© Kuch Latthias / Total

ECP/PRO
PUMPS
CONTENT

● Pump Terminology
● Types of Pump
● Pump Process Design
● Pump Operational Aspects
● Safety Aspect
● Other Technologies
● Real Case
● References
PUMP TERMINOLOGY

Pump Definition
A piece of equipment that absorbs power and transfers it to a liquid for
the purpose of bulk movement from one point to another and / or for the
generation of pressure.
 PUMP TERMINOLOGY

 Head
 Head represents the energy per unit mass imparted to the fluid. It is often expressed
in potential energy terms (meters or feet).

∆P = 9.81Hγ
(P2- P1), kPa Conversion Head, m

Relative Density

 A pump will produce the SAME HEAD regardless of the fluid it is pumping.

 A pump will have a different PRESSURE RISE for fluids having a different Relative
Density.

4
 PUMP HEAD

Equation 14.1
Gasoline

γ = 0.7 H = 100 m ΔP = 687 kPa

(6.87 bar)

Water
γ = 1.0
H = 100 m ΔP = 981 kPa
(9.81 bar)

Produced
Water
H = 100 m ΔP = 1 177 kPa
γ = 1.2 (11.77 bar)

5
 PUMP TERMINOLOGY

 Pump Power :
o Hydraulic Power is the amount of power imparted to the liquid as it
passes through the pump.
o Brake Power (or shaft power) is the amount of power delivered to the
pump (as opposed to the power used by the motor). The brake power
required will depend on the pump efficiency.

 Efficiency
Pump efficiency is equal to the ratio between the hydraulic power
required and the brake power. It refers to the mechanical efficiency of
the pump

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 PUMP TERMINOLOGY

 Net Positive Suction Head Required(NPSHR)

The head required by the pump in order to prevent the liquid stagnation
pressure dropping below the vapour pressure and resulting in liquid
boiling. Liquid boiling can lead to cavitation. The NPSHR is a
characteristic of the pump itself and is generally determined
experimentally by the pump manufacturer.
 Net Positive Suction Head Available (NPSHA)
The excess pressure of the liquid in height absolute over its vapour
pressure as it arrives at the pump suction. It is a characteristic of the
system
 NPSHA must be > NPSHR

7
PUMP TERMINOLOGY

● System head is the required head the pump must produce to attain
the required flow
- Consists of:
• Static Head
- Due to elevation change, is independent of flow
• Dynamic head
- Due to frictional loss in the system
- Control valve pressure drop
SYSTEM AND HEAD CURVES

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 PUMP TERMINOLOGY

 Shut Off
 The point on the pump curve where flow is zero, usually the point of
highest total dynamic head.
 Vapor Pressure
 The pressure absolute at which a liquid, at a given temperature
starts to boil or flash to gas

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TYPES OF PUMP

 Kinetic
 Centrifugal

 Positive Displacement
 Reciprocating
 Rotary
 TYPES OF PUMP

Kinetic (Centrifugal Pump)

 Energy is imparted to the pumped

liquid by means of a moving
impeller.
 This increase in energy is converted
to a gain in pressure when the
velocity is reduced prior to or as the
flow exits the pump into discharge
pipe.
 Approximately constant head, over Cross-sectional Look of a Centrifugal Pump

a wide range of capacity.

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 TYPES OF PUMP

Positive Displacement

 Allowing a fluid from a low-pressure source to flow into some

enclosed cavity, and then forcing it out into a high-pressure receiver
by decreasing the volume of the cavity.
 Approximately constant capacity, over wide variations in head.
 Positive displacement pump types :
Reciprocating : piston, plunger, diaphragm
Rotary : gear, vane, screw

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 POSITIVE DISPLACEMENT

Piston Pumps

 Fluid to move using one or more

oscillating pistons, plungers, or
membranes (diaphragms).

 For pumping highly viscous fluids

and special applications
demanding low flow rates against Animation of Reciprocating Pump Movement
high resistance.

 The volume is constant given

each cycle of operation.

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 POSITIVE DISPLACEMENT

Diaphragm Pumps

 Similar working philosophy as

the reciprocating pumps.

 Capable of delivering small,

precisely controlled amount of
liquid.
Animation of Diaphragm Pump Movement
 Commonly used as chemical
injection pumps because of their
controllable metering capability.

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 POSITIVE DISPLACEMENT

Rotary Pumps

 Applying the principles of

rotation.

