SECTION 3 - Major Auxiliaries Equipment

g GE ENERGY - Oil & Gas - Nuovo Pignone PVS
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• SECTION III:
MAJOR AUXILIAR EQUIPMENT
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SECTION III: MAJOR AUXILIARIES EQUIPMENT
FOLLOWING SYSTEMS ARE OFTEN INCLUDED IN THE CENTRIFUGAL PUMP EQUIPMENT:
• LUBE OIL SYSTEM
• FLUSHING SEAL PLAN SYSTEM

• CONTROL SYSTEMS
• DRIVERS AND INVERTERS
• COUPLINGS
LUBE OIL SYSTEM
Lube oil system provides oil in pressure to bearings and eventually to the motor or other
equipment. This requires:
1)Lube oil process equipment
2)Equipment for control and safety
3)Metering and monitoring system
4)Equipment for storing and movingoil

g GE ENERGY - Oil & Gas - Nuovo Pignone PVS P&ID of a lube oil system

Lube oil process equipment
MAIN PUMP:
It is a mechanical pump, usually gear

type, which has to move the oilthrough
lube oil system piping. Driver can be
electric motor or the pump can be
mounted on NDE side of the process
pump.
This pump delivers a flow which vary
only with RPM so discharge pressure
doens’t have the flow to vary.
- Mechanical pump is really viscosity
sensible, thus really temperature
sensible
Lube oil process equipment
AUXILIARY PUMP:
It’s a mechanical pump, usually gear

type, which works when the main pump
doesn’t, when main pump fails or in
start up and shut down in case main
pump is driven by process pump.
Usually it is driven by electric motor
It’s important to know that:
-Auxiliary pump has to work in all
those situations in which main doesn’t
-Auxiliary pump will start up whenever
the oil pressure goes down certain
limits
Global Services, ASTE/SER POCE ,Bari Lube oil process equipment
DOUBLE FILTER:
It’s a filter, which usually is just before the

manifold collecting oil for the end users.
Usually is a socket type and it complies with
two same filters and it is possible to swap
from one to the other by moving a lever
which drives a 2 ways valve.
It’s important to know that:
-Fliter get clogged after a certain number
of hours of use and we can detect that by
monitoring deltap. Thus when this occurs
it’s necessary to swap to the other filter and
clean the clogged one.
-Delta p trough the filter, considering
losses through it, depends on viscosity as
well, thus on temperature. Thus it’s normal
to have pretty high delta p when oil is still
cold
HEAT EXCHANGER:
They are used to cool down the oil . In

general , they use water or air as cooling
fluid. First ones are more compact, but they
need large amount of water at low
temperature. Last ones are larger and noisy
and less efficient, but they use the air from
the atmosphere so they are used when
there is not so much water availability.
heat exchanger usually are double in order
to let the system on while working on one of
them.
There is a double valve which allows the
swap.
The heat exchanger is in between the
discharge manifold and the termostatic
valve.
TERMOSTATIC VALVE (TCV):
It’s a valve with two different working

direction working on termo-mechanical
principle: oil from the pump splits into two
different ducts; one of them flows through
the heat exchanger and the other one goes
directly at the termostatic valve. On the
other side of the valve it arrives the cold oil
coming from the heat exchanger. The
actuator is an elestic thermo-expander
which acts on the stem and it is at the same
temperature as the oil in the discharge
manifold by means of a small tubing.
Against the effect of the actuator it insist a
spring. Adjusting this spring it’s possible to
fix the working temperature for the valve,
which is the temperature at which the oil in
the discharge manifold will be.
Global Services, ASTE/SER POCE ,Bari Control and safety equipment
PRESSURE CONTROL VALVE(PCV):
It’s a by-pass valve with a controlling plug,

which controls a by pass line which
controls the flow recirculating straight to
the main tank. The actuator is diaphagm
type and is governored on opening by the
oil pressure on the final delivery manifold
and on closure by a spring. When pressure
on the final delivery manifold is higher than
set point , the PCV opens the by pass line.
This means it can let a greater flow to pass
by, then flow delivered to end users is less.
This means that pressure losses on the line
to the end users and the pressure on the
manifold will lower.
Of course it happens the opposite when
pressure on the manifold is too low.
SAFETYVALVES FOR OIL PUMPS (PSV):
They are safety valve calibrated at the

maximum operating pressure for oil pumps
( auxiliary and main ) . Their task is to grant
that if delivery line is clogged some flow
can be discharged avoiding that pressure
raises too much, damaging pumps
Oil discharged from PSV goes back to the
tank.
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Control and Services,
safety ASTE/SER POCE ,Bari
equipment
FLOW ORIFICES (FO):
Orificies are used to split properly the

