Sulzer Presentation

Sulzer ISO 13709 (API 610) Sulzer Pumps
Type BB5 Barrel Pumps
The Heart of Your Process

Long History of Barrel Pumps Sulzer Pumps
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 2

Barrel Pumps: Diffuser Style Sulzer Pumps
45 MW SuperCritical
Boiler Feed
Types of Horizontal Multistage Pumps Sulzer Pumps
Volute - Horizontal Split Diffuser - Segmental Ring Volute Barrel
BB3
BB5
BB4 – Not used on H.C.
Diffuser Barrel Casing High Speed Diffuser Barrel

BB5
BB5

Volute vs. Diffuser Casings Sulzer Pumps
Radial loads increase at Single Volute Casing

lower flow, and at flow rates
beyond best efficiency point.
The result is an unbalanced
radial load on the rotating
element.
Small, low flow pumps have
relatively small radial loads. FR

Volute vs. Diffuser Sulzer Pumps
A dual volute casing has Dual Volute Casing

an additional
passageway 180º from
the main throat area
which will almost balance
the generated radial
force.
Horizontally split, dual FR ~ 0
Volute Multistage Pumps
have 1 throat are in the
top half, 1 in the bottom
half - to balance radial
forces.

MultiStage Dual (MSD) Volute Sulzer Pumps
Volute throat in top

half of casing.
Volute throat in
bottom half is on
Top Half Casing
opposite side for
radial force balance.
Bottom Half Casing

Volute vs. Diffuser Sulzer Pumps
A diffuser has multiple Diffuser Casing

discharge passageways
with equal area
distributed throughout
the circumference -
resulting in radial load
balance.
FR = 0

Diffusers Sulzer Pumps
Diffuser – Discharge Side Diffuser – Suction Side
Impeller runs in center

Return Channels feed next stage
Stage casings
Axial Thrust Development Sulzer Pumps
Opposed Impeller Design
Fr Total = 0
Fr 1st Fr xst
Pd 1st X X Pd 1st Pd xst

X X Pd xst
Unbalanced pressure distribution on impellers results in a thrust in the

direction of suction.
Opposed impeller design offsets the unbalanced pressure distribution (thrust)
effectively balancing axial thrust. When there are odd number of stages, thrust is
handled by adjusting the diameter of the throttle bushing with residual handled by a
thrust bearing.
Axial Thrust Development Sulzer Pumps
Inline Rotor Stack
Fr Total = Fr 1st+Fr xst FDrum ~ 85% Fr Total
Fr 1st Fr xst FDrum
Pd 1st Pd 1st Pd xst

X X Pd xst
X X
Ps
Unbalanced pressure distribution on impellers results in thrust in the

direction of suction.
Stacked impeller design results in adding thrust in the direction of suction.
Developed thrust must be compensated by a hydraulic balancing device.
Residual thrust is handled by a thrust bearing.
Axial Thrust Compensation
Balance Drum Sulzer Pumps
Balances 85 - 90% of generated

Close clearance thrust. Residual thrust handled by
pressure breakdown
a thrust bearing.
With inline rotor stack, this is most
reliable design for transient
conditions (start up and run down,
temperature changes, daily starts
and stops).
PSuction PDischarge
Easy and safe axial rotor setting
due to radial gap as compared to
axial gap (explained on next
slide).
Rotor is fixed in the axially
position by thrust bearing.
Balance Drum Liner Higher amount of leakage - less

Balance Drum
efficient.

Axial Thrust Compensation
balance disk - Not allowed by ISO 13709 (API 610) Sulzer Pumps
Balances 100% of the generated

thrust.
Axial gap will No thrust bearing required.
adjust in
response to Rotor floats axially for proper
thrust changes operation.
Least amount of leakage - higher
PSuction PDischarge efficiency.
Disc lift off device required for
frequent starts and stops
ISO 13709 (API 610) Para. 5.7.1
requires radial running clearance
be used for axial thrust balance.
That precludes the use of this
device.
Potential for contact causes this
Counter Disk
design to be considered less
Balance Disk
forgiving than balancing drum
Inline Impellers vs. Opposed Impellers Sulzer Pumps
Sulzer GSG:
Inline diffuser Barrel Pump
GSG Back-to-Back diffuser Barrel Pump
Sulzer CP:
Opposed Impeller Volute Barrel Pump
Note: All are ISO 13709 (API 610) type BB5
Inline vs. Opposed Rotor Stack Sulzer Pumps
Direct drive, inline diffuser barrel pumps are the

least expensive barrel pumps to build.
High Speed inline pumps require tilting pad thrust
bearings and lube system, high speed seals, VFD or
gear speed increaser, etc. which add to the cost.

