2010 Engineering Design Seminar

Pumps

Mike Van de Cotte, Instructor

© 2010 UOP LLC. All rights reserved.

 Pumps

 Introduction

 Pump Curves
– Head versus Capacity
– NPSH
– Efficiency

Pumps-2
 Pumps
(continued)

 Single-Stage Centrifugal Pump Design

– Pump Components
– Impellers
– Axial Thrust
– Shaft Sealing
– Cooling and Flushing
– Bearings
– Couplings

Pumps-3
 Pumps
(continued)

 Sealless Pumps
 Pump Selection and Performance
 Double Suction, Multi-Stage, and Sundyne Pumps
 Hydraulics
 Fan Laws
 Reliability
 Pump Control
 Standards
 Other Pumps

Pumps-4
PD-R00-02
Pumps-5
Total Differential Head In Feet
550 11" Dia.
500
450
400
350
300
250
200

0 400 800 1200 1600 2000 2400

Gallons Per Minute

PD-R00-03
Pumps-6
 Single Stage Centrifugal Pump
Discharge Cooling Outlet
Mechanical Seal
Volute
Seal Flush
Case Radial Bearing
Oil Slinger Ring
Impeller Oil Deflector

Bearing Box Vent

Axial Thrust
Suction Bearings
Coupling
Wear Rings
Shaft
Bearing Box

Oil Seal
Case Drain

Shaft Cooling Deflector Oil Level Bottle

Sleeve Inlet Ring
PD-R00-04
Pumps-7
 Identical Pumps Handling Liquids
of Different Specific

100 ft. 100 ft. 100 ft.

32.5 psi 43 psi 52 psi

Gasoline, S.G. = 0.75 Water, S.G. = 1.0 Brine, S.G. = 1.2

Disch. 100’ x 0.75 Disch. 100’ x 1.0 Disch. 100’ x 1.2

= 32.5 psi = 43 psi = 52psi
Pres. 2.31 Pres. 2.31 Pres. 2.31

PD-R00-05
Pumps-8
 Head Calculation

 Head (feet) = (P2-P1)(psi) (2.31)/S.G.

 Head (meters) = (P2-P1)(bar) (10.2)/S.G.

Pumps-9
Total Differential Head in Feet
550 11" Dia.
500
450 10"
400
350 9"
300
250
200

0 400 800 1200 1600 2000 2400

Gallons Per Minute

PD-R00-06
Pumps-10
 60
40
NPSH
20

Total Differential Head in Feet

0
550 11" Dia.
500

NPSH in Feet
450 10"
400
350 9"
300
250
200

0 400 800 1200 1600 2000 2400

Gallons Per Minute

PD-R00-07
Pumps-11
 Entrance Loss
Increasing
Friction Pressure Due
Increasing Pressure

to Impeller

B
A Turbulence, Friction,
Entrance Loss
at Vane Tips
Point of Lowest Pressure
Where Vaporization Starts
A B
Point Along Liquid Path

PD-R00-09
Pumps-12
 NPSH

Air or Gas
Pressure=Ps Normal
Lowest
Level

Pvapor

Hz Hs = Ps x 2.31
sp gr

Hv = Pv x 2.31
sp gr

H
Hff –– Friction
FrictionLoss,
Loss,ft.ft.
NPSHA = HS ± HZ - Hf - Hv
NPSHR – By Pump Manufacturer
NPSHA  NPSHR

PD-R00-08
Pumps-13
 Cavitation

 Vaporization
 Internal Recirculation
– Leading edge of impeller, Damage at suction
eye
– Avoid with 11000 max Suction Specific Speed
 Turbulence
 Vane Passing Syndrome
– Volute damage

Pumps-14
Suction Specific Speed

S = rpm (gpm)1/2 / (NPSH)3/4

 Can range between 3000 - 20000

 UOP limits to 11000

Pumps-15
Single Suction Impeller

Pumps-16
Cavitation Due to Recirculation

Pumps-17
 Failure Frequency vs SSS
US Refinery (235 pumps)
1.5
(24) (29) (39) (36) (31) (39) (23) (14)

1.15
1.07
1.04

1.0 .91

Failure
Frequency
.61
.53
0.5 .44 .44

<8,000 8-9,000 9-10,000 10-11,000 11-12,000 12-13,000 13-14,000 >14,000

Suction Specific Speed (S )

s
Ranges

Pumps-18
 60
40
20 NPSH
0
550 11" Dia.
Total Differential Head In Feet
40 50
500 60 65
70 74
450 76 78 BEP
10" 80%
400
80
350 9" 78
300
76
250 74
200 70

