Oil & Gas Processing Plants

Design and Operation

Training Course

DGEP/SCR/ED/ECP - 24
th
March-4
th
April 2003
ROTATING EQUIPMENT


DGEP/SCR/ED/ECP - 24
th
March-4
th
April 2003
DGEP/SCR/ED/ECP 3
CONTENT


Pumps

DGEP/SCR/ED/ECP 4
PUMPS
Pumps classification

Centrifugal pumps performance

Centrifugal pumps in operation

DGEP/SCR/ED/ECP 5
PUMPS CLASSIFICATION
Volumetric (Positive Displacement)
- Reciprocating (Chemical lnj : TEG Circulation, ...)
- Rotating (Lube oil, Viscous fluids, ...)

Dynamic (Variable Head)
- Centrifugal (General Process, Liquid Exports, ...)
- Axial (Very high flowrate : Cooling water, ...)
DGEP/SCR/ED/ECP 6
PUMPS
DGEP/SCR/ED/ECP 7
GEAR PUMPS
DGEP/SCR/ED/ECP 8
SCREW PUMPS
DGEP/SCR/ED/ECP 9
PUMPS
DGEP/SCR/ED/ECP 10
HORIZONTAL IN-LINE PUMPS
DGEP/SCR/ED/ECP 11
MULTISTAGE - AXIALLY SPLIT ALONG THE HORIZONTAL CENTER LINE
(HORIZONTAL JOINT SURFACE)

DGEP/SCR/ED/ECP 12
LIGHT PROCESS - PUMP - API
DGEP/SCR/ED/ECP 13
MULTISTAGE - AXIALLY SPLIT ALONG THE VERTICAL CENTER LINE
(VERTICAL JOINT SURFACE)

DGEP/SCR/ED/ECP 14
VERTICAL IN - LINE PUMP
DGEP/SCR/ED/ECP 15
LIGHT PROCESS - PUMP - EUROPEAN
DGEP/SCR/ED/ECP 16
HEAVY PROCESS - PUMP -
DGEP/SCR/ED/ECP 17
VERTICAL SUMP PUMP
DGEP/SCR/ED/ECP 18
VERTICAL BARREL OR CANNED PUMP
DGEP/SCR/ED/ECP 19
LIQUID HYDRAULIC PATH IN A CENTRIFUGAL PUMP
DGEP/SCR/ED/ECP 20
PRESSURE VELOCITY EVOLUTION IN A CENTRIFUGAL PUMP
DGEP/SCR/ED/ECP 21

The logical steps in the initial selection of a pump are as follows :
Determine the flowrate
Design the piping system
Determine the differential head = static + dynamic
Flow & head = the pump duty point
Net positive suction head available
Select a pump
Flowrate
Determined by No of pumps operated simultaneously.
No of pumps : Plants reliability and the criticality of the service.
In critical service :
2 x 100% or 3 x 50%
PUMPS
DGEP/SCR/ED/ECP 22

Static Head difference : the difference in levels
between the starting point of the system.

Pressure Head difference : the difference in static
pressure between the starting point and the finishing
point of the system.

Frictional Resistance : the head due to the resistance
to flow as the liquid moves through the system.
DIFFERENTIAL HEAD
DGEP/SCR/ED/ECP 23

Calculate system resistance (Conservatism : high static level and
pressure differential, and the highest expected pipe friction).

Calculate system resistance (best case : low of static level and
pressure differential and the lowest pipe).

Plot these curves as the extremes expected from the behaviour
of the system.

Select pumping equipment that successfully meets all
reasonably expected operating conditions.
STEPS FOR ESTIMATING PRESSURE DIFFERENTIAL
DGEP/SCR/ED/ECP 24



DIFFERENTIAL HEAD

Hmt = ---------------------- + (Zr - Za) + Hfa + Hfr
(Pr - Pa)
g
@ P,T
SYSTEM RESISTANCE CURVE
DGEP/SCR/ED/ECP 25

Qv = d UR

Qv = ---------------

W = m U

W = -------- = -----------
where :
d : flow coefficient
m : manometric coefficient
Qv : volumetric flowrate (m3/s)
U : peripheral speed (m/s)
R : impeller external radius (m)
N : rotational speed (RPM)
W : massic energy to fluid (J/kg)

2
d p NR
3
30
2
DP

m (pNR)
2
(30)
2
CENTRIFUGAL PUMP - SINGLE STAGE PERFORMANCE
DGEP/SCR/ED/ECP 26


DIFFERENTIAL HEAD
DGEP/SCR/ED/ECP 27
RELATIONSHIP HEAD - FLOW
DGEP/SCR/ED/ECP 28
PUMP AND SYSTEM CURVE
DGEP/SCR/ED/ECP 29



HEAD-CAPACITY AND PIPING SYSTEM RESISTANCE CURVE
DGEP/SCR/ED/ECP 30
RELATIONSHIP POWER - FLOW
DGEP/SCR/ED/ECP 31
WHEN HALF CAPACITY PUMPS ARE
IN PARALLEL SERVICE
QR1 = Rated capacity of each half capcity s pump
Qmax1 = Maximum capicity of single pump
Qmax2 = Maximum operating flow obtained by two half capcitys pumps in service
ANALYSIS OF MAXIMUM FLOW
DGEP/SCR/ED/ECP 32
FLOW OR TWO IDENTICAL PUMPS IN SERIES OPERATION

