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guidance. The user is strongly advised to contact the Technology Manual Sponsor to
determine the appropriate subject matter expert for consultation on applicability to the
users specific case.
Contents
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This section discusses engineering principles, pump types, application and selection
criteria, and describes two commonly used reciprocating pumps. See Section 1100
for troubleshooting information.
Engineering Principles
320
Pump Types
321
330
331
332
Power Pumps
333
334
300-2
300-4
300-7
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310
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300-1
Pump Manual
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Fig. 300-1
Figure 300-2 depicts the suction stroke of a plunger pump. When the plunger moves
away from the head end of the cylinder, the discharge check valve is held closed by
the higher pressure in the discharge pipe compared to the lower pressure in the
liquid cylinder. This lower pressure in the liquid cylinder also causes the suction
valve to be opened by the higher pressure in the suction line. Fluid then flows into
the cylinder until the plunger reaches the end of its travel.
300-2
May 2007
Pump Manual
Fig. 300-3
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Fig. 300-2
Figure 300-3 depicts the discharge stroke of a plunger pump. As the plunger moves
toward the head end, the increasing pressure in the cylinder closes the suction valve.
The pressure in the cylinder continues to rise until it exceeds the pressure in the
discharge line and the discharge valve opens, releasing the volume of fluid
displaced by the plunger.
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Unlike the centrifugal pump, which is a kinetic machine, the reciprocating pump
does not require velocity to achieve pressure. This is one of the reciprocating
pumps advantages, particularly for abrasive, slurry, and high-viscosity applications. High pressures can be obtained at low velocities, and fluid capacity varies
directly with pump speed.
The discharge pressure of a reciprocating pump is only that required to force the
desired volume of liquid through the discharge system. Within the constraints of
pump construction, the maximum pressure developed for gas-driven pumps is
limited only by the differential gas pressure available; for crank-driven pumps, the
driver torque is the only limit.
The flow of liquid from a reciprocating pump pulsates, varying both in flow rate and
pressure. As the piston or plunger moves back and forth in the cylinder, alternately
opening and closing the suction and discharge valves, a cyclic pulsation is set up in
the suction and discharge lines of the pump. Figure 300-4 shows the changes in flow
rate as a function of crank angle for duplex, triplex, and quintuplex single-acting
pumps. These changes become less severe as the number of stages increases.
May 2007
300-3
Pump Manual
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Fig. 300-4
300-4
May 2007
Pump Manual
Fig. 300-5
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300-5
Pump Manual
Diaphragm Positive Displacement Pump (Shown here as Double Diaphragm positive Displacement Pump)
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Fig. 300-6
2.
Direct-acting, gas-driven
b.
a.
Cylinder orientation
a.
Horizontal
b.
Vertical
a.
b.
c.
3.
Type of drive
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1.
4.
300-6
Simplex
b.
Duplex
c.
Triplex
d.
Quintuplex, etc.
May 2007
Pump Manual
5.
Type of action
a.
b.
Figure 300-7 illustrates these classifications. (Metering pumps that use a reciprocating motion are described in Section 500 of this manual.)
Reciprocating Pump Sub-types Permission granted. Chemical Engineering,
September 21, 1981.
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Fig. 300-7
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Single-acting pumps discharge on either the forward or return stroke of the piston or
plunger; every cycle of the pump displaces only one volume of liquid. In doubleacting pumps, liquid is discharged on both the forward and return stroke of the
piston. Plunger pumps are only single-acting; piston pumps can be either single- or
double-acting. Figure 300-5 illustrates this pump action.
The terms simplex, duplex, and multiplex refer to the number of piston-and-rod
assemblies in a pump. Simplex pumps have one piston-and-rod assembly; duplex
pumps have two; multiplex pumps have three or more.
May 2007
300-7
Pump Manual
2.
3.
4.
Steam for pumping is available at little or no cost (when, for example, exhaust
steam from pumps is used to heat the pumped product).
