TUTORIAL

ON
PUMPS

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CONTENTS OF PRESENTATION
TYPES OF PUMPS & MAIN SELECTION CRITERIA DESIGN STANDARDS PUMP PERFORMANCE CHARACTERISTICS CURVES

PUMP POWER CALCULATION & SELECTION OF DRIVER RATING

WHAT IS NPSH & WHY IS IT SO IMPORTANT NPSH CALCULATION / MARGIN BETWEEN NPSHA & NPSHR SELECTION OF MECHANICAL SEALS SELECTION OF API FLUSHING PLANS TYPICAL PROCESS DATASHEET FOR PUMP

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TYPES OF PUMPS
CENTRIFUGAL PUMPS: SINGLE / MULTI-STAGE PUMPS OPEN / CLOSED IMPELLER PUMPS VERTICAL / HORIZONTAL PUMPS

SELF PRIMING PUMPS

VERTICAL IN-LINE PUMPS VERTICAL SUSPENDED PUMPS VERTICAL BARREL PUMPS VERTICAL HIGH SPEED PUMPS HORIZONTAL SINGLE SUCTION PUMPS HORIZONTAL DOUBLE SUCTION PUMPS SEAL-LESS PUMPS CANNED MOTOR PUMPS

MAGNETIC DRIVE PUMPS

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TYPES OF PUMPS & MAIN SELECTION CRITERIA

ROTARY PUMPS: GEAR PUMPS SCREW PUMPS LOBE PUMPS VANE PUMPS RECIPROCATING METERING PUMPS PLUNGER PUMPS DIAPHRAGM PUMPS
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TYPES OF PUMPS

Single Stage Volute Pump

Flow Path in Volute Pump

Double Suction

Horizontally Split Pump

Volute Pump
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TYPES OF PUMPS

EXTERNAL GEAR PUMP

DIAPHRAGM PUMP

INTERNAL GEAR PUMP

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TYPES OF PUMPS

MULTIPLE PLUNGER PUMP

SEAL-LESS PUMP

SCREW PUMP

LOBE PUMP
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TYPES OF IMPELLER

OPEN IMPELLER

SEMI OPEN IMPELLER

SHROUDED IMPELLER

AXIAL FLOW IMPELLER

MIXED FLOW SHROUDED OPEN TYPE SHROUDED IMPELLER WITH COMBINED FLOW ORINETATION COURSEWARE FOR PROCESS DIFUSER IMPELLER GROUP

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MAIN SELECTION CRITERIA

SINGLE STAGE CENTRIFUGAL PUMPS ARE GENERALLY USED FOR LESS VISCOUS, HIGH CAPACITY & LOW HEAD SERVICES
MULTI-STAGE CENTRIFUGAL PUMPS ARE GENERALLY USED FOR LESS VISCOUS, HIGH CAPACITY & HIGH HEAD SERVICES OPEN IMPELLER PUMPS ARE GENERALLY USED FOR SLURRY SERVICES DOUBLE SUCTION CENTRIFUGAL PUMPS ARE GENERALLY USED FOR HIGH CAPACITY LOW HEAD SERVICES VERTICAL HIGH SPEED (THROUGH GEAR) VERTICAL PUMPS ARE USED FOR LOW CAPACITY HIGH HEAD SERVICES

SEAL-LESS PUMPS ARE GENERALLY USED FOR CLEAN, TOXIC AND EXPENSIVE SERVICES
GEAR PUMPS ARE GENERALLY USED FOR CLEAN HIGH VISCOUS FLUIDS SUCH AS LUBE OIL SERVICES
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MAIN SELECTION CRITERIA

SCREW PUMPS ARE GENERALLY USED FOR VERY HIGH VISCOUS FLUIDS EVEN CONTAINING SOLIDS SUCH AS MELTS SERVICES

LOBE PUMPS ARE GENERALLY USED FOR LESS VISCOUS FLUIDS, MODERATE CAPACITY AND HEAD WHERE POSITIVE DISPLACEMENT IS REQUIRED
VANE PUMPS ARE GENERALLY USED FOR LESS VISCOUS FLUIDS MULTI-PHASE, MODERATE CAPACITY AND HEAD WHERE POSITIVE DISPLACEMENT IS REQUIRED RECIPROCATING / METERING PUMPS ARE GENERALLY USED FOR LOW CAPACITY AND HIGH HEAD SUCH AS METERING / DOSING PURPOSE MULTI-PLUNGER PUMPS AREA USED FOR MODERATE CAPACITY AND HIGH HEAD SERVICES DIAPHRAGM PUMPS ARE GENERALLY USED FOR CORROSIVE LESS VISCOUS, LOW CAPACITY AND HIGH HEAD SERVICES
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MAIN SELECTION CRITERIA

