Pumps and Compressors

Quiz
Write down the steps to be followed for
accomplishing a pipeline project.
In two-axis graph, draw approximated curve to
indicate the relationships between friction loss vs
flow rate for a horizontal pipeline in laminar flow
regime and turbulent flow regime

Law of conservation of energy

Energy is defined as the ability to do work
Energy can neither be created nor destroyed;
it can only be changed from one form to
another.
Energy in pipeline is expressed in form of
pressure or pressure head
Examples of such energy in pipelines: kinetic
energy and potential energy.

Law of conservation of energy

Energy in pipelines

Pipelines pocess internal energy in both static

(non-flowing) and dynamic (flowing)
conditions.
In static condition the total energy at any
point is the internal static pressure head plus
elevation
In dynamic condition there is exerted energy
and dissipated energy
The exerted energy is from pumps or
compressors and the dissipated energy is due
to flow (pressure losses)

What is Pump?
A pump is a device that moves fluids (liquids or gases), or sometimes
slurries, by mechanical action.

Centrifugal pump is a kinetic pump

Schematic Diagram of Positive Displacement

Pump

http://www.youtube.com/watch?v
=kKpESDDJQso

Advantages and disadvantages of Positive

Displacement Pump
Advantages

Versatile
Compact Design
High-Viscosity Performance
Continuous Flow Regardless of Differential Pressure
Ability to Handle High Differential Pressure
Disadvantages
This form of transferring an emotional response

Pump Performance Trade offs

Parameter

Centrifugal Pumps

Reciprocating Pumps

Rotary Pumps

Medium/High Capacity,
Low/Medium Pressure

Low Capacity,
High Pressure

Low/Medium Capacity,
Low/Medium Pressure

100,000 GPM

10,000 GPM

10,000 GPM

No

Yes

Yes

6,000 PSI

100,000 PSI

4,000 PSI

No

Yes

Yes

Smooth or Pulsating Flow

Smooth

Pulsating

Smooth

Variable or Constant Flow

Variable

Constant

Constant

No

Yes

Yes

Space Considerations

Requires Less Space

Requires More Space

Requires Less Space

Costs

Lower Initial
Lower Maintenance
Higher Power

Higher Initial
Higher Maintenance
Lower Power

Lower Initial
Lower Maintenance
Lower Power

Suitable for a wide range including

clean, clear, non-abrasive fluids to
fluids with abrasive, high-solid
content.

Suitable for clean, clear, nonabrasive fluids. Specially-fitted

pumps suitable for abrasiveslurry service.

Requires clean, clear, nonabrasive fluid due to close

tolerances

Not suitable for high viscosity fluids

Suitable for high viscosity fluids

Optimum performance with

high viscosity fluids

Lower tolerance for entrained gases

Higher tolerance for entrained

gases

Higher tolerance for entrained

gases

Optimum Flow and Pressure

Applications
Maximum Flow Rate
Low Flow Rate Capability
Maximum Pressure
Requires Relief Valve

Self-priming

Fluid Handling

Centrifugal Pumps
Centrifugal pumps are a type of pumps
use centrifugal force to develop pressure
Centrifugal pumps can handle variable
head and flow rates
Centrifugal
pumps
can
handle
multiproducts and other liquids over wide
ranges of fluid properties

Centrifugal Pumps

Important terms for Centrifugal Pump

Flow is a volume measure to establish pump capacity per unit of time, usually as
GPM
Head is a pressure measure represented by how high the pump can lift a column
of liquid, usually in feet.
Point 2
Point 1

Centrifugal pumps operation

The sequence of the operation of centrifugal
pump is as follows:
1

2
3
4

Mechanical rotation of the shaft by prime mover

Rotation of impeller inside casing
Flow of liquid into the impeller from the suction
pipe

Liquid is accelerated by impeller rotation

Conversion of velocity energy into pressure

Centrifugal pumps characteristics

Below are some
centrifugal pumps:

characteristics

of

Most common and preferred for application to pipelines

Have minimal pulsation
Capable of efficient performance over a wide range of
pressures and flow rates
Discharge pressure is a function of liquid density
Cheaper than other pumps
High reliable
Can be used with viscosity up to 300 cp with high efficiency
Can be multistaged for higher pressure

Centrifugal pumps performance curves

Performance curves of an individual centrifugal
pump provides many information of the pumps
such as its model, size, rated speed, impeller type
and available diameters, pumps specific speed,
and net positive suction head required (NPSHR).
In addition, many curves are included such as:
1. H-Q curves for different impellers
2. Flow rate versus power (P-Q) curves based on water
3. Flow rate versus efficiency (efficiency-Q) curves

