Design Guide

Pumps and Pump Circuits

650100-ME-DEG-0035

24-Oct-17

www.worleyparsons.com
WorleyParsons Services Pty Ltd
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© Copyright 2017 WorleyParsons

DESIGN GUIDE
PUMPS AND PUMP CIRCUITS

SYNOPSIS
This guideline is based on the original WorleyParsons Services Pty Ltd “Pumps and Pump Circuit”
design guide 650100-PR-DEG-0012 rev 2, the WorleyParsons Canada Services Ltd “Process
Engineering Practice – Pumps” PREP-030 rev A (Sept 2010) and the Parsons legacy document
“Pump Specification Guidelines” PTD-DGS-101 rev 1 (Jan 2002).

Disclaimer

This report has been prepared for the exclusive use of WorleyParsons. WorleyParsons accepts no
liability or responsibility whatsoever for it in respect of any use of or reliance upon this report by any
third party.

Copying this report without the permission of and WorleyParsons is not permitted.

DESIGN GUIDE – PUMPS AND PUMP CIRCUITS

WorleyParsons Client
Rev Description Originator Reviewer Date Date
Approval Approval

0 Issued for Use 24-Oct-17 N/A N/A

J. Browne P. Rymer F. Moretto

N/A N/A

N/A N/A

N/A N/A

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CONTENTS
1 INTRODUCTION ...................................................................................................1
2 REFERENCED DOCUMENTS ............................................................................2
2.1 National Standards ...............................................................................................................2
2.2 WorleyParsons Design Guides ...........................................................................................2
2.3 WorleyParsons Standard Calculations ..............................................................................3
3 ABBREVIATIONS AND DEFINITIONS...............................................................4
3.1 Abbreviations .........................................................................................................................4
3.2 Definition of Terms ................................................................................................................5
4 PUMP TYPES .......................................................................................................8
4.1 Overview.................................................................................................................................8
4.2 Pump Selection .....................................................................................................................9
4.3 Centrifugal Pump Types and Applications ..................................................................... 11
4.4 Hydraulic Power Recovery Turbines............................................................................... 20
4.5 Positive Displacement (PD) Pumps ................................................................................ 21
4.6 Centrifugal versus PD Pumps .......................................................................................... 25
5 PHYSICAL PROPERTIES ................................................................................. 29
5.1 Influence of Liquid Properties........................................................................................... 29
5.2 Effect of Vapour or Gases ................................................................................................ 30
6 PUMP SPECIFICATION..................................................................................... 32
6.1 Design Flowrate ................................................................................................................. 32
6.2 Minimum Flow Recycle ..................................................................................................... 32
6.3 Design Head ....................................................................................................................... 33
6.4 Pump Centre Line Elevation............................................................................................. 33
6.5 Pump Power ....................................................................................................................... 34
6.6 Pump Motor Rotational Speed ......................................................................................... 34
6.7 Pump Specific Speed NS .................................................................................................. 35
6.8 Suction Specific Speed NSS .............................................................................................. 38

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6.9 Required Net Positive Suction Head (NPSHr) .............................................................. 39

6.10 Impeller Diameter for Centrifugal Pumps ....................................................................... 42
6.11 Suction Impeller.................................................................................................................. 43
6.12 Affinity Laws ........................................................................................................................ 43
7 SUCTION CONDITIONS .................................................................................... 44
7.1 Suction Vessel Pressure ................................................................................................... 44
7.2 Vapour Pressure ................................................................................................................ 44
7.3 Suction Liquid Level Elevation ......................................................................................... 45
7.4 Line / Fittings Pressure Drop ............................................................................................ 45
7.5 Available Net Positive Suction Head (NPSHa).............................................................. 46
7.6 Suction Head (Hs) .............................................................................................................. 47
7.7 Acceleration Head.............................................................................................................. 47
8 DISCHARGE CONDITIONS .............................................................................. 50
8.1 Discharge Vessel Pressure .............................................................................................. 50
8.2 Discharge Liquid Level Elevation .................................................................................... 50
8.3 Line / Fittings Pressure Drop ............................................................................................ 50
8.4 Pump Shut-off Pressure.................................................................................................... 51
9 CONTROL ........................................................................................................... 52
10 PARALLEL OR SERIES OPERATION ............................................................. 54
10.1 Parallel Operation .............................................................................................................. 54
10.2 Series Operation ................................................................................................................ 55
11 VARIABLE SPEED OPERATION...................................................................... 57
12 SEAL SELECTION.............................................................................................. 59
12.1 General ................................................................................................................................ 59
12.2 Mechanical Seal Selection ............................................................................................... 60
12.3 Mechanical Seal Definitions ............................................................................................. 61
12.4 Mechanical Seal Piping Plans .......................................................................................... 62
13 PUMP SPARING ................................................................................................. 65
13.1 Warm-up Piping for Spare Pumps................................................................................... 65

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14 REMOTE/AUTOMATIC PUMP START ............................................................ 67

15 HEATING / COOLING JACKET ........................................................................ 68
16 ADDITIONAL CONSIDERATIONS FOR PUMP PROTECTION .................... 69
16.1 Suction Line Routing ......................................................................................................... 69
16.2 Suction Strainers ................................................................................................................ 69
16.3 Eccentric Reducers............................................................................................................ 69
16.4 Check Valves on Pump Discharge .................................................................................. 69
17 RELIABILITY ....................................................................................................... 70
17.1 Hydraulic Reliability for Centrifugal Pumps .................................................................... 70
17.2 Mechanical Reliability ........................................................................................................ 71
18 DRIVERS ............................................................................................................. 72
18.1 Electric Motor ...................................................................................................................... 72
18.2 Steam Turbine .................................................................................................................... 73
18.3 Others .................................................................................................................................. 73
19 DATA SHEET PREPARATION ......................................................................... 74
20 RESOURCES ...................................................................................................... 77
20.1 Calculation Tools ................................................................................................................ 77
20.2 Software .............................................................................................................................. 77
21 REFERENCES .................................................................................................... 78

Appendices
APPENDIX 1 - PUMP PERFORMANCE CORRECTION METHODS FOR VISCOUS LIQUIDS
APPENDIX 2 - IMPELLERS
APPENDIX 3 - GENERAL GUIDE TO PROCESS PUMP SELECTION

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1 INTRODUCTION
This design guide is intended as a reference for Process and Mechanical Engineers to design and
specify pumps and pump circuits. It should be used in conjunction with validated pump sizing
calculation 650100-PR-CAL-0015 (Future - 650100-PR-CAL-0300 Simple Pump Sizing) or other
validated calculations listed in Section 2.2.
Because pump sizing is dependent on the physical configuration of the circuit and the selected pump,
this guideline provides a basis to select a pump type and size a pump, as well as to understand the
impacts on the rest of the process system. Ultimately, the pump sizing, power, efficiency and other
performance characteristics shall be determined by the pump vendor.
The approach to the pump calculations and the accuracy of the results will depend on the project
phase (conceptual/FEED/detailed engineering). The required basic information, determination of line
sizes and pressure losses are discussed. The information presented may be subject to changes due to
deviating project requirements. The responsible engineer at the start of each project shall list these
changes/exceptions.
The design guide is an introduction to pump and pumping systems. The engineer is directed to the
WorleyParsons intranet webpage entitled Pumps and Pumping at the following link:
http://teams-wst.worleyparsons.com/sites/wks/pp/SitePages/Community%20Home.aspx
Alternatively go to the WorleyParsons ONE page, select “Operations & Delivery” tag. From the drop
down menu, select “Engineering & Design”. Select “All Network/Discussion Boards” and then select
“Engineering Networks”. In the new intranet page select “Pumps and Pumping”. The subdirectories
are located on the left of the webpage where the engineer can select various topics specific to pumps
and pumping.

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2 REFERENCED DOCUMENTS

2.1 National Standards

Designation Title
ANSI B73.1 Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process
ANSI B73.2 Specification for Vertical In-Line Centrifugal Pumps for Chemical Process
ANSI B73.3 Specification for Sealless Horizontal End Suction Metallic Centrifugal Pumps for
Chemical Process
API 610 (ISO 13709) Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries
API Standard 674 Positive Displacement Pumps - Reciprocating
API Standard 675 Positive Displacement Pumps - Controlled Volume
API Standard 676 Positive Displacement Pumps – Rotary
API Standard 682 Pumps—Shaft Sealing Systems for Centrifugal and Rotary Pumps
API Standard 685 Sealless Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and Gas Industry
Services
AS 2417 Rotodynamic pumps—Hydraulic performance acceptance tests—Grades 1 and 2
Various Hydraulic Institute Standards for Centrifugal, Rotary & Reciprocating Pumps
ISO 2858 End-suction centrifugal pumps (rating 16 bar) — Designation, nominal duty point and
dimensions
ISO 5199 Technical specifications for centrifugal pumps -- Class II
ISO 9905 Technical specifications for centrifugal pumps- Class I
ISO 9906 Rotodynamic pumps — Hydraulic performance acceptance tests — Grades 1 and 2
ISO 9908 Technical specifications for centrifugal pumps- Class III
PIP REEP006 Pump Selection Guidelines

2.2 WorleyParsons Design Guides

Designation Title
650100-PR-DEG-0003 Design Guide Line Sizing and Hydraulic Analysis
650100-PR-DEG-0007 Design Guide Overpressure Protection by Pressure-Relieving Devices

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2.3 WorleyParsons Standard Calculations

Designation Title
650100-PR-CAL-0015 Pump Sizing - Simple (SI and English Units)
Future - 650100-PR-CAL-0300 Simple Pump Sizing]
WS-CA-PR-001 Single Phase Line Sizing Spreadsheet
Future - 650100-PR-CAL-0302 Liquid Hydraulic Pressure drop
WS-CGY-CA-PR-008 Centrifugal Pump and System Sizing Spreadsheet (SI and English Units)
Future - 65010-PR-CAL-0335

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3 ABBREVIATIONS AND DEFINITIONS

3.1 Abbreviatio ns
Abbreviation Description
ANSI American National Standards Institute
AOR Allowable Operating Region
API American Petroleum Institute
AS Australian Standards
ASME American Society of Mechanical Engineers
BEP Best Efficiency Point
BHN Brinell Hardness Number
Bhp Brake Horse Power
gpm Gallons per minute (US)
GPSA Gas Processors Suppliers Association
HI Hydraulics Institute
ISO International Standards Organisation
KO Knock Out
kPag / kPaa Kilopascals gauge/absolute
kW Kilowatts
MAWP Maximum Allowable Working Pressure
NFPA National Fire Protection Association
NPIPa Net Positive Inlet Pressure Available
NPIPr Net Positive Inlet Pressure Required
NPSH Net Positive Suction Head
NPSHa Net Positive Suction Head Available
NPSH3 Net Positive Suction Head sufficient to cause a 3% drop in pump head.
NPSHr Net Positive Suction Head Required
PD Positive Displacement
PIP Process Industry Practices
psi Pounds per square inch

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Abbreviation Description
RPM Revolutions per minute
SPM Strokes per minute
SS Stainless Steel
SSU Saybolt Seconds, Universal
TDH Total Developed Head
VSD Variable Speed Drive
VTP Vertical Turbine pump

3.2 Definition of Terms

The normal operating point is the point at which usual operation is expected.
The rated operating point is the point at which the vendor certifies that performance is guaranteed.
Performance includes the following factors: capacity, total head, power, efficiency, net positive
suction head required, rotational speed, strokes per minute (reciprocating pumps only) and rated
suction pressure at the specific gravity and viscosity of the pumped liquid.
Maximum allowable working pressure of the casing is the greatest discharge pressure at the specified
pumping temperature for which the pump casing is designed.
Maximum suction pressure is the highest suction pressure to which the pump is subjected during
operation. For parallel pumps, this may be equal to maximum pump discharge pressure in
installations incorporating closed suction block valves on non-operating standby pumps.
Maximum discharge pressure is the maximum suction pressure plus the maximum differential
pressure that the pump is able to develop when operating with the furnished impeller at the specified
speed, specific gravity, and pumping temperature.
Maximum allowable temperature is the maximum continuous temperature for which the
manufacturer has designed the equipment (or to any part the term is referred) when handling the
specified liquid at the specified pressure.
Maximum allowable speed (in revolutions per minute) is the highest speed at which the
manufacturer's design will permit continuous operation.
Maximum continuous speed (in revolutions per minute) shall be the speed at least equal to 105% of
rated speed for variable-speed pumps, and any fixed-speed pump sparing or spared by a pump whose
driver is capable of exceeding rated speed.
Minimum allowable speed (in revolutions per minute) is the lowest speed at which the
manufacturer's design will permit continuous operation.
Minimum continuous stable flow is the lowest flow at which the pump can operate without exceeding
the noise and vibration limits specified.

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Minimum continuous thermal flow is the lowest flow at which the pump can operate without its
operation being impaired by the temperature rise of the pumped liquid. The temperature of the
liquid in the pump casing is to be kept below the saturation temperature of the liquid. The
overheating of the liquid inside the centrifugal pump casing may occur because of two ways. First is
recirculation of liquid inside the casing and the second way is energy from drive equipment is
converted to heat and it raises the temperature of liquid inside the pump.
Allowable operating region is the flow range at the specified speeds with the impeller supplied as
limited by cavitation, heating, vibration, noise, shaft deflection, fatigue, and other similar criteria. This
range shall be specified by the manufacturer.
The pressure casing is the composite of all stationary pressure-containing parts of the unit, including
all nozzles, packing glands, and other attached parts.
Net positive suction head (NPSH) is the total suction head, in metres (feet) of liquid absolute,
determined at the suction nozzle and referred to the datum elevation, minus the vapour pressure of
the liquid, in metres (feet) absolute. The datum elevation is the shaft centreline for horizontal pumps,
suction nozzle centreline for vertical in-line pumps, and top of the foundation for vertically suspended
pumps.
Net positive suction head available (NPSHa) is the NPSH, in metres (feet) of liquid, determined by the
Purchaser for the pumping system with the liquid at the rated flow and normal pumping
temperature. Note that for positive displacement pumps the term Net Positive Inlet Pressure
Available (NPIPA) is used and is expressed in pressure absolute kPa (psi).
Net positive suction head required (NPSHr) is the NPSH, in metres (feet), determined by the
manufacturer's test, usually with water. NPSHr is measured at the suction nozzle and corrected to
datum elevation. NPSHr is the minimum NPSH at rated capacity required to prevent a head drop of
more than 3 percent due to cavitation within the pump. Note that for positive displacement pumps
the term Net Positive Inlet Pressure Required (NPIPr) is expressed in pressure absolute kPa (psi).
Net positive suction head 3% (NPSH3) is defined as the value of NPSHr at which the first-stage total
head drops by 3% due to cavitation. This is determined by the vendor by testing with water as
outlined in. ANSI/HI 14.6 Rotodynamic Pumps for Hydraulic Performance Acceptance Tests.
Head Rise to Shutoff is the increase in pump head resulting from a drop in pump flow to no flow,
given as an increase relative to the best efficiency point.
Specific speed is an index of pump impeller operating characteristics determined at the best efficiency
point with the maximum diameter impeller.
Suction Specific Speed is a parameter or index of hydraulic design descriptive of the suction
capabilities and characteristics of a given first stage impeller.
Displacement for a positive displacement pump it is the theoretical volume per revolution of the
pump shaft. Calculation methods and terminology may differ between different types of positive
displacement pumps.

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Slippage for a positive displacement pump is the rate at which liquid leaks from the discharge of the
pump back to the pump suction.
Flooded Suction is when liquid flows to pump inlet from an elevated source by means of gravity.
Self-Priming is when pumps draw liquid up from below pump inlet (suction lift), as opposed to pumps
requiring flooded suction. Any pump which does not require pre-wetting or pressurization in order to
produce liquid flow.
Newtonian fluids are those where the viscosity is constant at constant temperature and independent
of rate of shear and time of application of shear.
Non-Newtonian fluids are those in which the viscosity changes with rate of shear or time of
application of shear. Suspensions of clay or starch and solutions of potassium silicate, paper pulp,
mayonnaise, ketchup, paint, or gum arabic are examples of non-Newtonian fluids.
Slurry is any mixture composed of solid particles and liquid. Normally the solid and liquid phases are
inert with respect to each other and may be readily separated.

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4 PUMP TYPES

4.1 Overview
There are a number of different types of pump that can be selected, depending on capacity, head,
reliability, service and operator preference. The two main types of pump are:

a) Centrifugal Pump
A machine which moves liquid by accelerating it radially outward in a rotating impeller to a
surrounding stationary housing or casing providing kinetic energy which is transformed into a
differential head or pressure. Centrifugal pumps are typically either overhung impeller type,
impeller between bearings type or turbine type. Overhung impeller pumps include end suction
pumps, inline pumps, submersibles, centreline supported API 610 pumps, frame mounted ANSI
B73.1 pumps and axial flow impeller pumps. The impeller between bearings type pumps can be
single stage or multistage and include axial (horizontal) split case pumps and radial (vert) split
case pumps. Turbine pumps include vertical type single stage and multistage pumps such as
deep well turbines, barrel pumps and axial flow impeller (propeller) pumps.

b) Positive Displacement Pump

A pump in which a measured quantity of liquid is entrapped in space, its pressure raised, and
then delivered. Positive displacement pumps are either reciprocating or rotary types.
Reciprocating pumps include piston, plunger, and diaphragm types. Rotary pumps include
progressing cavity, screw, peristaltic, vane and gear types. They are usually installed for
services which require high head at moderate capacity.
The chart in Figure 4-1 from the GPSA Engineering Data Book [ref.3] gives an indication of typical
selection as function of capacity and head.
Note: More specialised pumps such as vane pumps and special effect pumps (rotating case) have
proprietary characteristics and should only be selected following discussion with the vendor to
determine suitability for the service. Refer to PIP REEP006 for additional types of pumps.