flow coming from the same manifold
to the different end users.
it’s important to know that :
-orificies can control flows by means
of the deltap they generate. This
deltap is caused by the restriction in
passage aerea in order to have high
velocity ( which implies high losses )
through it.
-Mounting properly orificies and the
accuracy of the drilling deeply
influence the flow which will go
trough the orifice under a datum
deltap
SWITCHES (xSL, xSLL, xSH, xSHH):
They electrical devices controlled by the

parameter they are applied to. Thus in a
lube oil system we have termo-switch,
pressure-switch, level-switch and
sometimes flow-switches. Whenever the
parameter measured overpasses the
treshold the switch will change its status.
Thus this works as a signal to the circuit
comprising this switch and usually allarm
and/or safety devices are involved.
- A switch has always an hysteresis :
meaning that if a switch changes its status
when a certain measure overpass a certain
treshold, then when this treshold is
overpassed again in opposite direction, the
switch will change it’s status not exactly at
the same value of the treshold but sliglty
later. A switch is as good as its hysteris is
low.
Global Services, ASTE/SER POCE ,Bari Metering and monitoringequipment
PRESSURE GAUGES (PG):
Pressure gauges, as all measuring

equipment, are mounted on a control panel
of the lube oil system all together.
At least there are a pressure gauge on the
discharge manifold from oil pumps, another
on the manifold delivering oil to the end
users and a differential pressure gauges
measuring the deltap trough the filters.
The pressure gauges ( as all the pressure
measurment equipment) are mounted on
manifolds through a piping which has a
buffer manifold with two valves one for
insulating the manifold ( blue collar ) and
the other for venting it ( red collar).
Whenver there are some doubts on the
correct operation of the pressure gauges
the insulating valves have to be closed and
the vent ones opened. On correct working
the pressure gauges should go to zero.
Global Services, ASTE/SER POCE ,Bari Metering and monitoring equipment
PRESSURE TRANSMITTER (PT):

Pressure transimetrs usually are mounted
in parallel with pressure gauges. Only lube
oil system where remote monitoring is
implemented include pressure transmiters.
PT are mounted on manifolds which, as all
the devices which measure pressure, have
two valves, with a blue and red collar,
respectively for insulating and draining.
Every time there some doubts on the proper
operation on the PT insultaing valve has to
be closed and vent open. On a good
transmiter output signal should go to zero.
Global Services, ASTE/SER POCE ,Bari Metering and monitoring equipment
TEMPERATURE GAUGES (TG):
Temperature gauges are wathc-wise.

There are always a TG on the main tank
and another one on the manifold delivering
oil to end users.
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Control and Services,
safety ASTE/SER POCE ,Bari
equipment
TEMPERATURE TRANSMITER (TT)and

TEMPERATURE ELEMENTS (TE):
Temperature transmiters, where

present, are mounted in parallel with
temperature gauges. Only lube oil
system where remote monitoring is
implemented include temperature
transmiters. Temperature element
can be an RTD or a termocouple.
Termocouple produce at their
terminals a very small deltaV(mV),
which is though related to
temperature in a really accurate way.
RTDs are electric resistances which
vary significantely with temperature.
Usually RTDs are used for
temperatures up to 200 °C,
termocouples (TC) for higher
temperatures ( up to 1200 °C)
LUBE OIL SYSTEM

Oil tubing and tanks
These are all the tubings which connect all the equipment previosuly described and store
the proper amount for the correct operation of the lube oil system.
Usually there are a main tank, from where the main pump suction and a way back tank, in
which the oil arrives under gravity action and then is pumped back to the main tank by a
retyrn pump.
Sometimes a rundown tank is used which is a tank mounted just above the end users
which gives oil to them in case of emergency trip.
LUBE OIL SYSTEM

Control equipment & flow monitoring
Flow control valves:
They are valves controlled by a pressure downstream an equipment which has upstream
of it some certain and fixed pressure : thus since the deltap through them depends on the
flow, at a certain flow it is associated a certain deltap, thus these valves act as PCV and
they are controlled by the downstream pressure which has to be held constant.
SECTION III: MAJOR AUXILIARIESEQUIPMENT
LUBE OIL SYSTEM
Control equipment & flow monitoring
Flow switches:
They are switches which operation depends on flow through them

API PLAN EQUIPMENT
Most commonly used equipment in API plans are as following:
1) Water heat exchanger
2) Air heat exchanger