0 400 800 1200 1600 2000 2400

Gallons Per Minute
PD-R00-10
Pumps-19
Impeller Offset in Casing

Pumps-20
 Impellers
Centrifugal Pumps
Casing
Impeller

Vane

Open Partially Open Enclose

Radial Forces

Flow Splitter

High Medium Low

Diffuser Side View of Pressure

Enclosed Impeller Developed by Different Vane Aperatures

Double-Volute Casing Diffuser

with Flow Split Stationary Diffuser Vane Ring
Around Impeller

PD-R00-15
Pumps-21
 Impellers
Centrifugal Pumps
Casing
Impeller

Vane

Open Partially Open Enclose

Radial Forces

Flow Splitter

High Medium Low

Diffuser Side View of Pressure

Enclosed Impeller Developed by Different Vane Aperatures

Double-Volute Casing Diffuser

with Flow Split Stationary Diffuser Vane Ring
Around Impeller

PD-R00-15
Pumps-22
 60
40
NPSH
20
0

Total Differential Head In Feet

550 11" Dia.
40 50
500 60 65
70 74
450 76 78
10" 81%
400
350 9" 80
78
300
76
250 74
200 70
bhp 11" Dia. 300
300
200
10" 200
9" 100
100
0
0
0 400 800 1200 1600 2000 2400
Gallons Per Minute
PD-R00-011
Pumps-23
PD-R00-02
Pumps-24
 Pump Selection
7500
60 Cycle Current
5000
2500 Multi Stage
1300 3550 r/min
1200
1100 Two Stage Process
Two Stage Process
1000 Single Suction Double Suction
900 3550 r/min 3550 r/min
800
Single Stage
700 Double Suction 3550 r/min
300
250 Single Stage Process Single Stage
Single Suction Double Suction
200 3550 r/min Single Stage Double Bearing
Process
150 Single Suction 3550 r/min
1750 r/min or 1750 r/min
100
50
0
0 20 40 60 80 100 120 140 160 700 800 900 1000 2100 2300 2500 3400 3600
2000 2200 2400 2600 3500 3700
Pump Capacity, gpm

PD-R00-12
Pumps-25
 Centerline-Mounted

Foot-Mounted

PD-R00-14
Pumps-26
Single Suction Enclosed Impeller

Pumps-27
Single Suction Impeller

Pumps-28
 Impeller Specific Speed

NS = rpm (gpm)1/2 / (H)3/4

 Below 4200 - centrifugal or radial

 Between 4200 - 9000 mixed flow

 Above 9000 - axial flow

Pumps-29
 Axial Thrust
Axial Thrust from Motion of Driver

Driver

Fixed Orifice
Thrust Discharge Pressure
Balance
Chamber

Vane This Force Balances

Thrust from
} Motor

Variable Orifice
(Varies with pressure
on the back of the
impeller)
Axial Thrust Suction
from Driver Pressure
Hole
PD-R00-16
Pumps-30
Impeller Offset in Casing

Pumps-31
Model 3735 High Temperature/High Pressure Process Pumps
Heavy Duty Design Features to Meet the Total Range
of Process Industries
Impeller Sealing Renewable Stuffing Box
Wearing Rings Reliability Throat Bushing
Heavy Cast
One Piece
Bearing Frame

Smoothly Large Cooling

Dual Efficient
Contoured Jacket
Volute Mechanical
Impeller
Casing Seal Cooling
PD-R00-13
Pumps-32
Single Stage Overhung Pump

Pumps-33
Single Stage Pump

Pumps-34
 Stuffing Box
Balancing Flush
Wear Hole or Coolant
Rings
Quench

Suction

Impeller Packing

Shaft Lantern Gland

Sleeve Ring Follower

Typical Packing

Covered Pre-formed Graphited

Asbestos Rings Asbestos
PD-R00-17/18
Pumps-35
Single Mechanical Seal

Pumps-36
 Single Seal
Connection A (refer to appropriate Connection B (refer to appropriate
primary seal piping arrangement) auxiliary seal piping arrangement)

Seal Box
Seal
End Plate
Throat
Bushing
Shaft
Sleeve
Stationary
Seal Member

Rotating Throttle Bushing (mechanical seal

Seal Member restrictive bushing) or auxiliary
sealing device

PD-R00-22
Pumps-37
Single Mechanical Seal

Pumps-38
PD-R00-19
 Welded Carbon or Tungsten Carbide
Puller Metal Bellows vs. Stellite Sealing Faces
Groove

Spiral Wound
Metal/Asbestos
Gasket
Gland

Rotating Shaft
Solid Steel Rotating Stationary
Drive Lugs Seal Seat
Assembly
Pumps-39
PD-R00-20
 Type PB-D
Dura Seal®

Secondary Seal Insert

Collar Packing
Set Screw
Secondary Seal
Insert Mounting
Cap Screw

Bellows Assembly
Collar
PD-R00-21
Pumps-40
 Single Seals

 <1000 ppm (Most <100 ppm)

 Comply with Regulations in Most Cases

 3+ Years Life

Pumps-41
Liquid Tandem Seals
(Unpressurized Dual Seals)

 <50 ppm (Most <10 ppm)

 Vent to Flare

 Diesel Buffer Liquid

 3+ Years Life

Pumps-42
 Unpressurized Dual Seals
Connection A (refer to appropriate Connection C (refer to appropriate
primary seal piping arrangement) tandem seal piping arrangement)

