WORKSHOP

PAN AMERICAN ENERGY - FLOWSERVE

Hydraulic re-rating of centrifugal pumps

By: Jan Verhoeven
 Pump Division

This presentation shows a general

overview of current state of technology
within Flowserve to change hydraulic
performance of existing centrifugal
pumps.

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 2
 Pump Division

There are various reasons to retrofit the hydraulics of a

centrifugal pumps
Changes in pump duties due to process changes (de-
bottlenecking, capacity increases, capacity decreases, etc.).
Pump is not operating near original design point selected at
BEP (Best Efficiency Point) (design margins, heat balance
controlled process, etc.)
Solving trouble pump units (unstable curves, etc.).
For large power pump units, where installed pump is
generating lower efficiency than best achievable efficiency
(energy savings).
Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4
October 2006 / 3
 Pump Division

Changes in Pump Duties

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 4
 Pump Division

Changes in Pump Duties

There are many possible changes in head and flow depending
on changes on existing friction line or by new duties due to new
friction lines of the pump system. They almost all result in
operation at off-BEP conditions, at lower efficiencies

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 5
 Pump Division

Off-BEP Operation
Reduced efficiency
Higher axial loads (bearings/vibrations)
Higher radial loads (bearings/vibrations)
Cavitation (NPSHR and NPSHA changes)
Suction re-circulation (impeller erosion, vibrations).
Discharge re-circulation (impeller erosion,
vibrations).
Etc.
Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4
October 2006 / 6
 Pump Division

Saddle type curve

THE Q-H CURVE OF THE INITIALLY

Very flat curve
INSTALLED PUMP CAN BE:

Unstable curve
SADDLE TYPE

TOO FLAT

UNSTABLE HEAD
USABLE OPERATING
WINDOW OF PUMP IF
THIS CAN CAUSE CONSIDERABLE APPLIED IN PARALLEL
PROBLEMS IN FLOW / HEAD OPERATION
REGULATION (CONTROL) AND ALSO IN
VARIABLE SPEED AND PARALLEL
PUMP OPERATION.
CAPACITY
Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4
October 2006 / 7
 Pump Division

Efficiency Improvement of Large Energy Pumps

Pump operating at lower efficiency than the best achievable efficiency
ROI for upgrade
by savings in energy

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 8
 Pump Division

MANY CUSTOMERS HAVE ALREADY IDENTIFIED THE PUMP HYDRAULIC

PERFORMANCE CHANGES, LIKE:

» NOT RUNNING AT BEP/NEW DUTIES

» UNSTABLE OPERATION CURVE, TOO FLAT Q-H CURVE
CAUSING PROBLEMS
» OPERATING WITH A TOO LOW EFFICIENCY PUMP

CUSTOMERS HAVE THE TENDENCY TO GO FOR COMPLETE

PUMP REPLACEMENT, USING NEW ENQUIRIES

FLOWSERVE, HYDRAULIC RERATING EXPERIENCE ALLOWS

FOR 90% OF THESE PUMPS TO RERATE RATHER THAN
PURCHASING NEW EQUIPMENT

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 9
 Pump Division

HYDRAULIC RERATING IS A BETTER ECONOMIC SOLUTION THAN PURCHASING

NEW PUMPS.

1) INVESTMENT NEW PUMPS = COST TO PURCHASE NEW PUMP X FACTOR

THE FACTOR COMPRISES OF COST FOR AMONGST OTHERS:

CUSTOMER S ENGINEERING AND PURCHASING GROUP
ENGINEERING COMPANY
REMOVAL AND DISPOSAL OF POLUTED SOIL
FOUNDATION (NEW OR MODIFIED)
PIPING CHANGES TO TIE IN THE NEW PUMP IN THE EXISTING SYSTEM
INSTRUMENTATION TIE-IN,
ERECTION TIME, POSSIBLY IMPOSING PRODUCTION LOSSES
LINE FLUSHING AND COMMISSIONING
ETC. CAUSE THE COST OF INVESTMENT TO RISE FAR ABOVE THE PRICE OF THE NEW
PUMP.

FACTOR = 1,5 to 3 - SOURCES: SHELL, EXXON

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 10
 Pump Division

2) INVESTMENT HYDRAULIC RERATING OF EXISTING PUMPS

IN AVERAGE BETWEEN 40 TO 75 % OF THE PRICE OF A NEW BARE PUMP

IMPLEMENTATION CAN BE VERY FAST COMPARED TO REPLACING THE
PUMP.

