API Pumps

design,
application
and selection
Pumps Technology - Classification of Pumps

• API 610 • ANSI/HI • ASME • ISO 5199 • NFPA 20 • 100-012

API STANDARDS

H.I.

ISO

Enppi SPECIFICATIONS
NFPA
ASME
• API 674 9.1-9.5 B73.1 • ISO 1940 • 100-014
• API 676 • ANSI/HI • ASME • ISO • 100-027
• API 682 1.3 B73.2 10816-1
• API 685 • ANSI/HI • ASME
6.1-6.5 B73.3
• API 686
• ANSI/HI
10.1-10.5
• ANSI/HI
3.1-3.5
• ANSI/HI
2.3

Law 4/1994 amended by the law 9/2009

٢ @ Pumps Technology Mechanical Dept. June 21

Introduction to Pumps Technology
Pump Types

٣ @ Pump Design Guide Mechanical Dept. June 21

Introduction to Pumps Technology
Pump Types

٤ @ Pump Design Guide Mechanical Dept. June 21

Scope:
• This International Standard specifies requirements for centrifugal pumps, including pumps running in reverse as
hydraulic power recovery turbines, for use in petroleum, petrochemical and gas industry process services.
• This International Standard is applicable to overhung pumps, between-bearings pumps and vertically suspended
pumps (see Table 1).
• Relevant industry operating experience suggests pumps produced to this International Standard are cost effective
when pumping liquids at conditions exceeding anyone of the following:

1. discharge pressure (gauge) 1 900 kPa (275 psi; 19,0 bar)

2. suction pressure (gauge) 500 kPa (75 psi; 5,0 bar)

3. pumping temperature 150°C (300 OF)

4. rotative speed 3600 rlmin

5. rated total head 120 m (400 ft)

6. impeller diameter, overhung pumps 330 mm (13 in)

Why:

The equipment (including auxiliaries) covered by this International Standard shall be designed and
constructed for a minimum service life of 20 years (excluding normal-wear parts as identified in Table 20) and at
least 3 years of uninterrupted operation. Shutting down the equipment to perform vendor-specified maintenance
or inspection does not meet the continuous uninterrupted operation requirement. It is recognized that these
requirements are design criteria and that service or duty severity, mis-operation or improper maintenance can
result in a machine failing to meet these criteria.
Pumps types
1-OH1
Pumps types
Pumps types
6.6.9 Shafts shall be machined and finished throughout their length so that the TIR is not more than 25 µm
(0,001 in).
6.9.1.3 To obtain satisfactory seal performance, the shaft stiffness shall limit the total deflection under the most
severe dynamic conditions over the allowable operating range of the pump with maximum diameter impeller(s) and
the specified speed and liquid to 50 !-1m (0,002 in) at the primary seal faces. This shaft-deflection limit may be
achieved by a combination of shaft diameter, shaft span or overhang, and casing design (including the use of dual
volutes or diffusers). For one- and two-stage pumps, no credit shall be taken for the liquid stiffening effects of
impeller wear rings. For multistage pumps, liquid stiffening effects shall be considered and calculations shall be
performed at both one and two times the nominal design clearances. The liquid stiffness of product-lubricated
bearings and bearing bushings shall be calculated at both one and two times the nominal design clearances.
7.1.7 Unless otherwise specified, motors for vertical pumps shall have solid shafts. If the pump thrust bearings
are in the motor, the motors shall meet the shaft and base tolerances shown in Figure 36
6.8.2 The seal cartridge shall be removable without disturbing the driver.
6.1.25 Except for vertically suspended pumps and integrally geared pumps, pumps shall be designed to permit
removal of the rotor or inner element without disconnecting the suction or discharge piping or moving the driver.
Basic design General Requirements:
6.1.11 Pumps that have stable head/flowrate curves
(continuous head rise to shutoff) are preferred for all
applications and are required if parallel operation is
specified. If parallel operation is specified, the head rise
from rated point to shutoff shall be at least 10 %. If a
discharge orifice is used as a means of providing a
continuous rise to shutoff, this use shall be stated in the
proposal.

6.1.12 Pumps shall have a preferred operating region of 80

% to 110 % of best efficiency flowrate of the pump as
furnished. Rated flow shall be within the region of 70 % to
120 % of best efficiency flowrate of the pump as furnished.
6.8.2 The seal cartridge shall be removable without disturbing the driver.
6.1.17 The need for cooling shall be determined by the vendor, and the method shall be agreed upon by the
purchaser. Fan cooling should be the first choice. If fan cooling is inadequate, one of the plans in Annex B shall be
selected. The cooling system shall be suitable for operation with the coolant type, pressure and temperature
specified by the purchaser. The vendor shall specify the required flow. To avoid condensation, the minimum
temperature at the cooling-water inlet to bearing housings should be above the ambient air temperature.
Testing
Pumps Technology – Pump Performance

Energy imparted to the fluid by a pump consists of useful energy in the form of:

Pressure
Fluid temperature rise and velocity
or it may become a loss through conversion to atmospheric heat and noise

All of these values may be arithmetically converted to head

STATIC HEAD
Head is equal to the height of a column liquid that could be supported by the available, or
useful energy.