Connection B
(refer to appropriate
auxiliary seal
piping arrangement)

Stationary
Seal Member

Rotating Throttle Bushing (mechanical seal

Seal Member restrictive bushing) or auxiliary sealing device

Pumps-43
PD-R00-23
 Pressure &
Instrumentation Port
Vent
Fill
Unpressurized
Pressurized
Reservoir
Dual Seal
Pressure
Ball
Sight Level
Gages
Using
Switch
Valve Axial Flow
Outlet from
Seal Chamber Vent
Pumping Ring
Ball
Type
Type Valve
8B1
8B1

Inboard Seal Safety Outboard Seal

Drain
By-Pass from Pumping
Disch. Ring Inlet to Seal Chamber

Pumps-44
PD-R00-25
 Micro Switch

Pressure
Vent
Flare
Unpressurized Dual
Alarm Fill
Plug Mechanical Seals
Max
Level with Buffer Fluid
Reservoir and Piping
should be suitable for
Min Gauge
Reservoir and
Main Seal Pressure Ancillary Equipment
Drain

Pumps-45
PD-R00-26
 Throttle Orifice Gate Valve

Gate Valve
Spring Loaded Check Valve
Check Valve
Welded Type Armored
Supplied Supplied Glass Sight Gauge
by by 1/2 NPT Schedule 80
Purchaser Pump 300” Flange
Vendor
Vent Valve

5 Gallon
ASME Tee Vented
Pressure Plugged
Rated 3/4 NPT
Vessel Schedule 80
18” 300” Flange
Rotation
Counter-
Gate Valve Clockwise
36”
Max.
Notes:
1. Maximum length 48” avoid bends if possible
10 Sewer 2. Threaded nipples schedule 160
Connection 3. Piping shall enter and exit the pumping ring connections to the seal flange as shown
4. Reservoir must be located on the pumping ring discharge side of the pump
5. Piping shall have minimum number of fitting and bends and continuous down slope to
avoid air traps.
PD-R00-27
Pumps-46
 Tandem Mechanical Seal
Rotating Faces Non-Rotating Faces

Primary Seal Secondary Seal

Barrier Fluid

Pumps-47
PD-R00-28
Arrangement 2: Standard Dual Seal
Buffer Pressure < Process Pressure

Pumps-48
PD-R00-29
Pumps-49
Pumps-50
Pumps-51
Pumps-52
Pressurized Dual Seal

Pumps-53
PD-R00-30
 Pressurized Dual Seals
Connection A (refer to appropriate
primary seal piping arrangement) Connection C (refer to appropriate
tandem seal piping arrangement)

Connection B
(refer to appropriate
auxiliary seal
piping arrangement)

Rotating Stationary
Seal Member Seal Member

Throttle Bushing (mechanical seal

restrictive bushing) or auxiliary sealing device

Pumps-54
PD-R00-24
Arrangement 3: Standard Dual Seal
Barrier P > Process P

Pumps-55
PD-R00-31
 Double Seal Piping
Regulator Vent (Normally Closed) Pressure Switch (Optional)
Pressure Gage
Heat Exchange (Optional)

Nitrogen
Bottle Level Gage
Reservoir Pipe Compatible Buffer Fluid
In & Out of Double Seal Cavity.|
Drain Maintain At 25 PSI
Note: Above S’Box Pressure.
3/8” O.D.x.035 Wall Tube Min.
Must Have Continuous Down-Slope Plug
from Reservoir to Seal Flange.
Two Smooth 45° Bends Allowable
Max. Minimum Fitting Thru Hole |
Is .280 Inches, Reservoir Must
Be Mounted 18 t0 24 Inches
Above Shaft Centerline.

Pumps-56
PD-R00-32
 WHY ARE MY
SEALS LEAKING?

Pumps-57
 Some causes for a leaking seal
1. Poor installation
2. Vibration
3. Pipe strain
4. Seal faces worn
5. Wrong seal face or ring material
6. Wrong seal design
7. Flush cooler inoperative
8. Mis-alignment
9. Rotating assembly out of balance
10. Seal flush inoperative
11. Seal flush vaporization
12. Cavitation
13. Operation off best efficiency
14. Particles or foreign objects from process or seal flush

Pumps-58
 Discharge Filter
Motor
Discharge Flange Windings
Stator Cavity
Circulation Tube

Bearings

Suction Flange
Rotor
Impeller

Pumps-59
PD-R00-33
Pumps-60
Pumps-61
Magnetic Drive Pump

Pumps-62
PD-R00-34
 Magnoseal™
Standard Features

 ASME/ANSI
Dimensions
 Magnetic Couplings to
100 HP
 Engineered Composite
and Metal
Containment Shells
 Precision Cast Semi-
Open Impeller
 Wear Resistant Silicon
Carbide Bearing
System

Pumps-63
PD-R00-35
Pumps-64
Pumps-65
 A Simple Flexibox Seal (Type R)
in a Typical Process Pump Application
Pump Discharge