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Figure 4-1 Pump Coverage Chart

4.2 Pump Selection

The specification of process pumps involves a step-by-step approach. The engineer must select a
pump with the best efficiency for the full range of process operating conditions.
The major types of pumps available are listed in the following table.

Table 4-1 Types of Pumps

Kinetic Positive Displacement

Centrifugal: Reciprocating:
1. Radial Flow 1. Piston
2. Axial Flow 2. Plunger
3. Mixed Flow 3. Diaphragm

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Kinetic Positive Displacement

4. Turbine
Special: Rotary:
1. Jet 1. Gear
2. Gas Lift 2. Screw
3. Hydraulic Ram 3. Lobe
4. Inertia 4. Vane
5. Peripheral (Regenerative) 5. Flexible Chamber
6. Flexible Tube

4.2.1 Pu mp Head and Capacity Ranges

A selection table showing the physical range of head and capacity suitable for the various types of
pump is provided below.

Table 4-2 Pump Selection Table

3
Pump Type Capacity m /h (usgpm) Head m (ft)
Minimum Maximum
Low Capacity
Peripheral 0.23 (1) 4.5 (20) 213 (700)
Vane Vendor to advise 17 (75) 122 (400)
Reciprocating Plunger 0.23 (1) 34 (150) Over 1,525 (5,000)
General Use
Reciprocating Power 4.5 (20) 227 (1,000) Over 305 (1,000)
Direct 1.4 (5) 114 (500) Over 305 (1,000)
Centrifugal 1 - Stage 2.7 (10) 1820 (8,000) Over 150 (500)
2 - Stage 2.7 (10) 1820 (8,000) Over 210 (700)
Multistage 2.7 (10) 680 (3,000) Over 305 (1,000)
Screw 2.7 (10) 180 (800) Over 305 (1,000)
High Capacity
Centrifugal 1 – Stage 1.4 (5) 11,350 (50,000) 15 – 122 (50 – 400)
(Low Head) 57 (250) 22,700 (100,000) 3 – 61 (10 – 200)
Mixed Flow 227 (1,000) 45,400 (200,000) 0 – 7.5 (0 – 25)

In general, the most common types of pumps apply centrifugal radial flow. Centrifugal pumps are
usually specified unless there is a special reason to apply an alternate type.

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A more comprehensive selection guide is provided in Appendix 3 and in PIP REEP006.

4.3 Centrifugal Pump Types and Applications

For centrifugal pumps, there are several types from which to select, depending on the process
requirements. These centrifugal pump types are discussed in the following sections.
Centrifugal pumps are preferred over positive displacement pumps because they are usually less
costly, require less maintenance, simpler flow control and less space.

4.3.1 Hor izontal Overh ung Imp el ler P ump s

The horizontal single stage overhung impeller pump is the most frequently used type of pump. The
two shaft bearings are mounted close together in the same bearing bracket, with the impeller
cantilevered or overhung beyond them. This design permits bearing maintenance without disturbing
the suction or discharge piping and the overhung impeller requires only one shaft seal assembly. It is
more accessible for maintenance and is usually more reliable than the between bearings impeller
pump primarily because of fewer parts. This style most commonly has an end suction flange and a
top discharge flange. Top suction is available and preferred for operating temperatures above 177oC
(350°F) and where warm up provisions for the standby pump is required.

Figure 4-2 - Typical Foot Mounted and Centreline Mounted Overhung Pumps

The horizontal single stage process pump is used for relatively low head and low flow applications.
Typical applications for this pump are reflux, circulation, booster and boiler feed.
The two-stage overhung pump is a variation on the single stage overhung pump which is capable of
achieving higher heads. Overhung two-stage pumps often have greater vibration and reliability
problems caused by the additional overhung weight.
ASME B73.1 should be typically used to specify a foot mounted overhung pump. A centreline
mounted overhung centrifugal pump is supported along the pump’s horizontal centreline. The API
610 designation for this type of pump is OH2. For reliability reasons, OH2 pumps should be limited to

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a maximum diameter impeller diameter of 330 mm (13 inches) at speeds greater than 3550 RPM and
to a maximum diameter impeller diameter of 690 mm (27 inches) at speeds greater than 1750 RPM.
ASME B73.1 and B73.2 pumps should not be used in hydrocarbon services.

4.3.2 Inl ine P ump s

Inline pumps are vertical pumps with the casing designed to be bolted directly into piping like a valve.
Inline pumps are commonly constructed in three styles. These include rigid-coupled, and close-
coupled (impeller on the extension of the motor shaft with no coupling), and bearing bracket style.
Vertical inline pumps are normally used instead of horizontal single stage pumps for light duty, non-
critical processes or water services where plot space is limited due to their compactness. Vertical
inline pumps of the rigid-coupled and close-coupled types are generally not as reliable as the
horizontal pump because the radial bearings are located in the motor and the resulting higher
moment reduces bearing and mechanical seal life compared to horizontal pumps.

Figure 4-3 - Typical Vertical In-Line Pump

The total installed cost of vertical pumps is frequently lower. Vertical inline pumps are generally used
for relatively low head and low flow applications and power no greater than 55 kW (75 hp).
Vertical coupled design with driver and pump shafts connected by a flexible coupling are designated
by API 610 as OH3 and bearings are normally grease or pure oil mist lubricated.

4.3.3 Bet ween-Bearing s Im peller Pu mps

A "between bearings" design is normally used for larger flow and head, or lower NPSH conditions
than are possible for a horizontal overhung impeller pump. The impeller is mounted between the
bearings and therefore, they have two stuffing boxes. The casings can be axially split for
temperatures up to 205oC (400°F) and are radially split for temperatures up to 450oC (850°F). This

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design is used for double suction, single stage or multistage (with either single suction or double
suction 1st stage) pump applications.
The API 610 designation for these types of pumps are BB1 (foot mounted), BB2 (centreline mounted)
and BB3 for single stage and multi-stage, respectively

Figure 4-4 - Typical Between Bearings Single Stage Double Suction Pump

4.3.4 Dou b le S uct ion v ersus S ingle Suct ion Pump s

Single suction pumps are normally used in low to medium flow services where the NPSHa is adequate
and the suction pressure is below approximately 1724 kPag (250 psig). The double suction pump
should be considered for flows above 230 m3/hr (1,000 usgpm) and suction pressures above 1724
kPag (250 psig) since this pump design balances axial thrust and requires less NPSH than a single
suction pump.
The single suction single stage pump is approximately 30-40 percent less expensive than a double
suction single stage pump. The double suction pump is more susceptible to impeller internal flow
recirculation problems, has a greater bearing span and requires more plot space than a single suction
pump. If possible, the NPSHa should be increased to use a single suction, instead of selecting a
double suction pump. Double suction pumps have special suction piping requirements especially for
horizontal type pumps where the first elbow nearest the nozzle is in the horizontal plane.

4.3.5 Hor izontal Mu ltistage P ump s

The horizontal multi-stage pump can handle a wide range of flows and heads. Normally this pump
has a split case to allow easy maintenance. Process applications of this pump include; treating
solution change, absorption oil, boiler feed, pipeline, water and NGL injection.
Horizontal multistage pumps are usually limited to about 12 stages due to the difficulty in limiting
deflection over the long span between bearings and consideration of rotor dynamics. They have
NPSH requirements approximately the same as single stage pumps of the same capacity. Horizontal
multistage pumps can be axially split or radially split.

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The API 610 designation for these types of pumps is BB3 (axially split), BB4 (radially split) and BB5
(double casing radially split).

Figure 4-5 – Typical Horizontal Multistage Pump

4.3.6 Rad ial Split Case versus Ax ial S plit Case Pu mps
The axially split (or horizontally split) case pump is normally used for discharge pressures up to
nominally 10,000 kPag (1,450 psig) except where the conventional single stage radially split overhung
pump is applicable. Above 10,000 kPag (1,450 psig) a radially split double case pump with confined
gasket is normally used to minimise potential product leakage. The radially split double case barrel
pump is significantly more expensive and more difficult to maintain than the axially split pump,
although the double case design offers a quick change out of the inner casing (complete with
impellers) which can be advantageous. Some double casing designs are available with full cartridge
design which allows the inner case and both the inboard and outboard bearing housings to be
removed as a complete assembly.

4.3.7 Low-Flow and High-Head Services

Regenerative turbine pumps, side channel, rotating case and high speed pumps are normally used for
low-flow, high-head service where a horizontal centrifugal pump cannot meet the process
requirements. They normally require clean service (i.e., no or very few particulates). These types
require more maintenance and are less efficient than horizontal pumps.
High-speed pumps are single impeller models designed for speeds up to 10,000-24,000 rpm and are
capable of producing heads up to 1600 m (5250 ft). High-speed pumps often have high NPSH
requirements because of the sudden velocity increase as the liquid enters the impeller and are usually
provided with an inducer. Maintenance requirements for high-speed pumps tend to be higher than
for standard-speed single stage pumps but comparable to that of multistage pumps with which they
compete.

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Sundyne typically manufactures a high speed centrifugal pump. This pump achieves a high head with
a small number of stages (usually only one). To achieve the high speed, a gear box is required.
Applications of this pump include flare knock-out (KO) liquids pump, loading, and pipeline booster
pumps.
For low-flow requirements, the horizontal centrifugal pump with a spillback line should be considered
if the head requirement can be met. The excess capacity must be recirculated back to the suction
system of the pump (normally returned to suction vessel/tank).

Figure 4-6 - Regenerative Turbine Pump with Low NPSH3 Impeller First Stage

4.3.8 Vert ical Mu lti st age P ump s

Vertical multistage pumps may have as many as 24 or more stages. The first stage is at the bottom of
the assembly, usually below grade.
Vertical multistage mixed flow pumps frequently employ high specific speed impellers which generate
relatively low head per stage. For this reason a large number of stages are often needed in vertical
pumps.
Due to the large number of close running clearances found in this design, vertical multistage pumps
are particularly sensitive to damage by solids or to operation in dry or two-phase conditions. When
maintenance is performed, a great many parts must be disassembled, repaired or replaced, and then
reassembled. These factors cause the vertical multistage pump to require maintenance more
frequently than horizontal pumps.
The cost of each servicing is also much higher than that of comparable horizontal pumps. Due to the
higher maintenance costs and lower reliability, these pumps should not be used if other types of
pump are available for the service.

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4.3.9 Vert ical Can Pu mp

Vertical can pumps are often used for liquids at their bubble-point temperature because the first
stage impeller is located below ground level and therefore requires less net positive suction head at
the suction flange. The vertical distance from the suction flange down to the inlet of the first stage
impeller provides additional NPSHa. Usually, the vertical can pump is placed into a cylindrical shaped
concrete base or fabricated metal can where the below grade portion of the pump resides.

Figure 4-7 – Typical Vertical Canned Pump

The disadvantage of a vertical can pump is that when maintenance is done, the pump, and drive,
must be lifted from the cylindrical shaped concrete base or can. Also the flanges (inlet and outlet)
have to be disconnected before the pump/driver is removed.
Applications of this pump include loading, transfer, pipeline, booster, and boiler feed water.

4.3.10 Sealless Cann ed Sty le Pu mps

Sundyne, and others, manufacture process pumps that utilise a magnetically coupled drive to turn the
impeller. In these applications, a mechanical seal is not required since the process is completely
contained inside the pump housing.
These pumps generally use graphite or silicon carbide bearings that can operate in the service, and
the bearing is cooled by the process fluid. These applications are generally limited to clean services
and typically to services that must be contained and which are considered hazardous

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Figure 4-8 - Typical Magnetic Drive Pump

Nikkiso, and others manufacture process pumps that utilise a canned motor design where the process
fluid is also contained within the motor, providing a sealless design. The pump and motor bearings
are cooled by the process fluid. This design offers a more compact arrangement than the magnetically
coupled pump and is also generally limited to clean services that must be contained. The canned
motor pump is preferred over the magnetic drive pump for lethal or extremely hazardous services.

Figure 4-9 Typical Canned Motor Pump

API 685 and ASME B73.3 provide requirements for canned motor pumps and magnetically coupled
pumps

4.3.11 AP I vs ANS I Centrifug al Pump s

ANSI pumps (built to ANSI B73.1 or B73.2 standards) are normally used in chemical service (e.g.,
caustic, acid, etc.) or non-critical water services (e.g. potable water, treated water, etc.) where a light-
duty pump is applicable and the operating temperature is less than 149oC / 300oF.

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API pumps (built to API 610 standards) are normally used in hydrocarbon service or in critical
chemical or water service where a heavy-duty pump is applicable.
As a general rule, all centrifugal pumps in hydrocarbon service will adhere to the latest version of API
610 unless the client advises otherwise.
The cost of an API pump compared to an ANSI pump of the same size can be 3-4 times more
expensive and even greater when constructed in stainless steel or other alloys. API pumps are more
reliable and require less maintenance than ANSI pumps due to their heavier construction. A
comparison is provided in Table 4-3.

Table 4-3 Comparison of API and ANSI Pump Standards

Item API ANSI

API 610 for horizontal single and ANSI B73. 1 for horizontal end suction
multistage pumps top discharge pump.
Type Pump and
Specification Vertical in-line, vertical single, and ANSI B73.2 for vertical In-line pumps.
multistage centrifugal pumps. All are single stage.
Maximum Allowable
Working Pressure Minimum 5170 kPag / 750 psig 1900 kPag / 275 psig
(MAWP)
370°C / 700°F 149°C / 300°F
Maximum Temperature Pump casing is centreline mounted. No Pump casing is foot mounted which limits
casing thermal growth limitations. allowable thermal growth

Maximum Head Practical limit is 3050 m (10,000 feet), 165 to 180 m (550 to 600 feet)
Differential although specific designs can go higher
ANSI pumps are only single stage.
Horizontal API pumps can have as many Maximum impeller diameter is about 330
as 14 stages. mm (13 inches).
Pump casings Carbon or alloy steel required in No requirements for flammable or toxic
flammable or toxic service service
Flange Rating 300# raised face is standard. 150# flat faced is standard. 150# raised
600, 900, 1500 and higher ratings are face is available.
available if required by the service.
Impellers – Note 1 Generally enclosed impellers and single Generally open impellers
piece castings
Secured to shaft with a key No requirements
Wear Rings Required. Minimum hardness of 400 BHN No requirements and generally not
or hardness difference of 50 BHN available due to open design of impellers
Mechanical Seals Required No requirements
Shaft Sleeves Required Not required, but available if specified

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Item API ANSI

Lubrication Oil lubrication is required. Usually ring oil Can be grease or oil lubricated
system is provided
Thrust bearing and Life Antifriction ball bearings must be duplex, Antifriction bearings only.
single row, 40-degree angular-contact B-10 bearing life of 17,500 hours at
type, installed back to back. design load is required.
L-10 bearing life must exceed 25,000
hours at rated condition, or 16,000 hours
at maximum axial and radial loads at
rated speed.
Shaft Critical Speed Lateral critical speed greater than 120 No requirements
percent of maximum pump speed
Baseplates Drip lip or drain pan required No requirements
Specifies shaft limit displacements at the No requirements for fixed baseplates
coupling for Baseplate design.
Standard Dimensions No standard dimensions apply ANSI Pumps are built for
interchangeability between
manufacturers
Testing Hydrostatic test to 1.5 items allowable Hydrostatic test to 1.5 times allowable
casing pressure for 30 minutes casing pressure for 10 minutes
Performance test required No performance test required

Note 1 – for more details on centrifugal pump impellers refer to Appendix 2.

4.3.12 Hor izontal Ver sus Ver ti cal

Many applications can be handled by a horizontal or vertical pump. Horizontal pumps are preferred
over vertical pumps because they are normally more reliable due to the pump bearings operating in a
clean and proper lubricating environment (bearing housing), and because the pump internals are
more readily accessible when maintenance is required. The following items should be considered by
the engineer when selecting horizontal versus vertical pumps.