P
Pumps Technology - Pump Performance
All forms of energy involved in a liquid flow system can be expressed in terms of
meter(feet) of liquid.
PRESSURE HEAD
The total of these heads is the total system head or the work which pump must
perform in the system

STATIC
DISCHARGE
SUCTION HEAD
VELOCITY HEAD

SUCTION
FRICTION HEAD
STATIC SUCTION
LIFT DISCHARGE
DISCHARGE FRICTION HEAD
VELOCITY HEAD
Pumps Technology - Pump Performance
The total head of a pump is the difference between the energy level at the pump discharge
(point 2) and that at the pump suction (point 1).
Pumps Technology - Pump Performance
The change in internal energy is equal to the
amount of energy added by heating minus the
amount lost by doing work on the environment.

The first law of thermodynamics for the pump can be

expressed in the form of the adiabatic steady-flow energy
equation

shaft power Ps is transformed into fluid power, which is

the mass flow rate times the change in the total enthalpy
Pumps Technology - Pump Performance

Leakage Losses past

the impeller and
back into the inlet
eye
Mechanical losses in
bearing, seals & fluid
friction on the outside
surfaces og the
impeller shrouds

Hydraulic Losses in
flow passages of the
pump
Pumps Technology - Pump Performance – NPSHA

PB = Barometric pressure in feet absolute.

VP = Vapor pressure of the liquid at
maximum pumping temperature, in
feet absolute.
P = Pressure on surface of liquid in closed
suction tank, in feet absolute.
Ls = Maximum static suction lift in feet.
LH = Minimum static suction head in feet.
hf = Friction loss in feet in suction pipe at
required capacity

Calculation of system Net Positive Suction Head Available for typical suction conditions
Pumps Technology - Classification of Pumps

IMPELLER DESIGN VS SPECIFIC SPEED

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Pumps Technology - Classification of Pumps

٦٨ @ Pumps Technology
Pumps Technology - Classification of Pumps

٦٩ @ Pumps Technology
Pumps Technology - Classification of Pumps

٧٠ @ Pumps Technology
Pumps Technology - Pump Performance - Curves

TDH NPSHR

Impeller Efficiency
Diam.

BkW
Min.
Continuou
s Stable
Flow line

Rated
Point

Flow
Pump Performance – NPSH

Vapor pressure is the pressure required to keep a liquid in the Vapor Pressure
liquid state.

NPSH stands for Net Positive Suction Head, and reflects the energy left in a fluid when
the fluid is captured by the impeller and flung out to the casing. There are two
expressions for NPSH: NPSHAvailable and NPSHRequired

NPSHAvailable is a function of the system in which the pump operates.

NPSHavail = hs - hvpa + hst - hfs

NPSHRequired is a function of the pump design.

Pump Performance – Cavitation

Cavitation occurs when a fluid's operational pressure drops below it's vapor pressure
causing gas pockets and bubbles to form and collapse.
The collapse or "implosion" is so rapid that it may be heard as a rumbling noise, as if you
were pumping gravel.

Collapse of a vapor bubble

Impeller cavitation regions
Pump Performance – Cavitation

The accompanying noise is

the easiest way to recognize
cavitation. Besides possible
impeller damage, excessive
cavitation results in reduced
capacity due to the vapor
present in the pump. Also,
the head may be reduced
and/or be unstable and the
power consumption may be
erratic. Vibration and
mechanical damage such as
bearing failure can also occur
Pumps Technology - Pump Performance – NPSHR

the pump is supplied from a closed tank in which the

level is held constant and the NPSHA is adjusted by
varying the air or gas pressure over the liquid, by
varying the temperature of the liquid, or by varying
both.

the pump is run at constant rate of flow and speed

with the suction condition varied to produce
cavitation. Plots of head shall be made for various
NPSH values.

As NPSHA is reduced, a point is reached where the

curves break away from a straight-line trend, indicating
a condition under which the performance of the pump
may be impaired.

The 3% drop in head is the standard to determine

NPSHR.

٧٥ @ Pumps Technology Mechanical Dept. June 21

Pumps Technology - Pump Performance – Affinity Law

To reduce cost, pump casings usually are designed to accommodate several different impellers.

Also, a variety of operating requirements can be met by changing the outside diameter of a given radial
impeller or changing pump speed.