ISO 13709 (API 610) requires stable rotordynamics with 2 times normal
ISO 13709 (API 610) specified wear ring clearances.
Back to back diffuser stack is often used on smaller pumps or high
energy pumps with many stages where rotordynamics require a
midspan bearing. The Sulzer Thunderhorse 650 Bar, 13MW injection
pumps are designed in this manner.

The “K” factor – large barrel pumps Sulzer Pumps
“K factor”
2000 120
K Factor • Rotor Wt. in lbs.
1800 Shaft Span, in. Back to
100
1600 Back • Shaft Span, in.
1400 GSG,
80 • Shaft Dia. in.
1200
HPCP or
CP K=(W*L^3/D^4)^0.5
1000 60
800
40
600
Some say K factor of
400
20 </= 1200 is good;
200
“Semi-stiff shaft” is
0 0 another term they
Inline 3.38 Inline 4.25 B-B 3.38 use
Type / shaft size, inches
Lower “K” factor is generally better. It can be achieved either with fewer
stages & large high speed shaft on inline rotor, or back-to-back rotor and
direct drive

Rotor Sag Sulzer Pumps
For small pumps with many stages, the rotor will rest on center
bushing. When the pump starts, Lomakin effect lifts rotor for non-
contact running.
Non-galling material selection is important. Sulzer uses a stellite coated, or

nitrided throttle bushing and center bushing on opposed impeller pumps.

Back to Back (Opposed impeller)

diffuser or volute design is also
used in remote locations where
customers prefer not to have a lube
system to maintain. Opposed
impellers balance axial thrust and
may allow use of an antifriction
thrust bearing.
Back to Back (Opposed impeller)

volute multistage barrel pumps are
used in abrasive services where 2
large throat diameters are preferred in
lieu of many smaller diffuser throats.
The inner volute casing is larger in
diameter than diffusers so volute style
barrel pumps often cost more than
diffuser style

Direct Drive vs. High Speed Sulzer Pumps
Flow of a centrifugal pump varies High Speed, VFD or Gear; fewer stages
directly with RPM. Head produced by a
stage varies as the square of the RPM.
In other words, to make the same head,
operating a smaller pump 42% faster
would make the same head with half
the number of stages.
However, some customers prefer direct
drive 2 pole pumps for reliability and
reduced items to maintain. Direct drive
pumps often do not require these costly
accessories:
Low Speed, Direct Drive; more stages
- lube system & sleeve/pivot shoe
bearings
- more extensive instrumentation
- gear increaser
- special mechanical seals

Cartridge vs Non-cartridge designs Sulzer Pumps
A “Cartridge” design barrel pump allows

the inboard bearing housing and seal
chamber to be withdrawn from the
barrel with the bundle.
On small pump sizes this is impractical

because the IB bearing housing is
larger than the barrel opening on the IB
end.
On smaller pumps, a “Non-Cartridge”

design barrel pump requires the
inboard bearing housing and seal
chamber to be removed before
withdrawal of the bundle from the
outboard end. That adds a little time
to disassembly/reassembly but parts
are relatively small and can often be
handled by hand
High Temperature – Thermal Expansion Sulzer Pumps
To accommodate axial growth due The discharge end is equipped with a

to high temperature operation the key slot which will allows the barrel to
suction end of the barrel is expand in the direction of the NDE end.
equipped with a pin which fixes the The barrel to pedestal bolts are torqued
Drive End of the pump. to a specific value to accommodate the
axial growth.

Barrel Head Closure Methods Sulzer Pumps
Studs & Nuts – Most common – requires stretching or torquing

Supernuts – more expensive, no stretching; hand tool torquing
or
Sulzer’s Patented Twist Lock
On lower temperature services, to speed overhaul, some customers prefer
Sulzer’s patented Twist Lock barrel end cover design – no studs/nuts and no
torquing required.
Head Installed
Head partially
rotated
Head Rotated &
Locked

Sulzer Pumps
GSG: SMALLER SIZES

50 Hz, 2 pole motor speed
Gray or white are inline

rotor
Light blue are only

available in back-to-back
rotor

Sulzer Pumps
GSG: LARGER SIZES


rotor
Light blue are only

rotor

Sulzer Pumps
GSG: SMALLER SIZES


rotor
Light blue are only

rotor

Sulzer Pumps
GSG: LARGER SIZES


rotor
Light blue are only

rotor

Hydraulics Sulzer Pumps
A double suction
impeller reduces the
NPSHr by about 30%
Double suction first stage available on larger sizes

Impellers and Diffusers Sulzer Pumps
Hydraulic layout
Multiple hydraulic impeller &
diffuser sets per pump size
Mixing of impeller / diffuser
hydraulics in single pump is
possible
Double suction first stage is
available in larger size pumps
Dynamic balanced impellers &
rotor > 3 stages
Radial load is balanced