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Duplex gas pumps are more generally used than simplex because of their larger
capacity, smoother discharge, and simpler valve mechanism. Duplex pumps are also
made in a greater variety of sizes and types than are simplex pumps, which were
developed largely for vacuum or other low-pressure service.
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The simplex is usually slightly more efficient than the duplex and has one less set of
packing. Simplex pumps are usually preferable in vacuum or other services where
gas or vapor must be handled. Duplex pumps may short-stroke and fail to clear
themselves of vapor. In fact, they may vapor lock and come to a complete stall.
Because the simplex valve mechanism prevents short-stroking, close-clearance
pumps, designed especially to handle gas or vapor, are commonly made only in the
simplex type.
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Reciprocating gas pumps range in size from a small 3 2.75 3-ft. pump, rated to
handle 23 gpm water, up to a 25 12 24-ft. pump capable of handling 1150 gpm
with a maximum liquid-end working pressure of 750 psi. Simplex pumps are ordinarily not made for capacities over about 500 gpm.
Selection of gas driven pumps requires attention to pump speed as it relates to the
required capacity in any given service. Figure 300-8 shows the maximum recommended piston speeds and corresponding revolutions per minute for direct-acting
gas pumps in various services. This figure represents the manufacturers recommendation for maximum speed in these services. These speeds are acceptable for
standby or infrequently operated pumps, but should be reduced for pumps in continuous service. For best operation, continuous duty pumps should be sized to run from
50 percent to 75 percent of the maximum speed shown on Figure 300-8.
See Figure 300-9 for additional application guidelines.
300-8
May 2007
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19992007 Chevron USA Inc. All rights reserved.
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May 2007
300-9
Pump Manual
Pump Manual
Fig. 300-9
Pump Description
Direct Acting
Power Plunger
Power Piston
Self Priming
Will Emulsify
N/A
P =
parallel
O =
oil
S =
stock
F =
flexible
N/A =
= no
not applicable
Pumps are commercially available outside the parameters shown. These pumps should be
avoided or, if they are used, special care should be taken to maintain reliability.
Note:
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Y =
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Legend:
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On the other hand, steam cylinders should not be too small. An adequate allowance
should be made for tight packing, leaking valves, and other bad service conditions.
Such an adequate allowance will result if steam inlet pressure is taken as the
minimum pressure actually available at the inlet to the pump after making proper
allowance for piping and valve losses, and the mechanical efficiencies given below
are applied.
In general, the tendency is to make the liquid piston too small and the steam piston
too big with the result that the pump has no difficulty in meeting the required pressure, but has to be overspeeded to meet its capacity. If the liquid piston is generously large, there is no incentive for the operator to overspeed the pump; and, if the
steam cylinder is not too large, it may be impossible to overspeed it.
A formula for estimating the required diameter of the steam-end cylinder is as
follows:
2
Pd Ps
DL
D s = ---------- ----------------E
Pi Pe
2
(Eq. 300-1)
300-10
May 2007
Pump Manual
where:
Ds = Steam piston diameter, inches
DL = Liquid piston diameter, inches
Ps = Pump suction pressure, psig
Pd = Pump discharge pressure, psig
Pi = Steam inlet pressure, psig
Pe = Steam exhaust pressure, psig
E = Mechanical efficiency
Approx. Eff.
Up to 6
.60
8 to 12
.70
.75
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Above 12
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Stroke Inches
Steam Consumption
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The steam consumption of a steam-driven reciprocating pump may vary considerably from one pump to another even though they are all identical in design and
under similar service conditions. The steam consumption will be affected by the
mechanical condition of the pump, the accuracy of the valve timing, the tightness of
the packing, etc. Figure 300-10 illustrates how to determine the approximate steam
rate of direct-acting duplex-steam pumps in pounds per hydraulic horsepower hour.
The steam rate of simplex pumps can be obtained by taking about 93% of that
obtained for a duplex pump. Figure 300-11 illustrates the formula with applicable
notes corresponding to Figure 300-10.
