Double seals can be used in an opposed arrangement.

Two seals are mounted face to

face, with the primary sealing rings rotating on a common mating ring (see Figure 15). In
this case, the neutral liquid is circulated between the seals at a pressure lower than that
of the process fluid. This pressure is limited since the outboard seal faces are in tension.
The inboard seal is similar to a single inside-mounted seal and carries the full differential
pressure of the seal chamber to the neutral liquid. The outboard seal carries only the
pressure of the neutral liquid to the atmosphere. The purpose of this arrangement is to fit a
seal installation having a shorter axial length than is possible with back-to-back double
seals and still form a buffered area for plant safety.
Tandem seals are arranged with two single seals mounted in the same direction (see
Figure 16). The outboard seal and neutral liquid create a buffer zone between the liquid
being pumped and the atmosphere. Normally, the pressure differential from the liquidbeing
sealed and atmosphere is taken across the inboard seal, while the neutral lubricating
liquid is at atmosphere pressure. This arrangement can also be used as a method to
break down the pressure on high-pressure applications. For example, the pressure
difference across each seal can be half the fluid pressure being sealed. The liquid in the
outboard seal chamber may be circulated to remove seal heat. Tandem seals are used on
toxic or flammable liquids, which require a buffered or safety zone.
PLAN 01 Internal flush
Integral (internal) recirculation is from pump discharge to seal.

PLAN 02 No flush, large open bore

Dead-ended seal chamber with no recirculation of flushed fluid.

PLAN 11
Recirculation from pump discharge through a flow control orifice to the seal. The flow enters the
seal chamber adjacent to the mechanical seal faces, flushes the faces, and flows across the seal
back into the pump.

PLAN 12
Recirculation from pump discharge through a strainer and flow control orifice to the seal.

PLAN 13
Recirculation from pump seal chamber through a flow control orifice and back to the pump suction.

PLAN 14
Recirculation from pump discharge through a flow control orifice to the seal and simultaneously from the seal chamber
through a control orifice (if required) to pump suction.

Plan 21
Recirculation from pump discharge through a flow control orifice and cooler, then into the seal chamber.

Plan 22
Recirculation from the pump discharge through a strainer, a flow control orifice, and a cooler and into the seal chamber.

Plan 23
Recirculation from a pumping ring in the seal chamber through a cooler and back into the seal chamber.

Plan 31
Recirculation from pump discharge through a cyclone separator delivering the clean fluid to the
seal chamber. The solids are delivered to the pump suction line.

Plan 32
Flush is injected into the seal chamber from an external source.
Plan 41
Recirculation from pump discharge through a cyclone separator delivering the clean fluid to a seal
cooler and then to the seal chamber. The solids are delivered to the pump suction line.
PLAN 51
External reservoir providing a dead-ended blanket for fluid to the quench connection of the gland.

PLAN 52
External reservoir providing buffer liquid for the outer seal of an Arrangement 2 seal. by an internal
pumping ring. The reservoir is usually continuously vented to a vapour recovery system and is at a
pressure less than the pressure in the seal chamber.

PLAN 53A
Pressurized external barrier fluid reservoir supplying clean fluid to the seal chamber. Circulation is
by an internal pumping ring. Reservoir pressure is greater than the process pressure being
sealed. This plan is used with an Arrangement 3 seal.

PLAN 53B
External piping provides fluid for the outer seal of a pressurized dual seal arrangement. Pre-
pressurized bladder accumulator provides pressure to the circulation system. Flow is maintained
by an internal pumping ring. Heat is removed from the circulation system by an air-cooled or
water-cooled heat exchanger. This plan is used with an Arrangement 3 seal.
PLAN 53C
External piping provides fluid for the outer seal of a pressurized dual seal arrangement. Reference
line from the seal chamber to a piston accumulator provides pressure to the circulation system.
Flow is maintained by an internal pumping ring. Heat is removed from the circulation system by an
air-cooled or water-cooled heat exchanger.

PLAN 54
Pressurized external barrier fluid reservoir or system supplying clean fluid to the seal chamber.
Circulation isby an external pump or pressure system. Reservoir pressure is greater than the
process pressure being sealed. This plan is used with an Arrangement 3 seal.
PLAN 61
Tapped and plugged connections for the purchasers use. Typically this plan is used when the
purchaser is to provide fluid (such as steam, gas, or water) to an external sealing device.

PLAN 62
Exterior source providing a quench. The quench may be required to prevent solids from
accumulating on the atmospheric side of the seal. Typically used with a close-clearance throttle
bushing.

PLAN 65
External drain piping is arranged to alarm on high seal leakage, measured by a float type level
switch. The orifice downstream of the level switch is typically 5 mm (0,25 in) and is located in a
vertical piping leg.

PLAN 71
Tapped connections for purchasers future use.
PLAN 72
Externally supplied gas buffer for Arrangement 2 seals, to dilute seal leakage or in conjunction
with Plan 75 or 76 to help sweep leakage into a closed collection system. Pressure of buffer gas is
lower than the process-side pressure of inner seal.

PLAN 74
Externally supplied barrier gas used to positively prevent process fluid from leaking to
atmosphere. Pressure of barrier gas is higher than process side of inner seal.

PLAN 75
Containment seal chamber drain for condensing leakage on Arrangement 2 seals. This plan is
used when pumped fluid condenses at ambient temperatures.

PLAN 76
Containment seal chamber drain for non-condensing leakage on Arrangement 2 seals. This plan
is used when pumped fluid does not condense at ambient temperatures.
API 682
Arrangement 1 seal
seal configuration having one seal per cartridge assembly

Arrangement 2 seal
seal configuration having two seals per cartridge assembly with a containment seal chamber which is
at a pressure lower than the seal chamber pressure

Arrangement 3 seal
seal configuration having two seals per cartridge assembly that utilize an externally supplied barrier
fluid

back-to-back configuration
dual seal in which both of the flexible elements are mounted between the mating rings

balanced seal
mechanical seal in which the seal balance ratio is less than 1

barrier fluid
externally supplied fluid at a pressure above the pump seal chamber pressure, introduced into an
Arrangement 3 seal to completely isolate the process liquid from the environment

bellows seal
type of mechanical seal which uses a flexible metal bellows to provide secondary sealing and spring-
type loading

buffer fluid
externally supplied fluid, at a pressure lower than the pump seal chamber pressure, used as a
lubricant and/or to provide a diluent in an Arrangement 2 seal

contacting seal
seal design in which the mating faces are not designed to intentionally create aerodynamic or
hydrodynamic forces to sustain a specific separation gap

containment seal
seal design with one flexible element, seal ring and mating ring mounted in the containment seal
chamber

face-to-back configuration
dual seal in which one mating face is mounted between the two flexible elements and one flexible
element is mounted between the two mating seal rings

face-to-face configuration
dual seal in which both of the mating seal rings are mounted between the flexible elements

flexible element
combination of components which move axially relative to the shaft/sleeve or seal chamber

mating ring
disk- or ring-shaped member, mounted either on a sleeve or in a housing such that it does not move
axially relative to the sleeve or the housing, which provides the mating seal face for the seal ring

non-contacting seal
seal design in which the mating faces are designed to intentionally create aerodynamic or
hydrodynamic separating forces to sustain a specific separation gap between the seal ring and the
mating ring

non-pusher seal
seal in which the secondary seal is not required to slide axially to compensate for wear and
misalignment

pusher seal
seal in which the secondary seal is mounted between the seal ring on the flexible element and the
sleeve or seal gland plate in which this secondary seal slides axially to compensate for wear and
misalignment

seal balance ratio

ratio of seal face area exposed to closing force by hydraulic pressure in the seal chamber, to the total
seal face area

seal ring
seal face that contacts the mating ring; it is flexibly mounted using springs or bellows

secondary seal
device, such as an O-ring or flexible graphite gasket, or bellows, that prevents leakage around other
seal components

throat bushing
device that forms a restrictively close clearance around the sleeve (or shaft) between the inner seal
and the impeller

throttle bushing
device that forms a restrictively close clearance around the sleeve (or shaft) at the outboard end of a
mechanical seal gland plate