PLUNGER / PISTON PUMPS MULTIPLE PLUNGER PUMPS MULTI-STAGE CENTRIFUGAL

HEAD

LOBE / GEAR VANE PUMPS

SINGLE STAGE SINGLE SUCTION CENTRIFUGAL

SINGLE STAGE DOUBLE SUCTION CENTRIFUGAL

CAPACITY
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DESIGN STANDARDS
DESIGN STANDARDS DEFINE BASIC DESIGN (MECHANICAL / HYDRAULICS/ MOC / DOCUMENTATION), ACCESSORIES, INSPECTION, TESTING AND SHIPPING OF PUMPS API 610 FOR HEAVY DUTY CENTRIFUGAL PUMPS

API 674 FOR RECIPROCATING PUMPS

API 675 FOR METERING PUMPS NFPA 20 FOR FIRE WATER PUMPS

ISO 13709 CENTRIFUGAL PUMPS FOR PETROCHEMICAL INDUSTRIES

MANUFACTURERS STANDARD PUMPS FOR SPECIAL / NON-CRITICAL CASES
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PERFORMANCE CHARACTERISTICS OF CENTRIFUGAL PUMPS

Shut-off Head

Shaft Power End of Curve (BKW)

BEP

Efficiency (% )

Operating Range Capacity (M3/H)

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CAPACITY CONTROL OF CENTRIFUGAL PUMPS

Shut-off Head
D1 D1 < D2 D2

Pr. Loss across Control Valve

H: HEAD (M)

H-Q Curve at Const. Speed

System Resistance Curves Q: Capacity (M3/H)

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CAPACITY CONTROL OF CENTRIFUGAL PUMPS

Shut-off Head

H: HEAD (M)

H-Q Curve at Speed N1 (N1>N2) System Resistance Curve Q: Capacity (M3/H)

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H-Q Curve at Speed N2

POWER CALCULATION
PUMP POWER (KW) = Q (M3/S) * PR. (N/M2) / (Pump Eff.) /1000 PUMP POWER (KW)=Q(M3/S)*H (M)* (Kg/M3)*g (M/S2) / (Pump Eff.) /1000 PUMP POWER (KW) = (m (Kg/S) * g (M/S2) * H (M) / (Pump Eff.) /1000 Example: Q: 5000 M3/H H = 50 M

= 1000 Kg/M3
(Pump Eff.) = 0.88 Power=5000/3600*50*1000*9.81/(1000*0.88) = 774.15 KW

Motor Rating: 774.15*1.1 = 852 KW

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NET POSITIVE SUCTION HEAD (NPSH)

NPSH INDICATES (IN TERMS OF ITS LIQUID HEAD) SUCTION PR. ABOVE THE LIQUID VAPOUR PRESSURE
THERE IS A PR. LOSS AT PUMP IMPELLER SUCTION INLET DUE TO CHANGE OF DIRECTION OF PUMPING FLUID, FRICTION, ACCELERATION ETC. THIS IS INDICATED AS NPSHR (REQUIRED) IF NPSHA (AVAILABLE) IS LOWER THAN NPSHR THEN SOME LIQUID WILL VAPOURISE SUDDENLY AT THE PUMP SUCTION, IT WOULD CREATE LOCALISED HIGH PR. AT THE ORDER OF 10^4 BAR THEN THE SAME VAPOUR WILL SUDDENLY CONDENSE AS PUMP DEVELOPS PRESSURE WHICH WILL ALSO GENERATE HIGH LOCALISED VACUUM / CAVITY WHICH WOULD CAUSE PUMP HIGH VIBRATION, NOISE AND CONSEQUENTLY MECHANICAL DAMAGE
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NET POSITIVE SUCTION HEAD (NPSH)

NPSH = (SUCTION. PR. VAPOUR PR.) /( * 9.81)
WHERE, NPSH: METER LIQUID COLUMN SUCTION PR. & VAPOUR PR. ARE IN N/M2

= LIQUID DENSITY IN KG/M3

EXAMPLE: SUCTION PR. = 1.5*10^5 N/M2 VAPOUR PR. = 1.013 * 10^5 N/M2 = 1000 KG/M3 NPSHA = 0.487* 10^5/ (1000*9.81) = 4.96 M
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NET POSITIVE SUCTION HEAD (NPSH)

LPG

P = 0.5 MLC (SUC. LINE), THEN NPSHA = 5 0.5 = 4.5 M

FOR LPG, VESSEL LIQUID PR. = VAPOUR PR.