A simple direct-acting steam pump cannot take any advantage of expansion of the
steam. Therefore, the steam rate is not materially reduced if steam pressures higher
than about 150 psi are used. Thermodynamically, it is better to take advantage of
expansion above this pressure in other equipment. Exhaust back pressure always
increases the steam rate materially.
Inlet steam pressure is not mentioned in the formula or the graph. The formula
assumes that enough initial steam pressure is available to do the required amount of
work. This will be true if the steam cylinder is of the proper size. Steam pumps are
almost invariably operated with a hand or automatic valve, throttling the inlet steam
to provide the required pressure, and limit or regulate the speed.
May 2007
300-11
Pump Manual
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300-12
May 2007
Pump Manual
Q
S = ---------------------- P + r P b + P + 18.5
57.5e s e v
(Eq. 300-2)
where:
Total steam consumed, pounds per hour.
Q =
P =
Difference between suction and discharge pressure, in pounds per square inch.
es =
Pb =
P =
Friction m.e.p. referred to steam cylinder in lbs. per sq. in. See table below.
ev =
Volumetric efficiency; usually over .95, and usually taken as 1.0 for rough figures; may be as low
as .5 for pumps in bad condition.
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cylinder ratio, or ratio of area of the steam cylinder to the liquid cylinder.
r =
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S =
Stroke of pump
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4"
5"
6"
8"
10"
12"
15"
18"
24"
.35
.375
.39
.40
.425
.45
.475
.50
.525
.55
Friction m.e.p., P
outside packed pumps
31.8
28.8
25.8
23.4
20.4
17.4
15.6
14.4
13.2
11.4
30
27
24
21
18
15
13.5
12
10.5
Steam eff., es
Notes: Simplex steam pumps will ordinarily have a steam efficiency from 7% to 10% higher than given for duplex pumps, largely
because they are built with smaller clearance and do not short-stroke when properly adjusted. The friction m.e.p. can be
markedly reduced by the use of high-class metallic packing.
Superheat. 100 of superheat will reduce steam consumption to 87%; 200 will reduce it to 78% of that shown.
May 2007
300-13
Pump Manual
460
---------------------P s + 18.5
(Eq. 300-3)
cu. ft per lb., which holds well between 25# and 125# (gage).
where:
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Ps = 1
--- P + P + P b
r
(Eq. 300-4)
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3. Steam efficiency is ratio of displacement of steam cylinder to steam actually used. The low efficiency invariably
found is mainly due to the clearance volume which traps steam from the steam pipe to the exhaust pipe without
doing any work, and secondarily, to cylinder condensation. Valve leakage also plays a part. Although taken as a
constant, this efficiency is apt to vary considerably with conditions.
This formula shows the steam consumed, but does not show whether the pump can actually perform the work
or not, either as regards capacity or pressure. The maximum pressure that the pump can put up is
theoretically
P = r P s P b P
(Eq. 300-5)
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However, at least a 25% additional margin of safety is desirable; the working pressure should be no more than
75% of that found above. The proper working capacity of a duplex pump in gallons per minute is
approximately
2
10D L
Q = ----------------L + 10
D =
L
where:
(Eq. 300-6)
300-14
May 2007
Pump Manual
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Injection of an external lubricant with an oil lubricator into the stuffing boxes of
both piston and plunger pumps is needed to prolong packing life. Internal packing
and piston rings are not lubricated directly by oil injection.
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When suction pressure is lower than atmospheric pressure, a piston pump should
usually be selected, because the plungers outside-packed construction generally
permits greater leakage of air and the design of the liquid passages is not suited to
clearing air accumulations.
When sizing suction lines for either power or gas-driven pumps, the following
guidelines are recommended:
Average fluid velocity should not exceed 3 ft/sec and should preferably equal
1 ft/sec.
Suction pressure should exceed the maximum fluid vapor pressure by at least
3 psi preferably 5 to prevent cavitation.
