Pumps

Apumpcanbedefinedasamechanicaldevicethataddsenergytoafluidtoincreaseitsflowrateandstaticpressure.[1]Thisprocesscanbeaccomplishedwithpositive
displacementpumpsorkineticenergypumps.

Contents
1Fluidprinciplesandhydraulics
1.1Typesoffluids
2Typesofpumps
2.1Positivedisplacementpumps
2.2Kineticenergypumps
2.3Pumpingsystemdesign
2.3.1MechanicalDesign
2.3.2VendorSelection
3Hydraulicprinciples
3.1Hydrostatics
3.1.1Pressure
3.1.2Temperature
3.1.3Airproperties
3.1.4Head
3.1.5Centrifugalpumpconsiderations
3.1.6Positivedisplacementpumpconsiderations
3.1.7Statichead,staticlift,andsubmergenceterminology
3.1.8Theoreticallift
3.1.9Actualsuctionlift
3.1.10Submergence
3.1.11Vaporpressure
3.1.12Suspendedsolids
3.1.13Dissolvedgases
3.1.14Viscosity
3.1.15Corrosivity
3.2Hydrodynamics
3.2.1Pressurehead
3.2.2Elevationhead
3.2.3Headlosses
3.2.4Controllosses
3.2.5Accelerationhead
3.2.6Totaldynamichead
3.2.7Suctionhead
3.2.8Dischargehead
3.2.9CalculatingTDH
3.2.10Netpositivesuctionhead(NPSH)
3.2.11Netpositivesuctionheadrequired
3.2.12Netpositivesuctionheadavailable
3.2.13NPSHmargin
3.2.14Powerrequirements
4Nomenclature
5Subscripts
6References
7NoteworthypapersinOnePetro
8Externallinks
9Seealso

Fluidprinciplesandhydraulics
Typesoffluids
Pumpsareusedtomovefluids,whichinclude:
Liquids
Dissolvedgasesdissolvedairandhydrocarbonvapors
Solidssand,clay,corrosionbyproducts,andscale
Themostcommontypesofliquidspumpedinupstreamoperationsare:
Crudeoil
Condensate
Lubeoils
Glycols
Amines
Water
Eachfluidhasdifferentphysicalpropertiesthatmustbetakenintoconsiderationwhensizingandselectingapump.Themostimportantphysicalpropertiesaresuctionpressure,
specificgravity,viscosity,vaporpressure,solidscontent,andlubricity.

Typesofpumps
Positivedisplacementpumps
Positivedisplacementpumps(/Positive_displacement_pumps)addenergytoafluidbyapplyingforcetothefluidwithamechanicaldevicesuchasapiston,plunger,or
diaphragm.Therearetwotypesofpositivedisplacementpumps:

Reciprocating
Rotary
Reciprocatingpumpsusepistons,plungers,ordiaphragmstodisplacethefluid,whilerotarypumpsoperatethroughthematingactionofgears,lobes,orscrewtypeshafts.

Kineticenergypumps
KineticEnergyPumps(/Centrifugal_pumps)(energyassociatedwithmotion)isaddedtoaliquidtoincreaseitsvelocityand,indirectly,itspressure.Kineticenergypumps
operatebydrawingliquidintothecenterofarapidlyrotatingimpeller.Radialvanesontheimpellerthrowtheliquidoutwardtowardtheimpellerrim.Asliquidleavesthe
impeller,itcomesincontactwiththepumpcasingorvolute.Thecasingisshapedtodirectliquidtowardadischargeport.Thecasingslowstheliquidandconvertssomeofits
velocityintopressure.Therearethreeclassesofkineticenergypumps:
Centrifugalradial,axial,andmixedflowdesigns
Regenerativeturbine
Specialeffectspumps
Centrifugalpumpsaccountformorethan80%ofpumpsusedinproductionoperationsbecausetheyexhibituniformflow,arefreeoflowfrequencypulsations,andarenot
subjecttomechanicalproblems.Fig.1illustratespumpscommonlyusedinupstreamproductionoperations.

(/File%3AVol3_Page_232_Image_0001.png)
Fig.1Pumpscommonlyusedinproduction
operations.

