STUDY CASE

There are several issues at the plant / plant related

to Mechanical problems and one of the problems is
as follows:
 38P001 steam condensate pump is a horizontal centrifugal
pump that functions to transfer the steam condensate
from the steam condensate tank to several existing
equipment at the plant, which is used in the heating
process (as a reference can be seen in the flow diagram
below). Because there is a need in the plant or there is an
addition of objects or equipment that must be heated by
steam condensate, the pump has an addition or change to
the "pump head".
 RESPONSE:
 To increase the head of the pump there are several alternatives:
 Change the impeller (Impossible)
 Consequences:
 The consequence of increasing the size of the impeller is the selection
of the motor capacity which must be larger. If the motor is not
suitable, there will be overload and overheating. If the motorbike is
upgraded, it is necessary to review electrical cable and other electrical
components.
 Add a booster pump
 Consequences:
 Pipe modification and there is an additional control panel for the
booster pump itself
 Replace the pump
 Consequences:
 Calculation from the beginning A little modification pipe
 Old pump existing is not used
 Add a booster pump
 Assumption of field conditions :
 Pipe line: 4 in
 Existing pump flowrate 38P001: A m3/hr
 Design Pressure of existing pump 38P001: 5 bar (end of use)
 New Equipment :
 Required pressure: 4 bars (end of use)
 Flowrate new equipment: B m3/hr
 With the addition of equipment, the required flow will increase.
 New flow = (A m3/hr + B m3/hr). This will affect the discharge
pressure of the existing pump, where for the centrifugal pump, if the
flow increases, the discharge pressure will drop.
Existing system

Pressure : 5 bar
Flowrate : A
m3/hr

Pump 38P001
Pressure : 5 bar
Flowrate : A m3/hr
 New Equipment
Modified system Required Pressure : 4 bar
Flowrate : B m3/hr

Steam Condensate
tank

Pressure : 5 bar
Booster Pump Flowrate : A
Design Pump 38P001 m3/hr
Pressure : 4 bar
Pressure : 5 bar
Flowrate : A m3/hr
Flowrate : A m3/hr
 Replace the pump
 Suction calculation
 Pressure drop in fitting (X)

 Pressure drop in pipe (Y)

 Head loss at suction = (X + Y)

 Net Positive Suction Head Available (NPSHa) = (5)

 NPSHa > NPSH req

 Replace the pump
 Discharge calculation
 Pressure drop in fitting (N)

 Pressure drop in pipe (M)

 Head loss at discharge = (N + M)

 Required pumping head, H required = (ΔHfs + ΔHfd + ΔP + ΔZ)=(9)
 Selected pumping head, H selected = Hrequired * 1,25
 Shaft Efficiency ζshaft : K
 Shaft power, Wshaft = Hselected*M*g/ζ
 Motor Efficiency ζmotor : L %
 Motor power, Wmotor = Wshaft/ζmotor
THANK YOU