Centrifugal pumps performance curves

Centrifugal pumps power and efficiency

Brake horsepower (BHP) is the actual power delivered to the
pump shaft expressed as:
Hydraulic horsepower is the liquid power developed by the pump
expressed as:
The pump efficiency is the ratio between the hydraulic
horsepower and brake horsepower

Centrifugal pumps affinity laws

Pressures and flow rate of a centrifugal pump can be
changed by changing its speed or its impeller size.
For radial-impeller centrifugal pumps the pressure head,
flow rate, and power are changed following the
equations below:
In case of changing impeller diameter only:
In case of changing speed only:

Centrifugal pumps affinity laws

In case of changing both diameter and speed:

Centrifugal pumps H-Q curve and system

H-Q curve
If the system (pipeline) H-Q curve is changed the pump
H-Q curve will consequently change.
For example if the throttle valve at discharge side of the
pump is partially closed the system pressure will
consequently increase (throttle control) which turn in
changing the system Q-H curve.
If the speed of the pump is reduced from N1 to N2 or
the impeller diameter is reduced from D1 to D2 the
pump Q-H curve will change

Centrifugal pumps H-Q curve and system

H-Q curve

NPSH

70%

50

60%

cien

cy

60

40

50%
40%

30
20
10
0

100

200

300
Q (m3/hr)

400

Efficiency
%

80%

Pump Curve

effi

H (m)

70

NPSH - m

6
4
2
0

General rules for sizing and selecting of

Centrifugal
Component General rule
Suction and Suction is never smaller than discharge
discharge
The bigger discharge the higher flow rate
Impeller
The larger impeller diameter the higher discharge
diameter
pressure (the pressure head is proportional to the
square of impeller diameter)
The impeller diameter is limited by speed (1200 rpm
for 26 and 3600 rpm for 12)
Speed
Flow rate varies linearly, the head varies with
square, and the power varies with cubic of speed
Suction
Determined by NPSHR

Centrifugal pumps cavitation

Cavitation is a phenomena that may lead to very severe
damage of the centrifugal pump. Cavitation occurs due to
the following:
A local pressure drop causes an increase in velocity and hence
acceleration
A liquid may convert to a vapor phase if the pressure falls below its
vapor pressure
The vapor occupies larger volume than liquid.

The effects of cavitation include:

Noise and vibration
Pump damage
Fall-off of the pump performance and efficiency

Net Positive Suction Head (NPSH)

NPSH is the total absolute suction pressure less the vapor
pressure of the pumped liquid.
It is the head required to push the liquid to the pump to
control cavitation.
Available and require NPSH

ha is the absolute pressure head at the surface of the liquid supply

level
hvp is the vapor pressure of the liquid at pumping temperature
hst is the static pressure head at the pump inlet centerline
hst is the suction losses including entrance losses and piping friction

Centrifugal Pump Characteristic Curves

Pump manufacturers provide information on the performance
of their pumps in the form of curves, commonly called pump
characteristic curves (or simply pump curves).
In pump curves the following information may be given:
the discharge on the x-axis,
the head on the left y-axis,
the pump power input on the right y-axis,
the pump efficiency as a percentage,
the speed of the pump (rpm = revolutions/min).
the NPSH of the pump.

Compressors

Compressors
What is a Compressor?
A mechanical device that increases the pressure of a gas by reducing its
volume.
Similar to a pump Increases the pressure on a fluid and transport it
through a pipe.
What is key difference between a Fluid and a Gas?
Compressibility a gas is compressible
What happens to gas volume as it is compressed?
Decreases
What happens to the Temperature of the Gas as it is compressed?
Increases

Compressors
Compressors are classified by how they work
Two Categories of Compressors
Positive Displacement
Dynamic
What is a Positive Displacement Compressor?
A compressor that confines successive volumes of gas within a closed
space in which the pressure of the gas is increased as the volume of the
closed space is decreased.
Intermittent Flow
What is a Dynamic Compressor?
A compressor using a rotating mechanism to add velocity and pressure
to gas.
Continuous Flow

SURGING
Surge - is the point at which the
compressor cannot add enough
energy to overcome the system
resistance.

Most turbo machines are designed to

easily withstand occasional surging.

http://www.youtube.com/watch?v=OT8
Y0DeQ_cw

Pressure

This causes a rapid flow reversal (i.e.

surge). As a result, high vibration,
temperature increases, and rapid
changes in axial thrust can occur.