Table 4-4 Pump Selection Guide

Feature Horizontal Pump Vertical Pump

Space Requirements Less head room Less floor area, more head room
NPSH Requires more Requires less
Priming Required Not required
Flexibility for future change Less More
Maintenance More accessible Major work project
Corrosion or abrasion No great problem Can be a problem

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Feature Horizontal Pump Vertical Pump

Cost Less More (requires more alloy to handle
corrosive fluid)

4.4 Hydraulic Power Recovery T urbines

As the cost of energy increases, recovering wasted energy makes a great deal of sense. A hydraulic
power recovery turbine can be visualised as a centrifugal pump running in reverse to recover energy.
In processing plants, there are liquid streams that are let down in pressure through a control valve
which may be candidates for a recovery turbine.
The hydraulic power recovery turbine can directly drive a pump or it can drive an electric generator to
reduce net plant power usage.
There are two main types of centrifugal hydraulic power recovery turbines:
1. Reaction – Single or multistage Francis – type rotor with fixed or variable guide vanes.
2. Impulse – Pelton wheel, usually specified for relatively high differential pressures.
In applications where the fluid that enters the hydraulic power recovery turbine has large dissolved
gas content, the available power is larger than the power that may be calculated using the liquid
equations, so the power shall be calculated using an adequate two-phase calculation method.
The following are some process applications for a hydraulic power recovery turbine;
• Rich sweetening solvent (e.g. Amines);
• Rich absorption oil;
• High pressure crude oil;
• Condensed high pressure natural gas liquids;
• Liquid refrigerant letdown, in mechanical refrigeration cycles.

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4.5 Posit ive Displacement (PD) Pumps

Virtually all centrifugal pumps comprise of a casing, impeller, shaft and volute, whereas PD pumps
come in a variety of forms and operations. Some of the more common PD pumps types are described
in the following sections.

4.5.1 Progressing Cavity

4.5.1.1 How It Wo rk s
Liquid is drawn into the suction of the pump as
the corkscrew shaped rotor revolves within the
elastomeric stator.
Liquid is captured in the cavity between the rotor
and stator. This cavity travels toward the
discharge during rotation.
The cavity opens into the discharge chamber and
delivers its contents as it reduces in size. Liquid is
forced out the discharge as more liquid is delivered by continued rotation

4.5.1.2 Fe ature s
• Abrasive Handling: the rotor/stator design allows the handling of abrasive and/or viscous
liquids;
• Low Shear: smooth gentle pumping action enables the pumping of shear sensitive and solid
entrained liquids;
• High Pressure: up to 4100 kPa (600 psi) can be achieved with low to high viscosity liquids.

4.5.2 Perist altic

4.5.2.1 How It Wo rk s
As the rollers compress the hose and move away from the inlet
a vacuum is created drawing in liquid.
The rollers work together to capture liquid between the
pinched areas of the tube and move the liquid toward the
discharge.
The front roller leaves the hose, opening the captured area
while the back roller pushes the liquid out the discharge.

4.5.2.2 Fe ature s
• No Liquid Contact: liquid comes in contact only with the hose utilised within the pump;

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• Self-priming: can lift up to 8m (26 ft);

• Viscous and Abrasive Liquids: designed to handle viscous, corrosive, abrasive and high purity
solutions.

4.5.3 External Gear

4.5.3.1 How It Wo rk s
As the gears separate on the inlet side of the pump, cavities
are created between the gear teeth which create a vacuum
that draws in the liquid.
Once the teeth clear the inlet port, the liquid is captured
between the gear teeth and the housing.
As the teeth mesh, the liquid is squeezed out of the cavity
and forced out the discharge port.

4.5.3.2 Fe ature s
• Metering: thin to viscous liquids can be dispensed in a smooth repeatable flow;
• High Pressure: up to 3500 kPa (500 psi) can be achieved with low to high viscosity liquids;
• Clean Liquids: close fitting gears require clean non-abrasive liquids.

4.5.4 Intern al Gear

4.5.4.1 How It Wo rk s
The inner gear (a) rotates in unison with the outer gear
(b) opening gaps between their teeth on the suction side
drawing in liquid.
Liquid is trapped in the gaps (c) between the teeth and
the stationary crescent (d) as the gears travel toward the
discharge side.
As the inner (a) and outer (b) gears mesh together liquid
is forced out the discharge side.

4.5.4.2 Fe ature s
• High Viscosities at Standard Motor Speeds: internal gear pump models that drive the inner gear
are capable of pumping viscosities of up to 10,000 SSU (Approx. 2100 cP) at the standard motor
speed of 1800 rpm.
• High Pressure: up to 4500 kPa (650 psi) can be achieved with low to high viscosity liquids.
• Clean Liquids: close fitting gears require clean non-abrasive liquids

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4.5.5 Lobe

4.5.5.1 How It Wo rk s
The motion of the counter rotating tri-lobe rotors creates a
partial vacuum which draws the liquid smoothly into the
pump chamber.
As the rotors revolve, liquid is captured between the rotor
cavities and the outer housing.
The liquid is forced out the discharge as the rotors mesh and
eliminate the cavities the liquid occupies.

4.5.5.2 Fe ature s
• Efficient: Improved efficiency and sterilizability over the traditional lobe pump design. Longer
sealing surfaces ensure high volumetric efficiencies with thin liquids.
• Solids Handling: gentle low shear solids and abrasive handling.
• Wide Viscosity Range: from 1 to 1,000,000 centipoise.

4.5.6 Screw

4.5.6.1 How It Wo rk s
As the “threads” of the screws rotate a vacuum is
formed and liquid is drawn into the suction port.
Liquid is captured between the screw “threads” and
the outer housing (a).
These cavities (b) move along the lower screw and
continue back along the top screw as their rotation
continues. The flow is divided and travels in opposite
directions through the pump in order to obtain axial
thrust balancing.
The liquid is forced out of the discharge as the
cavities open along the top screw at the end (c) of
the meshing screw “threads”.

4.5.6.2 Fe ature s
• High Pressure: Pressures of up to 34,500 kPa (5000 psi).
• Smooth Flow: Smooth continuous flow with practical no noise or vibration.
• Continuous Duty: Designed to run 24 hours a day, 7 days a week.

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• Dry Running: Because of non-contacting rotor screws, timed twin screw designs can run dry
intermittently in order to scavenge tank bottom.

4.5.7 Diaphrag m

4.5.7.1 How It Wo rk s
As the piston diaphragm is pulled away from the housing, the cavity
increases in size. This creates a vacuum that draws in the liquid through
the one way inlet valve.
As the diaphragm is pushed toward the housing, the cavity decreases in
size which forces the liquid out through the one way outlet valve.

4.5.7.2 Fe ature s
• Dry Running: can run dry indefinitely without damage
• Self-priming: can lift up to 4.5 m (15 ft) under ideal conditions.
• Self-adjusting: "air operated" diaphragm pumps automatically adjust their speed as viscosity
fluctuates.

4.5.8 Air Oper ated Dou ble Diap hrag m

4.5.8.1 How It Wo rk s
Compressed air powers the piston (1) moving it to the right
enlarging cavity “a”. This action creates a vacuum drawing in
liquid through the chamber’s inlet check valve (2).
While the piston (1) enlarges cavity “a” it compresses cavity “b”
forcing liquid out the one way check valve (3) toward the
discharge.
Once the piston (1) has fully extended to the right, it is redirected
(by compressed air) to the left compressing chamber “a” (forcing
liquid out the discharge) and enlarging chamber “b” (drawing in
liquid through the suction).
Once the piston (1) has fully extended to the left the cycle repeats
as compressed air redirects the piston (1) back to the right.

4.5.8.2 Fe ature s
• Dry Running: can run dry indefinitely without damage;
• Dead Head: will simply stall and will not be damaged when the discharge is blocked;
• Self-priming: can lift up to 6 m (20 ft) under ideal conditions;

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• Sealless: Does not utilise a seal;

• Forgiving: Self compensating design limits damage by misuse.

4.6 Centrifugal versus PD Pumps

When to use a centrifugal or a positive displacement (PD) pump is not always a clear choice. To make
a good choice between these pump types it is important to understand that the two types of pumps
behave very differently. By looking at the performance charts below you can see just how different
they are. By looking at Figure 4-10, the PD pump has more or less constant flow regardless of
pressure whereas the centrifugal pump has varying flow depending on the pressure or head.

Figure 4-10 Centrifugal Pump versus PD Pump Performance

By looking at Figure 4-11, another major difference between the pump types is the effect viscosity has
on the capacity of the pump. A centrifugal pump loses flow as the viscosity goes up but the PD pump
can actually increase flow. This is because the higher viscosity liquid fills in the clearances of the pump
causing a higher volumetric efficiency. It should also be noted that when there is a viscosity increase
there is also greater resistance in the system and so for a given flow, at higher viscosity, the pump will
need to generate more pressure.

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Figure 4-11 Centrifugal Pump versus PD Pump - Flows and Viscosity

The pumps behave very differently when considering mechanical efficiency as well. By looking at the
efficiency plot on Figure 4-12 you can see the impact of pressure changes on the centrifugal pump’s
efficiency. Changes in pressure have little effect on the PD pump efficiency but a dramatic one on the
centrifugal pump.

Figure 4-12 Centrifugal Pump versus PD Pump - Efficiency

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Another consideration is NPSHr. In a centrifugal pump, the NPSHr varies as a function of flow, which is
determined by pressure. In a PD pump, NPSHr varies as a function of flow which is determined by
speed. The lower the speed of a PD pump, the lower the NPSHr.
Another thing to keep in mind when comparing the two types of pumps is that a centrifugal pump
does best in the centre of a curve close to the Best Efficient Point (BEP). As you move either to the left
or right of the BEP, additional considerations come into play. If you move far enough to the left or
right pump life is reduced due to shaft deflection, increased vibration or increased cavitation. With a
PD pump you can operate the pump on any point of the curve. In fact the volumetric efficiency as a
percent actually improves at the high speed part of the curve. This is because the volumetric
efficiency is affected by slip, which is essentially constant (i.e. at constant pressure differential). At
low speed the percentage of slip is higher than at high speed.
• The most obvious reason to use a PD pump is when you have a high viscosity application. It is
common knowledge that a centrifugal becomes very inefficient at even modest viscosity.
However, there are many other reasons to select a PD pump over a centrifugal other than high
viscosity. In fact PD pumps are very commonly used on thin liquids like ammonia and solvents.
• A simple rule of thumb is you should consider using a PD pump whenever you might be
operating a centrifugal at other than at or near the Best Efficiency Point (BEP). For a centrifugal
pump the rated flow should be 80-110% of the BEP [ref 13]. Of course the further away from
the BEP you get the more likely a PD pump will be a better choice. This can typically happen at
low flow conditions, modest to high head conditions, or any type of elevated viscosity. As you
can see from the efficiency curve it takes more power to operate a centrifugal outside of its
BEP. This power has a cost, the initial cost of the larger motor plus a higher life cycle cost in
energy consumed. Many times the PD pump will have a lower initial cost as well as a lower
operating cost.
• Another reason to use a PD pump would be if the application has variable pressure conditions.
A centrifugal pump will “walk” up and down the curve which can cause process problems. A PD
pump will give near constant flow that makes it possible to match the flow to the process
requirements. The desire to have constant flow is the reason that a PD pump is the pump of
choice for metering applications.
• Obviously, if there is changing viscosity in the application the PD pump is the best choice. Even
a small change in viscosity, like 50-100 cP, has a large impact on the centrifugal.
• PD pumps generally can produce more pressure than centrifugal pumps. This will depend on
the design of each pump but pressures of 1800 kPa (250 psi) are not unusual for a PD pump
with some models going over 7000 kPa (1000 psi). This is a significant difference between the
two principles. The capability for a PD pump to produce pressure is so great that some type of
system overpressure protection is required. The engineer can refer to the WorleyParsons
“Design Guide for Overpressure Protection by Pressure-Relieving Systems and Devices”
650100-PR-DEG-0007 for more guidance on this topic.
• Generally speaking pumps tend to shear liquids more as speed is increased and the centrifugal
pump is typically a higher speed pump (one exception is the Discflo centrifugal pump which is

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suitable for handling shear sensitive fluids and large volumes of entrained air). This makes the
PD pump better able to handle shear sensitive liquids. Shear rates in PD pumps vary by design
but they are generally low shear devices, especially at low speeds. Internal gear pumps, for
example, have been used to pump very shear sensitive liquids. It is important to contact the
manufacturer for specific information on shear rates and application recommendations.
• By their nature, PD pumps create a vacuum on the suction side so they are capable of creating
a suction lift. The standard ANSI centrifugal does not create a vacuum so it cannot lift liquid
into the suction port. There are self-priming centrifugal designs that can lift liquid an average of
5m (15 feet). This corresponds to a vacuum of 44 kPa abs (330 mm mercury). Wetted PD pumps
(a pump that is not full of liquid but with some liquid in it) can often reach vacuums of 84 to 95
kPa abs (630 to 710 mm mercury). So a PD pump is a good option when there is a suction lift
required.
• As mentioned earlier, PD pumps tend to run at lower speeds than centrifugal pumps. This will
have an impact on seal life, so PD seals tend to last longer than seals in centrifugal pumps. In
addition, to assure adequate seal life a centrifugal will typically require one of the seal flush
plans. A PD pump, because of its lower shaft speed typically does not need an external flush
plan. Also, generally speaking, low speed mechanical devices tend to operate longer than high
speed mechanical devices.
• At certain combinations of flow and pressure centrifugal pumps are inherently inefficient, due
to the design of the impeller and the short radius turn the flow must make. These applications
are generally under 24 m3/hr (400 l/min or 100 usgpm) but particularly under 12 m3/hr (200
l/min or 50 usgpm). A PD pump, by contrast, is very well suited for low flow conditions.
Centrifugal pumps, by contrast, tend to do very well in high flow conditions.

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5 PHYSICAL PROPERTIES
The following physical properties of the fluid being pumped are required to carry out a pump
calculation:
• Dynamic viscosity at pumping temperature. The maximum viscosity, i.e. at minimum
temperature, is also important.
• Density at pumping temperature.
• Vapour pressure at the maximum temperature possible for the pump. This is dependent on
the process conditions in the suction vessel and particularly important for NPSH (net positive
suction head) considerations.
These physical properties can generally be obtained from HYSYS, but alternative estimating methods
are acceptable as well. Significant inaccuracies can occur in the HYSYS prediction of crude oil viscosity
above 20-50 cSt. In that case, validation against laboratory data is required.

5.1 Influence of Liquid Properties

5.1.1 Viscosity
The performance of centrifugal pumps is affected when handling viscous liquids. Particular attention
should be paid to smaller pumps, as they are generally subject to more significant derating of head,
capacity and efficiency than larger pumps when pumping viscous fluids. Correction factors also
become more significant with decreasing capacity and head. The maximum viscosity that can be
handled is dependent on the capacity of the selected pump.
The viscosity effect for centrifugal pumps can be summarised as follows:

Table 5-1 Viscosity effect

Viscosity
Effect of viscosity level
[cSt]
0 to 50 Minor corrections on Flow, Head and Efficiency
50 to 300 Considerable reduction in Flow, Head and mostly Efficiency
300 and over Consider selection of other type of pumps

The correction factors for flow, head and efficiency can be derived from the Hydraulic Institute
Standard [ref. 6] equations and charts as shown in Appendix 1.

5.1.1.1 Flu id Tempe ratur e and Visc os it y Var iat io n

When a heavy liquid undergoes significant cooling, the viscosity can dramatically change and thereby
affect the hydraulics of the system. In those circumstances the engineer should compensate for the
viscosity changes both in the hydraulic calculations and in the pump specification.

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Generally, heavy fluids are pumped at temperatures which reduce their viscosity so as to permit
relatively easy flow and the lines are insulated such that heat loss is minimised. In these situations
the engineer does not need to compensate for the minor temperature and viscosity changes that
occur. However, if a bare underground line is used to transfer a heated, heavy fluid with a high
viscosity at low temperatures, the subsequent cooling of the fluid toward ground temperature can
dramatically increase the pressure drop in the line and alter pump head requirements. If the
underground line is also the pump suction line, the NPSHa can also be dramatically different. The
engineer must estimate the temperature and subsequent viscosity changes and compensate for those
changes.

5.1.2 Density
As pump calculations have pressure expressed in metres (feet) of liquid at pumping conditions, a
change of fluid density upstream or downstream of the pump affects the pump head.
Such a change of fluid density can arise from:
• a change of fluid temperature;
• a change of fluid phase;
• mixing with other fluids.
To obtain the correct pressure drop expressed in metres (feet) liquid at pumping conditions the
pressure drop over sections with different density shall first be calculated and summarised.

