GS Pump Training From Korea Engineering

CENTRIFUGAL PUMPS
GS

PUMP PROVIDES AM MEANS OF ADDING ENERGY TO A FLUID IN ORDER
TO HAVE THE CAPABILITY OF TRANSPORTING THE FLUID FROM ONE
LEVEL OF POTENTIAL AND KINETIC ENERGY TO ANOTHER.
DEPENDING ON A MULTITUDE OF PARAMETERS, VARIOUS MEANS OF
ADDING ENERGY ARE EMPLOYED. SOME OF THE MOST PROMINENT
CONSIDERATIONS IN MAKING A PUMP SELECTION ARE THE FOLLOWINGS.
- CAPACITY (FLOW RATE, M3/HR, GPM)
- DIFFERENTIAL PRESSURE (DIFFERENTIAL HEAD): DISCH.-SUC. P
- FLUID CHARACTERISTICS: S.G., VISCOSITY, SLURRY, CONTENTS.
- TEMPERATURE
- SUCTION PRESSURE: KG/CM2, PSIG

PUMPS- Introduction of Pumps
2
CENTRIFUGAL
PUMP
PUMPS- Various Type of Pumps
Conventional
Pump
Sealless Pump
Diaphragm
Pump
Reciprocating
Pump
Rotary Pump
POSITIVE
DISPLACEMENT
PUMP
Vertical Pump
Magnetic Driven
Pump
Horizontal Pump
Canned Pump
Screw Pump
Gear Pump
3
Centrifugal pumps are the most frequently used pumps. They are widely
accepted because they combine a relatively low initial cost with high
reliability, compact size, non-pulsation flow, and easy maintenance. They are
also widely available, cover broad flow / pressure application ranges, and
can operate over a wide flow range.

-General and Chemical pumps: Non-critical, non-hazardous services.
ANSI B73.1 and ANSI B73.2, ISO 2858 pumps

-Heavy Duty pumps: Refinery application.
Critical, hazardous, heavy duty chemical. API 610.
PUMPS- Centrifugal pumps
OH1 : Single stage Overhung Impeller
ANSI or ISO
END SUCTION
TOP DISCHARGE
5
OH2 : Single stage Overhung Impeller
API 610
6
OH3 : Single stage Overhung
Impeller, Vertical In-Line
Separate Bearing Bracket
API 610
7
Rigidly Coupled
API 610
8
Closed Coupled
(Motor Shaft = Pump Shaft)
API 610
9
High Speed Integrally Geared
So Called Sundyne Pump
API 610
10
BB1 : Axially Split Between
Bearing 1 or 2 Stage Pump
API 610
11
BB2 : Radially Split Between
Bearing 1 or 2 Stage Pump
API 610
12
BB3 : Axially Split Between
Bearing Multi-Stage Pump
API 610
13
So Called Ring Section Pump
API 610
14
So Called Double Casing Pump
API 610
15
VS2 (Right)
Wet Pit, Vertically
Suspended Single Casing
Volute with Discharge
through the Column
VS1 (Left)
Wet Pit, Vertically
Suspended Single Casing
Diffuser with Discharge
through the Column
VS3 (Right)
Wet Pit, Vertically
Suspended Single
Casing Axial Flow
with Discharge
through the Column
16
VS5 (Right)
Vertically Suspended
Cantilever Sump Pump
VS4 (Left)
Vertically Suspended
Single Casing Volute
Line-Shaft Driven
Sump Pump
17
VS6 (Left)
Vertically Suspended Double Casing Diffuser
with Discharge through the Column Suitable
for Extremely Low NPSHa
18
Conventional Pump VS Magnetic Driven Pump
19
PUMPS- Basic Design
Suction Nozzle
Discharge
Nozzle
Impeller
Mechanical
Seal
Radial
Bearing
Thrust
Bearing
Shaft
Bearing
Housing
Sight Glass
Casing
Centerline
Mounted
Support
Shaft Key
20