Pump 6
Inlet 2 Anti-Rotation
Pin

Prime
Mover

Component Reference Key

8 Seal 1. Stationary Seal Ring (SSR)
7 Plate 2. Stationary Seal Ring (SSRP) Packing
5 5. Rotary Seal Ring (RSR)
1 6. Rotary Seal Ring (RSRP) Packing
7. Drive Spring
8. Spring Sleeve

Pumps-66
PD-R00-36
API Piping Plan 11

Pumps-67
API PLAN 11

Pumps-68
API Piping Plans 21 and 23

Pumps-69
API Piping Plan 52

Pumps-70
API Plan 52

Pumps-71
API Cooling Water Piping Plan M

Pumps-72
API Cooling Water Piping Plan K

Pumps-73
 Bearing Box
Double Axial
Radial Vent Thrust Bearings
Oil Seal Bearing & Filter
Oil Seal

Normal Oil Coupling

Deflector Level
Rings Oil Slinger Rings to
Lubricate Bearings

Pumps-74
PD-R00-37
Anti-Friction Ball Bearings

Pumps-75
 Single Stage Process Pump
w/Ring Oil Bearing Lubrication

Pumps-76
Flexible Couplings
T Series-Type TSC

Pumps-77
PD-R00-38
Cushioned Single-Engagement
Flexible Couplings

Pumps-78
PD-R00-39
 Laminated Metal Ring Couplings

Laminated
Metal Rings

Driven Shaft

Drive Shaft

Pumps-79
PD-R00-40
 Reliability and Maintenance

What is Reliability?

The main objective of reliability is to achieve the

highest plant availability at the lowest possible
cost in order to maximize profit.

The goal is to achieve the World Class target of

95+% plant availability!

Pumps-80
 Reliability and Maintenance

 Critical Equipment – Centrifugal Compressors,

Some pumps – Unspared
– Continuous Monitoring System
 Pumps, Reciprocating Compressors – Spared
– Periodic Monitoring of Vibration Data – Collect
and Analyze
– Root Cause Analysis

Pumps-81
Reliability and Maintenance

Equipment Specs and Standards

Vendor Selection
Design and Testing
Process Considerations
Operations and Monitoring

Pumps-82
 Reliability and Maintenance

95% on-line availability for pumps, 5 year MTBR

MODE RELIABILITY MAINT. $
1 Reactive Low High
2 Preventive Moderate High
3 Proactive High Low
1. Reactive – Run to failure
2. Preventive – Time-based maintenance
3. Proactive – Condition-based maintenance

Pumps-83
Reliability and Maintenance

Reactive – Run to Failure

 Process Interruption
 No Opportunity for Diagnosis
 Frequent Failures
 Other Parts are Effected
 Replace Good Parts

Pumps-84
Reliability and Maintenance

Preventive – Time-based Maintenance

 No Opportunity for Diagnosis

 Replace Good Parts

Pumps-85
Reliability and Maintenance

Proactive - Condition-based Maintenance

 Repair Before Pump Fails

 Replace Only Bad Parts
 Diagnostics and Root Cause Analysis

Pumps-86
Portable Vibration Monitor

Proactive - Condition-based Maintenance

 Repair Before Pump Fails

 Replace Only Bad Parts

 Diagnostics and Root Cause Analysis

Pumps-87
Pumps-88
Pumps-89
Pumps-90
 Reliability and Maintenance

Cause Frequency Amplitude

Unbalance RPM x 1 Steady

Bent Shaft RPM x 1 or 2, Axial high
Cavitation Random Fluctuating
Misalignment RPM x 1 and 2
Parallel Radial
Angular High Axial
Foundation, Unsteady RPM,

Pumps-91
 Reliability and Maintenance
Procurement

EPC during vendor/contractor proposal review

“I am concerned with 3 things:

Price, price and price”

Pumps-92
Reliability and Maintenance
Procurement

1. Price
2. Functionality

3. Utilities

4. Reliability

Pumps-93
Reliability and Maintenance
Procurement

Main Air Blower quits

Cost up to $500,000/day
in lost production

Pumps-94
 Procurement

1. Functionality

2. Reliability

3. Utilities
4. Price

Pumps-95
 Reliability and Maintenance
Procurement

Initial Cost
Maintenance
Operation
Installation

Prior to After 10 years

Startup

Pumps-96
 Reliability and Maintenance
Life Cycle Costs

100
90
80
70
60 Maintenance
50 Utilities
40 Capital
30
20
10
0

Pumps-97
 Reliability and Maintenance

Best Practices - Pump and System Design

 Suction Specific Speed < 11000
 L3/D4 < 60 (inches)
 Design system for operation at or near BEP
 5 foot NPSH margin
 Minimum 5 pipe diameters straight pipe on suction
 Install API Flush Plan 23 if pumping temperature
> 300°F (149°C)