With impeller diameter D held constant: With speed N held constant:

Q1 N Q1 D
A. = 1 A. = 1
Q2 N2 Q2 D2
H1 N H1 D
B. = ( 1 )2 B. = ( 1 )2
H2 N2 H2 D2
BHP1 N BHP1 D
C. = ( 1 )3 C. = ( 1 )3
BHP2 N2 BHP2 D2
Pumps Technology - Pump Performance – Affinity Law

300 1750
A.  Q2  343 gpm
Q2 2000
1601 1750 2
B. ( ) H 2  209 ft
H2 2000
201 1750 3
C. ( ) BHP  30 hp
BHP2 2000

Approximate characteristics of centrifugal pump

The effect of liquid characteristics on performance
The effect of increased viscosity on centrifugal pump performance can
be significant. Higher viscosity increases the friction losses, hence the
power. In addition, the head capacity curve drops off as viscosity is
increased. Based on higher power, and less head, the overall effect is a
significant drop in efficiency. The Hydraulics Institute has published
curves for estimating pump performance with liquids more viscous
than water.
There are application methods for using the viscosity correction
factors, they are: Initial pump selection
The procedure to use in pump selection is as follows:
1. Locate pump flow - G.P.M.
2. Proceed vertically to pump head - Ft.
3. Move horizontally to specified viscosity - SSU or CTS.
4. Draw a vertical line to locate Efficiency (Ce), Flow (Ca) and Head (Ch)
correction factors.
5. Using the correction factors obtained for flows from 60% to 120%
of flow, generate a head and efficiency curve vs flow for the specified
viscosity.
5. Multiply values on the pump curve (tested on water) by the
appropriate correction factors to obtain the actual values for the
specified viscosity.

As a rule of thumb, centrifugal pumps should not be used for liquids

whose viscosity is greater than 500 SSU. Figure 3.14 presents the effects
of viscosity on centrifugal pump head and horsepower curves.
Figure shows the relationship between specific gravity and head
(energy) produced by the pump to overcome the head (energy)
required by the system, and the horsepower required to deliver the
specified flow rate and head (energy). Also, once the performance of
a pump is known, the discharge pressure and horsepower will be
influenced by changes in specific gravity of the liquid being pumped.
head (energy) required is a result of the difference in static
pressure and elevation head, and friction loss which is plotted
against flow rate. Different process systems have different head
(energy) required curve shapes A reflux loop for example, is
comprised of friction loss only and will have a relatively steep
system resistance curve, whereas a boiler feed pump with a
relative small system resistance, will have a system resistance
curve which is less steep. One can see that the combination of
a relatively flat system curve and pump characteristic curve
which has the shutoff head lower than the maximum head, can
lead to unstable operation. The most common system
characteristic is the intermediate case - examples being
bottoms pump and pipeline pump
Pumps Technology -
Pump Selection Criteria

Process Conditions
(Fluid composition, solids, °C, S.G, cP, Pv, NPSHA, Q, ∆H)

Operating Philosophy
(Continuous, Intermittent, Spare, Criticality, NPSHA, Location )

Hydraulic Coverage Charts

(Head vs Capacity)

Pump Types
(+ve Displacement, Centrifugal, Horizontal, Vertical, High Speed, Seal, Driver ...etc.)
Introduction to Pumps Technology
Selecting the right pump

Operating a pump at or near its BEP not only

minimizes energy costs, also decreases
maintenance requirements.

Over-sized pump; requires flow control

(throttle valve or Bypass line) & efficiency is
reduced

٨٤ @ Pump Design Guide Mechanical Dept. June 21

Pumps Technology – Centrifugal Pump Selection

Operating
Philosophy

Process Hydraulic
Conditions Coverage Chart

End of Curve
Operation for Capacity
Centrifugal Control
pump

Parallel &
Series
Operation
٨٥ @ Pumps Technology Mechanical Dept. June 21
Introduction Pumps Technology
Process Conditions

 Fluid Composition
 Entrained solids, gases & corrosive materials
 °C, MDMT
 SG, cP, Pv
 Psuc
 Variation in operating conditions
 Flow
 ΔP, ΔH, Pdisch
 NPSH
 Acceleration head basic data

٨٦ @ Pump Design Guide Mechanical Dept. June 21

Introduction Pumps Technology
Operating Philosophy

 Is the intended service critical?

 Is downtime acceptable or should the pump be spared (33%, 50% or 100%)?
 Shall the spare pump be started manually or automatically?
 Is NPSHA sufficient for al modes of operation? (Parallel operation, series
operation).
 What type of foundation will be used?
 Is the site located onshore or offshore?
 Should space and weight be major considerations?
 Is the fluid toxic or flammable?
 Is a special shaft sealing method required?
 Will the service require special construction or pump design? Can operating
experience in this service be verified?
 What utilities are available and what is the preferred driver type?
 Are there abnormal or off-design operating conditions that need to be
addressed?