21
PUMPS- Basic Design
1. Casing
1) Corrosion allowance shall be Min. 3mm for C.S casing.
2) Min. Nozzle Rating
Axially Split 1or 2 stage Pump and Single casing Vertically
suspended Pump : 125 # for C.I and 150 # for C.S
All other Pump : 300 #
3) Radial Casing shall be considered if:
Pumping Temp 200
Flammable or hazardous liquid with S.G 0.7
Flammable or hazardous liquid with Disch. Press. 100 bar G.
4) Centerline Supported in general.
22
PUMPS- Basic Design
2. Rotor
1) Fully enclosed impeller in general.
2) Mechanical seal design conforms to API 682.
3) Renewable Casing Wear Ring and Integral Wear Surface or
Renewable Wear Ring for Impeller. H shall be 50 BH unless they
have at least 400 BH.
4) Component shall be Dynamically Balanced to ISO G2.5.
23
PUMPS- Basic Design
3. Bearing
Condition Bearing type and arrangement
Radial and thrust bearing speed and life within limits for
rolling element bearings and Pump energy density
below limit
Rolling-element radial and thrust
Radial bearing speed or life outside limits for rolling-
element bearings and Thrust bearing speed and life
within limits And Pump energy density below limit
Hydrodynamic radial and rolling-element thrust
or
Hydrodynamic radial and thrust
Radial bearing speed or life outside limits for rolling-
element bearings and Thrust bearing speed and life
within limits And Pump energy density above limit
Hydrodynamic radial and thrust
Limits are as follows.
a) Rolling-element bearing speed: Factor, n.dm shall not exceed 500 000 where
dm is the mean bearing diameter [(d + D)/2)], expressed in millimetres;
n is the rotational speed, expressed in revolutions per minute.

b) Rolling-element bearing life: basic rating life, L10, in accordance with ISO 281, equivalent to at
least 25 000 h with continuous operation at rated conditions, and at least 16 000 h at maximum
radial and axial loads and rated speed.

c) Hydrodynamic radial and thrust bearings shall be used if the energy density [i.e. the product of
pump rated power, kW (hp), and rated speed, r/min] is 4,0 10
6
kW/min (5,4 10
6
hp/min) or
greater.
24
PUMPS- Basic Design
3. Bearing
Most rolling bearings consist of rings with raceways (an inner ring and an outer ring), rolling elements
(either balls or rollers) and a rolling element retainer.
The retainer separates the rolling elements at regular intervals, holds them in place within the inner and
outer raceways, and allows them to rotate freely.

Rolling elements come in two general shapes: ball or rollers. Rollers come in four basic styles:
cylindrical, needle, tapered, and spherical.
Balls geometrically contact the raceway surfaces of the inner and outer rings at points, while the
contact surface of rollers is a line contact.

Theoretically, rolling bearings are so constructed as to allow the rolling elements to rotate orbitally while
also rotating on their own axes at the same time.
While the rolling elements and the bearing rings take any load applied to the bearings (at the contact
point between the rolling elements and raceway surfaces), the retainer takes no direct load.
The retainer only serves to hold the rolling elements at equal distances from each other and prevent
them from falling out.
25
PUMPS- Basic Design
3. Bearing - Rolling Element
Rolling bearings come in many shapes and varieties, each with its own distinctive
features. However, when compared with sliding bearings, rolling bearings all have
the followings advantages:

(1) The starting friction coefficient is lower and only a little difference between this
and the dynamic friction coefficient is produced.

(2) They are internationally standardized, interchangeable and readily obtainable.

(3) Ease of lubrication and low lubricant consumption.

(4) As a general rule, one bearing can carry both radial and axial loads at the
same time.

(5) May be used in either high or low temperature applications.

(6) Bearing rigidity can be improved by preloading.
26
PUMPS- Basic Design
3. Bearing - Ball versus Roller
Generally speaking, when comparing ball and roller bearings of the same
dimensions, ball bearings exhibit a lower frictional resistance and lower face run-
out in rotation than roller bearings.