5.2 Effect of Vapour or Gases

Qualitative data indicate that most centrifugal pumps can handle volumes of up to about 2-3 per cent
of flashed gas at the pump eye without encountering serious mechanical problems such as cavitation
and the formation and collapse of vapour bubbles [Ref 8]. Since the average density of a vapour
liquid mixture is less than for a liquid alone, the pump discharge pressure will be lower. Similarly, the
liquid capacity and efficiency are reduced as the vapour load is increased.
Vapour can be present in the pump suction as a result of:
• Entrainment due to the vortex in the feed vessel at the pump suction line nozzle;
• Leakage of air into the suction line when it operates below atmospheric pressure;
• Chemical reactions generating a vapour;
• Partial vaporisation of the fluid at low pressures prevailing in the impeller eye;
• Dissolution of gases from the liquid due to the low pressure in the impeller eye;
• Dissolved air in water for cooling tower services.
The most obvious effect of gas is the complete loss of prime. The action of the impeller is to separate
the gas which tends to remain in the eye area of the pump while the liquid component is radially
displaced by centrifugal force. Some vapour will be swept along by the drag effect of the liquid. At
conditions of reduced flow, the drag effect is low and vapours rapidly build up causing the pump to

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become gas bound. Once this happens, the pump must be shut down, the casing vented, primed and
then restarted.
Depending on the relative amount of vapour, the following options should be considered to mitigate
relatively high-vapour loads in pumped streams:
• Specify that the pump casing be capable of accepting an oversized impeller to counter the
resulting loss in head and capacity;
• Specify a self-priming type of pump;
• Increase pump suction pressure (to reduce flashing) by increasing elevation – i.e. lowering
pump or increasing suction vessel height or increasing minimum liquid level;
• Specify a low-speed pump;
• Consider a Discflo type centrifugal pump.
Published articles related to this topic are as follows:
• "Accounting for dissolved gases in pump design" by Mao J. Tsai, Published in Chemical
Engineering, July, 1982.
• “Cope With Dissolved Gases in Pump Calculations” by C. C. Chen, Published in Chemical
Engineering, October, 1993.
• “Pumping liquids loaded with dissolved gases” by Wood, Hart, Marra, Published in Chemical
Engineering, July 1998
• “Effects of Dissolved Gas on Vapour Pressure; NPSH Illustration; Example Calculations of
NPSHa” by Terry Henshaw, Published in Pumps and Systems, April 2009
• “Negative Effects of Entrained Air, NPSH Margin, and Suction Piping on Cavitation in centrifugal
pumps’ by Allan Budris & Phillip Mayleben, Proceedings of the 15th Inter’l Pump Users
Symposium, March1998
• “Entrained Air in Centrifugal Pumps” A white paper presented by LaBour Pumps 2005
Copies of these articles are available in the WorleyParsons Pumps and Pumping intranet page at the
following links:
http://teams-wst.worleyparsons.com/sites/wks/pp/Dissolved%20Gases%20and%20Pumps/Forms/AllItems.aspx

http://teams-wst.worleyparsons.com/sites/wks/pp/Entrained%20Air%20and%20Pumps/Forms/AllItems.aspx

Alternatively go to the WorleyParsons ONE page, select “Operations & Delivery” tag. From the drop
down menu, select “Engineering & Design”. Select “All Network/Discussion Boards” and then select
“Engineering Networks”. In the new intranet page select “Pumps and Pumping”. The subdirectories
are located on the left of the webpage where the engineer can select “Dissolved gases and Pumps“
and “Entrained Air and Pumps”.

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6 PUMP SPECIFICATION
Several pump characteristics can be estimated using some basic equations, charts and guidelines.
These characteristics can then be used to support the design process, including cost and size
estimates. The following sections outline the key parameters and equations for pump specification.

6.1 Design Flowrate

The Design flowrate is the flowrate from the process mass balance (Normal flowrate) plus an
allowance for a continuous flow recycle (where applicable, refer to section 6.2), future expansion, and
consideration for start-up, shutdown, pumpout, upset conditions and any other operating cases plus
a 10% design margin. Calculations should also be carried out for the normal and minimum flowrates
to populate the datasheet and give the best available information to the pump vendor.
Reflux pumps should be specified based on simulation runs with a minimum 20% capacity margin
above the simulation flow where loss of reflux will result in a relief event.

6.2 Minimum Flow Recycle

The minimum stable flow of a centrifugal pump is the lowest flow at which the manufacturer will
permit continuous operation to avoid mechanical damage. The factors which determine minimum
allowable rate of flow include the following:
• Temperature rise of the liquid -- This is generally accepted as 8°C/ 15°F and results in a very low
limit. Please note the temperature rise could be lower for low specific heat liquids and low
NPSHa. However, if a pump operates at shut off, it could overheat badly;
• Radial hydraulic thrust on impellers -- This is most serious with single volute pumps and, even
at flow rates as high as 50% of BEP could cause reduced bearing life, excessive shaft deflection,
seal failures, impeller rubbing and shaft breakage;
• Flow re-circulation in the pump impeller -- This can also occur below 50% of BEP causing noise,
vibration, cavitation and mechanical damage;
• Total head characteristic curve – Some pump curves droop toward shut off, and some vertical
turbine pump (VTP) curves show a dip in the curve. Operation in such regions should be
avoided.
There is no standard which establishes precise limits for minimum flow in pumps, but ANSI/HI 9.6.3
Centrifugal and Vertical Pumps – Allowable Operating Region (AOR) discusses all of the factors
involved and provides recommendations for the “Preferred Operating Region.”
If continuous operation at process flows below the pump minimum flow is required, a minimum flow
recycle must be installed. For preliminary calculations, this flow is set at 30% of the process flow until
better information (from the pump manufacturer) becomes available. If this recycle is directed
straight back to the suction flange then the pump may be overheat. Therefore, the recycle is

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normally routed to the suction vessel. Two types of recycle are used are described in the following
sections.

6.2.1 Flow Control

The flow control recycle valve opens when the pump flow drops below the set point. It has no effect
on the pump calculation since the calculation is for the rated flow.

6.2.2 Fixed Cont inu ous Flow

The recycle with a fixed flow, set by the installation of a flow orifice plate in the recycle line, increases
the pump flow under all conditions. The recycle flow shall be included in the specification of the
pump rated flow and included in the calculation of the suction line/fittings pressure drop. This is so
that the impact on NPSHa and power requirements is considered during pump selection.
Typically recirculation should be returned to the suction vessel or tank. Where this is not possible,
recirculation routed to the pump suction line shall be connected at a point that is a minimum distance
of 10 pipe diameters (10D) upstream of the pump suction flange.
The standard calculation 650100-PR-CAL-0015 includes a continuous flow recycle check box that
applies a user-defined flow margin for centrifugal pumps.

6.3 Design Head

The design or differential head is the difference between the pump discharge head and the pump
suction head. Suction head and discharge head are discussed in Sections 7 and 8 respectively.
The engineer should be aware that API 610 (11th Ed) and HI 14.6 (2011)/ISO 9906 (2012) allows
performance test tolerances for pump manufacturers on flow rate (HI 14.6 only), total head, power,
efficiency and shut–off head.
API 610 does not have a rated flow tolerance or an efficiency tolerance but it does allow ±3% on total
head and up to ±10% on shut-off head. HI 14.6 allows flow rate to vary by up to ±9% and total head
by up to ±7% for class 3 type pumps.

6.4 Pump Cent re Line Elevation

This is the elevation of the pump inlet nozzle above grade. It can be estimated for horizontal pumps
using the table below but will ultimately need to be confirmed by the pump supplier based on the
selected pump:

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Table 6-1 Pump Elevation Above Grade

Flowrate Elevation Above Grade

[m³/h] [USgpm] [m] [ft & in]
0 to 45 0 to 200 0.61 2’-0”
45 to 227 200 to 1,000 0.76 2’-6”
227 to 2,270 1,000 to 10,000 0.91 3’-0”
2,270 to 4,540 10,000 to 20,000 1.22 4’-0”

Note : This table applies to aboveground pumps. Do not use for submersible and sump pumps.

6.5 Pump Po wer

The absorbed or shaft power [kW and hp] for centrifugal and PD pumps, can be estimated according
to the following formulae;
Q ⋅ ∆H Q ⋅ ∆H
P= [kW] P= [hp]
3600 ⋅ η 1714 ⋅ η
Where, Where,
Q = Flowrate, [m³/h] Q = Flowrate, [gpm]

∆H = Differential head = Hd – Hs [kPa] ∆H = Differential head = Hd – Hs [psi]

Hd = Discharge head [kPa] Hd = Discharge head [psi]

Hs = Suction head [kPa] Hs = Suction head [psi]

η = Pump efficiency η = Pump efficiency

Typical pump efficiencies for centrifugal pumps can be obtained from Section 6.7. Many positive
displacement pumps such as reciprocating types are assumed to operate at 90% efficiency while
screw pumps typically operate at 70% efficiency. These values can be used for preliminary
calculations on PD pump power. For more accuracy, refer to the manufacturer's pump test sheets.

6.6 Pump Motor Rot at ional Speed

6.6.1 Centr if ugal P umps

Pump motor speed impacts centrifugal pump design on the basis that the number of stages,
efficiency and NPSHr are all dependent on the impeller speed. For fixed speed pumps the
synchronous speed for a two pole motor is 3000 rpm for 50 Hz power frequency (3600 rpm for 60 Hz),
and 1500 rpm (1800 rpm at 60Hz) for a four pole motor. When the pump drive is in loaded operation,
it will operate at slightly lower speeds dependent on motor size. Therefore, the actual pump speed
will be 2800-2980 rpm or 1440-1495 rpm for 50 Hz machines. The range is significant and a suitable
value should be selected by reference to data for a similar motor power.

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The above does not apply to variable speed drive (VSD) pumps where the pump speed can be
adjusted to exactly fit the process conditions.

6.6.2 Reciprocat ing Pu mps

180 rpm may be used as a typical operating speed for reciprocating pumps. For the maximum speed
of single and double-acting reciprocating pumps based on stroke length, refer to Ref. 7:Table 3.

6.6.3 Screw Pu mp s
Unless otherwise specified, screw pumps/progressive cavity pumps should be designed for speeds not
exceeding 300 rpm. For pumps in abrasive/erosive service, consideration should be made for reduced
speeds based on fluid properties and pump materials.

6.6.4 Gear Pump s

Gear pumps operate at speeds from 280 rpm (large pumps) to a maximum of 1500 rpm (50 Hz power
supply) or 1800 rpm (60 Hz power supply). Smaller, high speed gear pumps may operate at up to 3600
rpm [ref.11].

6.7 Pump Specific Speed N S

Pump specific speed is a pump design parameter which is applicable to centrifugal pumps only. Note
that specific speed is a characteristic of a given impeller, not of a pump, and is almost always
evaluated at the best efficiency point (BEP) of the maximum diameter impeller. It gives an indication
of the priority given to the performance (i.e. NPSH) for a given impeller.
It is calculated as follows for SI or English units:

N⋅ Q
Ns = 3
H 4
 
S
Where,
Ns = Pump specific speed
N = Rotative speed [rpm]
Q = Flow [m3/hr or usgpm] at BEP
H = Total head, [m or ft] at BEP
S = Number of stages
The dimension of specific speed in English units can be converted to SI equivalent (m3/hr, m) by using
Ns (SI)= 0.0194 Ns (English)

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The specific speed provides an indication of what type of centrifugal pump is suitable for the
particular application. They are traditionally divided into 3 types :
• radial flow Ns <100 (5000);
• mixed flow 100 < Ns < 175 (5000 < Ns < 9000);
• axial flow 175 < Ns < 250 (9000 < Ns < 13000).
Figure 6-1 [ref.3] shows the influence specific speed has on the impeller type.

Figure 6-1 Specific Speed and Impeller Type (SI and English Units)

The minimum specific speed in English units is calculated as:

Log10 (Q)
− 0.75
Nmin = 2 . 3026
0.0025
Where:
Nmin = Minimum specific speed [English Units]
Q = Flow [usgpm]
A preliminary indication of the number of stages is then estimated by setting Ns equal to Nmin Pump
Efficiency.
A reciprocating pump has an efficiency of approximately 90%, while a screw pump has an efficiency of
approximately 70%.

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The efficiency of a centrifugal pump can be estimated using the specific speed and the following
graph in Figure 6-2 from the Pump Handbook [ref.1].

Figure 6-2 Specific Speed Ns versus Efficiency Ns < 3000

If the specific speed is in excess of 3000 [English Units] then the graph in Figure 6 3 overleaf from the
Pump Handbook [ref. 1] may be used.
Viscosity of the pumped medium can have a considerable detrimental effect on pump efficiency. This
is explained in Section5.1.1.

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Figure 6-3 Specific Speed Ns versus Efficiency Ns > 3000

6.8 Suct ion Specific Speed N S S

Suction specific speed, similar to the pump specific speed, is a parameter or index of hydraulic design
except it is descriptive of the suction capabilities and characteristics of a given first stage impeller. In
SI and English units, it is defined by:

N⋅ Q
N ss =
(NPSHR ) 4
3

Where,
Nss = Suction specific speed
N = Rotative speed [rpm]
Q = Flow [m3/hr or usgpm] at BEP [note - use Q/2 for double suction pumps]
NPSHr = Net Positive Suction Head required, [m or ft] at BEP
The suction-speed should be evaluated at the best efficiency point (BEP) of the maximum size
impeller. Suction-specific speed is an indication of the range of stable operation of a pump.
Pumps with high suction-specific speeds often have difficulty with internal recirculation at flows
below the BEP. The NPSHr of high suction-specific speed pumps actually increases as the flow
decreases. Suction-specific speed, like specific speed, will be altered if a given impeller is reduced in
diameter, but not (theoretically) if the impeller varies in speed. In actual practice, however,

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significant differences may exist between the calculated suction specific speed and measured values
at different operating points (found by varying the speed and determining the NPSHr). The following
table gives guidelines which can be used in evaluating the acceptability of centrifugal pumps for a
given service.

Table 6-2 Pump use and Suction-Specific Speed Nss

Suction-Specific Speed Nssm Suction-Specific Speed Nss

Comments
(SI units) (English units)
115 - 175 6,000 - 9,000 Good, flexible operating range
175 - 215 9,000 - 11,000 Good, but reduced operating flexibility
215 - 250 11,000 - 13,000 Use with caution
+ 250 + 13,000 Normally not acceptable

The dimensions of suction specific speed in English can be converted to SI equivalent by Nssm =
0.0194 Nss (m3/hr & m NPSHr)
A large suction-specific speed indicates that the impeller eye is somewhat larger than normal and
consequently that the efficiency may be compromised to obtain a low NPSHr. Suction-specific speeds
of centrifugal pumps vary from about 21 to 290 (1,100 to 15,000 English units) but values above 250
(13,000 English units) are not considered commercially practical.
Industry has extensive published documentation indicating that pumps with high NSS defined as 215
(11,000 English units) and greater have reduced reliability. Hence for NSS greater than 215 (11,000
English units), specific approval should be required by the purchaser. A quotation for such a pump
shall include minimum continuous flow rate, maximum operating flow rate and operating experience.
Inducers have been applied successfully to as much as 580 (30,000 English units) NSS, although the
more common range is 290 to 480 (15,000 to 25,000 English units) NSS. When considering inducers,
particular attention should be devoted to the NPSHr curve shape and the pump manufacturer’s
experience. Care should be given when selecting inducers for pumps that have a large range in flow
rate because a narrow flow range is preferred for inducers.
Double-suction impellers require less NPSH than do single suction impellers and the suction specific
speed is calculated by using half the flow rate.

6.9 Required Net Posit ive Suctio n Head (NPSHr)

Cavitation is the formation and subsequent collapse of vapour bubbles in the liquid flow and is one of
the most significant causes of pump performance and maintenance problems. Net positive suction
head (NPSH) is a parameter that defines pump suction conditions and that allows prediction of the
occurrence of cavitation in a particular pump. There is a distinction made between required net
positive suction head (NPSHr) and available net positive suction head (NPSHa).
NPSHr is dependent on the pump design and is established by testing of the pump and has nothing to
do with the pump circuit. Initial estimates of NPSHr for centrifugal pumps can be read off the graphs

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(Figure 6-4 and Figure 6-5) from the Hydraulic Institute standard [ref.2]. These charts are based on
pump suction impeller design (single or double), speed and capacity. They are conservative and
should only be used as the first estimation for preliminary design. For detailed design, vendor data is
required.
If NPSHr is too high then this can be remedied in the following ways:
• Half the speed to 1500 rpm (1450 rpm actual).
• Change impeller design to double suction.
Alternatively, NPSHa can be increased in the following ways:
• Providing a booster pump upstream.
• Increase the suction vessel pressure if it is blanketed with an inert gas.
Note: If the liquid is in equilibrium with gas, which is usually the case in oil and gas applications,
then increasing the suction vessel pressure provides no benefit. Refer to Section 7.2.
• Increase the height of the suction vessel or increase the minimum operating liquid level.
• Cooling the liquid in the suction line.
NPSHa is discussed in Section 7.

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Figure 6-4 NPSHr for Single Suction Pump (first choice) (based on Nss (SA) of 8500)

Figure 6-5 NPSHr for Double Suction Pump (based on Nss (SA) of 8500)

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6.9.1 Pu mp ing Hydrocarbons and Water at E lev at ed Temper atures

The required NPSHr for centrifugal pumps is normally determined only for handling clean, cold water.
However, tests and accumulated experience over the years have shown that pumps can handle
hydrocarbons and water at elevated temperatures with less NPSHr than would be necessary for cold
water.
Based on tests and field observations, the Hydraulic Institute (refer ANSI/HI 1.3 -2013 Figures
1.3.6.3.5A and B) and the Natural Gas Processors Suppliers Association published NPSHr reduction
factor charts (based on suction vapour pressure and temperature) to use as multipliers for water
NPSHr.
The NPSH reduction charts will show you how to calculate this reduction. The engineer should keep
the following in mind:
• These charts were created using pure liquids of the type found in tank farms. Many liquids are
mixtures and have entrained gases, or air that could require additional NPSH;
• Your product may be a combination of several hydrocarbons with different vapour pressures;
• Sometimes the temperature at the suction side of the pump can vary with outside
temperature;
• Pump discharge recirculation lines can have a major effect on the pump suction temperature.
These recirculation lines frequently raise the temperature of the liquid at the pump inlet;
• This reduction is possible because the expansion rate of hot water and some hydrocarbons is
not as great as that of cold water.
It is important to note that the standard API 610 / ISO 13709 does not allow use of any "hydrocarbon
correction" for NPSH to allow a greater design margin of safety.