Type A seal
balanced, inside-mounted, cartridge-design pusher seal with multiple springs and in which the flexible
element normally rotates

Type B seal
balanced, inside-mounted, cartridge-design non-pusher (metal bellows) seal in which the flexible
element normally rotates, and in which the secondary sealing elements are elastomeric O-rings

Type C seal
balanced, inside-mounted, cartridge-design non-pusher (metal bellows) seal in which the flexible
element is normally stationary, and in which the secondary sealing elements are flexible graphite

Type A Type B Type C

-40 C to 176 C -40 C to 176 C -40 C to 400 C

Balanced, cartridge, inside seal chamber

Pusher Non pusher Non pusher

Rotating flexible Rotating flexible Stationary flexible

element element element

Multiple coil springs Bellows Bellows

Elastomer Elastomer Flexible graphite

 Clean Clean Clean water Sour water Caustic/ Acids Non flashing hydrocarbons Flashing hydrocarbons
water water crystallizing Abs vapour Abs vapour
pr < 1 bar pr >1 bar

Pumping <80C <80C >80C >80C >80C <80C -40C to -50C to 176C 176C to 260C 260C to -40C to -5C to 176C >176C
temp. -5C 176C to 260C to 400C -5C 176C to
260C 400C 400C
Seal <21 bar 21 to 41 < 41 bar < 41 bar < 41 bar < 21 <41 bar <41 bar < 21 21 to 41 < 21 21 to 41 <41 bar <41bar <21 21 to
chamber bar bar bar bar bar bar 41 bar
pressure
Standard Type A Type A Type A + Type A Type A Type A Type A Type A Type C Design Type C Design Type A Type A Type C Design
seal type Plan 23
Option Type B Type B or C Type B or C Type B Upto 21 bar Upto 21 Type A Design Design
or C (upto 21 bar, (upto 21 bar, &C Type B bar + Plan
with FFKM for with FFKM for (NBR) Type B 23
Type B) Type B) Type C (NBR)
(flexible Type C
graphite) (flex
graphite)
Secondary O ring or U FFKM FFKM NBR FKM NBR
seal cup FKM ( upto
0C)
Special Single FFKM FFKM Single <60C,
features spring, Plan 62 coil Plan 23
internal quench & Plan spring >176C,
circulating 32 flush to FFKM
device keep crystals
formation
Arrangement 2
Metal
bellows
rated for
21 bar
EN 10204:2004 material certification requirements to prove that the materials meet defined chemical and mechanical properties.

Summary of documentation requirements for EN 10204:2004

EN 10204
Documentation Type Document Content Authorized By
Certificates Type
Certificate of
Type 2.1 Statement of compliance with order Manufacturer
Compliance
Statement of compliance with order and indication of
Type 2.2 Material Manufacturer
results of non-specific inspection
Statement of compliance with order and indication of
3.1 Inspection Manufacturer's authorized representative,
Type 3.1 test results carried out as defined by product
Certificate independent of manufacturing department
specification
Statement of compliance with order, indication of test Manufacturer's authorized representative,
3.2 Inspection results carried out as defined by product specification independent of manufacturing department and
Type 3.2
Certificate and indication of 3rd Party witness to purchaser's purchaser's authorized representative or
specified scope of testing. inspector designated by official regulations.

True type 3.2 certification is produced by the manufacturer, with test results supplied.
The independent third party inspector will have witnessed test results and verified the materials identification and traceability.

Material covered by type 3.1 certification can be upgraded to material to the-intent-of type 3.2 by the stockist employing an independent third
party inspector to validate this material.
This includes a visual examination, sample dimensional checks and confirmation that the material is traceable back to the ladle chemical
analysis which may be in the form of a BS EN10204 type 3.1 certificate.
The traceable reference may be the cast or heat number, test number or some other reference clearly traceable back to the mill certificate.
API 670

phase reference transducer: A gap-to-voltage device that consists of a proximity probe, an

extension cable, and an oscillator-demodulator and is used to sense a onceper- revolution mark.

speed sensor: A proximity probe or magnetic speed sensor used to observe a speed sensing
surface. It provides an electrical output proportional to the rotational speed of the observed
surface.

accelerometer: A piezoelectric sensor containing integral amplification with an output

proportional to acceleration.

radial shaft vibration: The vibratory motion of the machine shaft in a direction perpendicular to
the shaft longitudinal axis.

piston rod drop: A measurement of the position of the piston rod relative to the proximity probe
mounting location( s) (typically oriented vertically at the pressure packing box on horizontal
cylinders).
This measurement is made to prevent the piston from contacting the cylinder liner by monitoring
the rider band wear

Radial Shaft Vibration Monitoring

The full-scale range for monitoring radial shaft vibration shall be from 0 to 125 micrometers (0 to
5 mils) true peak-to-peak displacement.

Radial shaft vibration shall be monitored in paired channels from the two transducers mounted at
each bearing.

Axial Position Monitoring

The full scale range for axial position monitoring shall be from 1.0 to +1.0 millimeters (40 to
+40 mils) axial
movement.
Axial position shall be monitored in paired channels.
API 610
AXIALLY SPLIT
Principal joint parallel to shaft centerline

ALLOWABLE OPERATING REGION

Based on upper vibration limit (30%) or temp. Rise

BEP
Flowrate at highest efficiency at rated impeller diameter (to determine Ns,Nss)

MAXIMUM DISCHARGE PRESSURE

Maximum suction pressure + maximum DP at rated speed & density, impeller diameter

MAXIMUM DYNAMIC SEALING PRESSURE

Highest pressure at seals during operating, start up & shut down

MAXIMUM STATIC SEALING PRESSURE

Highest pressure at seals when pump is shut down

MINIMUM CONTINUOUS STABLE FLOW

Lowest flow without exceeding vibration limits

MINIMUM CONTINUOUS THERMAL FLOW

Lowest flow without exceeding temperature rise

MULTISTAGE PUMP
Pump with 3 or more stages

NPSH3
NPSH that results in3% loss of head

OVERHUNG PUMP
Impeller mounted on cantilever shaft from bearing assembly

NORMAL OPERATING POINT

Pump operates under normal process conditions

PREFERRED OPERATING REGION

Based on base vibration limit

RADIALLY SPLIT
Principal joint perpendicular to shaft centreline

RATED OPERATING POINT

Point at which pump performance is within the API stated tolerances

THROAT BUSHING
Restricitive close clearance between inner seal sleeve & impeller

VERTICAL IN LINE PUMP

Vertical single stage, suction & discharge in same center line
PUMP OH1
Foot mounted, single stage, non API

PUMP OH2
Centreline mounted, single stage,single bearing housing, flexible coupled

PUMP OH3
Vertical inline, overhung, bearing housing integral to pump, driver supported by pump, flex
coupling

PUMP OH4
Vertical inline, overhung, rigid coupled, non API

PUMP OH5
Vertical inline, overhung, closed coupled9impeller mounted on drier shaft), non API

PUMP OH6
High speed, integral gear box, closed coupled impeller, flex coupled gear to driver

