Pump selection parameters technology Pump selection parameters

Review of design and other parameters for pump selection - Part 1

The selection of centrifugal pump unit is governed by factors like duty parameters, liquid properties, piping configuration, utilities and site conditions, safety requirements and provision of re-rating for future expansion.
he selection is relatively simple and straightforward when the pumps offered by various vendors are of the same design, type and code as mentioned in Table 1 of API 610-10th ed (The pump type and code classification referred in this article shall be as per table 1 of API 610-10th ed (1)). The selection, however, becomes tricky when different design, types and codes are available for the required parameters. The sales engineers of the pump manufacturers try to project their offered design as the most appropriate choice. Their claims and counter claims can lead to further confusion as in many process plants the plant engineers are unaware of the basic design factors that should govern pump selection. Under such circumstances the engineer responsible for technical recommendation/selection requires an understanding of the intricacies related to pump mechanical and hydraulic design and the implication of various factors to make an informed decision. The real life case studies explaining salient features of designs which may facilitate such selections are given below:

1) Bearing loads: The hydraulic thrust (axial and radial) acting on the bearings is higher for OH1 and OH2 types as explained below: The axial hydraulic thrust acting on bearing is due to the following factors: a) differential head generated across the pump. b) change in flow direction in impeller. c) suction pressure. d) high pressure in mechanical seal cavity (ref para 2.2.3 (2)). All these components get balanced in single stage double suction impeller type (BB1 and BB2) for complete range of suction pressures and resultant thrust is very low. For single suction impeller (OH1 and OH2) the resultant of these components can be moderate but with higher suction pressure (above 8 bar (g)) the thrust values due to(c) and (d) can be very high leading to higher resultant thrust on bearings. It is therefore necessary to review bearing designs for types OH1 and OH2. 2) Shaft deflection at mechanical seal and wear rings: A single stage double suction impeller pump of BB1 and BB2 type is designed with a shaft supported at both ends. This arrangement results in reduced shaft deflection at mechanical seal faces and wear rings when compared with cantilever type arrangement in types OH1 and OH2. Lower shaft deflection also ensures higher value of first critical speed and more stable rotor design. Lower shaft deflection is achieved in types OH1 and OH2 by increasing the shaft diameter which leads to higher bearings and mechanical seal sizes. A review of shaft deflec-

Case I: Overhung end suction impeller pump (OH1 and OH2) or between bearing single stage double suction impeller pump ( BB1 and BB2).
Both the types mentioned above can be quoted for a wide range of flow - head domain. For example a duty parameter with flow = 1000 m3/h at head = 132 m can be achieved either with horizontal single stage overhung end suction impeller pump (OH1 and OH2) or between bearing single stage double suction impeller pump (BB1 and BB2). The following factors can be useful while selecting the option:

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tion calculations is therefore necessary for OH1 and OH2 types. 3) Nozzle orientation: OH1 and OH2 types usually offer end/top (end suction and a top discharge) and as a special case top/top orientations. The BB2 types can offer side/side, top/side, side/top and top/top nozzle orientations. The BB1, however, is restricted to side/ side orientation. This means BB2 type can offer more options from piping point of view. 4) Impeller design: For same flow, the double suction impeller has lower inlet tip speed leading to less erosion due to abrasion. 5) Lower suction pressure: The double suction design requires less Net Positive Suction Head (NPSH) at the same speed and flow. This also means a smaller pump at higher speed can be selected which may cost less and may prove more efficient than OH1 and OH2. The pumps for atmospheric and vacuum and fines rich application in crude distillation are required to handle fluid rich in fine coke particles at lower suction pressure and high temperature (350 deg C). For such difficult services double suction impeller can be preferred. 6) Shaft seals: BB1 and BB2 types require two mechanical seal systems thereby increasing the initial equipment cost and possibly the maintenance cost. 7) Low mechanical seal cavity pressure: In case of BB1 and BB2 types the seal cavity is always subjected to suction pressure while in case of OH1 and OH2 type the seal cavity is subjected to suction pressure plus minimum 5 to 15% of pressure developed across the pump, depending on impeller design with or without balance holes and back wear rings. The lower seal cavity pressure and lower shaft deflection at seal may enhance seal reliability. 8) Casing gasket reliability: Casing gasket is always designed for maximum allowable working pressure (MAWP). In case of BB2 types the casing gasket is subjected to only suction pressure while in case of OH1 and OH2 types the casing gasket is subjected to discharge pressure which is higher. This can reduce the chances of probable hazard due to leakage from gasket in BB2 type. 9) Misalignment due to moments and forces on pump flanges. Distance between coupling shaft end and suction / discharge nozzle is relatively less in case of