This makes them more suitable for use in applications which require high speed,
high precision, low torque and low vibration.

Conversely, roller bearings have a larger load carrying capacity which makes
them more suitable for applications requiring long life and endurance for heavy
loads and shock loads.
27
PUMPS- Basic Design
3. Bearing - Radial and Thrust
Almost all types of rolling bearings can carry both radial and axial loads at the
same time.

Generally, bearings with a contact angle of less than 45 have a much greater
radial load capacity and are classed as radial bearings; whereas bearings which
have a contact angle over 45 have a greater axial load capacity and are classed as
thrust bearings.

There are also bearings classed as complex bearings which combine the loading
characteristics of both radial and thrust bearings.
28
PUMPS- Basic Design
Deep groove ball bearing Angular contact ball bearing
29
PUMPS- Basic Design
Cylindrical roller bearing Needle roller bearing
30
PUMPS- Basic Design
Tapered roller bearing Spherical roller bearing
31
PUMPS- Basic Design
Thrust ball bearing Thrust roller bearing
32
PUMPS- Basic Design
4. Lubrication
1) Unless otherwise specified, bearings and bearing housings shall be
designed for oil lubrication using a mineral (hydrocarbon) oil.
2) Pressurized Lube oil system may be required if High Energy shall be
supported by the bearing.
1 rotating equipment
2 filter
3 electric motor
4 pump
5 internal baffle
6 max. operating level
7 min. operating level
8 pump suction level
9 heater (optional)
10 sloped bottom
11 drain
12 shaft-driven oil pump with
integral pressure relief
13 TCV (optional)
14 cooler
33
PUMPS- Basic Design
5. Driver
1) It can be electrical motor and/or general purpose steam turbine.
2) For electrical motor, following information shall be issued by the
purchaser.
Area classification
Voltage / Phase / Hertz
Ambient temp / Elevation
Explosion Proof Grade, Weather Proof Grade
3) Driver shall have the margin as defined in API 610 as minimum. It
shall be sized to accommodate all specified process variation such
as changes in capacity, differential pressure, S.G and viscosity.
Motor nameplate rating Percentage of rated
pump power (%)
kW HP
< 22 < 30 125
22 to 55 30 to 75 115
> 55 > 75 110
34
PUMPS- Basic Design
6. Coupling
1) Metal flexible element, spacer-type
couplings in accordance with AGMA 9000
Class 9 shall be provided.
2) Flexible elements shall be of corrosion-
resistant material.
3) Couplings shall be designed to retain the
spacer if a flexible element ruptures.
4) Coupling hubs shall be steel.
5) The spacer nominal length shall be at
least 125 mm (5 in) and shall permit
removal of the coupling, bearings, seal
and rotor, as applicable, without
disturbing the driver or the suction and
discharge piping.
6) If specified, couplings shall be balanced
to ISO 1940-1 grade G6.3.
35
PUMPS- Basic Design
7. Materials Pump Parts
Service Temp ()
Material
Class
Casing Impeller Shaft Wear Ring
C-6
Axially Split
12% Cr 12% Cr 12% Cr 12% Cr Hd
Boiler Feed
Water
> 95
S-6
Barrel
Carbon Steel 12% Cr
AISI 4140
12%Cr (N1)
12% Cr Hd
Sea Water < 95 (N2) Ni Resist D2 316 S.S Alloy 400
Sour Water < 260
D-1
S-6 (N3)
Duplex S.S Duplex S.S Duplex S.S Duplex S.S Hd
< 230
S-1
S-4 (N4)
Carbon Steel Cast Iron Carbon Steel Cast Iron
230~370
S-6
S-4 (N5)
Carbon Steel 12% Cr AISI 4140) 12% Cr Hd
Hydrocarbon
> 370 C-6 12% Cr 12% Cr 12% Cr 12% Cr Hd
Amine < 150 S-8 Carbon Steel 316 S.S 316 S.S 316 S.S Hd
N1) When Pumping Temp > 175
N2) For Sea Water Service, Vendor and Purchaser shall agree on the Materials. It shows only
examples for vertical type Cooling Water Pumps.
N3) When H2S rate is not severe, S-6 can be applied. Such decision shall be made by Process.
N4) S-1 Class is getting less popular by the need of material uniformity for spare parts. S-4 now days generally
accepted for the minimum requirement for hydrocarbon service.
N5) When the corrosivity of pumping liquid is low, S-4 can be used.
36
PUMPS- Performance Evaluation
-Pressure
ATM (Atmospheric Pressure): ,
Gauge Pressure: +
Vacuum Pressure
Absolute Pressure: .