PUMP BB1
Axially split, 1- & 2- stage, between bearing

PUMP BB2
Radially split, 1- & 2- stage, between bearing

PUMP BB3
Axially split, multistage, between bearing

PUMP BB4
Single casing, radially split, multistage, ring section/tie rod pump, non API

PUMP BB5
Double casing, radially split, between bearing

PUMP VS1
Vertical suspended, wet pit, single casing diffuser, column discharge

PUMP VS2
Vertical suspended, wet pit, single casing volute, column discharge

PUMP VS3
Vertical suspended, wet pit, single casing axial flow, column discharge

PUMP VS4
Vertical suspended,single casing volute, line shaft

PUMP VS5
Vertical suspended, cantilever sump pump

PUMP VS6
Vertical suspended, double casing, diffuser

PUMP VS7
Vertical suspended, double casing, volute
 1. Pressure rating
2. Casing support - Pumps for
service temperatures below
Foot mounted OH1
Horizontal 150 C (300 F) may be
Flexibly coupled foot-mounted. (BB1, BB2,
BB3 & BB5)
Centreline mounted OH2
Vertical in-line with
--- OH3
bearing bracket
OVERHUNG

1. Pump thrust bearing are in

motor, the shaft & base
tolerances to be met
Rigid coupled Vertical in-line --- OH4
2. Bearing reqt as per 7.1.8,
for radial or axial loads
transmitted from the pump
1. Pump thrust bearing are in
motor, the shaft & base
tolerances to be met
2. Bearing reqt as per 7.1.8,
Vertical in-line --- OH5
for radial or axial loads
Close coupled transmitted from the pump
3. Seal cartridge removal
without disturbing the driver
VERTICALLY SUSPENDED BETWEEN BEARING

High-speed
integrally --- OH6 ---
geared
Axially split --- BB1 ---
1- &2- stage
Radially split --- BB2 ---
Axially split --- BB3 ---
Multi stage Single casing BB4 ---
Radially split
Double casing BB5 ---
Diffuser VS1 ---
Discharge through
Volute VS2 ---
column
Single casing Axial flow VS3 ---
Separate Line shaft VS4 ---
discharge Cantilever VS5 ---
Diffuser VS6 ---

Double casing
Volute VS7 ---
SERVICE LIFE
Service life of 20 years with 3 years of uninterrupted operation

IMPELLER
5% head rise by replacing next larger impeller diameter, for change in hydraulic reqt during
execution & not for future expansion

MAXIMUM CONTINUOUS SPEED

Synchronous speed of motor at maximum frequency
105% of rated speed for variable speed pumps

SEAL CHAMBER PRESSURE min 5 psi during operation

PUMP PERFORMANCE with viscous liquids water performance corrected using ANSI /HI 9.6.7

H-Q CURVE
Head rise from rated to shut off preferred. Required to be minimum 10% for parallel operatio
pumps

PREFERRED OPERATING REGION 70 to 120% of BEP

Rated flow 80% to 110% of BEP flow rate

Small pumps operate outside this region

High Ns pump have narrow POR
Low Ns pump have 105 to 110% of BEP

BEP flow rate between normal & rated

HIGH ENERGY PUMP

200 m per stage or 300 hp per stage
Vane passing frequency or low frequency vibration at low flows

PRESSURE CASING designed for

MAWP + worst case combination of twice nozzle loads OR hydrostatic pressure

TENSILE STRESS < 0.25 min ultimate or 0.67 times min yield stress

MAWP = max discharge pressure + 10% max DP

Axially split, 1- &2-, BB pumps & single casing VS pumps , pressure rating equivalent to 150
class
Minimum 40 bar at 38degC

All OH, BB1, BB2, pressure rating equivalent to Class 300

PRESSURE CASING CORROSION ALLOWANCE min 3 mm

Double casing- inner casing designed for greater of max DP or min 50 psi

RADIALLY SPLIT CASING for

Pumping temperature > 200degC
SG < 0.7
Discharge gauge pressure above 100 bar
Radially split casing to have metal to metal fit with confined gaskets

CASING CONNECTIONS
Min DN 15 for discharge nozzle DN 50 & DN 20 for discharge nozzle >= DN 80

SUCTION & DISCHARGE NOZZLES are flanged or machined & studded for forged casing

AUX CONNECTION SCH 160 (for DN 25 & less) and SCH 80 (for DN 40)

IMPELLER TYPE is fully enclosed, semi open or open type

Overhung impeller secured by cap screw or cap nut & mechanical locking device, threading
tighten by liquid drag

WEAR RINGS
Casin are renewable. Impeller can be renewable or integral.
Min BHN of 400, else difference in BHN to be min 50

Mating joint between seal gland & seal chanber

To have confined gasket , O ring or Spiral wound gasket

ROTOR
1- & 2- stage pumps- 1st dry bending critical speed to be 20% above max continuous speed
Shaft stiffness over AOR with max dia impeller & specified speed & liquid to be 0.002 inch at
primary seal faces.

VIBRATIONS
Minimum near BEP, increases on either side.
Change in vibration increases with increasing pump energy density, Ns & Nss.

Bearing housing vibration in RMS velocity mm/s

Shaft vibration in peak to peak displacement in micrometers

Horiz < 3.0 mm RMS

Vert < 5.0 mm/s RMS

Allowable increase 30%

Horiz- 3600 rpm or 300 kW per stage shall be as per graph.

BALANCING
Rotating components balanced to ISO 1940 Grade G2.5
Permissible residual unbalance

Uper ( g-mm) = 9549 x G x W/N

G = 2.5,W rotor weight in kg, N = rpm

BEARING
2 nos radial bearing (single row deep groove ball bearing with metallic cage) &
1 no double acting axial bearing ( paired back to back, single row, 40deg angular contact type
ball thrust )
L10 in million revolutions & L10h in hours
25000 hours with cont operation at rated conditions &
16000 hours at max radial & axial loads at rated speed

Bearings retained on shaft with interference fit and diametral clearance in housing, directly
mounted, positive locating devices.

Thrust bearing restricted with nut & tongue type lock washer

BEARING TEMPERATURE
Ambient temp. of 43 degC & specified operating conditions
For pressurized , oil outlet 70 degC & bearing metal 93 degC
Ring oiled & splash, oil sump 82 degC

BEARING TYPE & LUBRICATION

Ball bearings ndm
n : rpm, dm = d+D/2
500000 for oil lubricated
350000 for grease lubricated

Hydrodynamic bearings if energy density 4 x 106 kW/min ( pump rated power x rated speed )

Replaceable labyrinth or magnetic type end seals with deflectors provided

DRIVER
Power ta rated condition not to exceed motor nameplate rating
Smallest motor 4 kW

<22kW 25%
22 to 55 15%
>55 kW 10%

Accelerate the pump at 80% voltage against closed discharge valve

Thrust bearing at NDE

Hydrodynamic bearing < 50% of manufacturers rating

TESTING
Uncertainty as per ISO 9906 Grade 1
HI 1.6 for centrifugal pumps
HI 2.6 for vertical pumps

HYDROSTATIC TEST
1.5 times MAWP for 30 mins
Stress at test temp stress at operating temp, test pressure increased by stress at test/stress at
operating

PERFORMANCE TEST
Contract seals & bearing
Contarct seals can be separately tested

Measured head, flowrate, power & vibration

Shut off, MCSF, 95% to 99% of rated, rated flow & 105%, BEP, end of AOR

TEST SPEED within 3% of rated speed

PERFORMANCE TEST COMPLETE

Vibration at each test point is within limit
Oil & bearing metal temp recorded at start & end of test, are within API limits without no unusual
noise
Perform within tolerances

Retest not required if reduction in impeller diameter < 5% to meet tolerance for differential head,
but required for other corrections such as hydraulic perf., NPSH, mechanical operation.
Multistage pump require retest for all cases
Seals can be retested with clean air at 25 psi for min 5 min or 5 min per 30l, drop less than 2 psi.