BB1 / BB2 type and hence effect of misalignment due to moments and forces is less in case of BB1 / BB2 type when compared with OH1 / OH2 type. 10) Suction piping: BB1 and BB2 types are very sensitive to suction piping. Incorrect orientation and location of bends, and insufficient straight lengths can lead to uneven flows into impeller eye leading to cavitations, vibration and uneven hydraulic forces leading to bearing and seal failures. The suitability of available piping is to be checked with pump vendor. 11) In addition to above guidelines the following guide lines may also be used: a) The maximum impeller diameter for a single stage overhang pump design, operating at 2950 rev/min and higher shall be 15 inches (380 mm) (3,4). The permissible peripheral speed for a given material of construction is also to be checked.

b) Consider between bearing pumps whenever the product of power input and rotational speed (kW times rpm) exceeds 675000 (4). For duty parameter close to with flow = 1000 m3/h at head = 132 m as mentioned in the beginning of this case study we opted for between bearing single stage double suction impeller pump of BB2 type after reviewing the design based on above factors and also the guidelines given in (5) and (6).

Case II: Wet pit diffuser (VS1) or vertical sump line shaft (VS4) and vertical sump cantilever (VS5).
The following considerations can be useful while selecting the option: 1) Space: The VS1 pump design is compact requiring less mounting space. This also mean that for the available opening size on a tank or a pit the probability of mounting the VS1 type without requiring any modification is high. 2) Pump mounting, dismounting, assembly and disassembly of VS1 type is relatively simple and require relatively lesser head-room and assembly space. 3) Bearing load/life: The pump and line shaft bearing life can be higher for VS1 type as hydraulic radial thrust for diffuser type casing is low. The hydraulic radial thrust in case of VS4 and VS5 types is higher

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Pump selection parameters

as casing is volute type and hence bearing life can be relatively lower. 4) Higher efficiency: Specific speed of VS1 type can be higher as required head is achieved through multistaging while specific speed of VS4 and VS5 type is lower as head is achieved in a single stage. Higher specific speed leads to higher efficiency. 5) Setting height change: For the available VS1 type the setting height can be changed easily by simply changing the number of column pipes with the line shafts while for VS4 type number of column pipes with line shafts and also the discharge pipes are to be changed which is cumbersome. The setting height for VS5 which is of cantilever type is restricted by maximum possible single shaft length and is usually eight meters or less. As such setting height for VS4 and VS5 types is rarely above ten metres. The setting height above ten metres is possible in VS1 type. The VS4 and VS5 type can be offered with stand pipe arrangement to cater to change in setting height with limitations in operation. The pump can be switched on only when liquid level in the tank is above pump, which means switching on with higher submergence which also means blockage of more inventory. The ease of setting height change of existing VS1 type help during expansion projects. 6) Re-rating: The VS1 type can offer a very wide range of head and flow domain. This is due to the provision of stage addition to increase the head and possibility of modular design concept used during development of the pump series. The change in bowl assembly without changing the column pipe assembly is relatively easy for VS1 type pump. This means rearing of existing VS1 type pump assembly to cater to revised head and flow is easy. 7) Special applications: The VS4 and VS5 types are preferred for special applications like handling molten sulphur, concentrated acids, liquids containing sludge and fibrous materials, and slurries. For such applications single stage pumps, in general are suitable as head encountered in refineries can be handled by single stage pumps operated at 1450 to 2950 rev/min. The VS1 type multistage or under circumstances single stage are not preferred due to their lower clearances, non availability of suitable designs to handle sludge and other difficult liquids like molten sulphur which requires steam heating and an arrangement for drainage of molten sulphur on shut down (7). The VS4 and

VS5 in addition to advantages like simple design offer advantages of availability of different materials including plastic. Also the pumped liquid does not contact or pressurize the mechanical seal. The later is important as the mechanical seal is exposed to vapours in the tank which are usually at lower pressure. This low pressure operation simplifies mechanical seal selection and enhances the seal life. On other hand for VS1 type the mechanical seal is required to seal higher pressure pumped liquid which calls for more attention during selection. In Jamnagar Refinery we opted for VS1 type pumps as against VS4 or VS5 for many applications involving clean liquids and hydrocarbons requiring fulfilment of API 610-8th ed (13) after conducting design audit based on reference (8). For application like molten sulphur, and liquid containing solids and sludge VS4 and VS5 were selected.

Case III: Submersible vs conventional pumpsets.