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Adequate net positive suction head (NPSH) is the single most important design
parameter for reciprocating pumps. Suction-line flow to a simplex pump changes
from no flow to 100% within approximately the first 40% of the suction stroke. This
means that the liquid in the suction line is accelerated to full velocity in about
0.2 seconds when a pump is operating at 60 strokes per minute. The size, length,
and fluid velocity in the suction line must ensure that NPSHA is sufficient considering the pulsating flow. Some cases require a suction stabilizer.
Power pumps operate at higher speeds than gas-driven pumps, and have higher
valve velocities (due to limited valve area), and higher valve-spring loads (for fast
action). Consequently, they require a higher NPSH and, with an increase in RPM,
increasing suction line acceleration head. Figure 300-12 gives allowances for acceleration head for double-acting duplex power pumps handling water and similar low
viscosity fluids, based on empirical data developed by reciprocating pump suppliers.
May 2007
300-15
Pump Manual
Fig. 300-12 Suction Line Liquid Acceleration Head (ft) for Double-Acting Duplex Power Pumps
Suction Line Acceleration Head for Suction Line Length (ft)
25
50
75
100
0.5
1.7
3.3
5.0
6.5
1.0
3.3
6.0
59.8
13.0
2.0
6.5
13.0
19.5
26.0
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(9) Special close clearance simplex pumps are available when some vaporization on the suction side may be expected.
(10)For hydrocarbons, use 75% of the values shown.
1.
2.
3.
4.
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The following steps may be used to select a reciprocating pump. For additional
guidance, see Section 2100.
5.
6.
7.
8.
300-16
May 2007
Pump Manual
where:
hp = absolute pressure at suction source, e.g., a vessel (ft)
hs = static suction head (ft)
hf = friction head loss in suction piping including entrance losses (ft)
hvpa = vapor pressure of the fluid at pumping temperature (ft)
hacc = Acceleration head (ft)
(See Section 130 for calculating acceleration head.)
9.
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(Eq. 300-8)
where:
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where:
Using the pump manufacturers literature and catalogs, select the pump for the
conditions obtained in the calculation. If possible, avoid selecting the largest
piston or plunger size for the pump case. Also avoid pumps which would have
to operate continuously at maximum allowable speed.
May 2007
300-17
Pump Manual
Typical Service
0700 psig/0500gpm
350F
Construction Features
Advantages
Disadvantages
Specification
Data Sheet
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Pump Description
300-18
May 2007
Pump Manual
10
11
12
13
14
15
16
17
18
Valve Rod
Valve Rod Lever
Liquid End Piston Rod
Gland
Gland Bushing
Stuffing Box
Liquid Piston
Liquid Piston Rings
Cylinder Liner
Steam Cylinder
Steam Cylinder Head
Steam Piston
Steam Piston Rings
Steam End Piston Rod
Condensate Drain
Steam Chest
Slide Valve
Valve Rod Adjustment Nut
Name of part
Part
No.
19
20
21
22
23
Name of Part
Valve Cover
Valve Stem
Valve Spring
Valve
Valve Seat
1
2
3
4
5
6
7
8
9
Part
No.
Name of Part
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Part
No.
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May 2007
300-19
Pump Manual
Pump Description
Typical Service
0450 RPM
Construction Features
Advantages
Higher pressures available than with piston pumps (up to 30,000 psi).
Self-priming. Constant delivery at high efficiency over wide pressure range. Minimum fluid emulsification. Handles viscous stocks.
Can run dry for a limited time.
Pulsing flow. Low capacity. High first cost and maintenance cost.
Low tolerance for abrasives. Subject to vapor lock at low suction
pressure with high vapor pressure stock.
Specification
Data Sheet
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300-20
May 2007
Pump Manual
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Fig. 300-14 Reciprocating Plunger Power Pump Copyright 1995 Ingersoll Dresser Pumps. Worthington is a
trademark of Ingersoll Dresser Pump Company
May 2007
300-21
Pump Manual
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300-22
May 2007