MECHANICAL RUN TEST

Oil temperature is stabilized & pump run for 4 hours

NPSH test
NPSH3 is measured at each test point

COMPLETE UNIT TEST

Pump along with auxiliaries
Sound level test

AUXILIARY EQUIPMENT TEST

BEARING HOUSING RESONANCE TEST

Suction specific speeds

Minimum continuous stable flow increases as suction-specific speed increases.

NPSHR in centrifugal pumps is normally reduced by increasing the diameter of the impeller eye.
The large eye required to obtain low NPSHR leads to the problem of "eye recirculation" or
"suction recirculation.

Larger impeller eye does decrease the NPSHR at the BEP , but causes flow separation at the off-
peak low-flow conditions.
Users started to limit the value of the NSS upto 8500 as a typical guiding value.

The higher the suction-specific speed, the closer will be the beginning of recirculation to the flow
rate at best efficiency.
Unstable curves, for same head there two flow rates. Inparallel operating pumps, pump which
lags will run at less flow or may not achieve the half the flow.
The operating head is more than the shut off head of pumps, which will prevent the opening of
non return valve
API 675
acceleration pressure
anticipated system acceleration pressure
Pressure change due to changes in velocity in the piping system due tothe pulsating nature of
the flow in the pump suction line, in addition to NPSHR, vapor pressure, and pressure required to
overcome suction line losses.

flow repeatability
percent of rated capacity, describes the reproducibility of pump flow rate under a given set of
conditions when capacity setting is varied and then returned to the set point being tested.

linearity
The relationship between the actual volume of liquid discharged at a given capacity setting and a
best fit straight line drawn through the plotted points of volume and capacity setting determined
during calibration tests of a pump.

liquid end assembly

The pump liquid end assembly (also called the reagent head assembly or wet end) includes all
parts that contain the liquid being pumped.

lost motion
A means of changing displacement of a constant stroke pump by altering the effective stroke
length during each cycle. This may be accomplished either mechanically or hydraulically.

maximum rated input speed

Highest speed (in strokes per minute) at which the machine, as built and tested, is capable of
continuous, efficient
operation with the specified fluid at any of the specified operating conditions.

minimum allowable speed

The lowest speed (in strokes per minute) at which the manufacturers design will permit
continuous operation.

net positive inlet pressure

NPIP
Minimum instantaneous pressure determined at the datum elevation (underside of the pump
mounting plate) during pressure pulsations, minus the vapor pressure of the fluid at the maximum
operating temperature and at any specified operating point (see Annex E for further discussion).

net positive suction head available

NPSHA
Not the most appropriate term for reciprocating positive displacement pumps because this is only
based on steady state energy losses and doesnt include acceleration

NPIP is the most appropriate term for any reciprocating positive displacement pump because
NPIP includes the
additional energy losses due to acceleration.

packed-plunger pump
packed piston pump
The process fluid is in direct contact with the plunger.
pump efficiency
Ratio of the pumps hydraulic power at discharge to its brake power input.

pumphead
The displacement chamber for the pump hydraulic fluid that moves the diaphragm in a hydraulic
diaphragm pump.

rated capacity
The quantity of fluid actually delivered per unit of time at the stated operating conditions.

rated operating point

Point at which the supplier certifies that pump performance is within the tolerances stated in this
standard.

slip
Quantity of fluid per unit of time that leaks through the internal clearances of a pump.

steady state accuracy

The flow variation expressed as a percentage of mean delivered flow under fixed system
conditions. Steady state accuracy applies over the turndown ratio.

turndown ratio
The rated capacity divided by the minimum capacity that can be obtained while maintaining
specified steady state accuracy and linearity.

volumetric efficiency
Ratio of the pump rated point flow to the total theoretical displacement per unit time.

Purchaser shall specify the period of uninterrupted continuous operation.

The pump flow rate shall be adjustable over the specified turndown ratio while the pump is
running.

Rated capacity shall be at least 110 % of the maximum capacity specified.

The steady state flow accuracy shall be within 1 % of rated flow over a turndown ratio of at
least 10:1.

The flow repeatability shall be within 3 % of rated flow over the specified turndown ratio.

Deviation from linearity shall not exceed 3 % of rated flow over the specified turndown ratio.

the operating differential pressure shall be above the minimum pressure required to ensure the
specified flow accuracy.

Inlet and outlet connections shall be flanged or machined and studded, minimum CL300 (for steel
flanges)

Suction and discharge nozzles shall be flanged or machined and studded for sizes NPS 2 (50
mm) and larger.
Sizes NPS 11/2 (40 mm) and smaller may be threaded connections.
Diaphragms provide isolation and transmit hydraulic motion from one fluid to another.

double diaphragm designs intended for detecting diaphragm failure shall be provided with a
tapped hole for either a conductivity probe in the intermediate fluid or a pressure type detector
between diaphragms in a dry design.

Diaphragm pumps shall have an integral, adjustable hydraulic relief valve to provide full
protection of the pump drive mechanism from excessive discharge pressure. The relief valve
setting shall be at least 10 % or 175 kPa (25 psi) over the rated discharge pressure, whichever is
greater.

Packed-plunger pumps require external relief valves for mounting in the Purchasers piping

GEARS shall be designed as per AGMA with a minimum service factor of 1.5 per AGMA 6022 or
AGMA 6013

Antifriction bearings shall have a minimum L-10 rated life (see ABMA Standard 9 or ABMA
Standard 11) of25,000 hours with continuous operation at maximum rated conditions.

NACE MR 0103 applies to oil refineries, LNG plants and chemical plants.

NACE MR 0175 applies to oil and gas production facilities and natural gas sweetening plants.

Bolting material for pressure joints for cast iron casings shall be carbon steel (ASTM A307, Grade
B),
and for steel casings shall be high-temperature alloy steel (ASTM A193, Grade B7). Nuts shall
conform to ASTM A194, Grade 2H (or ASTM A307, Grade B, case hardened, where space is
limited). For temperatures below 30 C(20 F), low-temperature bolting material in accordance
with ASTM A320 shall be used.

Gray cast iron (ASTM A278) shall not be used for pressure-containing parts that handle
flammable or toxic fluids. With the Purchasers approval, nodular cast iron (ASTM A395) may be
used in such services.

Table 1Welding Requirements

Requireme
nt
Welder/operator qualification
Welding procedure qualification
Non-pressure-retaining structural
welding such as mounting plates
or supports
Magnetic particle or liquid
penetrant examination of the
plate edges
Post-weld heat treatment
Applicable Code or Standard
ASME IX or EN287
Applicable material specification
or, where weld procedures are not
covered by the material
specification ASME IX or EN 288
AWS D1.1
ASME VIII, Division 1, UG-93(d)(34)
Applicable material specification or
ASME VIII, Division 1, UW 40
Motor drives 1 HP or larger shall conform with IEEE 841.

The motor rating shall be at least 110 % of the greatest power required (including gear and/or
coupling losses) for any of the specified operating conditions.

The motor nameplate rating, including service factor, shall be suitable for operation at 100 % of
the PLV accumulation pressure.

The 110 % applies to the design phase of a project.

Electric motor drivers in accordance with IEEE 841 have a service factor of 1.0 for constant
speed services. Motors in accordance with API 547 have a standard service factor of 1.0;
however, many users of these motors prefer to use a 1.15 service factor.

couplings shall be balanced to AGMA 9000 Class 10.

couplings shall meet the requirements of API 671.