DGEP/SCR/ED/ECP 33
FLOW CONTROL BY VARYING PUMP SPEED
DGEP/SCR/ED/ECP 34
ESTIMATION OF CENTRIFUGAL PUMPS EFFICIENCY
DGEP/SCR/ED/ECP 35
PROCESS DATA SHEET PUMP
DGEP/SCR/ED/ECP 36
PUMP CALCULATION DATA SHEET
DGEP/SCR/ED/ECP 37
THE EFFECT OF VAPORIZATION ON THE HEAD-FLOW CURVE
DGEP/SCR/ED/ECP 38
THE DIFFERENCE BETWEEN REAL AND APPARENT CAVITATION
DGEP/SCR/ED/ECP 39
THE DIFFERENCE BETWEEN NPSH absolute AND NPSHR
MEASURED USING AERATED WATER

DGEP/SCR/ED/ECP 40








NPRHA = ------ + -------- - --------
Po

Co
2
2g
PVt

NPRHA = ----------------------------- + Za - Hfa
(Pa - PVt)
g
@ P,T
NPSH available
DGEP/SCR/ED/ECP 41

NPSH Required

NPRHR = From Pump vendor

NPSH Available
NPRHA = --------- + -------- - ---------
NPRHA = ---------------------- + Za Hfa
NPRHA = NPRHR + 1 m

P0

C0
2
2g
PVt

(Pa - PVt)
g
@ P,T
CENTRIFUGAL PUMP - SUCTION CAPACITY
DGEP/SCR/ED/ECP 42

Where:

Po = Dynamic press. at pump inlet
Co = Fluid velocity at pump inlet
P1 = Minimum pressure in pump
Pa = Pressure in upstream vessel (bar)
PVt = Vapor pressure of fluid @ T (bar)
= density
G = gravity constant
Za = Liquid level elevation in upstream vessel (m)
Hfa = Suction pressure losses (m)
P, T = Pumping conditions
CENTRIFUGAL PUMP - SUCTION CAPACITY
DGEP/SCR/ED/ECP 43
TYPICAL CENTRIFUGAL PUMP PERFORMANCE CURVES
DGEP/SCR/ED/ECP 44


TOTAL MANOMETRIC HEAD


Hmt = ------------------

SHAFT POWER

Ps = -----------


Ps = ----------------------------



SpGr@P,T
DP.10.2
36 h
DPQv
g
Hmt Qv SpGr@P,T
367 h
g
CENTRIFUGAL PUMP - CHARACTERISTICS
DGEP/SCR/ED/ECP 45

where :

Hmt : manometric head (m)
DP : pressure increase (bar)
SpGr : specific gravity (no unit)
Ps : shaft power (kW)
Qv : actual volumetric flowrate (m3/h)
h : overall efficiency
P,T : pumping conditions



g
CENTRIFUGAL PUMP - CHARACTERISTICS
DGEP/SCR/ED/ECP 46

Will cavitation occur at pump suction ?

The NPSH (available) :

NPSH(a) = Hs + hs - DPs - Pv

Hs = absolute pressure head (in suction vessel)
hs = minimum liquid level above pump suction centreline
DPs = friction losses in suction piping
Pv = vapour head

NPSHA > NPSHR
(NPSHR obtained from the pump manufacturer)
NPSH
DGEP/SCR/ED/ECP 47
The pump should be installed as close as practical to the liquid
source.

Inlet piping should be as short and as simple as possible.

Minimise friction losses and maintain Net Positive Suction Head
at adequate levels at all intended flow rates.

Avoid potential air or vapors traps ; eg : use flat-top reduces,
avoid inverted loops, etc

Avoid swirl or uneven flow-avoid elbows, bends and other
devices that change flow directions close to the pump. If
unavoidable, it may be necessary to install flow straighteners.
SUCTION PIPING
DGEP/SCR/ED/ECP 48



AFFINITY LAWS
DGEP/SCR/ED/ECP 49
LOW FLOW RECIRCULATION BY FIC
DGEP/SCR/ED/ECP 50
LOW FLOW RECIRCULATION BY OUTLET CHECK VALVE
DGEP/SCR/ED/ECP 51
DGEP/SCR/ED/ECP 52
DGEP/SCR/ED/ECP 53


Nautilus is a subsea 1.3 MW electrically driven
multiphase booster station.

The development of this project is being led by
TOTAL with Sulzer having overall responsibility for
thepump/motor unit.

Nautilus has been designed for installation up to
about 60 km (37 miles) from the receiving platform
which is therefore expected to improve significantly
the economic viability of subsea satellite or remote
fields.
NAUTILUS PROJECT
DGEP/SCR/ED/ECP 54
PUMP PACKAGE FEATURES AND BENEFITS
DGEP/SCR/ED/ECP 55
DGEP/SCR/ED/ECP 56








Centrifugal pump with inducer
DGEP/SCR/ED/ECP 57








Performance correction chart for viscous flow
DGEP/SCR/ED/ECP 58