Net Flow line

Surging
Line

Design
Line

Volume flow

These occurrences can damage

the rotor seals
rotor bearings
the compressor driver and
cycle operation.

Centrifugal compressors
The major characteristics are:
Size
Starts about 500 hp.
1,000 hp increments to 20,000 hp.
Advantages
High horsepower per unit of space and weight.
Turbine drive easily adapted to waste-heat recovery for high fuel
efficiency.
Easily automated for remote operations.
Can be skid mounted, self-contained.
Low initial cost.
Low maintenance and operating cost.
High availability factor.
Large capacity available per unit.
Disadvantages
Lower compressor efficiency.
Limited flexibility for capacity.
Turbine drives have higher fuel rate than reciprocating units.
Large horsepower units mean that outage has large effect on process
or pipeline capabilities.

Reciprocating compressors
The major characteristics are:
Size
Numerous sizes from 50 hp to 3000 hp.
2, 4, or 6 compressor cylinders are common.
Advantages
Can be skid mounted.
Self-contained for easy installation and easily moved.
Low cost compared to low-speed reciprocating units.
Easily piped for multistage compression.
Size suitable for field gathering offshore and onshore.
Flexible capacity limits.
Low initial cost.
Disadvantages
High-speed engines are not as fuel efficient as integral engines
(7,500 to 9,000 Btu/bhp-hr).
Medium range compressor efficiency (higher than centrifugal; lower
than low-speed).
Short life compared to low-speed.
Higher maintenance cost than low-speed or centrifugal.

Compressor Station Schematic

Absolute Pressure and Gauge Pressure

Pa = Pg + Patm

Absolute pressure is zero-referenced against a perfect vacuum, so it is equal to

gauge pressure plus atmospheric pressure.
Gauge pressure is zero-referenced against ambient air pressure, so it is equal to
absolute pressure minus atmospheric pressure. Negative signs are usually
omitted.

Compression Ratio

Problem

Consider Ps = 850 psig and Pd = 1430 psig

Problem 3- Characteristic curves

Consider a pipeline with the following data:
Total length=1504 km, D=28, viscosity=0.2Pa.s,
density=850kg/m3, flow rate=200000bbl/day. Draw
the characteristics curve within laminar and turbulent
ranges?
Solution
Using the exponential equation

Problem 3- Characteristic curves

1- calculate the kinetic viscosity (0.000236 m2/s)
2-convert the flow rate to SI unit (0.3686 m3/s) and
calculate velocity (0.931 m/s)
3- calculate Reynolds number (2809 turbulent)
4- calculate the critical velocity (0.696 m/s) and the
critical flow rate (0.275 m3/s)
5. Consider the pipeline is horizontal with negligible
secondary losses. Use the characteristic equation.
Substitute the values of and m according to flow
regime (laminar and smooth turbulent)

Problem 3- Characteristic curves

Results
Characteristic equations:
Laminar
H f 5779Q
Turbulent
H f 23330Q1.75

Problem 3- Characteristic curves

Results
Laminar Flow
Turbulent Flow

Flow rate m3/s Pressure loss m

0
0
0.1
578
0.12
693
0.15
866
0.18
1040
0.21
1214
0.24
1387
0.27
1560
0.3
2837
0.34
3531
0.37
4100
0.4
4690
0.43
5300
0.46
6000
0.5
6900

Problem 3- Characteristic curves

Results: Characteristic Curve

Turbulent
Laminar

CW
Redo the calculation considering uphill inclination
with 20, viscosity=100 mpa.s.
Draw three characteristic curves for pipelines with the
same data considering three diameters 20, 26, and
32.

Problem 3- Operating Point

A pump station is used to operate the pipeline above.
The pump station was operated at two flow rates, the
pressure head at each flow rate is listed in the
following table:
Flow rate m3/s
0.05

Pressure head m
10000

0.35

6000

Formulate the pump station performance equation in the

form
, draw the performance curve and
H A BQ
determine the operating point?
2

Problem 3- Operating Point

Procedure
1- Convert the flow rate units to m3/hr
2- form two equations using the flow rates and
corresponding pumping pressure from the table above.
3- determine the values of A and B in the pump performance
equation
4- use the same flow rates used to draw the pipeline
characteristics curve to draw the pump performance curve
on the same paper
5- the intersect point of the two curves is the operating pont

Problem 3- Operating Point

Results
The pump performance equation
H p 10083 0.00257Q 2

CW
What would be the pipeline diameter if we want to
increase the operating point 10%.

5 minutes Q&A