PLVs or other protective devices shall be used with all positive displacement pumps. Rupture
disks shall not be used. The sizing, selection and installation of pressure limiting valves should
meet the requirements of API 520, Part I and API 520, Part II.

Table 3Material Inspection Standards

Acceptance
Type of Method Criteria
inspection s For fabrications For castings

Visual Inspection ASME V, Note MSS SP-55

2
Radiography Section V, Articles 2 Section VIII, Division 1, Section VIII, Division 1,
and 22 of the ASME UW-51 (for 100 % Appendix 7 of the ASME
Code radiography) and UW-52 Code
(for spot radiography) of
the ASME Code

Ultrasonic inspection Section V, Articles 5 Section VIII, Division 1 Section VIII, Division 1,
and 23 of the ASME Appendix 12, of the Appendix 7, of the ASME
Code ASME Code Code

Magnetic particle Section V, Articles 7 Section VIII, Division 1, Section VIII, Division 1,
inspection and 25 of the ASME Appendix 6 of the ASME Appendix 7, of the ASME
Code Code Code

Liquid penetrant Section V, Articles 6 Section VIII, Division 1, Section VIII, Division 1,
inspection and 24 of the ASME Appendix 8 of the ASME Appendix 7, of the ASME
Code Code Code

NOTE 1 For visual inspection all surfaces shall be inspected.

NOTE 2 Acceptance criteria for fabricated parts shall be in accordance with the material specification
and the manufacturers documented procedures.
All pressure casing components shall be assembled as a single unit and tested hydrostatically
with liquid at a minimum of 1.5 times the MAWP, but not less than a gauge pressure of 150 kPa
(1.5 bar) (20 psi).

If the component handling the pumped liquid is to operate at a temperature at which the strength
of a material is below the strength of that material at the testing temperature, the hydrostatic test
pressure shall be multiplied by a factor obtained by dividing the allowable working stress for the
material at the testing temperature by that at the rated operating temperature.

The hydrostatic test shall be considered satisfactory when neither leaks nor seepage through the
pressure containing part or joints is observed for a minimum of 30 minutes.

Performance Test

tests shall be conducted in accordance with Section 3.6 of the Hydraulic Institute pump
standards, according to the tolerances specified in 8.3.6.

When flow repeatability and linearity tests are specified, they shall be run by using 100 %, 75 %,
50 %, 25 %, and 10 % of rated capacity points in descending and ascending order. The flow
variations shall not exceed 3 % of the value at rated capacity. Adjustable stroke length and
adjustable speed tests shall be conducted independently.

Mechanical Run Test

The mechanical run test shall be one hour or until oil temperatures have stabilized.

the pump shall be mechanically run for four hours.

NPIP Test
If specified, the pump shall be tested for NPIP. At rated speed and with NPIPA equal to quoted
NPIPR, the pump capacity shall be within 5 % of the non-cavitating capacity.

Table 4Test Tolerances

Characteristic Capacit Toleranc

y e
@ 100 % capacity 3
@ 75 % capacity 3
@ 50 % capacity 3
@ 25 % capacity 3
@ 10 % capacity 3
Rated power (at rated capacity and maximum +4
NPIP pressure) (at rated capacity) +0
R

Complete Unit Test

Sound Level Test

the sound level test shall be performed in accordance with ISO 3744 or other agreed standard

High Discharge Pressure Test

If specified, the pump will be operated at the PLV set pressure at the maximum rated pump
speed and a fluid viscosity agreed to by the Vendor and the Purchaser to confirm that the pump
continues to operate properly at these conditions typically 15 minutes. A single data point will be
collected.

Factory Acceptance Test

The Vendor shall provide complete performance curves, including discharge pressure,
NPSHR/Net Positive Inlet Pressure Required (NPIPR may be a single number stated for
maximum flow), and power at relief valve set pressure at the specified viscosity. Preferred and
allowable operating regions, and any limitations of operation shall be indicated.
API 612

API -611
General-purpose turbines,horizontal or vertical turbines, to drive spared quipments, small size
(power or non critical non-critical service, with steam conditions will not exceed a pressure of 48
bar (700 psig) and a temperature of 400 C (750 F) or where speed will not exceed 6,000 r/min.

API -612
Special-purpose turbines,horizontal turbines,to drive non spared equipment, large size (power)or
is in uninterrupted continuous critical service,not limited by steam conditions or turbine speed.
critical speed
shaft rotational speed at which the rotor-bearing-support system is in a state of resonance

maximum exhaust casing pressure

highest exhaust steam pressure that the purchaser requires the casing to contain, with steam
supplied at
maximum inlet conditions

potential maximum power

approximate maximum power to which the turbine can be uprated at the specified normal speed
and steam
conditions when it is furnished with suitable (that is, larger or additional) nozzles and, possibly,
with a larger
governor-controlled valve or valves

separation margin
margin between a critical speed and the nearest required operating speed

slow roll
speed recommended by the vendor (typically 400 r/min to 500 r/min) for warm-up and initial
check of
equipment integrity prior to full operation

SERVICE LIFE
minimum service life of 20 years and at least five years of uninterrupted operation.

Turbines shall be capable of the following:

a) operation at normal power and speed with normal steam conditions, with the steam rate
certified by the manufacturer at these conditions;

b) delivering rated power at its corresponding speed with coincident minimum inlet and maximum
exhaust conditions specified.
c) continuous operation at maximum continuous speed and at any other speed within the range
specified, with a maximum continuous speed of at least 105 % of rated speed;

d) continuous operation at rated power and speed with maximum inlet steam conditions and
maximum or minimum exhaust steam conditions;

e) continuous operation at the lowest speed at which maximum torque is required with minimum
inlet and maximum exhaust conditions, with the purchaser specifying both the speed and torque
values required;

f) continuous operation at specified conditions for extraction and/or induction;

g) operation with variations from rated steam conditions and steam purity levels recommended in
IEC 60045-1 or NEMA SM 23;

h) operation uncoupled with maximum inlet steam conditions.

turbine trip speed shall be 110 % of maximum continuous speed, normally 116 % of rated speed.

The tensile stress used in the design of the pressure casing for any material shall not exceed
0,25
times the minimum ultimate tensile strength for that material at the maximum specified operating
temperature, and, for castings, multiplied by the appropriate casting factor.

MAWP of casing >= specified relief valve set point(s).

For condensing turbines, the exhaust casing shall be designed for both full vacuum and for a
maximum allowable working gauge pressure of at least 70 kPa (0,7 bar) (10 psi).

turbine casing shall be axially split or radialy (between HP & LP secion) with metal-to-metal joint
that is tightly maintained by bolting with sealant but not gasket.

orientation of the main inlet and outlet steam connections by purchaser

All control stage nozzle rings shall be replaceable.

All other stationary blading shall be mounted in replaceable diaphragms or blade carriers.

Nozzle loading shall be as per NEMA SM 23

Rotors shall be capable of safe operation at maximum overshoot speed of 121 % of maximum
continuous speed at any specified operating temperature.

built-up rotors (disks shrunk on the shaft) when blade tip velocities exceed 250 m/s (825 ft/s) at
maximum continuous speed or when stage inlet steam temperatures exceed 440 C (825 F).

Rotor dynamics

Lateral analysis

Unbalanced rotor response verification test

Torsional analysis

Vibration and balancing

Major parts of the rotating element, such as the shaft, balancing drum, and discs, shall be
individually
dynamically balanced before assembly to ISO 1940 Grade G1 or better.

The rotating element shall be multiplane dynamically balanced during assembly.