6.10 Impeller Diamet er for Centrifugal Pumps

The diameter of the impeller (m and inches) can be estimated with the following formulas:

H H
84.6 ⋅ Φ ⋅ 1840 ⋅ Φ ⋅
D= S D= S
N N
Where: Where:
D = Impeller Diameter [m] D = Impeller Diameter [inch]
N = Rotative Speed [rpm] N = Rotative Speed [rpm]
H = Total Head [m] H = Total Head [ft]
S = Number of Stages S = Number of Stages
φ = Efficiency coefficient φ = Efficiency coefficient

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Church [ref 9] gives several charts for φ which have been based on a large number of tests. Most of
the plotted points fall within a range of 0.9 to 1.1. Noting that if the head on test is found to be too
high, the impeller diameter can be machined to an appropriate diameter, select 1.05 for φ.

6.11 Suct ion Impeller

The suction impeller can be designed for a single inlet nozzle (normal) or double inlet nozzles. Double
suction is used to reduce the required net positive suction head.

6.12 Affinity Laws

These are a series of mathematical statements correlating capacity, head and power with speed and
impeller diameter for centrifugal pumps. The equations shown in the table below may be used when
a pump with known performance curves is to be used in a new set of conditions requiring a change in
impeller diameter or speed, or both. For example, in the early stages of a debottlenecking study, the
affinity laws can be useful to check the suitability of existing centrifugal pumps for the revised duties.
A revised set of characteristic curves can then be constructed to reflect such changes. For modest
speed changes, the efficiency can be considered constant.

Table 6-3 Affinity Laws

Diameter Change Speed Change Diameter & Speed Change

D2 N2 D 2 N2
Flow Q 2 = Q1 Q 2 = Q1 Q 2 = Q1
D1 N1 D1N1
2 2 2
D  N  D N 
Head H2 = H1  2  H2 = H1  2  H2 = H1  2 2 
 D1   N1   D1N1 
3 3 3
D  N  D N 
Power bkW 2 = bkW1  2  bkW2 = bkW1  2  bkW 2 = bkW1  2 2 
 D1   N1   D1N1 
Generalised affinity law not 2 2
applicable. Proportionality N  N 
dependent on specific pump
NPSHr2 = NPSHr1  2  NPSHr2 = NPSHr1  2 
characteristics.
 N1   N1 

1: Values at initial conditions.

2: Values at new conditions.
These laws should be used cautiously. The actual effect of trimming an impeller is related to its
specific speed, which is based on its type and proportions. Generally, the lower the impeller design's
specific speed and the larger the impeller cut, the larger the discrepancy between affinity law
calculations and actual performance.

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7 SUCTION CONDITIONS

7.1 Suct ion Vessel Pressure

The suction vessel pressure is normally controlled. If large deviations in suction vessel pressure are
anticipated, the lowest suction pressure should be the governing case since this is the most arduous
duty for the pump.

7.2 Vapo ur Pressure

The vapour pressure used in determining the NPSHa must be the actual vapour pressure of the liquid
at maximum operating temperature. The following guidelines should be used in conjunction with
good engineering judgement.

7.2.1 Vessels in Equ ilibriu m

The vapour pressure of a stream from a suction vessel with vapour-liquid phase equilibrium is the
same as the maximum operating pressure of the vessel. This includes oil and water streams from 2-
phase or 3-phase separators, streams from storage tanks, and side streams, bottom products or top
refluxes from columns.

7.2.2 Gas-Blan ket ed Vessels

Gas-blanketed vessels should be treated as follows:
• For a fuel gas blanket of hydrogen or hydrocarbons over a liquid hydrocarbon, use the actual
blanket pressure as the pump vapour pressure;
• If the blanket gas is inert (e.g. nitrogen), use the vapour pressure of the liquid as the pump
vapour pressure.

7.2.3 At mospher ic St orag e Tanks

If suction is taken from an atmospheric storage tank containing a fluid such as dead oil, the vapour
pressure entered should be as per the vapour pressure of the fluid.

7.2.4 Flu ids with Dissolved Gas

In some cases, gas is dissolved in the liquid (e.g. hydrogen sulphide and carbon dioxide may be
dissolved in sour water). Depending on the solubility of the gas, the pump vapour pressure may range
from normal liquid vapour pressure to actual operating pressure.
For this case, the calculated NPSHa, based on the normal vapour pressure, should be multiplied by
the factor 0.5. This factor is based on experience, and good engineering judgment should be
employed in such cases.

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7.3 Suct ion Liquid Level Elevation

This must take into account the pump centreline elevation (Section 6.4), the minimum liquid level in
the suction vessel, and the vessel elevation above grade.
If a low-low level trip is provided on the vessel, the minimum liquid level can be considered as the
level of trip. If an alarm is not provided, use the vertical vessel bottom tangent line or the bottom of a
horizontal vessel as low level.
For preliminary design, the minimum elevation for horizontal vessels is 1 m above the pump centre
line taking into account piping and layout requirements. For vertical vessels the minimum elevation
can be estimated with the table below:

Table 7-1 Minimum Elevations Above Grade

Minimum Elevation OD Shell Minimum Elevation

OD Shell
Above Grade Above Grade
[mm] [m] [Inches] [ft]
0 to 800 1.7 0 to 32 5.6
800 to 1700 1.8 32 to 66 5.9
1700 to 2600 1.9 66 to 102 6.2
2600 to 3600 2 102 to 144 6.6
3600 to 4800 2.1 144 to 192 6.9
4800 to 6200 2.2 192 to 240 7.2
6200 over 2.3 240 over 7.6

7.3.1 Colu mn side draw-of f lin es

Side draw-off connections from a column to a pump suction are a special case. Due to the possibility
of foam being drawn down into the suction line to the pump, good engineering judgment must be
used when determining the pump suction head. To allow for foaming, a multiplying factor of 0.6 may
be applied to the liquid head. For example, if the difference in elevation between the pump centreline
and the and the side draw-off centreline is 15m, multiply 15m by 0.6, and use 9m when calculating
the pump suction head.

7.4 Line / Fittings Pressure Drop

Before the exact plant layout and number of fittings is known, the line size and the losses can be
estimated as outlined in the WorleyParsons Design Guide for Line Sizing and Hydraulic Analysis [ref 5].
The allowable pressure drop and velocity in centrifugal pump suction piping are also outlined in ref.5.
It is important that large pressure drops, such as across filters and control valves are estimated at this
stage. If the pump is expected to have a continuous flow recycle, this flow must be taken into account
when determining the suction line/fitting pressure drop.

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For reciprocating pumps, specific attention must be given to the effect of pulsation in the suction line.
If the pump is in metering service the pump type can initially be assumed to be single-acting simplex
and the peak flow for line / fittings pressure drop calculations can be taken as twice the average
flowrate. For more complex configurations, the following table [ref.10 - Figure 1 Flow variation] can
be used for determining the flow factor to be applied for calculation of the suction line / fittings
pressure drop. This flow factor shall be applied over and above any design margin.

Table 7-2 Flow Factor for Suction Line Pressure Drop for Reciprocating Pumps

Pump type Flow Factor

Double Acting Duplex 1.25
Triplex 1.07
Quadruplex 1.11
Quintuplex 1.02
Sextuplex 1.05
Septuplex 1.02
Nonuplex 1.01

7.5 Available Net Posit ive Suction Head (NPSHa)

The definition of net positive suction head is given in Section 3. Available net positive suction head
(NPSHa) is the suction head minus the vapour pressure of the liquid being pumped, thus it is the
pressure or head available above the vapour pressure to move and accelerate the fluid into the
impeller inlet. The NPSHa has nothing to do with the pump design. The NPSHa is calculated as
follows:

NPSHa = Hs − H v − Ha − safety margin

Where,

Hs = Suction head [m] or [ft]

Hv = Vapour pressure of the liquid [m] or [ft] at the temperature entering the pump suction

Ha = Acceleration head [m] or [ft] (only applies to reciprocating type pumps)

The recommended safety margin is 1 m (3 ft). For vacuum systems the safety margin is 2 m (6 ft).
It is important that the pump datasheet includes NPSHa at rated conditions.

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7.6 Suct ion Head (H s )

This is calculated with the following formula:
Hs = Hp + Hse − H f
Where:

Hp = Absolute pressure on the surface where the pump takes suction (suction vessel
pressure) [m] or [ft]

Hse = Static elevation of the liquid above the pump centre line [m] or [ft] (see Section 3)

Hf = Friction and entrance head losses in the suction piping [m] or [ft] [see ref. 5]
If the suction head is to be calculated based on a point within the suction piping where the pressure is
known and the liquid is flowing at a velocity, v, a velocity head term may be taken into account. This is
because total head in a flowing pipe is equal to the pressure head plus the velocity head. In this case,
the following formula may be applied:

v 2x
H s,x = Hp,x + Hse,x − H f ,x +
2⋅g
Where:

Hp,x = Pressure of the flowing liquid measured at point x in the suction piping [m] or [ft]

Hse,x = Static elevation of the liquid at point x above the pump centre line [m] or [ft] (see
Section 3)

Hf,x = Fiction and entrance head losses from point x to the suction nozzle [m] or [ft] (see
ref.5)

vx = Velocity of the liquid at point x [m/s] or [ft/s]

g = Gravitational constant = 9.81 m/s2 or 32.2 ft/s²

7.7 Accelerat ion Head

The pump sizing calculation 650100-PR-CAL-0015 breaks positive displacement pumps into two
categories, reciprocating and screw, as the design of reciprocating pumps requires the additional
consideration of acceleration head.
Acceleration head is the fluctuation of the suction head above and below the average due to the
inertia effect of the fluid mass in the suction line. It is therefore only applicable to reciprocating
pumps. The pressure fluctuation or acceleration head must be taken into account if the pump is to fill
properly without forming vapour which will cause pounding or vibration in the suction line.

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For reciprocating pumps the acceleration head must be taken into account with the following formula
from the Hydraulic Institute standard [ref. 2]:
L ⋅ v ⋅N⋅C
Ha =
k⋅g
Where:

Ha = Acceleration head [m] or [ft]

L = Actual length of suction line (not equivalent length) [m] or [ft]

v = Average liquid velocity in suction line [ft/s] or [m/s]

N = Speed of pump crankshaft [rpm]

C = Constant depending on type of pump

k = Constant depending on fluid compressibility

g = Gravitational constant = 9.81 m/s2 or 32.2 ft/s²

Numerical values for the constants C and k are shown in the following tables [ref.3, 7 & 12]:

Table 7-3 Acceleration Head Constant C for Reciprocating Pumps

Pump Type Constant C

Simplex - single acting 0.400
Simplex - double acting 0.200
Duplex - single acting 0.200
Duplex - double acting 0.115
Triplex – single or double acting 0.066
Quintuplex– single or double acting 0.040
Septuplex– single or double acting 0.028
Nonuplex– single or double acting 0.022

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Table 7-4 Fluid Compressibility Constant k for Reciprocating Pumps

Fluid Compressibility Constant k

High Compressibility Liquids e.g. Hot Oil, Ethane 2.5
Most Hydrocarbons 2.0
Most Liquids incl. Amine, Glycol, Water 1.5
Low Compressibility Liquids – e.g. Deaerated Water, Hot Water 1.4
Liquid with small amounts of entrained gas, urea 1.0

For controlled volume diaphragm pumps the formula is the same but C = 0.628 for a simplex single
acting pump.

7.7.1 Pu lsat ion Dampeners

Pulsation dampeners may be considered to minimise acceleration head. They should not be required
if the suction piping is adequately designed (i.e. oversized and short), or if the pump operates at less
than 150 rpm. A properly designed pulsation dampener should absorb the cyclical flow variations so
that the pressure fluctuations are about the same as those that occur when the suction piping is less
than 4.5 m long [ref.3].
If a pulsation dampener is required, L shall be set conservatively to whichever is greater of;
• 4.5 m, or
• the pipe length from the pulsation dampener to the pump suction flange.
It is recommended that the engineer includes the calculated acceleration head on the pump data
sheet and let the pump vendor determine the type and size of suction stabiliser (pulsation dampener)
required.

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8 DISCHARGE CONDITIONS

8.1 Discharge Vessel Pressure

The discharge vessel pressure will normally be controlled. If a large deviation of discharge vessel
pressure is anticipated, the highest pressure should be the governing case since this would give the
most arduous duty for the pump.

8.2 Discharge Liquid Level Elevation

This must take into account the level in the discharge vessel, and the vessel elevation relative to the
pump base plate. The maximum liquid level is assumed to be at:
• The centre line of a horizontal inlet nozzle when this nozzle is located in the vapour space of
the vessel;
• The maximum liquids level in the discharge vessel when the inlet nozzle is located in or
extended into the liquid space of the vessel; and
• The highest point of a discharge line entering the vessel from above the vapour space of the
vessel.
When the discharge vessel liquid level is considerably lower than the highest discharge line elevation,
the pump head shall be checked for the start-up situation.
Verify that pump can operate at lowest discharge vessel level elevation. In some cases, e.g. vertical
storage tanks, the difference between highest and lowest level may be considerable. When the level
is at its lowest, a centrifugal pump will run down its pump curve, but up its power curve, which may
cause it to trip.

8.3 Line / Fittings Pressure Drop

Before the exact plant layout and number of fittings is known, the losses can be estimated as outlined
in ref. 5. A more detailed pressure drop calculation can be carried out following the WorleyParsons
Design Guide for Line Sizing and Hydraulic Analysis [ref.5]. It is important that large pressure drops,
such as across filters and control valves, be estimated at this stage. The allowable pressure drop and
velocity in centrifugal pump discharge piping is outlined in ref.5.
The following guidelines may also be considered when determining the discharge line pressure drop:
• Flow orifice pressure drop may be assumed to be 20 kPa (3 psi) at normal flow for each orifice
in the system;
• If the pressure drop across equipment such as heat exchangers is known at a the normal flow,
the pressure drop at pump rated flow may be estimated as follows:

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2
 Q 
∆Prated = ∆Pnormal  rated 
 Q normal 

8.4 Pump Shut-off Pressure

The shut-off pressure is an estimated value for the maximum discharge pressure of a centrifugal
pump and is used to rate the pump flanges, casing and seals and as the design pressure for
equipment in the pump discharge circuit. The following formulas are applicable for an estimate of
shut-off pressure. The formulas are based on a head rise to shut-off of 25% from the rated point. The
actual head rise to shut-off is dependent on the selected pump characteristics. The Engineer needs to
verify actual pump shut off pressure after pump selection by the vendor is complete in order to
validate downstream discharge circuit design pressures.

8.4.1 Mot or-driv en C entrif u gal pu mps:

Pshut −off = Psuction,max + 1.25 ⋅ ∆Prated
Where,
Pshut-off = Maximum shut-off pressure in [kPa] or [psi]
Psuction, max = Maximum suction pressure in [kPa] or [psi]
ΔPrated = Pump differential head at rated flow in [kPa] or [psi]
Where Maximum Suction Pressure is defined as the greater of maximum upset suction pressure with
PSV at 110% plus normal liquid level or normal operating suction pressure with PSV at 100% plus
maximum liquid level.
Note that some companies use PSV at 100% plus maximum liquid level, and this should be clarified on
each project.

8.4.2 Turbin e-driven Centrifugal pu mps:

For a turbine-driven pump, an extra factor 1.1025 (1.052) is included which compensates for the 5%
overspeed allowance for the turbine:
Pshut−off = Psuction,max + 1.25 ⋅ 1.1025 ⋅ ∆Prated

The maximum suction pressure is required in order to estimate the shut-off pressure of centrifugal
pumps. It occurs at zero flow (i.e. no line/fitting frictional loss) as a result of one of the following
conditions:
• Maximum liquid level in open vessels;
• Maximum liquid level plus relief valve set pressure or HH pressure trip in pressurised vessels.

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9 CONTROL
A centrifugal pump operating in a system will deliver the capacity corresponding to the point of
intersection between the pump curve and the system curve. In order to vary the capacity, it is
necessary to change either one or both of these curves.

Figure 9-1 Simple Pump and System Head Curve

The pump curve can be changed by operating the pump at variable speed which can be achieved by
variable speed drive or variable frequency control. Both of these options can be expensive and should
be considered only for larger pumps. Refer to Figure 9-2.
The system curve can be altered by creating friction loss through a control valve. It should be noted
that the difference between the total head developed by the pump and the head required by the
system represents wasted energy lost in the throttling process. However, as the majority of
centrifugal pumps are driven by constant-speed motors, a control valve is the only way to vary the
flowrate. The control valve should always be installed on the discharge side of the pump downstream
of any minimum flow recycle line. Refer to Figure 9-3.
In brownfields applications, where the pump(s) are operating inefficiently (either due to poor original
design or change in process operations), the engineer should consider modifying (replacing or
trimming) the impeller to change the pump curve. This could be a moderately inexpensive option as
opposed to modifying piping layout, installing control valves, installing VSDs etc. The vendor will
normally specify the maximum and minimum diameter impeller size for the selected pump model

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Figure 9-2 Pump and System Head Curves at Variable Speeds

Figure 9-3 Throttled Pump and System Head Curves

Fluctuations in pump capacity will occur if one or more variables in the system change such as
suction/discharge pressure, liquid levels, flow diversion, etc.
Care should be taken that the pump operates within the operating limits as specified by the pump
vendor.