 For viscous liquids service

(for which centrifugal or
reciprocating pumps are not
suitable).
Animation of Rotary Pump Movement

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 POSITIVE DISPLACEMENT

Progressive Cavity Pumps

 Transfers fluid by means of

the progress, through the
pump, of a sequence of
small, fixed shape, discrete
cavities, as its rotor is turned
Animation of Progressive Cavity Pump
 Can be applied for sandy and
heavy oil wells

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PUMP TYPE SUMMARY
PUMP PROCESS DESIGN

● Selection Criteria
● Pump Sizing
● Pump Technology Supplier
PUMP SELECTION CRITERIA

● Flowrate (over the lifetime of the installation)

● Total differential head required
● Characteristics of the liquid to be pumped
● Type of liquid
o Erosive elements present (solids / sludge)
o Corrosive elements present (H2S, salts, etc)
o Temperature
o Viscosity
o Specific gravity
o Vapour pressure
PUMP SELECTION CRITERIA

Blue line  Positive displacement Pumps

Green Line  Centrifugal Pumps
PUMP SIZING

Simplified Process Calculation

PUMP SIZING

Input Data
PUMP SIZING

Output Data
 PUMP SIZING

 Pump Head

 Pump Differential Pressure

 Brake Pumping Power

PUMP SIZING

 Minimum Suction Pressure

 Maximum Discharge Pressure

 NPSHA
PUMP TECHNOLOGY SUPPLIER
PUMP OPERATIONAL ASPECTS

● Sealing Mechanism
● Pump Protection Device
● Cavitation
● Pump Arrangement : Series – Parallel
● Pump Control: Mini flow – Flow Control
SEALING MECHANISMS

The purpose of the seal is to retain the pumped liquid inside the pump
at the point where the drive shaft penetrates the pump body.

Centrifugal Pump Sealings:

Mechanical sealing
Braided packing material
Positive Displacement Pump Sealings:
Reciprocating pumps:
o Piston pumps are sealed by ring
seals
o Plunger pumps are sealed by
stationary sealing rings
Rotating pumps : mechanical seal
PUMP PROTECTION DEVICE

 Strainer  to "strain" large and small particles from the liquid before
it enters the pump
 Check valves  often installed in the discharge line of water pump
systems to prevent reverse flow.
 Pulsation dampeners  to reduce pressure pulsation from the
pumping action of reciprocating pumps (could lead to pipe failure)
 Open valve close valve - start up
 For centrifugal pump
It is preferable to start-up the centrifuge pump with the discharge
valve closed until normal operating speed is reached, the valve
must be opened quickly.
 For positive displacement pump
Pump must always be started with the suction and discharge
valves open.
PUMP OPERATIONAL ASPECTS

● Cavitation
The formation and subsequent collapse or implosion of vapor
bubbles in a pump
PUMP OPERATIONAL ASPECTS

How to Prevent Cavitation:

● Reduce the pressure drop in the pump suction piping by increasing

the line diameters and decreasing the number of pipe components
(bends,...).

● Increase the liquid suction static head by elevation of the suction

vessel level or by lowering the pumping station grade level.

● Reduce the vapour pressure value of the pumped liquid with the use
of a cooler installed on the pump suction piping (this solution is not
often feasible).

● Locate the pump as close as possible to suction vessel.

PUMP OPERATIONAL ASPECTS

Pump in Series
PUMP OPERATIONAL ASPECTS

Pump in Parallel
BOOSTER AND TRANSFER PUMPS IN BKP PP
PUMP CONTROL

Minimum flow
 Too low flows tend to create internal recirculations (similar to
compressor surge)
 This can induce severe vibrations
 Pump vendor shall specify minimum flow requirements to ensure
adequate flow (and/or provide specific mini-flow protection device)

Blocked discharge (No flow)

 If discharge is shut-off, all energy is converted to heat
 Liquid heats up rapidly and eventually vaporises
 Can result in catastrophic failures
PUMP CONTROL
PUMP CONTROL

● Throttle Control
Throttling a valve in the discharge piping of the pump creates extra
frictional losses so that pump capacity is reduced to that required.
PUMP CONTROL

Speed Control
● Not frequently done – most pumps are fixed speed
● Adjusting the rotational speed often consume less energy than
throttling
SAFETY ASPECT

● Centrifugal Pump
Generally no PSV's are provided and the design pressure of piping
and process components at pump discharge (pump excluded) shall
be the discharge pressure of the pump at no flow with the maximum
suction pressure and the maximum specific gravity (maximum shut-
off pressure).

● Positive Displacement Pump

PSV's shall be provided at pump discharge.
OTHER TECHNOLOGIES

● Multi Phase Pump

● Electric Submersible Pump
● Firewater and Jockey Pump
● Vacuum Pump
MULTI PHASE PUMP

● Pump two mediums at the same time. The liquid in the mixture is
pump and the gas is compressed.

● Multiphase pumping benefits:

 Enable liquid/gas mixture to be transported over long distance
without the need for prior separation
 Leads to simpler and smaller in-field installations, cost effective
production system
 Handle liquid/vapour fraction ranging from 0% to 100%

There are two principal types of MPP:

 Volumetric (Twin screw)
 Rotodynamic (Helioaxial)
MULTI PHASE PUMP

Twin Screw Pump Helio-Axial Pump

ELECTRICAL SUBMERSIBLE PUMP

● Electrical submersible pumps are

installed at the base of oil wells to
improve production.

