Professional Documents
Culture Documents
Surface Production Operations 6
Surface Production Operations 6
Pumps
Section 6
Pumps
Discharge Nozzle
Volute
Casing
Bearings
Impeller
Suction Seal
Nozzle Shaft
Oil Rings
Suction nozzle
Seal Gland
Bearing housing
Tip Velocity
2
ft/sec
HEAD developed ft
2g
RPM d impeller in
Tip Velocity =
229
HEAD ft .3 x 10 RPM d -6 2 2
2g ft / sec 2
“HEAD” Can be Converted to Pressure
P
P ==.433
.433 H
psi
psi
H xx SG
SG ftft LL
P
P == 9.794
9.794 H
kPa
kPa
H xx SG
SG m
m LL
SUCTION
MSD by SULZER
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
Centrifugal Pumps: Radial Flow
Fluid OUT
Centrifugal Pump
Head – Capacity
Curve
Against 90 ft. of
Centrifugal Head
Pump
Pump Head
delivers 70 GPM
– Capacity
WE wantCurve
100 GPM
N1
N2
N3
Head
Flow Rate Q
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
SOLUTION
N2
N1
System
Flow Rate Q
HEAD
PUMP
System
QQ
Flow Rate
PUMP
System
Flow RateQQ
Flow Rate Q
System
Flow RateQQ
Flow Rate Q
Q Available
Q Needed
HEAD
PUMP
System
Flow Rate Q
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
If Not Enough Fluid (Q) is Available: Slow Pump Speed
Q Needed
HEAD
PUMP
System
Flow Rate Q
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
Insufficient (Q) is even at the LOWEST Pump Speed?
Q Available
HEAD
System PUMP
Flow Rate Q
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
Change SYSTEM Curve
Change the
SYSTEM Curve
Change the
SYSTEM Curve
Q Available
Add Higher ∆P to System
HEAD
System PUMP
Flow Rate Q
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
Centrifugal Pump Affinity Laws: 1
N: Pump Speed
(rpm)
Q1 N1
=
Q2 N2
2
H1 N1
=
H2 N2
3
BHP1 N1
=
BHP2 N2
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
Centrifugal Pump Affinity Laws: 2
Q1 D1 D: Impeller Diameter
=
Q2 D2
2
H1 D1
=
H2 D2
3
BHP1 D1
=
BHP2 D2
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
Head Curves – Impeller Sizes
Problem A:
The Centrifugal Pump described above is to transfer 30API Oil from a Suction
Pressure of 10 psig to a Pressure of 55 psig.
CHOOSE an Impeller Size.
141.5
SG = 1 foot of WATER exerts 0.433 psi
131.5 + API
L
Problem A:
The Centrifugal Pump described above is to transfer 30API Oil from a Suction
Pressure of 10 psig to a Pressure of 55 psig.
141.5
SG = L
= 0.876
131.5 + 30
HEAD = ΔP in psi / .433 psi / foot SG L
Impeller Size: ___________________ = 55 - 10 / .433 .876 = 119 feet
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
Pump Exercise
What Q Results?
88
90 128
127
Q1 N1
= Q Results?
What
Q2 N2
88
90 128
127
Q1 N1
=
Q2 N2
88 127
1 x 1½ - 6
1 x 1½ - 6
1 - inch 6 - inch
Discharge maximum impeller
1½ - inch
Suction
Pump Affinity
Equations
Q N
= 1 1
Q N
Q N 2 2
1
= 1
QH =N N
2
N
2 1 2 1
H
H
N
2 2
2
1
= 1
H 2 N 2
Inexpensive
Few Moving Parts
– Lower Maintenance Cost
– Greater Up Time
Small and Lightweight for Q
No Close Clearances
– Dirty Fluid OK
Operates at Low Suction Head
Automatically Adjusts to Changes in Head
– ( Capacity Controllable Over Wide Range
even at Constant Speed )
Reciprocating Pumps
Displacement caused by LINEAR Motion
PISTON within a CYLINDER
PLUNGER sealed with Packing
Rotary Pumps
– Displacement caused by CIRCULAR Motion
Piston Outlet
Check
Valve
Cam
Inlet
Check
Head Valve
Seal
Simplex – 1 plunger
Duplex – 2 plungers
Triplex – 3 plungers
Quintuplex – 5 plungers
Discharge
Crankshaft Valve
Connecting Rod
Plunger
Crosshead
Suction
Valve
piston
head
end
suction valves
2
Q = .1166 D L S C
Q = BPD
D = Plunger DIAMETER, inches
L = Stroke LENGTH, inches
S = Stroke SPEED, rpm
C = Number of CYLINDERS
Higher Maintenance
Lower “Up Time”
> 330 1 3
Sliding Vane
PCP: Progressing Cavity Pump
Multiple Screw
Canned Rotary
85000 BLPD
200 psi
12 psi Suction
Runs Dry
Handles Some Solids
Self – Comps for Wear on Vanes
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
Sliding Vane Rotary: Positive Displacement Pump
Dry Self-Priming
Low Shear
High Starting Torque – Use Larger Pump Motor
Cannot Run Dry More than Several Minutes
High Cost Replacement Parts
MultiBooster
Aker Kvaerner
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved.