Pumpingsystemdesign
Designinganypumpingserviceinvolvesthreemajoractivities:processdesign,mechanicaldesign,andvendorselection.
ProcessDesign.Thefirststepinprocessdesignistoobtainadesignflowrate.Thedesignflowrateshouldbeselectedafterconsideringallflowvariations,suchas:
Startupconditions
Futureexpansion
Maximumanticipatedflow
Thenextstepistodeterminetheliquidpropertiescriticaltopumpdesign.Thesepropertiesinclude:
Specificgravity
Temperature
Viscosity
Pourpoint
etc.
Valuesarerequiredatpumpingconditionsand,insomecases,atambientconditionsaswell.Thenextstepistocalculateavailablesuctionconditionssuchasratedsuction
pressure,maximumsuctionpressure,andnetpositivesuctionheadavailable(NPSHA).(SeeHydrodynamicsforinformationonNPSHA.)Oncetheavailablesuctionconditions
havebeenestablished,theeffectoftheselectedcontrolsystemonpumpperformancerequirementsmustbedetermined(seeRegulationofFlowRate(/index.php?
title=Regulation_of_Flow_Rate&action=edit&redlink=1)).Thenextstepistocalculatetheminimumdischargepressurerequirementsofthepump.Thelaststepistocalculate
thetotaldynamichead(TDH)atthespecificgravitycorrespondingtoratedpumpingtemperature.
MechanicalDesign
Thefirststepinmechanicaldesignistodeterminethedesignpressureandtemperaturerequiredforthepumpanditsassociatedpiping.Oncethisisdone,apumptypeand
materialsofconstructionareselected.Thenextstepistodeterminethesparing(backup)requirements,theneedforparalleloperationandcontrolsystemdetails.Thenselecta
shaftsealtypeanddeterminetherequirementsforanexternalflushingorsealingsystemandestimatethepowerrequirementsandchooseadriver(motor,engine,orturbine)for
thepump.Lastly,documentthedesignbyincludingcalculations,studies,designspecifications,utilityrequirements,andestimatesummary.
VendorSelection
Factorsthathavethegreatestinfluenceontheselectionofthemostcosteffectivepumptypeinclude:
Capacity
TDH
Maintenance
Viscosity
Capacitycontrol
Withinthegeneraltypeselections,aparticularconstructionstyleismostinfluencedby:
Dischargepressure
NPSHA
Fluidtemperature
Spaceandweightlimitations

Hydraulicprinciples
Hydraulicsdealswiththemechanicalpropertiesofwaterandotherliquidsandtheapplicationofthesepropertiestoengineering.Hydraulicsisdividedintotwoareas:
Hydrostatics(fluidsatrest)
Hydrodynamics(fluidsinmotion)

Hydrostatics
Aliquidhasadefinitevolumewhencomparedtoagas,whichtendstoexpandtofititscontainer.Whenunconfined,aliquidseeksthelowestpossiblelevel.Becauseofits
fluidity,aliquidwillconformtotheshapeofitscontainer.
Pressure
Thepressureexistingatanypointinaliquidbodyatrestiscausedbytheatmosphericpressureexertedonthesurfaceplustheweightoftheliquidabovethatpoint.This
pressureisequalinalldirections.
Temperature
Formostliquids,anincreaseintemperaturedecreasesviscosity,decreasesspecificgravity,andincreasesvolume.Temperatureaffects:
Thetypeofpumpconstruction
Materialselection
Corrosivepropertiesofthefluid
Thepumpsflangepressure/temperaturerating
Airproperties
Airisamixtureofoxygen,nitrogen,andothercompounds.Thestandardpressureofairisdefinedat60F,36%relativehumidity,andsealevel.Theweightofacolumnofair
abovetheEarthssurfaceat45latitudeandsealevelis14.696psia(29.92in.ofmercury).Atmosphericpressuredecreasesbyapproximately0.5psiforeach1,000ftof
elevationabovesealevel.
Head
Therelationshipofheadtopressureisexpressedas
(/File%3AVol3_page_233_eq_001.PNG)(Eq.1)
where
h=heightofthefluidcolumnaboveareferencepoint
p=pressure.
Theheadofliquidisnotrelatedtotheareaoccupiedbytheliquid.Fig.2illustratestypesofhead.

(/File%3AVol3_Page_234_Image_0001.png)
Fig.2Typesofhead.