The close coupled (impeller mounted on motor shaft) submersible pumps are now available with special design features and material of construction (9) to suit liquid properties and plant requirements. The design features include compact and simple design aimed at ease of installation, modular construction leading to low cost and high interchangeability of parts, and incorporation of temperature, vibration and moisture sensors to enhance reliability. Due to these features they invariably offer an edge over conventional close coupled pumps or pumps with flexible or rigid coupling for many applications. The advantages are elaborated below: 1) Ease of installation: No need of pump house for the pump motor unit as it is submerged in the liquid to be pumped. The pump can easily be placed in tanks and containers or in a sump of simple construction requiring prefabricated concrete and steel structure which means much shorter construction times. The pump requires less head-room for raising it from the sump. All these features are available for less floor space and less civil cost. These features make it possible to install the pump closer to the point of need, thereby simplifying the piping. Floor space can be kept clean which means better working conditions. Submerged installation also means that they are safe against flooding. 2) Alignment: The close coupled pump and motor are mounted on single short shaft which eliminates costs like alignment equipment, skilled manpower

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Pump selection parameters

trained for alignment and downtime required to carry out the alignment. 3) Noise pollution: The noise level of these pumps is very low and hence offers environmentally better working condition, eliminates the need of acoustic hood and permits the installation near residential buildings. 4) Simple piping: As the unit is submerged in liquid no special suction piping is required. This means suction pipes, bends, valves, strainers and support structures are eliminated. This simplifies system calculations and also sump design. The discharge piping can be provided with automatic bolt free connection which is operator friendly and allows easy installation and fast removal of pumpset for replacement or maintenance. The other advantages include lower capital investment cost, lower construction cost and fewer components to service. 5) Reliability: The submerged operation and absence of suction piping offers more NPSHA thereby reducing chances of cavitation damage leading to higher impeller life. A smaller pump can be selected due to higher NPSHA. The excessive motor heat is transferred to the surrounding liquid thereby enhancing the motor life. The need of cooling system is eliminated. The shorter shaft length minimizes strain on bearings and shaft sealing. Due to absence of suction piping the problems related to clogging of suction strainer and valves are avoided. Submerged operation avoids the problem of corrosion and/or freezing of water lines. The submersible units can be provided with special protection devices like moisture, temperature and vibration sensors which can enhance the overall life and meantime between failures. 6) Wide range of application: These units are usually available in modular design which means the performance of the pump can be easily modified to suit changing needs. In other words re-rating of the existing unit can be simple. The pumps can be used for cryogenic applications involving handling of liquid like LNG, LPG, and liquid ammonia where very low NPSH is available. They are also available for handling hydrocarbons like Oil, Gasoline, Butane. They are suitable for all kind of effluents, sewage and dirty water applications. They can find application in iron and steel, food processing, sea water, industrial water and sugar industries.

For such applications in case of pump breakdown the submersible pumps prove safer as leakage to environment does not occur. 7) Energy consumption: The submersible motor efficiency is relatively lower than conventional dry motor but overall economics based on above factor is in favour of submersible pump sets (9, 10). The submersible units, however, can have following disadvantages: 1) They cover relatively limited Q-H domain when compared with conventional dry motor driven pumps. 2) The repair of submersible motor requires additional facilities and skills.

Case IV: Suction specific speed

Suction specific speed (nqs) of a centrifugal pump is an index relating flow (Q per impeller eye in m3/s), net positive suction head required (NPSHR in m) and rotative speed (N in revolution/minute). It is expressed mathematically by the following equation: nqs = N (Q)0.5 / (NPSHR)0.75 Suction specific speed is calculated for the pumps performance at best efficiency point with the maximum diameter impeller and provides an assessment of a pumps susceptibility to internal recirculation (1). The need for reliable and trouble free operation makes the pump users/ consultants impose various evaluation criteria for pump selection and limiting the acceptable nqs to 213 (11000 US Units, i.e. speed in rev/min, flow in US gpm and NPSHR in ft) is one of them. The basis for this limitation on acceptable nqs could be traced to the pump failure analysis carried out in the U.S.A in the sixties and seventies for which the collected data pertained to the then available pump designs in the U.S.A. The statistical analysis of the pump failures seemed to indicate that pumps with nqs 213 (11000 US Units) have higher probability of failure (11). On the other hand the German and European pump manufacturers experience, though not substantiated with statistical study, suggested that there was a large population of pumps with nqs 213 (11000 US Units) operating without any problem. The German pump industry had conducted systematic scientific research on pumps with nqs 213 (11000 US Units) at a German University in which extensive performance tests involving measurement of factors like vibration, shaft deflection and pressure pulsation were carried out (12). The tests proved that high nqs