Mixing of Impeller Hydraulics with
Interstage Bleed Off Sulzer Pumps
Pumped Medium : Boiler Feed Water Speed : 3570 rpm MD 100-300 / 8

Density : 909.2 kg/m³ Stage Number : 8
Temperature : 318 °F nq : 20.0 Note the all “B”
kinem. Viscosity : 0.19 mm²/s Impeller Set : B/B/B Tender : /1
Head (design) : 4,600 ft Basis 4335.11.11/2 & 4335.11.11/2
impeller hydraulics
Characteristic : TS/1
Capacity (design) : 900 gpm & 4335.11.11/2 Impeller diameter : 11.1 inch
Total efficiency : 75.8 % Extraction head : 1,268 ft Impeller dia. (max) : 11.8 inch
Pump Power : 1,350 HP Extraction capacity : 250 gpm NPSHR : 19 ft
6000
Note efficiency = 75.8%

and power is 1,350 hp
5000
RATED
4000
Max. ∅
By mixing impeller
H [ ft ]
3000
hydraulics efficiency and

power can be optimized
2000
Max. ∅
1000
RATED
0
0 gpm 200 gpm 400 gpm 600 gpm 800 gpm 1000 gpm 1200 gpm 1400 gpm 1600 gpm 1800 gpm 2000 gpm

Mixing of Impeller Hydraulics with
Interstage Bleed Off Sulzer Pumps
Pumped Medium : Boiler Feed Water Speed : 3570 rpm MD 100-300 / 9

Density : 909.2 kg/m³ Stage Number : 9
Temperature : 318 °F nq : 20.0 Now the “B” hydraulics have
kinem. Viscosity : 0.19 mm²/s Impeller Set : B/B/S Tender
been replaced : /1 with “S” after
Head (design) : 4,600 ft Basis 4335.11.11/2 & 4335.11.11/2 Characteristic : TS/1
Capacity (design) : 900 gpm & 4335.11.21/1 thediameter
Impeller interstage bleed
: 10.9 inch off.
Total efficiency : 78.7 % Extraction head : 1,268 ft Impeller dia. (max) : 11.0 inch
Pump Power : 1,301 HP Extraction capacity : 250 gpm NPSHR : 19 ft
6000
Efficiency now = 78.7% and power is

1,301 hp (49 hp reduction)
5000
RATED
4000
Max. ∅
By mixing impeller
H [ ft ]
3000
hydraulics efficiency and

power can be optimized
2000
Max. ∅
1000
RATED
0
0 gpm 200 gpm 400 gpm 600 gpm 800 gpm 1000 gpm 1200 gpm 1400 gpm 1600 gpm 1800 gpm
0

Bearing Type Selection Sulzer Pumps
Power @ BEP - HP (3600 rpm)
5000
4000 Pivot Shoe Thrust & Sleeve

Radial – Lube System required
3000
Anti-Friction Thrust & Sleeve
2000 Radial – Ring Oil Lube
1000 Anti-Friction Thrust & Radial –

Ring Oil Lubrication
0
0%
0%
0%
0%
%
%
20
30
40
50
60
70
80
90
11
12
13
10
Pump Flow - % of BEP
Exact bearing system will depend upon application GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 32
Anti-Friction with Ring Oil Lubrication Sulzer Pumps
Radial Bearing
Thrust Bearing
Cooling Fan
Oil Rings
Oil Reservoir
Ring Oil Lubrication – Oil rings rotate with shaft, dip down into an oil reservoir
and “throw” oil onto bearings. Grooves or channels are located in the bearing
housing to distribute oil throughout the bearing(s). Shaft mounted cooling fans
provide cooling up to a liquid temperature of 177o C (350° F).
Anti-Friction Thrust & Sleeve Radial Bearings
with Ring Oil Lubrication (GSG Back-to-Back only) Sulzer Pumps
Thrust Bearing
Radial Bearings
Cooling Fan
Oil Rings
Oil Reservoir
Ring Oil Lubrication – Oil rings rotate with shaft, dip down into an oil reservoir and “throw”
oil onto bearings. Grooves or channels are located in the bearing housing to distribute oil
throughout the bearing(s). Shaft mounted cooling fans provide cooling up to a liquid
temperature of 177o C (350° F). Optional water cooled finned tubing is available.
Double Acting Tilting Pad Thrust & Sleeve
Radial Bearings with Force Feed Oil Lubrication Sulzer Pumps
Double Acting, Tilting Pad Thrust

Bearing Sleeve Radial Bearings
Shaft Driven Oil Pump
Forced Feed Lubrication – Bearing lubrication is provided by an external lube oil

system. Depending on specification requirements lube oil systems can be very
basic or very elaborate. Standard lube system could cost < 20,000 Euro/USD.
ISO 13709 (API 610) Lube system is typically 40,000 Euro/USD. ISO 10438 (API
614) could be 3 to 4 times that cost. If customers specify lube systems, they often
specify bearing RTD’s and vibration measurement instrumentation which adds
further cost. GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 35
Journal and Thrust Bearing Arrangement Sulzer Pumps
Sleeve Bearings

Tilting Pad Thrust Bearing Arrangement Sulzer Pumps
Thrust Bearing Lubrication
An “oil wedge” builds up

between each stationary thrust
pad and the rotating collar, and
no metal-to-metal contact
occurs during normal
operation.
The babbit lining of the

pads is designed to be
tolerant of any minute
particles of grit that may get
through.