Pumps-98
 Reliability and Maintenance

Best Practices – Pump Operation

 Do not start and stop often  Check cooling water and seal
 Do not run pump dry flush temps
 Operate at or near BEP  Inspect and change bearing
 Visually inspect pump often oil (3-6 months)
(once per shift)  Do not “hose down” pumps
 Measure and record  Report problems immediately
vibrations  Training

Pumps-99
Reliability and Maintenance

Best Practices – Pump Reliability

 Alignment
 Balance
 Bearings
 Lube oil
 Monitoring – trend analysis
 Repeat

Pumps-100
Reliability and Maintenance

Reliable Reciprocating Compressor Design

 Limit Piston Speed

 Limit Piston RPM
 Limit Cylinder Size
 Limit Discharge Temp (250°F)
 Lubricate Cylinders
 Coat Piston Rod
 Vibration and Temperature Monitor

Pumps-101
 Reliability and Maintenance

Reliable Centrifugal Compressor Design

 Limit Maximum Impeller Yield Strength

 Dry Gas Seals
 Report all Operating Cases
 Voting Type Shutdown
 Anti-surge controls (where required)

Pumps-102
 Affinity Relationships

 N2   D2 
Q2 = Q 1    
 N1   D1  Q = Capacity, gpm
N = Rotative Speed, rpm
 N2  2  D2  2 H = Head, feet
H2 = H 1    
 N1   D1 
HP = Horsepower
D = Impeller Diameter
 N2  3 D2  3
HP 2  HP 1    
 N1   D1 

Pumps-103
 Horsepower

GPM  Head  SP. GR. lb / min  Head GPM  PSI

BHP = = =
3960  Eff. 33,000  Eff. 1714  Eff.

kW = m3/hr x  P (bar)
35.98 (Eff)
60 - 50 Cycle

Q60 = 1.2 Q50

H60 = 1.44 H50

NPSH 50
NPSH60 =
0.76

Pumps-104
 Horsepower in Field

Measure amp draw of motor

Watts = Amps x Volts

BHP=1.73 x Amps x Volts x motor eff x motor power factor
746

kW=1.73 x Amps x Volts x motor eff x motor power factor

1000

Motor eff = 0.95 (Approx)

Motor power factor = 0.90 (Approx)

For single phase motor don’t multiply by 1.73 (31/2)

Pumps-105
 Horsepower in Field
Power Factor

Power factor is the ratio between the KW and the KVA drawn
by an electrical load where the KW is the actual load power and
the KVA is the apparent load power.
It is a measure of how effectively the current is being converted
into useful work output and more particularly is a good indicator
of the effect of the load current on the efficiency of the supply system.

Pumps-106
 Horsepower in Field

Example
Amps = 30
Volts = 360

BHP = 1.73 ( 30) (360) (0.95) (0.90)/746

BHP = 21.4

GPM = 300 Eff = (300) (170-95)/(1714)(21.4)

P2 = 170
P1 = 95 Eff = 61%

Pumps-107
 70 psig 0 GPM
30 psig
TDH
ΔP = ?41
ΔP= psi ft ?
135.3
psi
29 psig

Head = psi *2.31/S.G.

70 psig
S.G. = .7 Pumps-108
 System Resistance Curve
350
Differential Head, ft

300

250

200

150
0%
100
0 200 400 600 800 1000
Flow, gpm Pumps-109
 75.5 psig 200 GPM, 33% Flow
30 psig 1.5 psi
ΔP ==46.5
TDH 153 psi
ft
0.5 psi
29 psig

0.5 psi

1 psi 1 psi
0.5 psi 0.5 psi
1

70 psig
Pumps-110
 System Resistance Curve
350
Differential Head, ft

300

250

200

150
33%
0%
100
0 200 400 600 800 1000
Flow, gpm Pumps-111
 88 psig 360 GPM, 60% Flow
30 psig 9 psi
ΔP = 59
TDH 195psi
ft
1 psi
29 psig

1 psi

2 psi 2 psi
1 psi 2 psi
1

70 psig
Pumps-112
 System Resistance Curve
350
Differential Head, ft

300

250

200
60%
150
33%
0%
100
0 200 400 600 800 1000
Flow, gpm Pumps-113
 120 psig 600 GPM, 100% Flow
30 psig TDH = 300 ft 25 psi
ΔP 91 psi
2 psi
29 psig

2 psi

5 psi 5 psi
2 psi 9 psi
1

70 psig
Pumps-114
 Pump Performance
System Resistance Curve
Curve
350
Differential Head, ft

300
100%

Discharge
250
Throttle
200
60%
150
33%
0%
100
0 200 400 600 800 1000
Flow, gpm Pumps-115
 Pump Performance Curve
Variable Speed Driver
350 100% Speed
Differential Head, ft

330
110%
310
290
100%
90% Speed
270
250
80% Speed
230
210
190
170
150
0 200 400 600 800 1000 1200

Flow, gpm
No discharge throttling No wasted utilities
Pumps-116
 Two Centrifugal Pumps in Parallel

150

100
Head Feet

Combined Curve

50
Pump B Pump A

0
0 400 800 1200 1600 2000 2400
Capacity gpm

Pumps-117
PD-R00-53
Two Centrifugal Pumps in Series
250

200

Combined Curve
Head Ft.