(/File%3AVol3_page_233_eq_002.PNG)(Eq.2)
where
=specificgravityoftheliquid
f=densityoftheliquidbeingpumped
w=densityofwateratstandardconditionsoftemperatureandpressure.
Itisimportanttorealizethatalthoughtheheadsofdifferentliquidsarethesame,theirpressuresaredifferentbecauseofthedifferencesinspecificgravities.Forexample,
assumethree100fttalltanksfilledwithgasoline,water,andmolasses,respectively.Thepressuremeasuredatthebottomofeachtankisdifferentbecauseofthedifferencesof
specificgravitiesofgasoline(0.75),water(1.0),andmolasses(1.45).
Centrifugalpumpconsiderations
Operatingpressureisexpressedinfeetoftheliquidthatisbeingpumped.Suctionanddischargepressuresareexpressedassuctionheadanddischargehead,respectively.
Pressuresareexpressedinfeetofhead,becauseitismoreimportanttoknowhowmuchapumpcanraisetheliquiditispumping,ratherthantheamountofpressurethepumpis
addingtotheliquid.
Positivedisplacementpumpconsiderations

Operatingpressuresarealmostalwaysexpressedintermsofpressure(psi).
Statichead,staticlift,andsubmergenceterminology
Fig.3illustratestherelationshipbetweenstatichead,staticlift,andsubmergence.Staticheadistheverticaldistancebetweenaliquidlevelandadatumline,whenthesupplyis
abovethedatum.Staticliftistheverticaldistancebetweenaliquidlevelandadatumlevel,whenthedatumisabovetheliquid.Datumlineisthecenterlineofthepumpinlet
connection,orthehorizontalcenterlineofthefirststageimpellerinverticalpumps.

(/File%3AVol3_Page_232_Image_0001.png)
Fig.3Relationshipbetweenstatichead,static
lift,andsubmergence.

Theoreticallift
Apumpthatdevelopsaperfectvacuumatitssuctionendcanliftacolumnofwater34ft.Thisverticaldistanceiscalledtheoreticallift.Thepressuretolifttheliquidcomes
fromatmospherepressure.Atsealevel,atmospherepressureisapproximately14.7psia.
Actualsuctionlift
Becauseaperfectvacuumisneverachievedandbecausesomeliftislosttofrictioninthesuctionline,themaximumactualsuctionliftforapositivedisplacementpumpis
approximately22ft.Themaximumactualsuctionliftforacentrifugalpumpisapproximately15ftwhenpumpingwaterfromanopenairtank.Positivedisplacementpumps
canoperatewithlowersuctionpressuresorhighsuctionliftsbecausetheycancreatestrongervacuums.Suctionliftwillbegreaterifthepressureinaclosedtankisgreaterthan
atmosphericpressure.
Submergence
Submergenceisoftenconfusedwitheithersuctionstaticheadorstaticlift.Forverticalpumps,submergencerelatestheliquidleveltothesettingofthepump.Forhorizontal
pumps,submergencerelatestotheheightofliquidlevelnecessaryinthesourcevesselortanktopreventtheformationofvortexingandtheresultingflashingofvaporsinthe
pumpsuction.
Vaporpressure
Asthepressureonaliquidisdecreased,thereisatendencyforthebubblesofvaportobeliberated.Thevaporpressureofaliquidisthepressureatwhichthefirstbubbleof
vaporappearsatagiventemperature.At60F,thevaporpressureofwateris0.3psia(0.7ft).At212F,thevaporpressureofwateris14.7psia(34ft).Fig.4illustratesthe
vaporpressureofwaterforvarioustemperatures.Forotherfluids,refertostandardreferences(e.g.,HydraulicInstituteEngineeringDataBook1).

(/File%3AVol3_Page_236_Image_0001.png)

Fig.4Vaporpressureofwaterforvarious
temperatures.

