Petromax Refinery Ltd.

Dept. of Maintenance and Utility

Presentation on Process
Pump (Centrifugal) &
Seal Cooling Technology
Tarek Ahmed
 WHAT IS THE PUMP?
A hydrodynamic pump is a machine that
transfers its mechanical energy into a
fluid (kinetic energy pressure energy)

A pump creates-
1. Flow from a region of lower pressure to that of higher
pressure.
2. Flow from a lower level to a higher level.

3. Flow at a faster rate.

 Classification of Pumps

PUMP
Roto-Dynamic
Positive
Displacement

Centrifugal Gear
Axial Lobe
Piston
Turbine Sliding
vane Diaphram
Mixed Flow
Screw
plunger
 Centrifugal pump ?
Is a hydraulic m/c that
convert kinetic energy to pressure
energy before fluid leaves it casing

Main component :
Prime mover (motor)
Impeller
casing
A typical centrifugal pump
 How a centrifugal pump works
The work takes place at an Impeller which
accelerate the liquid by whirling it through
the impeller thus adding centrifugal force
and hence velocity

The impeller is surrounded by a volute casing that

converts kinetic energy into pressure energy
Fluid rotates and leaves with high velocity
Outward flow reduces pressure at inlet (Eye of the
impeller), more fluids comes in
 Centrifugal pump- Important notes
1) NPSH
NPSH Available (NPSHA): The absolute pressure at the
suction port of the pump.

NPSH Required (NPSHR): The minimum pressure required

at the suction port of the pump to keep the pump from
cavitation.

For better operational condition

NPSHA >> NPSHR

NPSHA = Ha ± Hz - Hf+ Hv - Hvp

Centrifugal pump- Important notes

1) Cavitation
2) Priming
3) Shut off head
4) Pump Curves
5) Parallel and Series operations etc.
6) Pump interlock for our plants
Construction of Centrifugal Pump
 Construction of Centrifugal Pump
-Impeller

Closed impeller Semi open impeller Open impeller

Radial Flow
 Centrifugal Pump Casing
The main function of casing is to enclose the
impeller at suction and delivery ends and thereby
form a pressure vessel. The pump casing should be
designed to
• Provide easy access to all parts of pump for
inspection , maintenance and repair

Casing Type:
a. Volute casings for a higher head
b. Circular casings for low head and high
capacity.
Centrifugal Pump Coupling

A Coupling is a device is used to connect

two shafts together at their end for the
purpose of transmitting power.
Couplings do not allow disconnection of shafts
during operation. However there are torque limiting
couplings which can slip or disconnect when some
torque limit is exceeded.
Centrifugal Pump Coupling
 Function of Shaft Coupling
To transfer power from one end to another end
To provide for misalignment of the shaft or to
introduce mechanical flexibility
To reduce the transmission of shock loads from
one shaft to another
To introduce protection against overloads
To alter the vibration characteristics of rotating
units.
slips when overload occurs
P-203B Coupling Problem
Vibration Data Record of P-203B

Vibration data was found extremely abnormal

Bearing House Top -7.5 mm/sec
Bearing House Left -10.1 mm/sec
Bearing House Right -9.8 mm/sec
Bearing House Bottom -7.8 mm/sec
Most frequently encountered causes of coupling
problems (P-203B)

Misalignment

Torsional
 vibration
Improper fit or assembly

Rupture of material


Misalignment Indicators (changes in the running

noises or vibration, Premature wear of the coupling
insert or cracking of disc pack )
 Types of centrifugal pump

Based on stages Available :

a) Single Stage Pump : A single Stage has

one impeller and is best suited for low
head service.

b) Multistage Pump : A multistage pump has

three three or more impellers in series
for high head service.
Single stage centrifugal pump (P-160 A/B)
P-160 A/B Material and Part Name
Multistage Centrifugal Pump
Multistage Centrifugal Pump (P-203A/203B)
P-203 A/B Material and Part Name
 Comparison to use a pump
Rotary Pumps  Reciprocating Pumps Centrifugal Pumps Parameter
Low/Medium Capacity, Low Capacity, Medium/High Capacity, Optimum Flow and
Low/Medium Pressure High Pressure Low/Medium Pressure Pressure Applications

10,000+ GPM 10,000+ GPM 100,000+ GPM Maximum Flow Rate

Yes Yes No Low Flow Rate Capability
4,000+ PSI 100,000+ PSI 6,000+ PSI Maximum Pressure
Yes Yes No Requires Relief Valve
Smooth Pulsating Smooth Smooth or Pulsating Flow
Constant Constant Variable Variable or Constant Flow
Yes Yes No Self-priming
Requires Less Space Requires More Space Requires Less Space Space Considerations
Lower Initial Higher Initial Lower Initial Costs
Lower Maintenance Higher Maintenance Lower Maintenance
Lower Power Lower Power Higher Power