150

Pump A
100

50
Pump B

0
0 400 800 1200 1600 20000
Capacity gpm

Pumps-118
PD-R00-54
Typical Motor/Motor Spare Pump
Arrangement
Discharge

Open

PG PG

M P1 P2 M

Open

Suction

Pumps-119
PD-R00-55
 Typical Motor-Auto Cut-In Turbine
Spare Pump Arrangement
Discharge

Slow Roll
By-Pass
Control

PG E Steam
PG
11.3 Kg/cm2g
M P1 P2 T

S.T. Exhaust Steam

Suction 3.5 Kg/cm2g

Pumps-120
PD-R00-56
Rolling Element (Ball) Bearings
Double Axial
Radial Vent Thrust Bearings
Oil Seal Bearing & Filter
Oil Seal

Normal Oil Coupling

Deflector Level
Rings Oil Slinger Rings to
Lubricate Bearings

Pumps-121
Constant Level Oiler

Pumps-122
Rolling Element Bearings

Pumps-123
Ball Bearings

Pumps-124
Ring Oil Bearing Lubrication

Pumps-125
 Rolling Element Bearings

 Per API 610 Minimum Requirements

 25000 hours (3 yrs) at rated capacity

 16000 hours (2 yrs) at max radial & axial loads

Pumps-126
Bearings Enemies

 Wrong oil level

 Water
 Solids

Pumps-127
 Bearings Oil Level

 Just Right - Half way up bottom bearing

 Too Low - Inadequate Lubrication
 Too High - Excessive Heat
 Per SKF, oil has useful life of 30 yrs @ 30C (80F)
Cut in half for every 10C (18F) rise
 At 100C (212F) useful life is 90 days

Pumps-128
Bearings Water Where Does It Come From?

 House Cleaning
 Seal Gland Quench
 Aspiration
 Open Oil Cans
 Other

Pumps-129
Bearings Water What Are Problems?

 Pitting and Corrosion increase fatigue

 Free atomic H2 causes hydrogen embrittlement
accelerating fatigue
 Water/oil emulsion is poor lubricant
 0.002% H2O can reduce bearing life 48%
 6% H2O can reduce bearing life 83%

Pumps-130
Bearings Solids Where Do They Come From?

 Seal Cage and Bearing Box Seal Wear

 Oil Flinger Ring
 Solids in contaminated oil
 Air borne particles
 Introduced during assembly

Pumps-131
 Oil Mist

Wrong oil levels, water contamination,

solid abrasion all go away with oil mist
lubrication

Pumps-132
Pure Oil Mist

Pumps-133
Pure Oil Mist

Pumps-134
Pure Oil Mist

 Engineered for large Process

units:
 Serve up to 80 Pumps with
Drivers
 required Maximum of 30
SCFM of Air
 Consume Less than 2 Gallons
of Oil per Day
…justifying use of Synthetic
Oils for Maximum Benefits
 1 part oil per 200,000 parts air

Pumps-135
Pumps-136
Pumps-137
Pumps-138
PURE OIL MIST
Dry Sump (Ball bearings)

PURGE OIL MIST

Wet Sump (Sleeve bearings)

Pumps-139
 Oil Mist Benefits

 The Proper Amount of Clean Oil is Applied Continuously

 Clean Once Through Lubrication
 Bearing Housings are Pressurized Preventing External
Contamination
 Internal Metal Surfaces are Always Coated with oil which
Prevents Corrosion (Important For Stand-by Equipment)
 L10 Bearing Life is Extended by a Factor of 6
Source: Texas A&M University Research

Pumps-140
 Oil Mist Benefits

 Bearing failures reduced up to 90%

 Dirt particles are not delivered to the bearings
 Dirt particles do not accumulate in the oil sump
 Wear particles are carried away
 Bearings operate 18 to 27°F cooler
 Bearings see only fresh oil
 Seal failures may be reduced up to 30%

Pumps-141
 BEDQ 5.6e

UOP specifies an open loop centralized oil mist

lubrication system for new process units with more
than five pumping services to maximize equipment
availability and Mean Time Between Repair (MTBR)

Open loop oil mist

Closed loop oil mist
Other

Pumps-142
Determining Pump Performance
When Handling Viscous Fluids

Pumps-143
Minimum Continuous Flow
Depends On:

 Temperature Rise H2O =

Head at Min Flow  1 
 - 1
778  Eff 

 NPSH

 Radial Reactions On Impeller

Pumps-144
 Double Suction Single Stage Pump
Discharge
Suction Double Suction
Impeller
Vent
Connection Wear
Inboard Rings Seal
Bearing Housing Vent
Flush
Deflector
Oil Seal Ring Outboard
Bearing
Tachometer
Hole