٨٧ @ Pump Design Guide Mechanical Dept. June 21

Shaft Sealing
Leakage along pump shaft can be minimized by
Packing and Mechanical Seal.

Sealing area in a typical centrifugal pump

Packing is used to minimize leakage along the
shaft by filling the stuffing box but it can’t
prevent leakage by 100%.

Mechanical Seal is used when NO leakage is

required specially in hazard cases mechanical
seal shall be used.

Centrifugal Pump, Liquid End

Shaft Sealing – Packing

Packing on shaft sleeve

Lantern ring
Shaft Sealing – Mechanical Seal Basic Design

Non-Pusher Pusher
The non-pusher or bellows seal does not have to Incorporate secondary seals that move axially along
move along the shaft or sleeve to maintain seal a shaft or sleeve to maintain contact at the seal
face contact. The main advantages are its ability to faces. This feature compensates for seal face wear
handle high and low temperature applications, and and wobble due to misalignment. The pusher seals
does not require a secondary seal (not prone to advantage is that it’s inexpensive and commercially
secondary seal hang-up). A disadvantage of this available in a wide range of sizes and configurations
style seal is that its thin bellows cross sections
must be upgraded for use in corrosive
environments
Shaft Sealing

Plan 11, Single Seal

Shaft Sealing – Mechanical Seal Selection

The proper selection of a mechanical seal can be made only if the full operating conditions are
known:

1. Liquid
2. Pressure
3. Temperature
4. Characteristics of Liquid
5. Reliability and Emission Concerns
Centrifugal Pump – Bearing House

Bearing
House
Cooling Fan

Constant
Level Oiler

Bearing
House Bulls
Eye
Pumps Technology – Shaft Sealing – Packing
Pumps Technology – Shaft Sealing – Packing
Pumps Technology – Shaft Sealing – Packing

A typical pump packing failure

٩٩ @ Pumps Technology Mechanical Dept. June 21

Pumps Technology – Shaft Sealing – Packing

Advantages Disadvantages

It is relatively inexpensive to purchase. It lower pump efficiency.

It is rarely the cause of catastrophic Packing and sleeve require regular
pump failure. replacement.
It can be adjusted or replaced without The packing requires regular
pump disassembly. adjustment.
Most maintenance personnel are Adjustment requires the touch of an
accustomed to its use. experienced personnel
It often requires considerable volume of
flush water, to ensure lubrication
between packing and sleeve. It is
acceptable if the pumps are handling
clean water.

١٠٠ @ Pumps Technology Mechanical Dept. June 21

Firewater Pumps – Pumps Basics - Mechanical Seal

١٠١ @ Firewater Pumps Mechanical Dept. June 21

 PUMP SHAFT

IMPELLER BEARINGS
 A LIQUID IS SUPPLIED TO THE PUMP
“SUCTION”

CENTRIFUGAL FORCE EXPELS THE LIQUID OUT FROM

THE IMPELLER

AS THE PUMP SHAFT ROTATES

Firewater Pumps – Pumps Basics – Mechanical Seal

١٠٤ @ Firewater Pumps Mechanical Dept. June 21

Firewater Pumps – Pumps Basics – Mechanical Seal

١٠٥ @ Firewater Pumps Mechanical Dept. June 21

Pumps Technology – Shaft Sealing – Mechanical Seal Basic Design

Non-Pusher Pusher
The non-pusher or bellows seal does not have to move Incorporate secondary seals that move axially along a shaft
along the shaft or sleeve to maintain seal face contact. or sleeve to maintain contact at the seal faces. This feature
The main advantages are its ability to handle high and low compensates for seal face wear and wobble due to
temperature applications, and does not require a misalignment. The pusher seals advantage is that it’s
secondary seal (not prone to secondary seal hang-up). A inexpensive and commercially available in a wide range of
disadvantage of this style seal is that its thin bellows cross sizes and configurations
sections must be upgraded for use in corrosive
environments

١٠٦ @ Pumps Technology Mechanical Dept. June 21

Pumps Technology – Shaft Sealing – Mechanical Seal Selection

The proper selection of a mechanical

seal can be made only if the full
operating conditions are known:

1. Liquid
2. Pressure
3. Temperature
4. Characteristics of Liquid
5. Reliability and Emission Concerns

١٠٧ @ Pumps Technology Mechanical Dept. June 21

 General and Default Materials

Silicon Carbide 316SS Gland Plate

“Premium Grade”
Carbon

Setscrews
Hastelloy C harder than
Springs shaft

Viton O-Rings 316SS Sleeve