Suspendedsolids
Theamountandtypeofsuspendedsolidsentrainedintheliquidcanaffectthecharacteristicsandbehaviorofthatliquid.Increasedconcentrationsofsolidsincreasethespecific
gravity,viscosity,andabrasivenessofaliquid.Thetypeandconcentrationofsuspendedsolidscanaffectthestyleofpumpselectedandthematerialsofconstruction.Suspended
solidsalsoaffecttheselectionofimpellerdesignincentrifugalpumps,whichinturnaffectsthewearrate,efficiency,andpowerconsumption.
Dissolvedgases
Smallamountsofdissolvedgaseshavelittleeffectonflowrateorotherpumpingrequirements.Iflargeamountsofgasentertheliquidthroughpipingleaksorasaresultof
vortexinginvessels,thespecificgravityoftheliquidwilldecrease.DissolvedgasescanalsoreducetheamountofNPSHAatthepumpsuction.(SeeHydrodynamicsfora
discussionofNPSHA).

Viscosity
Viscosityoffersresistancetoflowbecauseoffrictionwithinthefluid.Viscositylevelshaveasignificantimpactonpumptypeselection,efficiency,headcapacity,andwarmup.
Highviscosityliquidsdecreaseacentrifugalpumpsefficiencyandheadperformance,whileincreasingthepowerrequirements.Theviscosityofallliquidsvarieswith
temperature.Forviscositiesofliquids,refertostandardindustryreferences(e.g.,HydraulicInstituteEngineeringDataBook[1]).
Corrosivity
Thecorrosivenatureofthefluidbeingpumpedhasabearingonpumptypeselection,materialsofconstruction,andcorrosionallowance.Specialmechanicalsealsandflushing
arrangementsmayberequired.

Hydrodynamics
Hydrodynamicsisthestudyoffluidsinmotion.Bernoullisequationstatesthat
(/File%3AVol3_page_237_eq_001.PNG)(Eq.3)
where
v=averagevelocityoftheliquidinthepipe
g=accelerationofgravity
p=pressure,=density
Z=heightaboveadatum
hf=frictionlossbetweenpoints1and2.Subscripts1and2refertolocationsalongapipe.AnexaminationofeachofthetermsinEq.3providesabetterunderstandingofthe
generalequationformodelingapumpingsystem.
VelocityHead.Velocityheadisthepotentialenergythathasbeenconvertedtokineticenergy.Velocityheadcanbeexpressedas
(/File%3AVol3_page_237_eq_002.PNG)(Eq.4)
(/File%3AVol3_page_237_eq_003.PNG)(Eq.5)where
Q=flowrate
d=insidepipediameter.
Thevelocityheadincreasestheamountofworkrequiredofapump.Thevelocityheadisusuallynotincludedinactualsystemcalculationswhenpipingvelocitiesarekept
withintheprescribedlimitsof3to15ft/sec.Thevelocityheadisincludedinthetotaldynamicheadonthecentrifugalpumpcurves.
Pressurehead
Theenergycontainedintheliquidisexpressedaspressureheadandexpressedasp/inEq.3.
Elevationhead
TheenergycontainedintheliquidasaresultofitselevationrelativetoadatumiscalledtheelevationheadandisexpressedasZinEq.3.
Headlosses
Headlossesarepotentialenergythathasbeenlostbecauseoffrictionalresistanceofthepipingsystem(pipe,valves,fittings,andentranceandexitlosses).Unlikevelocityhead,
frictionheadcannotbeignoredinsystemcalculations.Headlossvaluesvaryasthesquareoftheflowrate.Headlossescanbeasignificantportionofthetotalhead.
Controllosses
Controllossesoccuronthedischargesideofacentrifugalpumpthathasbeenequippedwithabackpressurevalvetocontrolflowrate.Astheliquidflowsthroughthecontrol
valve,energyislost.Nexttostatichead,controllossesarefrequentlythemostimportantfactorincalculatingthepumpstotaldynamichead.Forpumpapplications,control
lossesaretreatedseparatelyfromheadlosses,eventhoughtheyareincludedinthehfterminEq.3.
Accelerationhead
Accelerationheadisusedtodescribethelossesassociatedwiththepulsatingflowofreciprocatingpumps.Theoretically,accelerationheadshouldbeincludedinthehftermof
Eq.3.TheHydraulicInstituteEngineeringDataBook[1]discussesthecalculationofaccelerationhead.
Totaldynamichead
TDHisthedifferencebetweenthepumpingsystemsdischargeheadandsuctionhead.Itisalsoequaltothedifferenceinpressuregaugereadings(convertedtofeet)acrossan
existingoperatingpump(discountingvelocityhead).
Suctionhead
Suctionheadisdefinedasthesumofthesuctionvesseloperatinggaugepressure(convertedtofeet),theverticaldistancebetweenthesuctionvesselliquidlevelandthepump
referencepoint,lessheadlossesinthesuctionpiping[discountingchangeinvelocity,
(/File%3AVol3_page_237_eq_004.PNG)(Eq.6)
andaccelerationhead].Suctionheadcanbeexpressedas
(/File%3AVol3_page_238_eq_001.PNG)(Eq.7)
whichcanbereducedto