● ESP characteristics:
 Can function up to 220°C and 340 bar
 Can be installed up to 3700m deep
Capacity from 100 to 100 000 bbl/d
 Power rating up to 750kW
 Can be adapted to sand, high viscosity
and high GOR (multiphase models
available).
FIREWATER PUMP

● A fire pump is a part of a fire sprinkler system's water supply and

can be powered by electric, diesel or steam. The pump intake is
either connected to the public underground water supply piping, or a
static water source (e.g., tank, reservoir, lake).

● A jockey pump, or a pressure maintenance pump, is a small

apparatus that works in conjunction with a fire pump as part of a fire
protection sprinkler system.
VACUUM PUMP

5 types of Vacuum Pumps:

● Ejectors: The simplest and most widely used the ejector works by converting pressure
energy of a motive fluid into velocity energy as it flows through a converging-diverging
nozzle.

● Liquid Ring: Similar to a rotary vane pump. The rotation forces the liquid to the outside
of the cylinder to form a liquid ring. The entering vapours are trapped within the vane
slots between the rotor shaft and the liquid ring where they are compressed and
discharged to atmosphere.

● Dry Pumps: These pumps work by either of two mechanisms, volumetric reduction or
the mixing of lower-pressure gas with higher pressure discharge gas.

● Once through Oil (OTO) Pump: A sliding vane type pump - As the rotor assembly
rotates, centrifugal force pushes the vanes out of the slots and against the chamber
walls, creating pockets whose size varies similarly to those of the liquid ring pump.

● Rotary piston pump: Gas is drawn out via the suction stroke then compressed above
atmospheric pressure and ejected by the discharge stroke.
TEPI REAL CASE

Liquid Transfer Pump (LTP) Repetitive Failure

● NPU: 46 failures in 44 months
● SPU: 36 failures in 44 months
 BLOCK DIAGRAM

● SMP Liquid Transfer Pump (11-PA-1211 A/B/C)

SPU SMP Slug Catchers Parameter Design Condition Current Operating Condition

From LP To Gas Sparing policy 3x50% @ 183 m3/hr 1-2 duty due to 232 m3/hr (35
Manifold Manifold
(27.6 kBPD) kBPD) limitation to TCP slug
SMP Liquid Transfer • 2 duty, 1 standby catcher
Pumps
11-V-1111A • 3 duty during pigging
LIC HS

PIT FIT

PIT
P suction/discharge (barg) 6-14/44 9/36-38
11-PA-1211A
PSDV
MP Manifold pressure (barg) 34-42 24-25 (normal condition)
PIT FIT

PIT To MP
Manifold
LV 111102 A/B:
11-V-1111B LV
LIC
dP across valve (bar) 0.7 ~13
11-PA-1211B
Cv 975 (rated) 44-56
PIT FIT Opening 22-62% 2-4%
PIT
PSDV

11-PA-1211C

● NMP3 Condensate Transfer Pump (12-PA-1211 A/B/C)

NPU NMP3 Slug Catchers Parameter Design Condition Current Operating Condition

From LP To LP Sparing policy 3x50% @ 19.6 m3/hr Q = 15-24 m3/hr (common FT

Manifold Compressor
(2.96 kBPD) for 3 pumps)
NMP3 Condensate
Transfer Pumps • 2 duty, 1 standby • 1-2 on duty
12-V-1111A • 3 duty during
LI LIC
pigging

P suction/discharge (barg) 10.7/23.72 6-7/18

12-PA-1211A

FIT PIT

To NCP Slug
Catchers
12-V-1111B LV
LI
PSDV
12-PA-1211B

To OWTU

12-PA-1211C
Presentation title - Place and Country - Date Month Day Year 48
FINDINGS ON FAILED PUMPS
- No trace of cavitation (Pump impellers in good Sand Lot
condition) Found
- Fine sand inside pump Eroded
by Sand
- Mechanical defect :
1. Erosion on Bushing
2. Erosion on Shaft Sleeve
3. Erosion on Wearing Ring

Shaft sleeve in Shaft sleeve

good condition deeply scratched

IN OUT

Erosion will increase clearance and

lead to vibration:
- Normal: 0.16 mm
- Failed Pump: 4 mm

SAND carry over is the main root cause of SMP and NMP3 transfer pump
repetitive failures
REFERENCES

● GS EP ECP 103 Rev 8 Process Sizing Criteria

● API STD 610, 10th Edition Centrifugal Pumps for Petroleum,
Petrochemical and Natural Gas Industries
● API STD 674, 3rd Edition Positive Displacement Pumps –
Reciprocating
● GS EP MEC 271 Rev 6 Centrifugal Pumps for The Petroleum,
Chemical, and Gas Industry Services According to API Standard 610
● GS EP MEC 273 Supply of Centrifugal Pump Class II According to
ISO 5199
● GS EP MEC 275 Multi-Phase Pumps
● Prodem Chapter XX : Pumps
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and the entity making the presentation.

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Accordingly, no reliance may be placed on the accuracy or correctness of any such
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