Oil Slinger
Ring Bearing
Bearing Shaft
Mechanical Sleeve
Seal

Pumps-145
PD-R00-43
Single vs. Double Suction

Pumps-146
Double Suction

Pumps-147
Single Stage Double Suction

Pumps-148
Two Stage Single Suction
Between Bearing

Pumps-149
Pumps-150
PD-R00-44
 8 Stage Centrifugal Pump
Opposed Impellers
Mechanical Wear
Seal Cross
Rings Vent Over
Seal
Quench
Seal Shaft Suction Impeller
Flush Sleeve Guide
Deflector Vane
Ring Diffuser Wear
Rings

Oil Outboard
Seal Bearing
Suction Housing

Discharge Cross Over from

4th Stage Discharge to 5th Stage Suction
PD-R00-45
Pumps-151
Horizontally Split Multi-Stage

Pumps-152
Pumps-153
Double Case Centrifugal Pumps

Pumps-154
PD-R00-46
 Multi-Stage Pump with Balancing Drum

Discharge Balance Line

at Suction Pressure
Suction
Diffuser Balancing Thermometer
Cooling Drum
H2O Inlet Labyrinth One Stage
Seal Flush Seal Thrust
Collar
Sleeve Bearing

Mechanical Kingsbury
Seal Assembly Pump Case Assembly
Impeller Sleeve
Bearing

Pumps-155
PD-R00-47
Radially Split Multi-Stage

Pumps-156
Pumps-157
 Model
LMV-311
Sundyne
Process
Power
Unit
Pump

Gearbox Filter
Integral
Mechanical Seal
Centrifugal Separator
Diffuser Impeller
Inducer
Pump Casing

Pumps-158
PD-R00-36
Pumps-159
Pumps-160
Pumps-161
Impeller and Inducer

Without Inducer
100 Percent
Impeller 50 of npsh

Percent of Design Head

With Inducer 0 required
100
Head-Flow
75
Efficiency
Inducer 50
Horsepower
25

0
0 25 50 75 100 125 150
Percent of Design Flow

Pumps-162
PD-R00-50
 TROUBLESHOOTING GUIDE
TROUBLE POSSIBLE CAUSES
Liquid not delivered Pumps not primed
Air or vapor pocket in suction line
Pump not up to rated speed
Wrong rotation
Impeller or passages clogged
Failure to deliver rated Available npsh not sufficient
capacity and pressure
Pump not up to rated speed
Wrong rotation
Impeller or passages partially clogged
Wear rings worn or impeller damaged
Air or gases in liquid
Viscosity or specific gravity not as specified
Air or vapor pocket in suction line
Air leak in stuffing box
Total head greater than head for which pump
designed
Injection of low vapor pressure oil in lantern
and ring of hot pump

Pumps-163
 TROUBLESHOOTING GUIDE
TROUBLE POSSIBLE CAUSES
Pump loses prime Air leak in suction line
Air leak in stuffing box
Air or gases in liquid
Pump overheats driver Speed too high
Specific gravity or viscosity too high
Packing too tight
Misalignment
Total head lower than rated head
Low voltage or other electrical trouble
Trouble with engine, turbine, gear or other
allied equipment
Pump vibration Available npsh not sufficient
Air or gases in liquid
Misalignment
Worn bearings
Damaged rotating element
Foundation not rigid
Pump operating below minimum
recommended capacity
Impeller clogged

Pumps-164
 TROUBLESHOOTING GUIDE
TROUBLE POSSIBLE CAUSES
Stuffing box overheats Packing too tight
Packing not lubricated
Incorrect type packing
Gland cocked
Bearings overheat or wear Incorrect oil level
rapidly
Misalignment or piping strains
Insufficient cooling water
Bearings too tight or preleaded
Oil rings not functioning
Suction pressure appreciably different than
specified
Improper lubrication
Vibration
Dirt or water in bearings

Pumps-165
 Purchasing Pumps
Technical Evaluation

1. Does it meet flow and head?

2. Check completed API data sheets line by
line Does it meet the spec?

3. % of BEP

4. L3/D4

Pumps-166
 Purchasing Pumps
Technical Evaluation

5. Suction Specific Speed

6. Seals

7. Materials

8. Efficiency

9 Exceptions to Specs and Standards

10. Experience

Pumps-167
 ASME vs. API
ASME API
Pump Type End Suction End or Top Suction
Single Stage Only Single or Multi-Stage
Dimensions Standardized Non-Standardized
Impeller Open or Closed Closed
Std. Materials Cast Iron or 316SS Steel or 11-13% CR
Stuffing Box Packed or Mechanical Seal Mechanical Seal
Support Foot Centerline
Minimum Bearing Life 17,500 HR 25,000 HR
Wearing Rings Optional Required
Flanges CL. 125 or CL. 150 Min. CL. 300 Min.
Running Clearances None Specified Specified
Shaft Runout 0.05 MM 0.025 MM
Temperature Limits 500ºF 800ºF
300ºF for Cast Iron
Throat Bushing Optional Required
Cost 30 to 50% of API