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10 PARALLEL OR SERIES OPERATION

10.1 Parallel Operatio n

Centrifugal pumps may be combined into parallel operation for numerous reasons. These include:
• Capacity increase is required for an existing pumping service and a new pump is added in
parallel to one or more existing pumps. The engineer should be aware that the system flow will
not necessarily increase in proportion to the number of pumps added;
• Very high reliability is required of the pumping service without total reliance on the functioning
of an auto-start control mechanism for a spare pump. Also, the loss of one pump will not cause
sudden total shutdown of the system;
• In order to meet a requirement for flow capacity higher than normal on an infrequent basis, it
may be preferable to have the primary pump and its spare operate in parallel, instead of
designing each pump for the full above-normal flow rate;
• The required service capacity may exceed the utility energy supply available for a single driver
or driver type. Desire for operating flexibility in power supply or type could result in multiple
pumps with different driver types;
• The use of multiple pumps may allow investment savings. For example, three 50%-pumps may
require lower a total investment than two pumps sized for 100% for the service capacity. (This
would be possible but unusual.);
• Parallel pumps are recommended for pipeline applications where discharge line head loss is
mostly static head.
For parallel operation, the head-capacity curve is obtained by adding the individual pump capacities
at any one given head. Refer to Figure 10-1.
Pumps with different pump curves should not operate in parallel. When this cannot be avoided, the
pump with the lower shut-off head must be protected against operating at flows below the allowable
minimum flow. The engineer must be certain that one pump is not "backed out" or forced to operate
below its minimum flow.
When pumps are operated in parallel it is imperative that their performance curve rise steadily to
shut-off. A drooping type of performance curve gives two possible points of operation and pumps
may oscillate between each other and cause surging. In parallel operation additional pumps can be
started up only when their shut-off heads exceed the head developed by the pumps already running.
Pumps operating in parallel should have a shut-off head at least 10% higher than the rated head
[ref.13].
Another difficulty may occur as a result of inadequately engineered suction lines, such that one pump
suction line “steals” from the other. The remedy is to design for equal suction heads as much as
possible by employing symmetrical suction piping. Where one pump is closer to the outlet nozzle on
the suction vessel/tank, it will naturally draw more flow (less friction loss). The engineer should base

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suction friction loss on the pump furthest form the suction vessel outlet nozzle. The engineer must
also to assure that available NPSH is sufficient to satisfy each pump.

Figure 10-1 Parallel Pumping

Adequate check valves must be used on pump systems operating in parallel to minimise possible back
flow through pumps and to minimise the effects of surge which is possible on some parallel pumping
systems.
It is advisable to provide a piping bypass system so that either pump can be operated without the
other. Aside from flexibility, a bypass system permits operation at reduced conditions during
maintenance, inspection or repair of either pump.
The shut-off head of the combined pump discharge system is determined by the pump with the
highest shut-off head.
The engineer should consider start-up and non-routine operations when determining pump shut off
head. For example, in hot fluid systems (boiler feed water) temperatures are elevated (150 to 200OC)
entering the boiler feed water pump , but at start up 20OC water will produce a different result for
shut-in pressure.

10.2 Series Operatio n

Centrifugal pumps may be designed to operate in series arrangement for any of the following
reasons:

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• The head requirement exceeds the capability of a single pump.

• The differential pressure requirement is low enough at times that one of several pumps in
series can be turned off, as in transportation pipe lines.
• The primary pump has a high NPSHr requirement. Therefore, a low-head booster pump is
installed to pressure the suction of the higher-head pump.
• Plant feed must be transferred from a remote storage area to the suction of an on-site high-
head pump.
• Two or more pumps are preferred over a multistage pump in erosive slurry operation
• Series pumps are recommended for pipeline applications where discharge line head loss is
mostly friction loss.
For series operation, the head-capacity curve is obtained by adding the two heads at any given
capacity. Refer to Figure 10-2

Figure 10-2 Series Pumping

It is important that adequate suction pressure be available to all pumps, especially to the first pump
in series operation. If the first pump in a series system is deprived of adequate NPSH, its capacity will
be reduced until NPSHr equals NPSHa. Then the capacity through all the pumps in series will be
reduced, resulting in a significant overall flow loss.
The design pressure for piping and equipment, including the pumps themselves, should be carefully
examined in a series-flow operation especially if the pumping system can be deadheaded.
The engineer should be aware that reliability is reduced for the series-flow service since operation is
now dependent on not just one pump but each pump in the series

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11 VARIABLE SPEED OPERATION

The speed of a pump can be varied by the following means:
• Gear box, this is not a true variable speed drive because it only enables variation of the speed
in discrete steps;
• Fluid coupling, this allows unlimited variation within the limitations of the pump;
• Variable frequency drive, this also allows unlimited variation within the limitations of the
pump.
Although not advisable (see Section 10), where pumps with different pump curves are operated in
parallel service with variable speed drives , each pump must be provided with minimum flow
protection for the lowest minimum flow.
Variable speed drive enables the pump to meet various service conditions without throttling, by
reducing the pump operating speed.
The energy savings that can be achieved with a variable speed drive system can be considerable when
prolonged operation at reduced capacity is required. To decide whether such a system is
economically feasible, it is necessary to plot the system-head curve, to calculate the speed required at
various capacities over the operating range, and to determine the required motor power over this
range, including losses incurred by variable speed devices. The difference between this motor power
and the motor power required at constant speed represents the potential energy saving. It is then
necessary to assign a predicted number of hours at various capacities, and to calculate the potential
annual energy savings. These savings have to be measured against the initial capital costs of
supplying and installing a variable speed drive system.
In pump circuits with multiple discharge lines, speed control is usually combined with throttling valves
in each branch to allow individual flow control.
Published articles related to this topic include:
• “Variable Speed Driven Pumps - Best Practice Guide” British Pump Manufacturers Association;
• “Variable Speed Pumping — A Guide to Successful Applications, Executive Summary” A
collaboration between the Hydraulic Institute, Europump, and the U.S. Department of Energy’s
(DOE) Industrial Technologies Program;
• “Adjustable Speed Pumping Applications – Hydraulics Institute Knowledge Series published in
World Pumps February 2010;
• “Watch out with VSD Pumping” C Smith, published in Chemical Processing magazine May 2008.
Copies of these articles are available in the WorleyParsons Pumps and Pumping intranet page at the
following link:
http://teams-wst.worleyparsons.com/sites/wks/pp/VSD%20and%20Pumps/Forms/AllItems.aspx

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Alternatively go to the WorleyParsons ONE page, select “Operations & Delivery” tag. From the drop
down menu, select “Engineering & Design”. Select “All Network/Discussion Boards” and then select
“Engineering Networks”. In the new intranet page select “Pumps and Pumping”. The subdirectories
are located on the left of the webpage where the engineer can select “VSD and Pumps”.

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12 SEAL SELECTION

12.1 General
Pump seal failure is responsible for most unscheduled shut-downs of pumps with loss of containment
(depending on the type of seal/seal system used) and possible fires/explosions in hydrocarbon
services. The seal maintenance costs through a pump life are also the most expensive cost associated
with a pump operation and maintenance. Some pumps may require the mechanical replacement
every 1-3 years dependent on operating conditions and fluid characteristics.
Mechanical seals are also susceptible to changes in operating conditions and fluid characteristics
(including containments) and any existing installations should be checked for to ensure satisfactory
seal and seal system performance with the new conditions.
The cartridge seal design is always preferred (especially in vertically suspended pumps) to other seal
designs such as the component seal because it is simpler, safer and more reliable. The cartridge seals
are available for wide ranges of services and applications (for nearly all types of seal).
A thin film of liquid should be provided between the rotating face and the stationary face of the pump
mechanical seal to offer some lubrication effects and cooling. Usually, a flushing liquid from a suitable
source should be used since some pumped liquids if employed without proper processing (for the
flushing) can cause problems.
For example, high temperature, contaminants/solid, chemical traces, etc. could result in serious
damages to the seal. Sometimes, a flushing liquid from an external source should be used.
The flushing is piped from a reliable source at a pressure higher than the pressure of pumped liquid at
the seal location.
For many services, an external flushing source may not be available or suitable and the high pressure
pumped liquid at the discharge nozzle of the pump could be used for the flushing after some
processing such as the cooling(by a small heat exchanger), filtration/separation (by a filter/separator)
and pressure adjustment.
In any mechanical seal, there is a requirement for the closing force to the seal faces during the
transient operation (for example, start-up or shut-down), which is provided by the spring or bellows.
A well-known combination could be the carbon rotating face and the ceramic stationary face. Other
materials such as the tungsten carbide or the silicon carbide can also be used.
Traditionally, a series of springs have been used to provide an even loading. A recommended design is
the metal bellows which are made from a series of thin metal discs welded together to form a leak
tight configuration suitable for aggressive/critical services. The material selection of the seal
components is extremely important.
Some critical applications such as the volatile, toxic, carcinogenic, hazardous, poor-lubricating and
other difficult and risky liquids require a dual arrangement 3 (double) seal system. A dual

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arrangement 3 mechanical seal is a combination of two seals mounted back-to-back with a non-
hazardous barrier fluid injected between the two seals at an operating pressure above the stuffing
box (or seal chamber) pressure.
A barrier fluid is required with the dual arrangement 3 seal systems, usually in an external closed
loop, containing a fluid reservoir and the pressure/temperature control (and adjustment) devices. The
barrier fluid should be compatible with the pumped liquid, and it cools and lubricates the outboard
seal (the secondary seal) at low pressure. For special “zero emission” seal systems a “gas barrier seal’
system may be employed, which uses an inert gas (usually nitrogen). This is a complicated seal system
that should only be used if required.
Dual arrangement 2 (Tandem) mechanical seals are also used in services involving toxic, flammable,
or hazardous liquid to prevent the pumped liquid, or its vapour, from escaping into the environment
due to primary seal failure. The arrangement is also a combination of two seals but they are mounted
in the normal position, face to back position with the secondary seal acting as a back-up seal. A buffer
fluid is injected between the two seals from an external reservoir in a closed loop piping system but it
is normally not pressurised or pressurised below seal chamber pressure.. Alternatively, a gas buffer
fluid or no buffer fluid can be utilised. Dual arrangement 2 (Tandem) double seals are usually
employed in petrochemical and refinery plants, where service with high vapour pressure and low
specific weight on centrifugal pumps is required.
The advantages of a Dual arrangement 2 (tandem) design include:
• two completely independent seals that do not depend on the other one for sealing:
• seals orientated in this configuration can withstand much higher pressures in the pump casing
when compared to a double seal pump
During the seal selection process with a pump vendor, the seal selection may also be discussed with
the mechanical seal vendor, especially for difficult duties and/or complex seal systems.
For large projects with multiple pumps or where the client has a seal manufacturer preference, it may
be beneficial to engage the seal vendor(s) to provide an initial seal selection for the pumps, which can
be discussed and agreed with the pump vendor(s) during the bidding process.
Nowadays, seal “packing” is not used even in the small and inexpensive pumps and the mechanical
seals should always be employed, except for some specific applications. The old-fashioned “packing”
offered some well-known disadvantages such as an efficiency penalty, constant liquid leakage, regular
maintenance requirement, high rate of wear, leading to frequent unscheduled shut downs and many
other operational issues.

12.2 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;

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3. Temperature;
4. Characteristics of Liquid;
5. Reliability and Emission Concerns.

12.2.1 Liquid
Identification of the exact liquid to be handled is the first step in seal selection. The metal parts must
be corrosion resistant, usually steel, bronze, stainless steel, or Hastelloy. The mating faces must also
resist corrosion and wear. Carbon, ceramic, silicon carbide or tungsten carbide may be considered.
Stationary sealing members of Buna, EPR, Viton and Teflon are common.

12.2.2 Pressure
The proper type of seal, balanced or unbalanced, is based on the pressure on the seal and on the seal
size.

12.2.3 Temperatur e
In part, determines the use of the sealing members. Materials must be selected to handle liquid
temperature.

12.2.4 Charact eristic s of Liq uid

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.

12.2.5 Reliab ility and E mission C on cern s

The seal type and arrangement selected must meet the desired reliability and emission standards for
the pump application. Double seals and double gas barrier seals are becoming the seals of choice.

12.3 Mechanical Seal Definitio ns

API 682 defines shaft sealing systems for centrifugal and rotary pumps and is commonly used with API
610 process pumps.
API 682 defines the seal categories, types and arrangement of mechanical seals as summarised as per
the following sections.

12.3.1 Seal Cat egories

• Category 1. Seals intended for non API 610 pumps, preferably meeting the dimensional
requirements of ASME B73.1, ASME B73.2 and ISO 3069;
• Category 2. Seals intended for API 610 pumps, with defined temperature and pressure limits;

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• Category 3. Seals intended for API 610 pumps, with defined temperature and pressure limits
and increased testing and documented seal design.

12.3.2 Seal Types

• Type A. Balanced pusher seal with multiple springs and in which the flexible element normally
rotates;
• Type B. Balanced non pusher (metal bellows) seal in which the flexible element normally
rotates;
• Type C. Balanced non pusher (metal bellows) seal in which the flexible element is normally
stationary.

12.3.3 Seal Arrangement s

• Arrangement 1. Seal configurations having one seal per cartridge assembly;
• Arrangement 2. Seal configurations having two seals per cartridge assembly, with the space
between the seals at a pressure less than the seal chamber (also known as a tandem seal);
• Arrangement 3. Seal configurations having two seals per cartridge assembly, utilising an
externally supplied barrier fluid at a pressure greater than the seal chamber pressure (also
known as a double or back to back seal).
For full details refer to API 682. API 682 also has a recommended seal selection procedure (including
seal flush plans as detailed below) to enable the end user to determine a recommended mechanical
seal and seal system.

12.4 Mechanical Seal Piping Plans

API 682 mechanical seal piping (flush) plans are commonly used with API 610 process pumps. The
difference between the flush plans is the construction which provides applicable pressure-
temperature capability for each type of pump. Each plan helps provide critical lubrication and cooling
of seal faces to maximize seal reliability. The following seal piping plans are referenced in API 682.

Plan Recommended Applications

No.
01 Single mechanical seals and total developed head (TDH) less than 38m (125 ft).
02 Used with some outside seals. In most cases not recommended. Cooling jacket seal
chambers in high temperature services.
03 Single mechanical seals. Used on smaller, lower duty pumps such as ASME B73 in
chemical duty services
11 Single and tandem seals. Always consider a plan 11 with balanced seals. Apply when TDH
is greater than 38m (125 ft). Default API Plan for most single seals.

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Plan Recommended Applications

No.
12 Same application as 11. Additionally, a 12 will strain particles from the flush liquid. This
helps prevent solid impingement on seal faces. In general used in slightly dirty and non-
polymerizing fluids
13 Single and tandem seals. Use when difference in pressure between the seal chamber or
stuffing box and pump suction exceed 240 kPa (35 psi)
14 A combination of Piping Plan 11 and Piping Plan 13. Used in vertical pumps and in light
hydrocarbon services.
21 Single and tandem seals. Required when the flush needs to be cooled before flushing at
the seal faces. (ex. water above 80 °C / 180°F, light hydrocarbons or any other liquids with
poor lubricating qualities and high vapour pressures.)
22 Same application as 21. Additionally, a plan 22 will strain particles from the flush liquid.
This helps prevent solid impingement on seal faces. For high temperature applications
with slightly dirty liquid
23 Single and tandem seals. Use when difference in pressure between the seal chamber or
stuffing box and pump suction exceed 240 kPa (35 psi). 3000 / 3600 RPM only. In hot and
clean services e.g. in boiler feed water and hot hydrocarbon services
31 Single and tandem seals. Used in media with suspended solids. Apply when strainers are
inadequate to clean flushing liquid.
32 Single and tandem seals. Required when pumpage is not suitable to lubricate seal faces.
Use of bushing or lip seal is also recommended.
41 Apply with liquids that require simultaneous cyclone separation and cooling ( i.e. in hot
services containing suspended solids). For single and tandem seals.
51 Single seals. Required when sealed liquid will crystallize, coke, solidify, etc. at seal faces if
contact with air. Common blankets are isopropyl alcohol, glycol, and water.
52 Tandem seals. Plan provides buffer liquid for outside seal. A plan 01 or plan 11 is also
recommended with tandem seals to properly flush inboard seal. Pumping rings
recommended. For media where product dilution is not allowed but leakage to
atmosphere in diluted form may be allowed
53 Double seals. Plans provide flushing and cooling to both sets of seal faces with
A/B/C pressurised barrier fluid – source can be direct, elastomer bladder or piston accumulator

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Plan Recommended Applications

No.
54 Double seals or packed auxiliary stuffing box, with an external pressurised barrier fluid.
Applications where no leakage to atmosphere can be tolerated e.g. hazardous, toxic,
inflammable and for dirty, abrasives or polymerizing products where media is unsuitable
as a lubricant for inboard seal faces
55 Double seals with an external unpressurised buffer fluid.
61 Single or double seal arrangement - Tapped connections for purchaser's use
62 Single or double seal arrangement – External quench. Applications include caustic or
crystallising fluids and oxidising fluids or hot hydrocarbons
65A/B Single seal – Leakage monitoring/management. Plan 65A is used to detect an excessive
leakage flow rate and Plan 65B to detect a certain amount of cumulative leakage.
66A/B Single seal – Leakage monitoring/management. These plans detect and restrict excessive
leakage rates in case of a seal failure
71 Tandem seals – Leakage monitoring/management.
72 Tandem seals – Leakage monitoring/management. Unpressurized buffer gas control
system.
74 Double seals. Externally supplied pressurized buffer gas control system.
75 Double seals. Leakage of condensate from inboard seal of a dual containment seal is
directed to a liquid collector
76 Double seals. Vapour leakages from inboard seal of dual containment seal are directed to
a vapour recovery system via a vent connection
Additional information and technical articles on pump seals are available in the WorleyParsons Pumps
and Pumping intranet page at the following link:
http://teams-wst.worleyparsons.com/sites/wks/pp/Pump%20Seals/Forms/AllItems.aspx

Alternatively go to the WorleyParsons ONE page, select “Operations & Delivery” tag. From the drop
down menu, select “Engineering & Design”. Select “All Network/Discussion Boards” and then select
“Engineering Networks”. In the new intranet page select “Pumps and Pumping”. The subdirectories
are located on the left of the webpage where the engineer can select “Pump Seals”.