-Head: m = {10 x Pressure (kg/cm2)} / S.G

-Specific Gravity (S.G.): , 4

-Power (kw)
kw = {(kgf/m3) x Total head (m) x flowrate (m3/h) } / 102
BHP: pump motor pump

-Efficiency
37
38
HEAD INCREASE
Pumps shall be capable of at least a 5 % head increase at rated conditions
by replacement of the impeller(s) with one(s) of larger diameter or different
hydraulic design, variable-speed capability or use of a blank stage.
Q
H
Min. Impeller
Max. Impeller
Rated Impeller
Rated Capacity
Rated Head
Head @ Max.
Impeller
Head @ Max. Impeller
Head Increase = ------------------------------
Rated Head
39
HEAD RISE
Pumps that have the 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.
Q
H
Min. Impeller
Max. Impeller
Rated Impeller
Rated Capacity
Rated Head
Shutoff Head
Shutoff Head
Head Rise = ------------------
Rated Head
40
NPSH Margin
NPSHa = Net Positive Suction Head Available
This is the pure suction head (or pressure) that system can give to the pump
after extracting all and any losses. It shall be calculated by the system
designer.

NPSHa = Suct. Press.+Liquid Elevation (Liquid Vapor Press.+All Losses)
To match the unit to Head (length), Press. To be divided by Density

NPSHr = Net Positive Suction Head Required
This is the pure suction head (or pressure) that pump needs from the
system. It is peculiar of each model of pump, hence, it shall be proposed by
pump vendor.
NPSH margin = NPSHa - NPSHr specified requirement
41
SPECIFIC SPEED
The best way to describe the shape of an impeller is to use its specific
speed number. Specific speed is calculated for the pumps performance at
best efficiency point with the maximum diameter impeller. This is a
dimensionless number that was generated by the formula :
0.75
BEP
BEP
Head
Q
Speed Ns
42
SUCTION SPECIFIC SPEED

Suction-specific speed is calculated for the pumps performance at best
efficiency point with the maximum diameter impeller and provides an
assessment of a pumps susceptibility to internal recirculation. It is
expressed mathematically by the following equation:
75 . 0
BEP
BEP
NPSHr
Q
Speed Nss
43
MINIMUM FLOW

-Minimum Continuous Stable Flow (MCF)
Shaft, Bearing pump vibration, noise
( BEP 10% )

-Minimum Thermal Flow (MTF)

44
CAVIATION
The pressure of the liquid in a centrifugal pump drops as it flows
from the suction flange through the suction nozzle and into the
impeller. The amount of pressure drop is a function of many
factors, including pump geometry, rotational speed, frictional
and hydraulic shock losses, and flowrate. If the pressure at any
point within the pump falls below the vapor pressure of the
liquid being pumped, vaporization or cavitation will occur.

HOW TO DETERMINE NPSHr
The pump manufacturer determines the NPSHr of an impeller
pattern by conducting a suppression test using water as the
pumped fluid. These tests are usually only made on the first
casting for an impeller pattern, not on individual pumps.

