‘© Non Pulsating: Nearly constant, non pulsating flow can be delivered against varying discharge pressure Limitations: ‘© Cost: Both maintenance and initial cost are high ‘© Control: Control of positive displacement pumps is complex ‘* Solids: liquids should be clean to avoid rapid wearing. An application of a rotary type pump suitable in the solid service is gear pump.GS East Asia nila Inc, Table 2.1-1 Character 2.1 PUMPS GENERAL__11 of Various Kinds of Pumps Construction Pump Type | Construction Style Remarks p Tv vy Characteristics ih . er canti Centrifugal | Single-stage overhung, [impeller cantilevered beyond | - 4) varies with head (horizontal) | process type bearings two-stage overhung | MO impellers cantilevered | used for heads above single- 8 8 | beyond bearings stage capability single-stage impeller | impeller between bearings; | used for high flows to 1083R between bearings | casing radially or axially spit | (330 m) head casting patterns designed with chemical thinsectionsorhigh-ost | MV /0W pressure and alloys Pe id designed with rge ow Tow speed and adjustable axial slurry eines clearance; has erosion control passa features no stuffing box; pump ani 0 stuffing box; pump ané | oy head capacity limits when canned motor enclosed in a pressure mon used in chemical services mutate | monte toated in bat tat] have moderate temperate rizontally spi ozs ave moders tong of casing pressure ranges Centrifugal | 5s te stage, process ‘used to exploit low net positive (vertical) we vertical orientation section head (NPSH) ves requirements many stages with low head per multistage ¥y stages with low head Per | joy, cost instalation stage inline Installation, similar inline inline installation, similar £021 jowcost installation speeds to 380 rp5, heads to__| high head/low flow; moderate hi ich speed $5800 ft (1770 m) costs ump casing immersed in sump for | 15 coge ea5y priming and installation rmukistage, deep well_| long shafts used for water well service aaa propeller propeller-shaped impeller vertical orientation Turbine fluted impeller. Flow path capacity independent of head; regenerative resembles screw around periphery low flow/high head performance Reciprocating piston, plunger slow speeds driven by steam engine cylinders or motors through crankcases ‘consists of small units with ‘diaphragm and packed plunger metering precision flow control system _| types used for chemical slurries; can diaphragm no stuffing box be pneumatically or hydraulically actuated Rota for high-viscosity, high-flow rv screw 1,2, or 3 screw rotors for high viscosity, high-fl high-pressure services Tor high-viscosity, moderate- gear intermeshing gear wheels, pressure / moderate-flow12__ CHAPTER 2 PUMPS. Table 2.1-2 Compat n Table for Pump Types GS East Asia Manila Inc Parameter Centrifugal Pumps | Reciprocating Pumps Rotary Pumps Optimum Flow and Medium/High is Low/Medium Pressure Capacity, Low Capacity, Capacity, High Pressure Applications Low/Medium Pressure Low/Medium Pressure Maximum Flow Rate 100,000+ GPM 10,000+ GPM 10,000+ GPM Low Flow Rate No Yes Yes Capability Maximum Pressure 6,000+ PSI 100,000+ Psi 4,000+ PSI Requires Relief Valve No Yes Yes th or Pul sideiaiialaied Smooth Pulsating Smooth Flow Variable or Constant Variable Constant Constant Flow Self-priming No Yes Yes Space Considerations Requires Less Space Requires More Space Requires Less Space Costs Lower Initial Lower Maintenance Higher Power Higher Initial Higher Maintenance Lower Power Lower Initial Lower Maintenance Lower Power Fluid Handling Suitable for a wide range including clean, clear, non-abrasive fluids to fluids with abrasive, high-solid content. Not suitable for high viscosity fluids. Lower tolerance for entrained gases Suitable for clean, clear, non-abrasive fluids. Specially-fitted pumps suitable for abrasive-slurry ser e, Suitable for high viscosity fluids, Higher tolerance for entrained gases Requires clean, clear, non-abrasive fluid due to close tolerances. Optimum performance with high viscosity fluids. Higher tolerance for entrained gasesEast Asia Manila Inc. Se xr NGNEERSHANOSOOE 2.1 PUMPS GENERAL__13 2.1.4 Pump Selection Ranges. CAPACITY, m’'/h 1 10 100 3,000 10,000 100,000, 1,000 10,000] x__ RECIPROCATING CENTRIFUGAL 100 3 PRESSURE, Ib/in” PRESSURE, bar 100 10 1 10 700 1,000 10,000 100,000 CAPACITY, US gal/min Figure 2.1-3 Pumps Selection RangesGS East Asia Manila Inc 14__ CHAPTER 2 PUMPS. roratmatcuns NGS OOK Table 2.1-3 Typical Performances of Various Kinds of Pumps Capacity MaxHead —MaxP—~=«NPSH~=~=CMaxT’—efcency Tee Se (gom) o) (a (eo Ca co Centiogal Single-stape overhung 75-5,000 292 600656197 851 2080 (horizontal) two-stage overhung, 351,200 1384 600 656220 asi 2078 single-stage impeller 15.40.00 1088 980 656-219 ores: 3090, between bearings chemical 1000 239 200 398197 401 2075 slucry 1000 334 600 492289 asi 20.80 canned 320000 4821» 10.000 6.56197 1004 2070 mutistage horizontal soit ——20-11,000 «2495, 3000 656197 401-500 «65.90 multistage, barel type 209,000 S495 5000 656-197 851, 4075 Centitgal single stage 20:10,000 808 600 098197 653 2085 (vertical muttstage 2080000 6008 700 098197 500 25.90 inline 2032000705 500 656197 500 2080 high speea 5-400 #07 2000 787-39 © 500 10-50 sumo 10-700 197 200 098-220 4575 multistage deep well 5-400 6008 2000 098-197 ac 30-75 ial propeller 20-100,000 39) 1506.56 49 65-85 Turbine Regenerative 1.2000 2493 1500 656520 248 55.85 Reciprocating piston, plunger ao19000 13x10 >50,000 2.2 554 65.8 metering 040 170x10° 50,000 351 S72 20 diaphragm 4100 13x10 3500 at 500 20 Rotary serew 120006 79x10' 3000.8 00 50-80 gear 15000 14,55 500384 653 50.80