(/File%3AVol3_page_238_eq_002.PNG)(Eq.8)
where
Hs=suctionheadofliquidbeingpumped
p1=suctionvesseloperatingpressure
H1=heightofliquidsuctionvesselabovepumpreferencepoint
pf1=pressuredropresultingfromfrictioninthesuctionpiping.
Dischargehead
Dischargeheadisdefinedasthesumofthedischargevesseloperatinggaugepressure(convertedtofeet),theliquidlevelinthedischargevesselabovethepumpreferencepoint,
pressuredropbecauseoffrictioninthedischargepiping,andcontrollosses(discountingvelocityhead).Itcanbeexpressedas
(/File%3AVol3_page_238_eq_003.PNG)(Eq.9)
whichcanbereducedto
(/File%3AVol3_page_238_eq_004.PNG)(Eq.10)
where
Hd=dischargeheadofliquidbeingpumped
p2=dischargevesseloperatingpressure
H2=operatingornormalheightofliquidinthedischargevesselabovethepumpreference
pf2=pressuredropresultingfromfrictioninthedischargepiping
Pc=dischargeflowcontrolvalvelosses.
CalculatingTDH
ThepumpTDHisthedifferencebetweenthesuctionanddischargeheads.
(/File%3AVol3_page_238_eq_005.PNG)(Eq.11)
whichcanbesubstitutedas
(/File%3AVol3_page_238_eq_006.PNG)(Eq.12)
where
Htd=totaldynamicheadrequiredofapump.
Netpositivesuctionhead(NPSH)
NPSHisdefinedasthetotalsuctionheadinfeetofliquid(absoluteatthepumpcenterlineorimpellereye)lessthevaporpressure(infeet)oftheliquidbeingpumped.
Netpositivesuctionheadrequired
Netpositivesuctionheadrequired(NPSHR)isdefinedastheamountofNPSHrequiredtomoveandacceleratetheliquidfromthepumpsuctionintothepumpitself.Itis
determinedeitherbytestorcalculationbythepumpmanufacturerforthespecificpumpunderconsideration.NPSHRisafunctionofliquidgeometryandthesmoothnessofthe
surfaceareas.Forcentrifugalpumps,otherfactorsthatcontrolNPSHRare:
Thetypeofimpeller
Designofimpellereye
Rotationalspeeds
NPSHRisdeterminedonthebasisofhandlingcoldwater.Fieldexperiencecoupledwithlaboratorytestinghaveconfirmedthatcentrifugalpumpshandlinggasfree
hydrocarbonliquidsandwateratelevatedtemperatureswilloperatesatisfactorily,withharmlesscavitationandlessNPSHRthanwouldberequiredforcoldwater.
Netpositivesuctionheadavailable
NPSHAmustbeequaltoorgreaterthanNPSHR.Ifthisisnotthecase,cavitationorflashingmayoccurinthepumpsuction.Cavitationoccurswhensmallvaporbubbles
appearintheliquidbecauseofadropinpressureandthencollapserapidlywithexplosiveforcewhenthepressureisincreasedinthepump.Cavitationresultsindecreased
efficiency,capacity,andheadandcancauseseriouserosionofpumpparts.Flashingcausesthepumpsuctioncavitytobefilledwithvaporsand,asaresult,thepumpbecomes
vaporlocked.Thisusuallyresultsinthepumpfreezingup,whichiscalledpumpseizure.
NPSHAisnotafunctionofthepumpitselfbutofthepipingsystemforthepump.Itcanbecalculatedfrom
(/File%3AVol3_page_239_eq_001.PNG)(Eq.13)
where
pA=atmosphericpressure
pva=liquidvaporpressureatpumpingtemperature.