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13 PUMP SPARING
Spare pumps are generally used for essential services such as process unit feed, charge to heaters,
reflux, boiler feed, cooling water circulation, fire water, etc. where high availability is required A
common spare may be acceptable provided pumping requirements are similar, contamination is not a
serious factor and suction piping is not overextended to the point of giving NPSH problems.
In plants where the supply of electricity is considered to be reliable, electric motors will generally be
used to drive the spare pumps. Exceptions exist and these are limited to important process services
in refinery applications where steam turbine drives are selected because of safety and other
considerations.
The spare fire water pump is often driven by a diesel (or occasionally a gasoline) engine.
Steam turbine driven pumps are common in services such as cooling water, boiler feed water and
emergency pump-out in refinery applications.

13.1 Warm-up Piping for Spare Pumps

Spare single stage pumps in services over 260oC (500oF) and spare multistage pumps in services over
204oC (400oF) must be kept warm (30oC / 50oF below pumping temperature) for quick start-up.
Otherwise, warm-up could take from two to eight hours.
There are a number of arrangements used to accomplish this. If the pump operates under positive
pressure on the suction, the pumped liquid can be permitted to drain out through the pump casing
drain connection to some point at a pressure lower than the suction pressure – refer Figure 13-1

Figure 13-1 Arrangement for Warm Up through Pump casing Drain connection

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Alternatively one can add a bypass line around the discharge check valves of each pump and
controlling the bypass flow with a globe valve (some clients use a gate valve) or an orifice. The
suction and discharge valves of the spare pump are opened and the hot bypass flow is throttled by
the globe valve or orifice so that the impeller of the spare pump does not counter-rotate. Also it is
imperative that the piping be arranged so as to avoid bypassing most of the pump (and thereby
creating a significant temperature gradient across the pump).

Figure 13-2 Arrangement for warm-up through jumper line around discharge check valve

Some clients require two reverse flow bypass lines, minimum size of DN20 (¾”), for all pumps that
handle hot (above 177oC / 350oF) or high-pour-point fluids. One line must be connected to the pump
casing drain; the other bypass line is connected to the pump discharge line. Both lines are kept open
with block valves. The purpose of this arrangement is to minimise thermal stresses across the pump
and associated discharge line.
The manufacturer’s recommendations should be sought in all cases as to the best means of providing
an adequate warm-up procedure. Care must be taken to ensure that the pump is warmed uniformly.
Stratification of the warm-up flow, or inadequate warmup flow volume, can result in casing distortion
or rotor bowing, or both.

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14 REMOTE/AUTOMATIC PUMP START

Remote pump start enables a pump to be started from a control panel via a sequential starting
control system.
Automatic pump start (auto-start) can be applied in a spared pump configuration, where automatic
change-over to the spare pump upon failure of the running pump maintains the product flow.
Automatic pump start can also be activated by a process requirement.
Pumps will preferably be started with a closed discharge valve (zero flow). This reduces the starting
current required by the electric motor drive. Depending on the size, the pump may be started with
an open discharge valve or open / partially open minimum recycle valve, but this may increase the
electric motor rating.
When two or more pumps are used in parallel, with an open discharge valve arrangement the pump
driver power should be suitable for the pump run out conditions when one pump is running. The
system NPSHa will also have to be suitable for the increased pump NPSHr for one pump operation.

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15 HEATING / COOLING JACKET

A heating/cooling jacket shall be considered if any of the following conditions exists:
• Temperature of pumped fluid is above 150ºC (300ºF);
• Boiler feed-water pumps;
• Dead-ended seal chambers;
• Liquids with low flash points;
• Products with high melting points.
The following are the types of jackets typically used on centrifugal pumps:
• Seal Chamber/Stuffing box jacket;
• Pump casing jacket;
• Bolt-on or external steam jacket (casing).
Cast bearing housing jackets are not recommended because the outer race is constrained by the
cooling. Instead, oil sump fin tube coolers are recommended.
Jackets are used to remove or add heat to the local area to which they are applied. Liquids that flash if
heat is added, such as through rubbing friction or mechanical seals, require cooling.
High-temperature liquids that solidify if the temperature decreases require the addition of heat,
especially during start up when piping and pumps are at ambient temperature.
Jackets must be hydrostatically tested before the pump is shipped. Leakage to the atmosphere could
be hazardous in some processes.
Cooling/heating jackets or inserts for seal chambers shall be provided by the pump vendor if specified
by the purchaser.
If the temperature of the pumped fluid is greater than 150ºC (300ºF), the pump and seal vendors
shall be jointly consulted about using cooled flush or running the seal chamber dead-ended with
jacket cooling.
Cooling/heating jackets for seal chambers shall have connections arranged so that the entire
passageway can be mechanically cleaned, flushed, and drained

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16 ADDITIONAL CONSIDERATIONS FOR PUMP PROTECTION

16.1 Suct ion Line Rout ing

Routing of the suction line from the suction vessel to the pump inlet should not contain any pockets.
Trapped vapour in the suction line may result in the loss of prime, requiring the pump to be shut
down so the inlet line can be vented.
Additionally, the pump suction line should have a minimum of straight run of five pipe diameters (5D)
between the pump suction flange and the first elbow, tee, valve, reducer, strainer or other
obstruction. The straight run shall be of the same size line size as the pump suction nozzle (Ref. 4).
Pump line sizing is covered in ref. 5.

16.2 Suct ion Strainers

The inlet line to each pump should contain a strainer to protect the pump from debris that may be
present in the suction piping.

16.3 Eccentric Reducers

The suction of a pump should be fitted with an eccentric reducer positioned with the flat side up to
prevent the formation of a vapour pocket at the pump inlet, as shown in the following figure [ref.1]:

Figure 16-1 – Eccentric Reducer Orientation

16.4 Check Valves on Pump Discharge

Adequate check valves must be installed on pump discharge lines to minimise possible back flow
through pumps, as well as to minimise the effects of surge which is possible on some pumped
systems.

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17 RELIABILITY

17.1 Hy draulic Reliabilit y for Centrifugal Pumps

To ensure hydraulic reliability for centrifugal pumps the following items should be considered:
• Pumps selected for the pumping system should have head capacity characteristic curves that
rise continuously as flow is reduced to shutoff.
• Pump should be capable of a 5% head increase minimum at rated condition with the
installation of a new impeller.
• If pumping system is designed for pumps to operate in parallel, the head rise to shutoff should
be a minimum of 10% of the head at rated capacity.
• Minimum diameter of selected pump impeller should be 105% of the minimum diameter
impeller for the generic pump curve for the specific pump.
• If the pumped fluid has a variable specific gravity, the head required to be developed by the
pump should be based on the lowest specific gravity and the greatest system differential
pressure for the required flow rate.
• If viscosity corrections are required, head, capacity, and efficiency corrections should be the
responsibility of the pump manufacturer. These corrections should be calculated in accordance
with the “Centrifugal Pump” section of ANSI/HI 1.3.
• Suction specific speed can be a good predictor of pump reliability. Refer Section 6.8 for
preferred operating ranges in metric units. Industry has extensively published documentation
indicating that pumps with high NSS (11,000 and greater} have reduced reliability. Pumps with
high NSS should not be permitted for services with widely varying operating flow rates. If no
reasonable alternative to a high NSS pump exists, steps should be taken to ensure pump
operation at or very near the BEP. A controlled bypass should be considered or a complete
shutdown if the pump is used in a batch operation. Vibration instrumentation should be
considered for proper monitoring.
• Pump operation at flow rates less than stated minimum continuous stable flow rate causes
increased process fluid recirculation within the pump and may cause increased cavitation,
which may result in increased noise, high vibration level, bearing or seal failure.
• Minimum flow rates for reliability depend on many factors, including the preferences of the
person setting the limit. Effects of operating at flows less than the BEP include discharge
recirculation suction recirculation, decreased impeller life, reduced bearing and seal life, low
flow cavitation, and (at very low flow rates) high temperature rise.
• Maximum flow rates for reliability depend on many of the same factors that determine
minimum flow rates. Effects on reliability of operating a pump at flows greater than BEP
include reduced bearing and seal life, and cavitation as the NPSH3 curve continues to rise. Any
pump operated at excess capacity -- at a flow significantly greater than best efficiency point

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(BEP) and at a low head -- surges and vibrates. These reactions create potential bearing and
shaft-seal problems, as well as require excessive power.
• A spillback or recycle line may be employed to control the flow rate through a pump at a high
enough value to meet acceptable minimum criteria. If a spillback line is available, running a
pump closer to BEP typically results in improved reliability.
Some of the preceding points are graphically represented in the figure below which shows that
operating on either side of the BEP on the pump curve is accompanied by a myriad of issues.

Figure 17-1 Pump Reliability Curve

17.2 Mechanical Reliability

Mechanical factors affecting reliability of centrifugal pumps are covered in the following industry
standards as appropriate for the type of pump:
• API 610/ISO 13709;
• API 685;
• ASME B73.1;
• ASME B73.2;
• ASME B73.3.

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18 DRIVERS

18.1 Electric Motor

For applications in which the pumped fluid has a variable specific gravity, the rated power of the
motor shall be based on the greatest specific gravity.
If viscosity corrections for the pumped fluid are required, the power requirements specified in
Sections 5.1.1 shall be increased an appropriate amount by the pump manufacturer. Start-up at cold
temperature when the viscosity of the pumped fluid is higher than viscosity under operating
conditions shall be taken into consideration.
Use of a variable speed drive for the motor may be considered under any of the following
circumstances:
a) If the process operating conditions have a large range in operating flow rates or if a
significant portion of the flow is recirculated;
b) In slurry service if reduction in pump speed reduces erosion and eliminates throttling
valves;
c) If the process does not require a constant head, which is typically controlled by throttling.
If the end-of-curve power is less than 4 kW (5 hp), the next standard size larger motor shall be used.
The purpose of this requirement is to overcome start-up problems caused by slow acceleration of
small motors overcoming inertia and drag of seals. Seal drag increases as suction pressures increase.
Failure to consider these factors can result in tripping.
Driver power shall, as a minimum, be equal to the rated shaft power at the rated point multiplied by
the percentage listed in the table below.

Table 18-1 Electric Driver Sizing

Rated Pump Power Rated Pump Power Multiplier

kW Bhp % of Rated Shaft Power
< 22 < 30 125
22-75 30 – 100 115
> 75 > 100 110

If the end-of-curve power is greater than 75 kW (100 hp), the motor shall be sized to cover the end-
of-curve power or 110% of rated power, whichever is less. For applications that are expected to
operate at the end-of-curve, such as cooling-water circulating pumps, motors shall be sized to
operate at the end-of-curve.
The motor and coupling shall be sized to meet any specified future increase in power or head
requirement.

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18.2 Steam Turbine

Steam turbine drivers shall be in accordance with API Std. 611.
Steam turbine power rating shall be 110% of the greatest calculated power requirement of the
pump at any operating condition
Steam turbine driven pumps are common in services such as cooling water, boiler feed water and
emergency pump-out in refinery applications.
Generally, turbine speeds are set by the pump speed. Efficiency is sacrificed as turbine speeds
decrease but this is economically acceptable particularly in the case of infrequently used spare
pumps. Steam turbines are used as pump drivers primarily for the following reasons:
• To drive spare pumps in key process services during an emergency situation;
• To improve a plant's steam balance;
• To obtain pump flexibility as a result of the wide speed range characteristics of turbines
without resorting to gears.

18.3 Others
Pumps can also be driven by Gas Turbines and reciprocating engines, but applications for these are
rare in the industry (with the exception of mobile engine driven pumps).
Variable Speed Drives (VSD’s) are covered in Section 11.

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19 DATA SHEET PREPARATION

The location of a pump with respect to the fluid being pumped will determine the terms that apply
to an installation. If the pump is above the liquid as shown in Figure 19.1, the distance between the
liquid level and the centre of the pump is called the suction lift.
When pumping liquids that vaporise easily, it is often necessary to have a positive pressure on the
suction side of the pump. The vertical distance from the centre of the pump up to the free level of
liquid suction supply is called the suction head. (Refer Figure 19.2)
Specification of a pump involves several steps. These are:
1. Prepare PFD sketch showing pump circuit with flowrates and fluid properties.
2. Prepare the Pump calculation worksheet.
• Provide normal flow case;
• Calculate safety factor or rated flow;
• Calculate NPSHa;
• Evaluate operating cases to determine maximum vapour pressure;
• Evaluate operating cases to determine minimum flow temperature verses minimum exposure
temperature.
The engineer responsible for the system then summarises the calculation sheet information and
prepares the datasheet.
The engineer normally specifies pump type; however for borderline applications a rotating
equipment specialist may recommend the type of pump.
Datasheet items that require process input are listed below.
1. Pump Service
• The name used for the service descriptor should preferably give a general idea of the fluid
being pumped.
2. Number of Units
• Consideration should be given to pump turndown to determine 1x 100% or 2x 100% or 3x 50%
configurations. The Rotating Equipment Specialist may also recommend a configuration.
3. Fluid Properties
• Pumping temperature for normal maximum and minimum are given. For low temperature
applications consideration has to be given to minimum fluid temperature verses minimum
exposure temperature. The pump must be capable of full operation with viscosities and
specific gravity which correlate to the minimum fluid temperature. However, for pumps
exposed to low ambient temperatures a note on the datasheet should advise the vendor that

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the pump must be capable of moving fluid at a rate with properties at the minimum exposure
temperature. Low fluid temperatures and exposure temperatures may warrant specification
of low temperature casing or heat tracing.
• Specific gravity of the fluid should be given at the normal operating temperature. Specific
application may warrant providing a specific gravity verses temperature table or graph.
• Vapour Pressure of the fluid should be given at the temperature that was used in the NPSH
calculation (normally maximum temperature).
• Viscosity should be given at the minimum fluid temperature. As with specific gravity, a table
or graph of viscosity verses temperature may be given to the vendor. Note that oil viscosity
predictions from HYSYS, Aspen Plus or other simulation programs may be notably inaccurate
once viscosity exceeds 20 cP, and reference data should be used to validate property data
where available.
• Component contaminations in the fluid that affect pump materials of construction selection
such as H2S, chlorides, etc.
4. Operating Conditions
• Pump capacity at normal conditions is usually set at the maximum of all simulation cases.
• Pump minimum operating flow should be given in the notes as it may necessitate a minimum
flow bypass to protect the pump.
• Pump rated flow or design flow is the normal flow multiplied by a Design Factor. This design
factor is addressed in Section 6 within this document
• NPSHa, the net positive suction head available, must be calculated for all pumps. Section 7
provides details for this calculation.
• Discharge pressure is given for the maximum pressure expected at discharge while the pump
is operating.
• Suction pressure is given at the minimum operating pressure conditions. Consideration
should be given to off-design cases where the pump may be required to operate before the
suction vessel is fully pressurised.
• Maximum Suction Pressure is the maximum suction operating condition of the pump (refer to
Section 7). Design pressure of the suction system does not need to be used unless mandated
by the client.
• Differential pressure should be given for specific design cases where suction pressure and
discharge pressure are coincident. Maximum and minimum system curves should be
generated to provide the full operating range to the vendor.
• Estimated hydraulic power for the stipulated differential pressure, at the rated flow.
For designs which have several different operating cases, additional datasheets should be given for
each possible design case.