Requires clean, clear, non- Suitable for clean, clear, non-
abrasive fluid due to close abrasive fluids.  Specially-
tolerances fitted pumps suitable for
   abrasive-slurry service.
Optimum performance with Suitable for high viscosity
high viscosity fluids fluids
Higher tolerance for  
entrained gases Higher tolerance for
entrained gases
Suitable for a wide range Fluid Handling
including clean, clear, non-
abrasive fluids to fluids with
abrasive, high-solid content.
Not suitable for high viscosity
fluids
 
Lower tolerance for entrained
gases
Centrifugal pump-Sealing system

Almost everywhere where pumps

with rotating shafts are used, a
shaft seal is involved.
The shaft seal forms a barrier
between what is inside the pump
and the atmosphere.
 Centrifugal pump-Sealing system
Types of Sealing
Among numerous types of sealing system
3 types can be given good attention

Stuffing Box
Lip Seal
Mechanical Shaft Seal
Centrifugal pump-Sealing system
Stuffing Box

soft packing ring

is
axially
compressed until
it makes contact
with the shaft
 Centrifugal pump-Sealing system
Lip Seal
A universal lip seal
type is a rubber ring
sliding against the
shaft

 with a low
differential
pressure and low
operating speed
 Centrifugal pump-Sealing system

Mechanical Shaft Seal

 Centrifugal pump-Sealing system
Mechanical Seal(Contd.)
Consists of Two Parts
1. Rotating Part
2. Stationary part

The rotating part is axially

pressed against the stationary
part
Mechanical Seal(Contd.)

The rotating part

The rotating part of the seal is fixed on the pump
shaft and rotates in the liquid during pump
operation

The stationary part

The stationary part of the seal is fixed in the pump
housing. It consists of a stationary seat and a
stationary secondary rubber seal
Position Of Shaft Seal
 Circulation of Shaft Seal
 Sometimes it is necessary to cool the seal
faces of single mechanical shaft seals or
remove deposits in the seal chamber
 The cooling liquid flows from the seal
chamber back to the pumped medium.
 This ensures a good exchange of liquid in the
seal chamber
Circulation Circuit for Cooling
 What is a Pump Seal Cooler?

 Mechanical seals installed on pumps handling medium

and high temperature fluids require cooling of the seal
fluid to ensure proper seal operation. Reliable pumping
system performance, extended mechanical seal life, and
the prevention of unplanned outages depends upon
efficient, dependable mechanical seal cooler
performance.

36
 Seal Cooler Potential
Applications 
 An effective seal cooler will prolong the life of a
pump’s mechanical seals
 leading to greater system reliability
 lower maintenance costs, and less process downtime.

37
Centrifugal pump-Sealing system

Seal Cooling Was done by 3 ways in PRL process

Pump:
 By taking fluid from pump discharge line
 By using seal cooling circuit (water cooling)
 By using intermediate seal cooling agent (Barrier
fluid + Water)
Different Parts of Seal Cooler
Circuit
 DISCHARGE RECIRCULATION

 Circulation pipe from the pump discharge side to the

seal chamber can be fitted. The cooling liquid flows
from the seal chamber back to the pumped medium.
This ensures a good exchange of liquid in the seal
chamber.
 The only legitimate use of this technique is to
pressurize the stuffing box to prevent a liquid from
vaporizing
Centrifugal pump-Sealing system
Seal Cooling system

Used for P-100, P-160,P-304,P-306,P-405,P-400

 Seal Cooling System by External
Cooling Circuit

Used for P-120, P-140,P-150,P-201,P-202,P-203,P-301,P-302,P-303,P-303,P-305 42

 Barrier Fluid
 An arrangement with two shaft seals mounted in
opposite directions
 Between the two seals is a pressurized Barrier fluid
 If the operating temperature is near the vapor point of
the process medium then there is a increased risk of
evaporation in the sealing gap and as a consequence
dry running and destruction of the seal. The
application of a barrier / buffer medium can avoid this.
 Barrier Fluid Function

Cooling of the seal

Lubrication of the seal faces and therefore
prevention of dry running
Prevention of seal face destruction e.g. by solid
particles
Prevention of deposits in the area of the seal
faces
Complete separation of the process medium
from the environment.
Barrier Fluid Circuit
Barrier Fluids Example
Water and glycol solutions
Petroleum-based hydraulic and
lubricating oils
Alcohols
Synthetic hydraulic oils
Kerosene and diesel fuels
Heat transfer fluids
Seal Cooling System by External
Seal Cooling agent

Used for P-304 & P-306

48
Probable Reasons of Mechanical Seal
Failure

Allowing the pump to run dry

Vibration
Improper use or completely omitting
Mechanical Seal Flush Plan
 Selecting the wrong Materials
Thanks Everyone