NPSHAdecreaseswithincreasesinliquidtemperatureandpipefrictionlosses.Becausepipefrictionlossesvaryasthesquareoftheflow,NPSHAalsovariesasthesquareof
theflow.Thus,NPSHAwillbethelowestatthemaximumflowrequirement.Accordingly,itisimportanttorecognizetheneedforcalculatingNPSHA(andNPSHR)at
maximumflowconditionsaswellasmaximumfluidtemperature,notjustatdesignconditions.Unlesssubcooled,apurecomponenthydrocarbonliquidistypicallyin
equilibriumwiththevaporsinapressurevessel.Thus,increasesinthevesseloperatingpressuresarealmostfullyoffsetbyacorrespondingincreaseinthevaporpressure.When
thisoccurs,
(/File%3AVol3_page_239_eq_002.PNG)(Eq.14)
NPSHmargin
TheNPSHmarginisNPSHAlesstheNPSHR.TheHydraulicInst.recommendsanNPSHmarginof3to5ft.[1]
WhenanewsystemoffersinsufficientNPSHmarginforoptimumpumpselection,eithertheNPSHAmustbeincreased,theNPSHRmustbedecreased,orboth.Toincreasethe
NPSHA,onecanraisetheliquidlevel,lowertheelevationoftheselectedpump,changetoalowNPSHRpump,orcooltheliquid.ToreducetheNPSHR,onecanusedifferent
designimpellersorinducersoruseseveralsmallerpumpswithlowerNPSHRsinparallel.
WhenanexistingpumpingsystemexhibitsinsufficientNPSHmargin,itistoolatetousethesesolutionswithoutgoingthroughanexpensivechange.Mostoftheseproblems
canbetracedtosuctionflowrestrictions(orificeplates,pluggedstrainers,partiallyclosedvalves,etc.)andinadequatesourcetankliquidlevels.
Powerrequirements
OncetheTDHhasbeencalculated,thepowerrequirementscanbedeterminedwith
(/File%3AVol3_page_239_eq_003.PNG)(Eq.15)
Forkineticenergypumps,
(/File%3AVol3_page_239_eq_004.PNG)(Eq.16)
Forpositivedisplacementpumps,
(/File%3AVol3_page_239_eq_005.PNG)(Eq.17)
where
PB=brakehorsepower
e=thepumpefficiencyfactorobtainedfromthepumpmanufacturer.
Forelectricmotordrivenpumps,theenergyconsumptioncanbeestimatedwith
(/File%3AVol3_page_240_eq_001.PNG)(Eq.18)

Nomenclature
h
p

=
=
=
=

heightofthefluidcolumnaboveareferencepoint
pressure
specificgravityoftheliquid
densityoftheliquidbeingpumped

w = densityofwateratstandardconditionsoftemperatureandpressure
v
g
p

Z
hf

=
=
=
=
=

averagevelocityoftheliquidinthepipe
accelerationofgravity
pressure
density
heightaboveadatum

= frictionlossbetweenpoints1and2.

Q = flowrate
d = insidepipediameter
Hs = suctionheadofliquidbeingpumped
p1 = suctionvesseloperatingpressure
H1 = heightofliquidsuctionvesselabovepumpreferencepoint
pf1 = pressuredropresultingfromfrictioninthesuctionpiping

Subscripts
1,2 = locationsalongapipe

References
1. 1.01.11.21.3WorldLNGSourceBook2001.2001.DesPlaines,Illinois:GasTechnologyInst.

NoteworthypapersinOnePetro
UsethissectiontolistpapersinOnePetrothatareaderwhowantstolearnmoreshoulddefinitelyread

Externallinks
UsethissectiontoprovidelinkstorelevantmaterialonwebsitesotherthanPetroWikiandOnePetro

Seealso
PEH:Pumps(/PEH%3APumps)
Positivedisplacementpumps(/Positive_displacement_pumps)
Centrifugalpumps(/Centrifugal_pumps)
Pumpdrivers(/Pump_drivers)
Category(/Special%3ACategories): 4.1.6Compressors,engines,andturbines(/Category%3A4.1.6_Compressors,_engines,_and_turbines)

(https://www.onepetro.org/search?q=Pumps)

(http://scholar.google.ca/scholar?q=Pumps)

(http://www.worldcat.org/search?q=Pumps)

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