The maximum allowable residual unbalance per plane (journal) shall be calculated as follows:

Umax = 6350 x m /n , gm-mm

m- journal static mass in kg, n MCS in rpm

Hydrodynamic radial bearings shall be provided with axially split babbitted replaceable liners,
pads or shells.

Thrust bearings shall be hydrodynamic and steel-backed, with babbitted multiple segments,
designed
for equal thrust capacity in both directions, and arranged for continuous pressurized lubrication to
each side.

Thrust bearings shall be selected at no more than 50 % of the bearing manufacturers ultimate
load
rating.

rise in oil temperature through the bearing and housings shall not exceed 30 C (50 F)

bearing outlet oil temperature shall not exceed 80 C (180 F)

Cast iron bearing housings or bearing housing supports shall not be used.

replaceable labyrinth end seals and deflectors where the shaft passes through the housing; lip-
type end seals shall not be used.

Provision shall be made for mounting two non-contacting radial-vibration probes in each bearing
housing, two axial-position probes at the thrust end of each machine, and a one-event-per-
revolution probe in each machine.

Grounding
condensing turbines shall be provided with at least two grounding brushes on the same end of
the shaft, replaceable during operation

Shaft seals
casing end seals shall be replaceable labyrinth seals.

Labyrinth casing end seals operating at less than atmospheric pressure shall be designed for
admission of dry steam to seal against air ingress.
a separate vacuum system shall be furnished to reduce external leakage from the end labyrinth
seals and possible contamination of the bearing oil

Controls and instrumentation

Turbine governing system

primary function of the governing system shall be to maintain the turbine speed at a set value by
regulating the steam flow through the turbine.

dedicated digital microprocessor-based governor unit shall be furnished.

speed regulation at rated speed and rated steam inlet and exhaust conditions shall not exceed
0,5 %.

steady state speed variation at rated speed, rated power and rated steam inlet and exhaust
conditions, shall not exceed 0,25 %.

The maximum speed rise shall not exceed 7 % of the maximum continuous speed. The
maximum speed
rise is the maximum momentary increase in speed when the turbine is developing rated power at
maximum continuous speed and rated steam inlet and exhaust conditions, and the load is
suddenly and
completely reduced to zero.
A multi-toothed surface for speed sensing may be shared by the speed governor, overspeed
shutdown system, and tachometer.

speed governing system shall include at least two speed sensors dedicated for speed control.

governing system shall provide for both slow roll (typically 400 r/min to 500 r/min) and startup
using the governor-controlled valves.

Overspeed shutdown system

The system shall prevent the turbine rotor speed from exceeding 127 % of the rated speed on an
instantaneous, complete loss of coupled inertia and load while operating at the rated conditions.

In the event of loss of load without loss of coupled inertia, and unless otherwise specified by the
driven equipment vendor, the system shall prevent the speed from exceeding 120 % of rated
speed.

If specified, a turbine with an exhaust pressure less than atmospheric pressure shall be provided
with an exhaust vacuum breaker actuated by the shutdown system.

Even when the emergency trip valve is closed, a turbine exhausting to sub-atmospheric pressure
can leak
enough steam to prevent the turbine and driven equipment from coming to a complete stop.

On controlled extraction turbines, the vendor shall supply a non-return valve, equipped with a
spring-loaded hydraulic or pneumatic actuated cylinder to assist in closing the valve, on each
extraction line.

On turbines with uncontrolled extractions, two non-return valves in series shall be provided on
each
extraction.

Electronic overspeed detection system

An overspeed detection system based on three independent measuring circuits and two-out-
ofthree
voting logic in accordance with API Std 670 shall be supplied.

Electro-hydraulic solenoid valves

The turbine shall be provided with a minimum of two, separate electro-hydraulic
solenoidoperated
valves located in the shutdown system, de-energized to shutdown.

If energize to shutdown is specified, the solenoid valves shall be in parallel and the solenoids and
relays shall have a detection system to alarm on failure of the coil.

A separate independent trip valve(s) or combined trip and throttle valve(s), as specified, shall be
provided for each steam inlet.

If specified, duplicate trip valves shall be provided, arranged in parallel. Each trip valve shall be
sized to pass the full steam flow.
In normal operation, one valve shall be closed. The purpose of the second valve is to enable the
normally
open valve to be completely tested with the turbine on line.

partial stroking capability which does not interrupt operation of the turbine when redundant valves
are not
specified;

The trip valve(s) shall be designed to be closed by the action of a spring and shall be held open
by direct hydraulic means.

trip valve steam strainer

The effective free area of the strainer shall be at least twice the cross-sectional area of the valve
inlet connection. The steam strainer shall be capable of withstanding a pressure differential at
least equal to 25 % of the inlet pressure.

a manual trip shall be provided local to the turbine to allow

an operator to trip the unit.

instrument and control panels shall conform to ISO 10438/API 614.

Tachometers

two electronic digital-speed indicators shall be furnished. The minimum tachometer range shall
be from 0 % to 125 % of the maximum continuous speed. One indicator shall be locally mounted
and the other shall be supplied to the purchaser for remote mounting.

Temperature gauges

Gland vacuum systems

It shall include a gland condenser and steam ejector sized for three times the expected flow with
as new shaft seal clearances.

a vacuum pump shall be provided in place of a steam ejector.

Insulation and jacketing

Provided if normal operating temperature of turbine casing is 74 C (165 F) or higher.

Turning gear
A turning gear shall be provided if specified by the purchaser or required by the vendor.

Casing pressure hydro tests

Casing integrity test

All pressure-containing parts shall be hydro pressure tested to prove casing integrity with liquid at
a gauge pressure of at least 1,5 times the maximum allowable working pressure but not less than
140 kPa (1,4 bar) (20 psi).

If the part tested is to operate at a temperature at which the strength of a material is below the
strength of that material at the testing temperature, the hydro test pressure shall be multiplied by
a factor obtained by dividing the allowable working stress for the material at the testing
temperature by that at the rated operating temperature.

The pressure casing integrity hydro test shall be considered satisfactory when neither leaks
nor seepage through the casing is observed for a minimum of 30 min.

Use of a sealant compound or gasket on the casing joints is acceptable during the casing
integrity hydro test.

Casing joint leakage test

A hydro test for casing joint leakage shall be performed. The hydro test pressure shall be 1,5
times the maximum allowable working pressure in that pressure zone.

This test should be performed after the casing hydro integrity test.
Gaskets shall not be used at the casing joint for this test. Suitable joint compound may be used .
The test shall be considered satisfactory when neither leaks nor seepage through the casing joint
is observed for a minimum of 30 min.

The casing joint leakage test may be combined with the casing hydro integrity test, provided
casing joint gaskets are not used
Mechanical running test
Contract shaft seals and bearings shall be used

Test-stand oil filtration shall be 10 m nominal or better.

The mechanical running test shall be performed with the contract half coupling and a coupling
mass
simulator, or moment simulator, in accordance with ISO 10441 or API Std 671, in place (15.1.7).

All contract vibration probes, cables, oscillator-demodulators and accelerometers shall be in use
during the test.

Shop test facilities shall include instrumentation with the capability of continuously monitoring and
plotting revolutions per minute, peak-to-peak displacement and phase angle

Operate the equipment at speed increments of approximately 10 % from zero to the maximum
continuous speed (avoiding any resonant speeds) and run at maximum continuous speed until
bearings, lube-oil temperatures and shaft vibrations have stabilized.

Increase the speed to trip speed and run the equipment for a minimum of 15 min.

Check overspeed trip devices and adjust them until values within 1 % of the nominal trip setting
are attained.
Mechanical overspeed devices, when supplied, shall attain three consecutive non-trending trip
values that meet this criterion.