FOR WATER AT 30 C, NPSHA IS NEARLY 14.5 M

5M

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MARGIN BETWEEN NPSHA & NPSHR

NPSHA-NPSHR 1.0 M FOR PRESSURE SERVICES
NPSHA-NPSHR 2.0 M FOR VACUUM SERVICES

NPSHA-NPSHR 5.0 M OR 1.5*NPSHR FOR LIQUIDS WITH DISSOLVED GASES WHICHEVER IS HIGHER
MARGIN IS NEEDED TO TAKE CARE OF UNCERTAINTIES IN CALCULATIONS / FLUID CHARACTERISTICS, PIPE ROUTING ETC.

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AFFINITY LAWS
GEOMETRICALLY SIMILAR PUMPS NORMALLY CONFIRM TO THE FOLLOWING AFFINITY LAWS Q2/Q1 = (N2/N1) * (D2/D1)3

H2/H1 = ((N2*D2) * (N1*D1))2

P2/P1 = (2/1)(N2/N1)3*(D2/D1)5 WHERE Q IS CAPACITY (M3/H) N IS SPEED (RPM) D IS IMPELLER DIAMETER (MM) H IS HEAD DEVELOPED BY PUMP (M LC) P IS POWER (KW) IS DENSITY (KG/M3) THE ABOVE LAWS ARE APPLICABLE AT THE SIMILAR OPERATING POINTS.

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PUMP CAPACITIES

NORMAL CAPACITY: THIS IS NORMALLY PFD FIGURE WITHOUT ANY SAFETY MARGIN
MAXIMUM CAPACITY: THIS FIGURE IS WITH SUFFICIENT MARGIN / FUTURE / CONTRACT REQUIREMENT. PIPING SHALL BE SIZED FOR MAXIMUM CAPACITY

RATED CAPACITY: THIS COULD BE MAXIMUM CAPACITY. PUMP VENDOR SHALL GUARANTEE THE PUMP FOR RATED CAPACITY INCLUDING MOTOR RATING
MINIMUM CAPACITY: CONTINUOUS SAFE MINIMUM CAPACITY IS THE FIGURE AT WHICH PUMP CAN RUN CONTINUOUSLY WITHOUT UNDUE ADVERSE EFFECT ON THE PUMP PUMP MAY GET DAMAGED IF IT IS RUN AT CAPACITY BELOW MINIMUM CAPACITY OR ABOVE RATED CAPACITY PUMP SHUT-OFF HEAD CORRESPONDS TO ZERO FLOW
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TYPES OF SEALS
Seal
Static Seal Dynamic Seal

Clearance Seal

Contact Seal

Labrynth Seals

Bushings

Compression Seal Gland Packing Lip Seals

Face Seal/ Mechanical Seal

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SEAL SELECTION FACTORS

1. 2. PROCESS LIQUID: DETERMINES THE MOC OF THE SEAL, STATIONARY SEALING MEMBERS AND THE MATING FACES. PRESSURE: THE PROPER TYPE OF SEAL, BALANCED OR UNBALANCED IS BASED ON THE PRESSURE ON THE SEAL AND ON THE SEAL SIZE. TEMPERATURE: DETERMINES THE USE OF THE SEALING MEMBERS. MATERIALS MUST BE SELECTED TO HANDLE LIQUID TEMPERATURE. CHARACTERISTICS OF LIQUID: ABRASIVE LIQUIDS CREATE EXCESSIVE WEAR AND SHORT SEAL LIFE. DOUBLE SEALS OR CLEAR LIQUID FLUSHING FROM AN EXTERNAL SOURCE ALLOW THE USE OF MECHANICAL SEALS ON THESE DIFFICULT LIQUIDS. ON LIGHT HYDROCARBONS BALANCED SEALS ARE OFTEN USED FOR LONGER SEAL LIFE EVEN THOUGH PRESSURES ARE LOW.

3.

4.

5.

RELIABILITY AND EMISSION CONCERNS: THE SEAL TYPE AND ARRANGEMENT SELECTED MUST MEET THE DESIRED RELIABILITY AND EMISSION STANDARDS FOR THE PUMP APPLICATION.
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SEAL / API FLUSHING PLAN SELECTION

REFER TO
API 682 FOR SHAFT SEALING SYSTEMS FOR CENTRIFUGAL AND ROTARY PUMPS

ISO 21049 FOR SHAFT SEALING SYSTEMS FOR CENTRIFUGAL AND ROTARY PUMPS

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TYPES OF SEALS

LABRYNTH SEALS

CLEARANCE BUSH

COMPRESSION PACKING

SIMPLE MECH SEAL

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TYPES OF SEALS

TANDEM SEAL

DRY GAS SEAL

DUAL BACK TO BACK

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TYPES OF SEAL FLUSH PLAN

API PLAN 11

API PLAN 52

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TYPES OF SEAL FLUSH PLAN

API PLAN 53

API PLAN 62

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THANK YOU !!!

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