Helicoaxial Multiphase Pump Skid
( Variable Frequency )
PUMP
HHP = SG L
Q ft 3 /sec
H / 8.82 ft
= SG L
Q gpm
H / 3960 ft
= Q gpm
P / 1714 psi
HHP = Q BLPD
P / 58766 psi
HHP watts
= 9797 SG L
Q m3 /sec
H
m
= 9.797 SG L
Q liter/sec
H
m
BHP = HHP / E
E = Efficiency of the Pump
CENTRIFUGAL PUMPS
GREEN LINE
Pump Curve for
EACH Pump
H A
( ft )
Add
Add
3rd
3rdPump
Pump
3 Pumps
3 Pumps
Add
2nd Pump
2 Pumps
1 Pump
1st Pump
Pump 2 BOTH
Pump 1 2
Appendix 6A
Section 6
Centrifugal Pumps: Trouble Shooting
Trouble Probable Cause: Trouble Probable Cause:
1. Failure to deliver liquid a. Wrong direction of rotation 5. Pump overloads driver a. Speed too high
b. Pumped not primed b. Total head lower than rated head
c. Suction line not filled with liquid c. Excessive Recirculation
d. Air or vapor pocket in suction line d. Either or both the specific gravity and viscosity of liquid different
e. Inlet to suction pipe not sufficiently submerged from that for which pump is rated
f. Available NPSH not sufficient e. Mechanical defects
g. Pump not up to rated speed 1. Misalignment
h. Total head required greater than head which pump is 2. Shaft bent
capable of delivering 3. Rotating element dragging
4. Packing too tight
2. Pump does not deliver a. Wrong direction of rotation
rated capacity b. Suction line not filled with liquid 6. Vibration a. Starved suction
c. Air or vapor pocket in suction line 1. Gas or vapor in liquid
d. Air leaks in suction line or stuffing boxes 2. Available NPSH not sufficient
e. Inlet to suction pipe not sufficiently submerged 3. Inlet to suction line not sufficiently submerged
f. Available NPSH not sufficient 4. Gas or vapor pockets in suction line
g. Pump not up to rated speed b. Misalignment
h. Total head greater than head for which pump designed c. Worn or loose bearings
i. Foot valve too small d. Rotor out of balance
j. Foot valve clogged with trash 1. Impeller plugged
k. Viscosity of liquid greater than that for which pump 2. Impeller damaged
designed e. Shaft bent
l. Mechanical defects: f. Improper location of control valve in discharge line
1. Wearing rings worn g. Foundation not rigid
2. Impeller damaged
3. Internal leakage resulting from defective 7. Stuffing boxes overheat a. Packing too tight
gaskets b. Packing not lubricated
m. Discharge valve not fully opened c. Wrong grade of packing
d. Insufficient cooling water to jackets
3. Pump does not develop a. Gas or vapor in liquid e. Box improperly packed
rated discharge b. Pump not up to rated speed
pressure c. Discharge pressure greater than pressure for which pump
designed
d. Viscosity of liquid greater than that for which pump 8. Bearings overheat a. Oil level too low
designed b. Improper or poor grade of oil
e. Wrong rotation c. Dirt in bearings
f. Mechanical defects d. Dirt in oil
1. Wearing rings worn e. Moisture in oil
2. Impeller damaged f. Oil cooler clogged or sealed
3. Internal leakage resulting from defective g. Failure of oiling system
gaskets h. Insufficient cooling water circulation
i. Insufficient cooling air
4. Pump loses liquid after a. Suction line not filled with liquid j. Bearings too tight
starting b. Air leaks in suction line or stuffing boxes k. Oil seals too close fit on shaft
c. Gas or vapor in liquid l. Misalignment
d. Air or vapor pockets in suction line
e. Inlet to suction pipe not sufficiently submerged
f. Available NPSH not sufficient
g. Liquid seal piping to lantern ring plugged 9. Bearings wear rapidly a. Misalignment
h. Lantern ring not properly located in stuffing box b. Shaft bent
c. Vibration
d. Excessive thrust resulting from mechanical failure inside the
pump
© 2011 Dr. Omar Barkat PetroSkills, LLC. All rights reserved. e. Lack of lubrication
Centrifugal Pump Trouble – Shooting Chart
Symptom Possible Causes
Insufficient Flow 1-2-3-4-6-7-10-11-12-13-20
Pressure Too Low 1-2-3-4-6-9-10-11-12-14-20
High Amp Reading 5-6-7-8-9-10-13-15-17-18-22-23-26
Packing Leaks Too Much 15-17-21-22-23-24-25-27-28
Seal/Packing Fails Early 1-7-11-15-17-19-21-22-23-24-25-26-27-28
High Vibration/Noise 1-2-3-7-8-11-13-15-16-17-18-19-20-24-25
Bearings Short Lived 1-6-7-9-11-15-17-24-25-28-29-30
Bearings Run Too Hot 1-7-11-15-18-19-24-25-29-30-31-32
1. Air entrainment 17. Shaft bent
2. Suction obstructed 18. Impeller or wear ring rubbing
3. Poor sump design 19. Worn bearings
4. Speed too low 20. Damaged impeller
5. Speed too high 21. Shaft scored at packing/seal
6. Incorrect rotation 22. Packing installed improperly
7. Pump flow too low 23. Incorrect type of packing
8. Pump flow too high 24. Excessive shaft runout
9. Change in density 25. Impeller or coupling unbalanced
10. Change in viscosity 26. Gland too tight
11. Cavitation 27. Stuff box bushing clearance high
12. Leakage joint excessive 28. Dirt or grit in pumped liquid
13. Foreign matter in impeller 29. Bearing cooling water failure
14. Loose impeller 30. Inadequate bearing lubrication
15. Misalignment 31. High ambient temperature
16. Foundation not rigid 32. High process liquid temperature