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does not have direct correlation with the above factors that contribute to pump failure. This clearly indicates that with improved hydraulic design it is possible to have higher reliability of pump performance of pumps having nqs 213 (11000 in US units). It is interesting to note that the standard API 610, 8th edition (13) very clearly mentions that apart from other factors the vendor experience on pump design should be taken into account before selecting the acceptable nqs while API 610-10th edition (1) leaves it totally to the purchaser to decide. Based on the above it can be concluded that good pump designs with higher nqs can have reliable and trouble free performance and there is no solid basis for imposing the limitation of 213 (11000 US Units) on the acceptable nqs (14). It would be better to check with other end users performance of identical pumps for similar duty parameters to decide the selection. Our plant experience had proved that pumps with nqs 213 (11000 US Units) are working without any problem. The second and concluding part will discuss cooling water pump selection and will appear in next issue of this publication.

respect to the relevance of suction specific speed for the performance and reliability of centrifugal pumps. Proceedings of the thirteenth international pump users symposium. (13) API Standard 610, 8th ed: Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and Gas Industry Services. (14) J. F. Glich: Selection criteria for suction impellers of centrifugal pumps, Part 1. World Pumps, January 2001.

Acknowledgement
The authors would like to thank the management of Reliance Engineering Associates Limited for granting permission for publication.

PetroMin thanks D. K. Shukla, D. K. Chaware and R. B. PET Swamy for contributing this paper.
D. K. Shukla is Process Engineering Manager with Reliance Engineering Associates Limited at Refinery Complex, Jamnagar - India. He has more than 25 years of experience process and systems engineering in hydrocarbon processing industries including oil/gas production facilities, refining and petrochemical processes. His previous experience include working with Engineers India Ltd., New Delhi; MW Kellogg, Houston; and BOC Gases in Murray Hill (NJ)/Guildford (UK). Deepak K Chaware is Rotating Equipment Engineer with Reliance Engineering Associates Limited at Refinery Complex, Jamnagar - India. He received an M.Tech degree in Mechanical Engineering from Indian Institute of Technology, Chennai - India. He has more than 20 years of experience in the field of centrifugal pump design, testing and selection. He has worked with leading pump manufacturers such as Beacon Weir Ltd, Sulzer Pumps India Ltd and KSB Pumps India Ltd. Rajkumar B Swamy is a Process Engineer working with Reliance Engineering Associates Limited at the Jamnagar Refinery Complex - India. He has six years of experience in the field of process design, plant design, detailed engineering in the petroleum refineries. He is a chemical engineering graduate from Gulbarga University, Karnataka India and his previous experience include working with Hindustan Petroleum Corporation Limited, Mumbai Refinery.
ENQUIRY NUMBER:
07-06

Reference:
(1) ANSI/API Standard 610, 10th ed. October 2004: Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries. (2) API Standard 682, 2nd ed: Shaft Sealing Systems for Centrifugal and Rotary Pumps. (3) UOP Standard Specification No. 5-11-4 for Centrifugal Pumps. (4) Heinz P. Bloch: A hundred-plus points to improve pump reliability, Part 3 Hydrocarbon Processing, May 2004. (5) Charles C Heald, DG. Perry: Design and operation of pumps or hot standby service. Proceedings of Fifth International Pump Users Symposium. Texas A & M University, Houston May 1998. (6) William E. Nelson, John W. Dufour: Problem-free pumping system A guide to holistic design. Chemical Engineering, January 1995. (7) Correspondence with Mr. J. Fatzinger of Lewis Pumps USA. (8) Heinz P Bloch: Auditing vertical pump mechanical reliability. Hydrocarbon Processing August 2003. (9) Dipl.-Ing. A. Kratzer et al: Tauchmotorpumpen aus Korrosions und verschlei_bestndigen Werkstoffen; wirtschaftliche Alternative zu Wellentauchpumpen fur die chemische und verfahrenstechnische Industrie. Pumpentagung Karlsruhe84, 02, bis 04, Oktober 1984. (10) Dr. Ing. Heinz Dieter Hellmann et al: Unterwassermotorpumpe; Konzept mit vielen Anwendungs-mglichkeiten. Pumpentagung Karlsruhe84, 02, bis 04, Oktober 1984. (11) J. L. Hallam: Centrifugal pumps: which suction specific speeds are acceptable? Hydrocarbon Processing, April 1982. (12) Bernd Stoffel and Ralf Jaeger: Experimental investigations in

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