Normally, the NPSHr plotted on the traditional pump curve is
based on a 3% head loss due to cavitation, a convention
established many years ago in the Hydraulic Institute Standards.
Permitting this large a head loss means that cavitation would
already have been occurring, at some higher flow condition,
before performance loss was noticed.
45
CLASSIC CAVIATION
Classical cavitation occurs when the absolute pressure of a moving liquid is reduced to, or even below, the
vapor pressure of the liquid in the impeller eye. Bubbles are formed as a result of this pressure drop. Lower
pressures in the impeller eye are caused by variations in velocity of the fluid and friction losses as the fluid
enters the impeller.
The bubbles are caught up and swept outward along the impeller vane. Somewhere along the non-visible
side of the impeller vane, the pressure may once again exceed the vapor pressure and cause the bubbles to
collapse.
Implosions of these vapor pockets can be so rapid that a rumbling/cracking noise is produced (it sounds like
rocks passing through the pump). The hydraulic impacts caused by the collapsing bubbles are strong enough
to cause minute areas of fatigue on the metal impeller surfaces. Depending on the severity of the cavitation, a
decrease in pump performance may also be noted.
The first reaction to a cavitation problem is usually to check the NPSHa at the eye of the impeller and
compare this to the NPSHr by the impeller design. The ratio of NPSHa/NPSHr must be sufficiently large to
prevent the formation of cavitation bubbles.
Keep in mind that very few process applications call for a pump to handle a pure liquid such as water. Most
services handle a mixture of various components (e.g., crude oil, blended gasoline or even paint). As such,
they will have a range of vapor pressures or boiling points, which depend on the volatility of each component.
Cavitation damage to a centrifugal pump may range from minor pitting to catastrophic failure and depends on
the pumped fluid characteristics, energy levels and duration of cavitation.
46
INTERNAL RECIRCULATION CAVIATION (1)
Recirculation cavitation is a term used to describe the
formation of vapor-filled pockets. This type of cavitation is
less well known and understood than classical cavitation.

As the pump is operated back on its curve, eddy currents
begin to form in the eye of the impeller. There is no reduction
in mass flow through the pump at a given point on this curve.
This means that the velocity through the impeller fluid
channels must have increased. That is, the eddy currents at
the eye have effectively reduced the flow channel size,
thereby increasing liquid velocity for the fixed flowrate.

When the velocity increases, the pressure drop due to friction
must also increase.

If the drop is large enough to cause the pressure to fall below
the liquid's vapor pressure, the pump will develop classical
cavitation because of the initiating action of recirculation
cavitation.
47
INTERNAL RECIRCULATION CAVIATION (2)
Another cause of recirculation is that as the fluid flows over
an impeller vane, the pressure near the surface is lowered,
and the flow tends to separate.

This separated region occurs when the incidence angle--the
difference between flow angle and pump impeller vane inlet
angle--increases above a specific critical value.

The stalled area eventually washes out but is reformed as
rotation continues. The area contains a vapor surrounded by
a turbulent flowing liquid at a higher pressure than the vapor
pressure.

This separated region will then fill with liquid from the
downstream end. The vapor pocket collapses, which causes
damage to the surface of the impeller vane. This may occur
up to 200 to 300 times per sec.
48
HOW TO IDENTIFY CLASSIC
CAVIATION AND INTERNAL
RECIRCULATION CAVITATION
1. Classical cavitation.
Damage is located on the non-visible or
underside of the vane. It starts near the
leading edge and can extend up to
approximately two-thirds of the vane length
before the pressure implodes the bubbles.
Either feeling or looking at the underside of
the vane with a mirror is necessary to
evaluate the damage.

2. Suction recirculation.
Damage is on the visible or the pressure
side of the vane's leading edge. If tip
recirculation has occurred, damage will be
on the visible or pressure side of the vane
near shroud walls.
Note that this damage will be on the opposite side of
the vane as that which occurred with classical cavitation.
This continuous recycling results in noise, vibration and
pressure pulsations. These results imitate classical
cavitation, and thus recirculation is often incorrectly
diagnosed as such.

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