The speed governor and any other speed-regulating devices shall be tested for smooth
performance over the operating speed ranges. Check no-load stability and response to the
control signal.

Record data for governors such that it includes at least the sensitivity and linearity of relationship
between speed and control signal, and, for adjustable governors, the response speed range.

Run the turbine continuously at the maximum continuous speed for at least 4 h.

Hydrodynamic bearings shall be removed, inspected and reassembled after the mechanical
running test is completed.

If replacement or modification of bearings or seals, or if dismantling of the case to replace or

modify other parts, is required to correct mechanical deficiencies, the initial test shall not be
acceptable.

When spare rotors are ordered to permit concurrent manufacture, each spare rotor shall also be
given a mechanical running test in accordance with this International Standard.

Optional tests and inspections

Performance test
The machine shall be tested in accordance with IEC 60953 or ASME PTC 6.

Complete unit test

Components such as compressors, gears, drivers and auxiliaries, which make up a complete
unit, shall be tested together.

Auxiliary equipment test

Auxiliary equipment such as oil systems and control systems shall be tested in the vendors
shop.

Post-test internal inspection of casing

The steam turbine shall be dismantled, inspected and reassembled after satisfactory completion
of the mechanical running test.

Overspeed shutdown systems test

The response time of the overspeed shutdown systems shall be recorded to confirm compliance
with the requirements of 12.3.1.1.

Spare parts test

Spare parts such as couplings, gears, diaphragms, bearings and seals shall be tested as
specified by the purchaser.

Inspection of hub/shaft fit for hydraulically mounted couplings

After the running tests, the shrink fit of hydraulically mounted couplings shall be inspected by
comparing hub/shaft match marks to ensure that the coupling hub has not moved on the shaft
during the tests.

Trip valve test

Complete valve assembly shall be tested by the vendor in its specified orientation and tripped
closed from the full open position. Travel versus time shall be recorded. The trip time shall not
exceed the required trip time (see 12.3.4.7).

Governor system response test

If a load test is performed at a specific operating point, the response time of the turbine governing
system shall be continuously recorded to confirm compliance with the requirements of 12.2.4.

Sound level test.

The sound level test shall be performed in accordance with ISO 3744 or other agreed upon
standard.
The pump head & liquid end assembly is divided into 3
chambers:
Chamber A: the fluid is conveyed through this.
Chamber B: is the hydraulic pressure chamber and contains the
hydraulic fluid
Chamber C: used as reservoir for the hydraulic fluid and is
pressureless (atmospheric pressure)
The multi-layer diaphragm (also called sandwich diaphragm)
separates chambers A and B At the same time it is used to seal
Chamber A and B away from the atmosphere. Since it is a static
seal, so the pump head is considered hermetically sealed. The
condition of the multi-layer diaphragm is permanently monitored.
The hydraulic fluid between the piston and diaphragm transmits
the displacement movement of the piston to the metering fluid.
The diaphragm is only used here as a separating element it
transmits no forces.
The combination of hydraulic snifting valve, the control gate
valve and the pressure relief valve ensures the complete fail-
safety of the pump if suction pressure is too low or back
pressure is too high.
The venting valve ensures a continuous discharging of possible
existing gas bubbles in the hydraulic system and thus optimizes
the metering accuracy. The pressure relief and venting valves
are combined into a combination valve.
The hydraulic snifting valve compensates hydraulic leakages
at the end of the suction stroke, as soon as the pressure drops
under the set opening pressure.
Hydraulic leakages are completely normal and occur at
1. the piston seal
2. the venting valve
3. all valve seats and seals of the hydraulic drive system
The control gate valve ensures that if the leakage increases in
the hydraulic system, no more than the actual required quantity
of hydraulic fluid is compensated. This system also called
diaphragm position control - allows the pump head to operate
without a front diaphragm support plate.
With amechanically arming, pressure-sensitive refill valve, the
hydraulic fluid can only bereplenished when the diaphragm is in
the most rearward position. This eliminates thepossibility of
overfilling the hydraulic chamber and therefore overdisplacing
thediaphragm during system upsets (blocked suction or
discharge lines).
The pressure relief valve protects the entire pump from
overloading. In case of an upset condition on the discharge side
of the pump, it can be temporarily loaded.
While the pump head is blowing off, the hydraulic fluid is
pumped via the pressure relief valve from Chamber B into
Chamber C and afterwards replenished into Chamber B
through the hydraulic snifting valve.
During this the hydraulic fluid foams somewhat. The foam limits
the temperature increase during blow off. It is pumped out of the
hydraulic system with the venting valve as soon as the upset
condition is gone.
The venting valve is placed at the highest point of the hydraulic
system. The permanently set low leakage rate ensures that gas
bubbles, which may occur during operation (see "blow off "), are
reliably pumped out of the hydraulic system.
Diaphragm monitoring
The space between the diaphragms in normal operation is
pressureless. If one of the diaphragms is damaged, fluid
(conveyed fluid or hydraulic fluid) penetrates into this space.
This leads to a pressure increase, which is used for the
detection of the diaphragm damage.
IP as per IEC standard 60529
IP 55
Limited Ingress of dust not harmful to operation
Protected against lowpressure jets if waterfrom all directions limited ingress permitted.
IP 68
No ingress of dust
Suitable for continuous immersion in water under conditions
IP 65
No ingress of dust
Protected against lowpressure jets if waterfrom all directions limited ingress permitted
IP66
No ingress of dust
Protected against strongjets of water e.g. for useon shipdecks limitedingress permitted

IEC 60079- ELECTRICAL APPARATUS FOR EXPLOSIVE GAS ATMOSPHERES

Ex d flameproof protection (En 60079-1)

Ignition within the apparatus enclosure is contained and will not ignite the surrounding explosive atmosphere

Ex n Non Incendive(En 60079-15)

Equipment will not ignite explosive gas in normal operation, faults unlikely to occur

Ex e Increased Safety(En 60079-7)

Design excludes the possibility of incentive arcs, sparks or hot surfaces

Ex ia Intrinsic safe (En 60079-11)

Energy in circuit and temperature on components reduced to safe level

Local gauges - IP65

Junction boxes IP66 Ex eT3
Cabinets IP 54 /IP65
Motor IP 55 Ex d or Ex n IIC T3
Cableglands - Ex de

Temperature classification
The surface temperature or any parts of the electrical equipment that may be exposed to the hazardous
atmosphere should be tested that it does not exceed 80% of the auto-ignition temperature of the specific
gas or vapor in the area where the equipment is intended to be used.
T1 -450C T3 - 200C T6-85C
Pump P1 running, with system head Hc > H shut off. The pump P2 cannot develop head to open check
valve

Pump-1 will increase its flow, and its head will decrease (Qcc, Hcc). The new system head Hcc will now
"push" the Pump-2 to lower flow (Qee). Eventually, a "stronger" pump may completely "take out" the
weaker pump to near, or at the shut-off head.

Viscosity index (VI) is an arbitrary measure for the change of viscosity with variations in temperature.
The viscosity of liquids decreases as temperature increases. The viscosity of a lubricant is closely related
to its ability to reduce friction.
VI is the viscosity of oil at 40C

The lower the VI, the more the drop in viscosity as the oil warms up.
The higher the VI value, the less the drop in viscosity as the oil warms up.

Centistoke units (cSt). 1 cSt = 1 mm2/s.

Lubricating oils are identified by an ISO Viscosity Grade (VG) number.

The VG number is the viscosity of the oil at 40C (104F).