3)Accumulating vessels
4) Pressurized vessels
5)Cyclon separators
6) Presurization system
API PLAN EQUIPMENT
Water heat exchanger:
They are most commonly used: simple and compact, they are made up of a vessel in
which cooling water flows and a tubing is immerged, in which the barrier fluid to be
cooled flows through.
It’s important to grant not excessive fouling occurs on the internal tubing and a proper
vent on water side is done before starting up in order to prevent damages to mechanical
seals
API PLAN EQUIPMENT
Air heat exchanger:
They are used in API plans were it is necessary to cool down barrer fluid but it is not
available any water. They are usual air coolers which can be provided of fans for forced
ventilations or just fins for exchangingheat by natural convection
API PLAN EQUIPMENT
Accumulating vessels :
They are used to create a buffer for the barrier fluid supplied to no pressurized double
mechanical seals. So basically they are small tank of atmosferic pressure at slightly higher
height than mechanical seal in order to grant some head and avoid air pockets.
It’s important to know that level in the vessel has always to be kept under control, since
eventual leakages (fisiologic-normal or not ) from outboard mechanical seal can have it
lower whereas from the inboard one can have it increase.
API PLAN EQUIPMENT
Pressurized vessels:
They are used to grant a pressurized bladdder/reservoir for the liquid leaked from API
plans with barrier fluid. ( meaning double seal with pressurized intermedie room ). They are
pressurized vessel assembled at higher position than mechanical seals , in order to grant
some head to the circuit for granting no gas pockets to be in the circuits.
It’s important to know that level in the vessel should be kept under control , since eventual
leakages ,normal and not, from the seals canmake it empty.
API PLAN EQUIPMENT
Cyclon separators :
They are used for plans which include a spillage from the discharge whenever the process
fluid entraints particles.
These particles are separated from the liquid inside the cyclon, so that clean liquid comes
our from the top oand goes to the mechanical seal and the dirty one which entrains the
particles comes our from the bottom and comes back to the pump in a poit at a lower
pressure than the one where it comes from the spillage (usually directly into the suction or
into the suction of first stage) .
PLAN 31
API PLAN EQUIPMENT
Presurization:
They are used all the times is included a barrier fluid (meaning a barrier pressurized line
and relative vessel ).
They are pressurized system which have a bladder with some inert gas (nitrogen usually )
and/or barrier fluid, maintaing a constant level and pressure in the barrel.
Most common api plans according API 610

Api plans according

API610:
Seal types
Api plans according

API610:
Symbols
DRIVERS AND SPEEDCONVERTERS: DRIVERS

Most common drivers are:
1) Triphases electric motors

2)Gas turbines
3)Steam turbines
4) Internal combustion engines

3phases electric motors
Description:
They work on the principle of the rotating magnetic field. Power supply is by means of
three shielded cables, which are connected to the terminal board
Swapping two of the trhee cables can make the direction of rotation to change, so it’s
fundemanetal to check at the first start up the direction of the motor having the pump dis-
coupled.
These kind of motors undergoes to a decrease in the RPM while load increases, thus just a
55 drop in the rotating speed can mean not normal load on train.

Gas turbines
Description:
They are used on high power trains (over 1.5 - 2 MW).They are pretty copmplex and require
the presence of qualified technicians for start up. These machinery are hot and have fuel,
thus all the relative precautions shouldbe taken.
It’s important to know that despite what electric motors do, turbines increase their RPM
progressively, thus the pump can be started with discharge valve opened and then
controlling while increasing speed

Steam turbines
Description:
They are used for avarage size pumps (over 20-30 kW). Generally there are two different
types : smallest turbines are radial-axial , reaction type build up by a disc with some
cavities on the outer diameter in which steam is deviated changing its momentum and
supplying torque. Greatest turbines are multistage kinds and are even more complex. It’s
important to know, as gas turbines, those increase their RPM progressively, thus it is
possible to start the pump with discharge open valve and then control manually

Internal combustion engines
Description:
They can be mounted in trains of different power sizes. Usually they are diesel, since they
use the sources eventually available on site, where electric power is not in large amount so
it is used for auxiliaries and services.
Usually they are larger drivers than gas turbines. It’s important to consider that, as
turbines, these engines can raise in RPM progressively so it’s possible to start without
shutting off the discharge valve andto control manually
DRIVERS AND SPEEDROTATION CONVERTERS: CONVERTERS
Most common speed converters :
1) Gearboxes (overgear or reducers)
2) Hydraulic converters (only reducers)