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DISCHARGE HEAD
TOTAL HEAD

SUCTION
LIFT

TOTAL HEAD WITH SUCTION LIFT

FIGURE
Figure 19.1 3A
TOTAL HEAD

DISCHARGE HEAD
SUCTIO HEAD

TOTAL HEAD WITH SUCTION HEAD

Figure 19.2 3B
FIGURE

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20 RESOURCES

20.1 Calculat ion Too ls

WorleyParsons in-house Pump Sizing Calculation 650100-PR-CAL-0015 is used to size centrifugal,
reciprocating and screw type pumps.
The WorleyParsons other (advanced) pump sizing spreadsheet WS-CGY-CA-PR-008 (Future 65010-
PR-CAL-0335) is used to size centrifugal pumping systems.
The internally developed WorleyParsons program, SeleXpress, can be used for preliminary pump
sizing as well. Details of the SeleXpress software can be found in the WorleyParsons intranet page at
the following link:
https://worleyparsons.sharepoint.com/sites/select/kit/selexpress/default.aspx

20.2 Soft ware

FluidFlow 3 and AFT Fathom are both commercially produced software used by WorleyParsons to
analyse steady state liquid flows and pressures for pipe distribution systems for Newtonian and non-
Newtonian fluids.
Bentley WaterCAD, Bentley WaterGEMS and Innovyze H2OMAP are water distribution modelling and
analysis software packages used by WorleyParsons in Infrastructure sector for complex water
network systems.
HYSYS is also available to process engineers to carry out preliminary pump and line sizing.
The engineer should consult the WorleyParsons Global Software Register (GSR) to confirm the list of
available software for use and confirm that the software has been verified.

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21 REFERENCES
1. Karassik I.J et al, Pump Handbook, 4th Ed., 2008

2. ANSI / Hydraulic Institute Standards for Centrifugal, Rotary & Reciprocating Pumps

3. GPSA Engineering Data Book, SI version, 12th Edition, 2004

4. API 686 Recommended Practice for Machinery Installation and Installation Design, 2nd Edition
5. WorleyParsons Knowledge System (WKS) Technical Standard, Design Guide for Line Sizing and
Hydraulic Analysis, 650100-PR-DEG-0003, Rev 2, 2017

6. Hydraulic Institute Standard ANSI/HI 9.6.7 - Effects of Liquid Viscosity on Rotodynamic

(Centrifugal and Vertical) Pump Performance, 2015.

7. API Standard 674 Positive Displacement Pumps – Reciprocating 3rd Edition, December 2010

8. Doolin, JH Centrifugal Pumps and Entrained Air Problems, Chem Eng., Jan 1963, P103

9. Centrifugal Pumps and Blowers, AH Church, John Wiley & Sons, 1950
10. Cameron Hydraulic Data, Ingersoll-Rand, 16th Ed., 1984.

11. Viking General Purpose Pumps Catalogue, Series 32 and 432, Section 310, Revision J, 2016.

12. Hydraulic Institute Standard ANSI/HI 6.1-6.5 - Reciprocating Power Pumps, 2015
13. API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries 11th Edition

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Appendix 1 - Pump Performance Correction Methods for

Viscous Liquids

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This section presents the procedure for determining correction factors for head, CH, flow rate, CQ,
and efficiency, Cη, when pumping viscous Newtonian liquids for given water curves and rotary
speed. The engineer is referred to ANSI/HI 9.6.7 [Ref 6] for more details. The method is summarised
below.
The method is based on a performance factor, called Parameter B, and includes terms for viscosity,
speed, flow rate and total head as follows;

 (ν )0.5 (HBEP − W )0.0625 

B =K 
 (Q BEP − W ) (N)0.25  Eq. 1
0.375

Where:
K = constant - 16.5 for SI units and = 26.5 for English (US) units

ν = Kinematic viscosity of liquid - Cst

HBEP-W = water head at BEP – m or ft

QBEP-W = water rate of flow at BEP – m3/h or USgpm

N = shaft rotational speed - rpm

Parameter B is coupled to various empirical relationships for the correction factors which are
represented graphically in Figure 21-1 and Figure 21-2 below. CH and CQ express the viscous fluid
head over the water head and the viscous fluid flow rate over the water flow rate, respectively. Cη
expresses the efficiency in viscous service at the reduced flow rate over the efficiency for the
unaffected flow rate in water service.

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Figure 21-1 - Flow and head correction factors versus parameter B when pumping a viscous
Newtonian liquid

Figure 21-2 - Efficiency correction factor versus parameter B when pumping a viscous Newtonian
liquid, ANSI/HI
The correction factor for flow rate CQ can be represented by the following formula rather than using
the graph in Figure 21-1.

CQ = e − 0.165 (log B )
3.15

Flow Correction Factor Eq. 2

The correction factor for head at BEP can be represented by the following formula rather than using
the graph in Figure 21-1.

C H((BEP ) = C Q = e −0.165 (log B )

3.15

Head Correction Factor Eq. 3

The correction factor for head for q* ≠ 1 which is not at the BEP can be represented by the following
formula rather than using the chart above.

C H( q*) = 1 − (1 − C Q( BEP ) )(q * )

0.75
Correction Factor Eq. 4
QW
q* =
Q BEP − W
where flow ratio
Similarly, the correction factor for efficiency can be represented by the following formula rather
than using the graph in Figure 21-2.

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Eq. 5 where β = 0.0547(B )

C η =B −β 0.69
Efficiency Correction Factor
Once the correction factors have been derived, the engineer can calculate the Viscous Flowrate QVIS,
the Viscous Head HV and the Viscous Efficiency ηVIS as follows:
QVIS = (CQ)(QW)
HVIS = (CH)(HW)
ηVIS = (Cη)(ηW)
To calculate the values for viscous shaft absorbed power PVIS, the following equation is available for
flow in m3/h, head in m, efficiency in decimal and shaft power in kW.
Viscous Absorbed Power
9.81Q VIS H VIS SG Slurry
PVIs =
3600 η VIS Eq. 6
It follows from the equation above that large flow rates, i.e. large pumps, are affected less than
smaller pumps and that higher rotary speeds reduce the effect for a given head and viscosity.

Figure 21-3 - Correction factors are defined and related to water pumping

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A final comment on HI’s procedure for correcting centrifugal pump performance - When should a
pump performance curve be corrected for fluid viscosity? Pump manufacturers and /or vendors are
the best source to answer this question. They can provide performance curves for any pumping
condition including viscous fluids. However, with available computer software (refer Section 20.2),
the user should always check how fluid viscosity will affect the pump flow rate, total head and most
importantly power.
The following are some factors derived from the latest addition of the HI procedure for correcting
pump performance. They may be helpful when considering when to correct pump water-
performance curves for viscous fluids.
• The performance factor, Parameter B, is a good indicator of how viscosity influences pump
performance. Parameter B takes into consideration fluid viscosity, speed, total head and flow
rate at BEP;
• Whenever the performance Parameter B is one or less the fluid has no effect on the head
curve, Q-H. Figure 21-1 shows that the head and flow correction factors are less than 3%
when Parameter B equals 3 and about 10% when Parameter B equals 7; and
• Viscous fluids have a more dramatic effect on pump power. Figure 21-2 shows that the
efficiency decreases by almost 12% when Parameter B equals 3 and over 30% when
Parameter B equals 7.

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Appendix 2 - Impellers

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Centrifugal pump impellers or rotating vanes are classified according to the major direction of flow
in reference to the axis of rotation.
A2.1 Classifications
Pump impellers are classified as:
1. Radial-Flow Impellers (Figure 21-4)
2. Axial-Flow Impellers (Figure 21-5)
3. Mixed-Flow Impellers, which combine radial- and axial-flow principles (Figure 21-6)

Figure 21-4: Example of a Straight-Vane Radial Single-Suction Closed Impeller

Figure 21-5 Example of an Axial-Flow Impeller

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Figure 21-6 Example of an Open Mixed-Flow Impeller

A2.2 Additional Classification

Impellers are further classified as:
1. Single-suction, with a single inlet on one side (Figure 21-4)
2. Double-suction, with liquid flowing to the impeller symmetrically from both sides (Figure 21-7)

Figure 21-7 Schematic Diagram of a Double-Suction Impeller (Courtesy McGraw Hill)

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A2 .2.1 Descr ip tion and Applicat ions

In a single-suction impeller, the liquid enters the suction eye on one side only, while in a double-
suction impeller the liquid enters from both sides. A double-suction impeller is, in effect, two single-
suction impellers arranged back to back in a single casing.
Theoretically, a double-suction impeller would be favoured because it is in axial hydraulic balance.
In addition, the greater suction area of a double-suction impeller permits the pump to operate with
less net absolute suction head. However, units with single-suction impellers are more practical for
manufacturing reasons.
End-suction pumps with single-suction impellers have both first-cost and maintenance advantages
not obtainable with double-suction impellers. Because they do not require the extension of a shaft
into the impeller suction eye, single suction impellers are preferred for pumps handling suspended
matter. Single-suction impellers are normally used in multistage pumps.

A2.3 Mechanical Construction Classification

Mechanical construction of the impellers gives a further classification of:
1. Open Impeller (Figure 21-8, Figure 21-9)
2. Semi-Open Impeller (Figure 21-10)
3. Closed Impeller (Figure 21-4, Figure 21-11)

Figure 21-8 Front and Back Views of an Open Impeller with a Partial Shroud and Pump-Out Vanes
on the Back Side (Courtesy Worthington Pump)

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Figure 21-9: Examples of Open Impellers; Note Impellers at the Left and Right are Strengthened
by a Partial Shroud (Courtesy Worthington Pump)

Figure 21-10: Example of a Semi-Open Impeller (Courtesy Worthington Pump)

Figure 21-11: Example of a Francis-Vane Radial Double-Suction Closed Impeller (Courtesy

Worthington Pump)

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A2 .3.1 Open Impeller s

Open impellers consist of vanes attached to a central hub for mounting on the shaft without any
form of sidewall or shroud. The disadvantage of this impeller type is structural weakness. If the
vanes are long, they shall be strengthened by ribs or a partial shroud. Generally, open impellers are
used in small, inexpensive pumps. One advantage of open impellers is that they are better suited for
handling liquids containing stringy materials. The open impellers are much more sensitive to wear
than closed impellers. As a result, their efficiency deteriorates rather rapidly in erosive service. An
open impeller rotates between two side plates, between the casing walls of the volute, or between
the stuffing box head and the suction head. The clearance between the impeller vanes and the
sidewalls allows a certain amount of water slippage, which increases with wear. To restore the
original efficiency, both the impeller and the side plate shall be replaced. This, incidentally, is much
more expensive than similar work in a closed-impeller pump, where simple rings form the leakage
joint.

A2 .3.2 Semi-Op en Impellers

Semi-open impellers incorporate a single shroud, usually at the back of the impeller. This shroud
may or may not have pump-out vanes, which are located at the back of the impeller shroud. Pump-
out vanes prevent foreign matter from lodging behind the impeller and interfering with the proper
operation of the pump and stuffing box.

A2 .3.3 Closed Impel lers

Closed impellers, which are almost universally used in centrifugal pumps that handle clear liquids,
incorporate shrouds or enclosing sidewalls that totally enclose the impeller waterways from the
suction eye to the periphery. Although this design prevents the liquid slippage that occurs between
an open or semi-open impeller and its side plates, a running joint shall be provided between the
impeller and the casing to separate the discharge and suction chambers of the pump. This running
joint is usually formed by a relatively short cylindrical surface on the impeller shroud that rotates
within a slightly larger stationary cylindrical surface. If one or both surfaces are made renewable,
the leakage joint can be repaired when wear causes excessive leakage.
The closed-type impeller is more efficient than the other impeller designs (such as semi-open
impeller designs) since it properly contains the flow of liquid. Also this design is mechanically more
robust and more reliable. The closed-type impeller is the selected impeller for many services
particularly critical applications.

A2 .3.4 Overhung Impeller s

If the pump shaft terminates at the impeller so that the latter is supported by bearings on one side,
the impeller is called an overhung impeller. This type of construction is the best for end suction
pumps with single-suction impellers.

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PUMPS AND PUMP CIRCUITS

Appendix 3 - General Guide to Process Pump Selection

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DESIGN GUIDE
PUMPS AND PUMP CIRCUITS

Fluid Capacity Limit Driver Non- Dry Run

Viscosity Discharge Speed / RPM Differential Solids & Self- Low Fluid
Pump Type Standard Temperature Horsepower Lubricating Corrosive Toxic Flammable for Short
Range Pressure Limit Limit Head Abrasives Priming Shear
Limit Limit Fluid Periods

Centrifugal
Horizontal API
API 610 <200 cP - - - - - Limited Y Y Y Y N N N
OH1 700 F / 370 C
700 psig / 4,825
API 610 <200 cP 3,600 rpm - <400 ft / 120 m 150kW / 200 hp Limited Y Y Y Y N N N
In-Line API OH3 400 F / 200 C kPag

Vertical Turbine API 610 <200 cP 450 F / 230 C - 3,600 rpm - - - N Y Y Y Y - N N

275 psig / 1,900
ASME B73.1 <200 cP 3,600 rpm - <400 ft / 120 m 185kW / 250 hp Limited Y Y Y Y N N N
Horizontal ANSI 300 F / 150 C kPag
275 psig / 1,900
ASME B73.2 <200 cP 3,600 rpm - <400 ft / 120 m 150kW / 200 hp Limited Y Y Y Y N N N
In-Line ANSI 300 F / 150 C kPag
Regenerative 500 psig / 3,450 150 usgpm / 34 <1,600 ft / 490
Manufacturer <30 cP 3,600 rpm - N Y Y Y Y Y N N
Turbine 500 F / 260 C kPag m3/hr m

Reciprocating
1,000 psig / 2,000 usgpm /
API 674 <2,000 cP 140 rpm - - N Y Y N Y some N Y
Power Piston 400 F / 200 C 6,900 kPag 450 m3/hr
20,000 psig / 5,000 usgpm /
API 674 <2,000 cP 450 rpm - - Y Y Y N Y some N Y
Power Plunger 700 F / 370 C 137,900 kPag 1,135 m3/hr
<0.1- 10,000 10,000 psig / 150 usgpm / 34
API 675 - - - N Y N N Y Y N Y
Plunger Metering cP 750 F / 400 C 68,950 kPag m3/hr
Hydraulic
<0.1- 10,000 15,000 psig / 50 usgpm / 11
diaphragm API 675 - - - Y Y Y Y Y Y Y Y
cP 103,400 kPag m3/hr
Metering 400 F / 200 C
Air Operated <0.1- 20,000 125 psig / 860 300 usgpm / 68
Manufacturer - - - Y Y Y Y Y Y Y Y
Double Diagram cP 250 F / 120 C kPag m3/hr

Rotary
150 psig / 1,030 2,000 usgpm /
API 676 1- 20,000 cP 350 rpm - - N Y N Y Y Y Y Y
Sliding Vane 225 F / 107 C kPag 450 m3/hr
0.1- 100,000 400 psig / 2,760 500 usgpm / 180
API 676 350 rpm - - Some Y Y Y Y Y Y Y
Lobe cP 350 F / 175 C kPag m3/hr
0.1- 500,000 225 psig / 1,550 1,500 usgpm /
API 676 1,200 rpm - - N N Y Y Y some N Y
Gear Internal cP 800 F / 425 C kPag 340 m3/hr
0.1- 500,000 500 psig / 3,450 1,500 usgpm /
API 676 1,800 rpm - - Some Some Y Y Y some some some
Gear External cP 500 F / 250 C kPag 340 m3/hr
0.1- 200,000 1,200 psig / 8,000 usgpm /
API 676 3,600 rpm - - Some Y Y Y Y Y Y Y
Screw (2 No.) cP 500 F / 250 C 8,275 kPag 1,800 m3/hr
2,000 psig / 3,000 usgpm /
API 676 1- 50,000 cP 3,600 rpm - - N N N Y Y some N Y
Screw (3 No.) 500 F / 250 C 13,795 kPag 680 m3/hr
Progressing 0.1- 1500,000 500 psig / 3,450 2,000 usgpm /
API 676 300 rpm - - Y Y Y Y Y some N Y
Cavity cP 350 F / 175 C kPag 450 m3/hr

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DESIGN GUIDE
PUMPS AND PUMP CIRCUITS

Notes
1. Generally select a centrifugal pump as a first choice. If criteria such as high viscosity, low fluid shear, needing constant volume for differing pressures, etc. are required, a different pump should be selected
2. Generally select a horizontal centrifugal pump before a vertical centrifugal pump, unless NPSHa restricts this selection.
3. The values contained in this general guide are the normal operational parameters that are either commercially available or the maximum recommended general practice. Working outside these limits may be acceptable under
expert guidance and where manufacturers offer pumps for the specific requirements. Operating limits differ among manufacturers for pumps of similar pumping mechanism.
4. Note that a high value in one parameter usually limits other parameters. For example, high viscosity may limit operational speed, or high flow may limit differential head or discharge pressure, etc. In order to arrive at a successful
installation, a thorough understanding of the pump design, the pumping system, and the characteristics of the liquid pumped is required. Most unsuccessful application result from insufficient understanding of one or more of
these areas.
5. The abrasiveness of slurries is very difficult to define due to the number variables involved. Hence, the solids and abrasives column is a generalization and refers to low solids concentration and small particle size. When solids and
abrasives are present consideration of slurry pumps may be warranted.

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