Rolling bearing lubricant requirements depend onbearing size, dm, and operating speed n but
little on bearing load. The minimum required lubricant viscosity v1 needed at the bearing
operating temperature is obtained from Figure 7-19. The actual lubricant selected for an
application should provide greater viscosity v than the minimum required viscosity v1
At lower speeds, higher viscosity grades should be considered and at higher speeds, lower
viscosity grades should be considered. The viscosity ratio, Kappa, should be the guideline for
evaluation of viscosity.
Kappa > 1.5 is preferred. The lubricant viscosity should not be too high, since this would cause
excessive bearing friction and heat.
 Gas turbines are classified into different types in terms of design, number of shafts, drive
location, and cycle

The advantages of an aeroderivative gas turbine are:

Shorter maintenance times

Small foot print
Low specific weight
Higher efficiency
Faster start sequence
The disadvantages are that the cycle time between maintenance are shorter, it has lower tolerance
to upsets, and has shorter bearing life (anti-friction bearings).

Gas turbines are configured as single, dual or triple shaft designs.

Single shaft gas turbine, the gas generator and power turbine are mounted on the same
shaft.

Limited to generator drive applications, as starting turbine load is lower for a generator
application, due to zero starting load.

Dual shaft gas turbine, the gas generator and power turbine are mounted on different
shafts.

Dual shaft turbines are used for mechanical drive, pump and compressor applications.

Gas turbines can be designed as hot end drive or cold end drive. The majority of first and
second generation gas turbines were of a hot end drive, but most third generation gas
turbines are of the cold and dry type.

A cold end drive configuration is more reliable, since the coupling environment is
significantly reduced in terms of temperature. This results in a much lower axial expansion
of the drive coupling and subsequently increases the reliability of the gas turbine.

There are essentially three types of gas turbine cycles: first is the simple cycle, where the
gas is exhausted directly to atmosphere; secondly, the regenerative cycle, where the
exhaust gas is used in an exchanger (regenerator) to preheat the compressor discharge
prior to the combustor; and finally, there is the combined cycle, where the exhaust gas is
used in a heat recovery steam generator (HRSG) to either generate steam for plant use or
as an expansion fluid is a steam turbine. Typical efficiencies are: simple cycle 20 to 43
percent; regenerative cycle 30 to 45 percent; and combined cycle 55 to 60 percent.

Single shaft

The gas turbine can have either a single-shaft or a two-shaft design. The single-shaft design
consists of one shaft connecting the air compressor, gas producer turbine, and power turbine as
one rotating element (Fig. 1). This design is best suited for constant-speed applications such as
driving electric generators for a constant frequency.

Two shaft

The two-shaft design has the air compressor and gas producer on one shaft and the power
turbine on a second independent shaft. This design provides the speed flexibility needed to cover
a wider performance map of the driven equipment more efficiently. This allows the gas producer
to operate at the speed necessary to develop the horsepower required by the driven equipment
such as centrifugal compressors or pumps. Fig. 6 shows a cutaway view of a typical two-shaft
gas turbine. Major components include the compressor, combustion system, gas producer
turbine, and power turbine. This design includes a two-stage gas producer turbine and a two-
stage power turbine.

Single shaft engines

Compressor speed =gas generator tubrine speed

Compressor load <turbine power

Gas turbine operates at constant speed means that any operating point of engine compressor
lies on a single speed line.
Load is increased by increasing fuel flow which in turn increases the firing temperature
First turbine nozzle is choked, to compensate for reduced density, the pressure ratio is increased

Reduction in output power, small change in compressor mass flow and pressure ratio

Two shaft engines

Consists of a compressor, combustor, gas generator turbine & power turbine
Power turbine (along with driven equipment) will run at a speed independent of the speed of
compressor & gas generator turbine.

Gas generator is controlled by the fuel flow, limited by firing temperature & max gas generator
speed

As fuel flow is increased, both firing temeprature & gas generator speed is increased.
This provides power turbine with gas at higher energy (P,T & mass flow).

Variable stator vanes are used to optimize gas generator speed & not the air flow.
Air flow is controlled by gas generator turbine & power turbine nozzles.

Compressor speed =gas generator tubrine speed

Compressor load =gas generator turbine power

2-s turbine adapts to load requirements by changing speed & firing temperature
6FA HEAVY DUTY GAS TURBINE

Gas turbine is an air-breathing engine, its performance is affected by ambient air conditions.
ISO conditions : 15F/1.013 bar/60%RH
Ambient temperature, altitude, relative humidity ,inlet & exhuast loss correction factors are applied
ISO rating (SC) 77MW (35.5%)
6FA
6540 kJ/kWh
ISO rating (CC) 118MW ( 55.0%)
106FA
10295 kJ/kWh
Stage 18 stage
Compressor Pressure ratio ISO pressure ratio 15.8:1
Air flow 203 kg/s
Stage 3
Exhaust temp. 592 degF
Turbine
Air-cooling for all nozzle stages
Air cooling for 1st & 2nd bucket stages.
High strength, corrosion resistant GTD-450 stainless steel airfoil material
is used on the first eight stages, with the remaining airfoils made of
403+Cb steel alloy.
reverse flow, 6 chamber
Dry Low NOx (DLN) 2.6 combustion system
Combustor 6 fuel nozzles per chamber
2 retractable spark plugs
4 flame detectors
Single shaft, two bearing design
internal air-cooling for the entire turbine section.
Rotor Counter-clockwise when facing the gas turbine output flange
Load gear reverses the rotation as it drives the generator rotor at cold
end
Axial, In-line Exhaust Diffuser

Mark* VIe Control System

Accessory Compartment
Compartment
Turbine, Load Shaft & Exhaust Diffuser Compartments

Starting System
Cooling & Sealing Air system
To start the gas turbine rolling, crank it to firing speed and assist
the fired turbine to self-sustaining speed.
To rotate the turbine rotor at slow speed for cool down purposes
Charge pump, torque converter, reversing gear, ratchet system, self
synchronizing clutch
Compression pulsation protection
Cooling internal parts, turbine exhaust frame & bearing no. 2
Sealing of bearing housing

Cooling Water System
Heating & Ventilation System
Fire Protection System
Hydraulic System
Wash Water System
NFPA 37: STANDARD FOR THE INSTALLATION AND USE OF STATIONARY COMBUSTION
ENGINES AND GAS TURBINES
NFPA 750: STANDARD ON WATER MIST FIRE PROTECTION SYSTEMS
9th & 13th stage are bled into turbine exhuast diffuser to prevent
pulsation (upto full speed & shutdon)
1st & 2nd stage buckets, 1st stage nozzle/shorud- internal cooling circuit
from 17th & dischage bleed
2nd & 3rd stage nozles-external cooling air circuit from 9th & 13th stage
bleed
Off base centrifugal blowers for cooling Bearing 2 area & exhaust
diffuser, provides sealing air for Bearing 2.
Required for oil coolers and cooling of flame detectors
Load compartment & exhaust compartment
Above atmosphere
Gravity operated inlet dampers ( for blower inlet) and CO2 operated
outlet dampers ( on enclosure)
Turbine Compartment
Accessory Compartment fuel gas module & lube/hydraulic oil module
Below atmosphere
CO2 actuated inlet damper (for blower inlet)
CO2 Extinguishing System as per NFPA 12
For opening or resetting the fuel stop valves
For operating the variable turbine inlet guide vanes
Supply fluid to the hydraulic control & trip devices, starting system
Offline & online cleaning
ON-CRANK - Engine operation at maximum speed obtainable on starter
alone with fuel and ignition deactivated. Every 4000 hours or full load
degrades by 5%
ON-LINE - Engine fired and operating at any power level ranging from
idle (no load) to full rated power and load. 1st 48 hours or 72 hours...