DRIVERS AND SPEEDROTATION CONVERTERS: CONVERTERS
Gearboxes:
Advantages:
- reduced maintenance
- high efficiency (usually up 95 - 98%)
- Compact and robust
- small cost
- they canbe used even for increasing RPM
Flip back:
- Fixed RPM ratio
DRIVERS AND SPEEDROTATION VARIATORS: CONVERTERS
Hydraulic clutch:
Advantages:
- Wide rangeability of speed conversion ratio(variable)
Flip back:
- there is a decrease (at least 10%)with respect to the driver speed
- They don’t work overgear
- High costs
- Efficiency is not as hig as for gear boxes (genearally , between 70% to 85% max)
- Maintainance and exercise more complex
BACK
COUPLINGS
Most common couplings are :
1) Flexible disc couplings
2) Dog clutch
3)Overrunning clutch
COUPLINGS
Flexible disk coupling:
Advantages:
- No need of particularmaintainance
- Small wear
-Compact and robust
-Not too high cost
-High capability to abosorb mis-alignment
Flip backs:
- Limited axialcompensation
gGlobal
OIL & Gas Services, ASTE/SER
- Nuovo Pignone PVS POCE ,Bari
Global Services, ASTE/SER POCE , Bari
COUPLINGS
Assembly drawing for a flexible disk coupling


COUPLINGS
Dog clutch:
Advantages:
- High capability for axial compensation

Flip back:
- High weight
- Need for precise assembling
- Need for lubrication
- Wearable

COUPLING
Overrunning clutch :
Description:
They are machinery which can transmit the torque only when the speed of the entering
shaft is greater than the one of the exiting shaft. Torque can be transmitted only from the
shaft getting inside to the one outside and ver the opposite.
Use:
Generally , they are used to couple HPRT to pump: in this way it can be prevented they
are driven when they don’t produce anytorque.

SECTION 3 - Major Auxiliaries Equipment

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g GE ENERGY - Oil & Gas - Nuovo Pignone PVS

Global Services, ASTE/SER POCE ,Bari

SECTION III: MAJOR AUXILIARIES EQUIPMENT

FOLLOWING SYSTEMS ARE OFTEN INCLUDED IN THE CENTRIFUGAL PUMP EQUIPMENT:

• LUBE OIL SYSTEM

• FLUSHING SEAL PLAN SYSTEM

• DRIVERS AND INVERTERS

SECTION III: MAJOR AUXILIARIES EQUIPMENT

LUBE OIL SYSTEM

1)Lube oil process equipment

2)Equipment for control and safety

3)Metering and monitoring system

4)Equipment for storing and movingoil

Global Services, ASTE/SER POCE ,Bari

Global Services, ASTE/SER POCE ,Bari

Lube oil process equipment

It is a mechanical pump, usually gear

Global Services, ASTE/SER POCE ,Bari

Lube oil process equipment

It’s a mechanical pump, usually gear

Global Services, ASTE/SER POCE ,Bari Lube oil process equipment

It’s a filter, which usually is just before the

Global Services, ASTE/SER POCE ,Bari Lube oil process equipment

They are used to cool down the oil . In

Global Services, ASTE/SER POCE ,Bari Lube oil process equipment

TERMOSTATIC VALVE (TCV):

It’s a valve with two different working

Global Services, ASTE/SER POCE ,Bari Control and safety equipment

PRESSURE CONTROL VALVE(PCV):

It’s a by-pass valve with a controlling plug,

Global Services, ASTE/SER POCE ,Bari Control and safety equipment

SAFETYVALVES FOR OIL PUMPS (PSV):

They are safety valve calibrated at the

FLOW ORIFICES (FO):

Orificies are used to split properly the

Global Services, ASTE/SER POCE ,Bari Control and safety equipment

SWITCHES (xSL, xSLL, xSH, xSHH):

They electrical devices controlled by the

Global Services, ASTE/SER POCE ,Bari Metering and monitoringequipment

PRESSURE GAUGES (PG):

Pressure gauges, as all measuring

Global Services, ASTE/SER POCE ,Bari Metering and monitoring equipment

PRESSURE TRANSMITTER (PT):

Global Services, ASTE/SER POCE ,Bari Metering and monitoring equipment

TEMPERATURE GAUGES (TG):

Temperature gauges are wathc-wise.

TEMPERATURE TRANSMITER (TT)and

Temperature transmiters, where

SECTION III: MAJOR AUXILIARIES EQUIPMENT

LUBE OIL SYSTEM

SECTION III: MAJOR AUXILIARIES EQUIPMENT

LUBE OIL SYSTEM

Flow control valves:

SECTION III: MAJOR AUXILIARIESEQUIPMENT

LUBE OIL SYSTEM

Control equipment & flow monitoring

They are switches which operation depends on flow through them

SECTION III: MAJOR AUXILIARIESEQUIPMENT

API PLAN EQUIPMENT

Most commonly used equipment in API plans are as following:

1) Water heat exchanger

2) Air heat exchanger