Note:
If hydraulic re-rate is done when a pump is up for a major overhaul, the actual
investment is considerably lower than the mentioned percentage.
This is caused by the fact that the cost for a major overhaul of the pump might
already be 50 to 75% of the total cost for the re-rate.

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 11
 Pump Division

What is so special about changing the hydraulic

performance?
Just reduce impeller diameter
Just install large impeller diameter
This indeed can be the correct method. The family curves of the
pumps will tell what the possibilities would be (the window in which
changes can be made within the given pump).

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 12
 Pump Division

Q -H and Characteristics of a Pum p

IN FIN ITIVE N U M B ER
THE OF V AN ES
OR
ETI
CA
LQ
,H C
HA
THE R AT E
ORE R IS
THE INFLUENCE O F T IC T IC
AL Q AC
,H C CO
RECIRCULATION , AND H AR
AC T
RD
IN G
ERI TO
FRICTIO N LO SSES S T IC EU
LE R
SL
AW
FRICTIO N
LO SSE S

SHO C K
LO SSE S LE AK AG E LO SS ES

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 13
 Pump Division

THE ORETICAL
IMPELLER/VOLUTE CURVE

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 14
 Pump Division

CHANGING IMPELLER/VOLUTE CHARACTERISTICS

OLD DUTY POINT
a) IMPELLER, STEEPER Q-H LINE

NUMBER OF VANES
OUTLET BLADE ANGLE
BA OF IMPELLER
NEW DUTY

b) VOLUTE, FLATTER CHARACTERISTIC POINT 2

CHANGE VOLUTE THROAT AREA

(LARGER)
VOLUTE LIP ANGLE CHANGED NEW DUTY POINT 1

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 15
 Pump Division

It is extremely important to include both impeller and

casing (volute or diffuser) changes for hydraulic re-rating
of centrifugal pumps.

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 16
 Pump Division

R AN G E O F M O D IFIC ATIO N S B Y
Im peller and/or V olute M odifications

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 17
 Pump Division

Range of Modifications by Speed Changes

Effect is similar as impeller diameter changes, although it can be
done over much larger duty envelope.

Ideal solution if friction line is

quadratic, and low cost speed
regulation can be fitted on
existing motors.

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 18
 Pump Division

Multistage Pumps
Head changes => Destaging

Flowserve has the capability to modify any multistage pumps for most
reduced head applications similar to the example given.
Head/Flow Changes
Multiplex pumps
Replacement of rotors and volute modifications
Barrel pumps
Replacement inner hydraulic cartridges
(Example Sulzer Barrel pump BASF Antwerp)
Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4
October 2006 / 19
 Pump Division

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 20
 Pump Division

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 21
 Pump Division

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

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 Pump Division

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

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 Pump Division

Modification of Volute ...

Volute Chip (Slabbing)

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

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 Pump Division

Modification of Volute...
Volute Lip Insert

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 Pump Division

Modification of Volute...
Throat Insert

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 Pump Division

Volute inserts

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 27
 Pump Division

EXAMPLE REDUCED FLOW/HEAD DEMANDS

LOW FLOW IMPELLER
WITH INSERT FOR STEEP
RESISTANCE LINES

SHOWN IN FIGURE 3 IN
BOLD LINES IS A SINGLE
STAGE SINGLE SUCTION, H
CANTILIVERED PROCESS
PUMP, MODIFIED FOR A
50% REDUCTION IN FLOW
AGAINST A 45%
REDUCTION IN HEAD. Q

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 28
 Pump Division

REDUCED FLOW/HEAD DEM ANDS

LOW FLOW
IMPELLER W ITH
INSERT
FOR STEEP
RESISTANCE LINES

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 29
 Pump Division

REDUCED FLOW/HEAD DEMANDS

Volute Insert
THE FABRIC ATED
INSERT IS A FOUR
PORT VOLUTE
SHOW N IN FIGURE 5
W HICH BOLTS
AG AINST THE PUMP
COVER.

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 30
 Pump Division

EYE NARROWING RING

RINGS ARE INSTALLED TO CHANGE THE IMPELLER EYE GEOMETRY,
SHOWN IN FIGURE 10.

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 31
 Pump Division

EYE NARROWING RING

THE EXAMPLE (4) SHOWN

IN FIGURE 9 IS A SINGLE
STAGE, DOUBLE SUCTION
PROCESS PUMP MODIFIED
TO RESOLVE PROBLEMS
ASSOCIATED WITH
SUCTION RECIRCULATION.

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

October 2006 / 32
 Pump Division

Workshop PAN AMERICAN ENERGY/ Hydraulic re-rating of centrifugal pumps 4

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