Pumps-168
ASME vs. API

Pumps-169
 ASME vs. API

 API is engineered product

 ASME is off-the-shelf

 100 GPM, 200 FT

– API $14,000, ASME $6000
 600 GPM, 300 Ft
– API $30,500, ASME $14,500

 Affect ~20% of pumps

Pumps-170
 ASME vs. API

 API 8th Edition

 Nonflammable, nonhazardous
 Max discharge pressure 275 psig
 Max suction pressure 75 psig
 Max temp 300 F
 Max speed 3600 rpm
 Max head 400 ft
 Max impeller diameter 13 in

Pumps-171
 ASME vs. API

 API 9th Edition (Released this Spring)

 Same limitations
 Removed nonflammable, nonhazardous

Pumps-172
 ASME vs. API

 Allowed (endorsed) by API

 Major pump vendor says no difference in reliability
in allowable range
 Much UOP experience (non-hydrocarbon)
 Cheaper

Pumps-173
 API 610

5-11-8

ASME B 73.1

5-21-5

Pumps-174
 ASME vs. API
ASME API
Pump Type End Suction End or Top Suction
Single Stage Only Single or Multi-Stage
Dimensions Standardized Non-Standardized
Impeller Open or Closed Closed
Std. Materials Cast Iron or 316SS Steel or 11-13% CR
Stuffing Box Packed or Mechanical Seal Mechanical Seal
Support Foot Centerline
Minimum Bearing Life 17,500 HR 25,000 HR
Wearing Rings Optional Required
Flanges CL. 125 or CL. 150 Min. CL. 300 Min.
Running Clearances None Specified Specified
Shaft Runout 0.05 MM 0.025 MM
Temperature Limits 500ºF 800ºF
300ºF for Cast Iron
Throat Bushing Optional Required
Cost 30 to 50% of API

Pumps-175
 Isolating Pressure
Diaphragm Lubricated
Lubricating Oil
Relief Valve Drive
High Speed
Worm
Micrometer
Stroke
Adjustment

Lubricating Oil
Magnetic
Strainer

Pumps-176
PD-R00-57
 Discharge

Pre-formed Packing
Double
Ball
Lantern Ring Valves

Pump
Body

Double
Ball
Gland Adjuster Valves

Suction
Pumps-177
PD-R00-59
Pumps-178
Discharge
Automatic Air-Bleed
Valve
Valve
Ball Check
Relief Lubricating Oil Isolating
Valve Relief Valve Diaphragm

Diaphragm Pressure
Lubricated
Drive

Lubricating
Hydraulic Fluid
Oil
Suction
Ball Check Refill Valve Magnetic
Valve Behind Piston Strainer

Pumps-179
PD-R00-58
Pumps-180
Pumps-181
Pumps-182
 Rigid Positively Aligned Individual Bolted
Plunger Hook-Up Valve Covers
Carburized Alloy Steel
Crosshead Pin Optional
“Triple” Seal Plunger Forged Steel
Protection Cover Cylinder

Cylinder Head
Extension for
Controlled
Volumetric
Clearance

Suction
and Discharge
Valves
and Seats are
Interchangeable

Babbitt Lined Full Piston Wing-Guided

Connecting Rod Type Crosshead Valve Service
Bearings

Pumps-183
PD-R00-60
 Oscillamatic™
CP125B

Pneumatic Chemical Injectors

Extremely Low Volume
Highly Accurate
Pumps-184
PD-R00-61
Large Suction
Idler Thrust Bearing
Discharge

Packed Under
Positive
Pressure

Roller
Thrust
Bearing

Idler Rotors

Power Rotor
Replaceable Rotor Housing

Pumps-185
PD-R00-62
Pumps-186
PD-R00-63
Traditional Slurry Pump

Pumps-187
Pumps-188
Pumps-189
Pumps-190
Pumps-191
Pumps-192
Pumps-193
Replaceable Liners

 Material
– 28 % Chrome Iron
 Tolerances
– Each Liner has
Machined Fits
 Installation
– Each Liner is
Bolted into Place

Pumps-194
Liners in Pressure Casing

Pumps-195
Slurry Impeller Design

Pumps-196
Pumps-197
Pumps-198
Pumps-199
 Vertical Inline Pump
Motor Drive Shaft
Removable Drive
Sleeve To Allow
Maintenance On Pump
Seal
Flush Shaft Sleeve

Mechanical Seal

Impeller
Discharge
Suction

Impeller Balance Wear Rings

Hole

Pumps-200
PD-R00-65
 Flexible Coupling
Grease Point Shaft Bearing
Bearing Housing 2-Stage
Gland Follower
Submersible
Stuffing Box
Discharge Lift Pump

Bearing Spider
Shaft Sleeve
Bearing

Sleeve Bearing
Impellers
Volute Casing
Sleeve Bearing
Strainer

Suction
Pumps-201
PD-R00-66
 Gear Pump

Internal
Relief Valve
Assembly
Heating
Steam Inlet

Gear
Heating
Steam Outlet

Pumps-202
PD-R00-67