Journal and Thrust Bearing Arrangement Sulzer Pumps
Double Acting “Pivot Shoe” or “Tilting Pad” Thrust Bearing

Forced Feed Lube Oil Systems Sulzer Pumps

Seal Chambers & Jackets Sulzer Pumps
Seal Chambers are

designed to ISO 13709
(API 610) Table 6
dimensions and features.
ISO 21049 (API 682)
single, double or tandem
seals are available
Seal Chamber cooling or

heating jackets are
available on this model
pump.

Seal Flush Plans Sulzer Pumps
TI
FO FI Q/D
A variety of seal flush plans are available

Instrumentation - options Sulzer Pumps
NDE X-Y Shaft vibration Balance Leakoff flow DE Shaft vibration
DE Bearing
NDE Bearing temperature
temperature
In lieu of more expensive X-Y

probes & proximitors, normally Barrel Temperature,
bearing bracket velocity is Bottom & Top (for hot
adequate for direct drive pumps standby)

Vibration Instrumentation Sulzer Pumps
Firm contact from shaft

to bearing frame
Velomitors
With anti-friction bearings the shaft is firmly connected to the bearing frame via
the bearings.
Any vibration of the rotating element will be transferred from the shaft to the
bearings to the bearing housings and there will not be any relative movement of
the shaft to the bearing housings.
Vibration is measured by the relative RMS velocity or acceleration of the
bearing frame - by either velomitors or accelerometers.
Vibration Instrumentation Sulzer Pumps
Film contact from shaft

to bearing frame
Probes and Proximitors
With sleeve bearings, the shaft “floats” on a film of oil and is free to move
within the clearance of the sleeve bearings.
This allows the rotating element to vibrate within the sleeve bearings while
the actual bearing frame may not vibrate at all.
Vibration is the relative movement of the shaft within the bearing frame.
Probes are mounted with very close proximity to the shaft (Bently Nevada
type systems) to detect displacement movement.
API Material Classes Sulzer Pumps
Material classes and abbreviations
S-1 S-5 S-6 C-6

Part
12% Chrome/ 12%
CS/Cast Iron CS/CS CS/12% Chrome
Chrome
Pressure Casing Carbon Steel Carbon Steel Carbon Steel 12% Chrome
Inner Case Cast Iron Carbon Steel 12% Chrome 12% Chrome
Impeller Cast Iron Carbon Steel 12% Chrome 12% Chrome
12% Chrome 12% Chrome 12% Chrome

Case Wear Rings Cast Iron
Hardened Hardened Hardened

Impeller Wear Rings Cast Iron
Shaft Carbon Steel AISI 4140 AISI 4140 12% Chrome

Throat Bushings Cast Iron

Interstage Sleeves Cast Iron

Interstage Bushings Cast Iron
Case and Gland Studs AISI 4140 AISI 4140 AISI 4140 AISI 4140

API Material Classes Sulzer Pumps
Material classes – cont’d.
A-8 D-1 D-2

Part
316SS/316SS Duplex SS Super Duplex
Pressure Casing 316L SS Duplex S.D.
Inner Case 316L SS Duplex S.D.
Impeller 316L SS Duplex S.D.
Case Wear Rings Duplex SS Duplex S.D.
Impeller Wear Rings 316l SS HF Duplex S.D.
Shaft Duplex SS Duplex S.D.
Throat Bushings 316L SS HF Duplex S.D.
Interstage Sleeves 316L SS Duplex S.D.
Interstage Bushings 316L SS HF Duplex S.D.
Case and Gland Studs AISI 4140 AISI 4140 AISI 4140

Pre-Warming Sulzer Pumps
On Horizontally split multistage pumps, the casing is not uniformly thick. It

has very heavy cross sections that take time to reach operating
temperature.
The rotor & lower

half casing gets
hot and expands
quickly.
Pre-warming of this style pump is required. Maximum ramp-up temperature

is 10º C (20ºF) per minute and 110ºC (200 ºF) instantaneous thermal shock

Pre-Warming Sulzer Pumps
The Sulzer GSG Pumps are designed with uniform thicknesses and
clearances on the inner case components to minimize distortion. Warmup
is not required on many applications < 260oC (500oF).
Above that temperature, the barrel drains can be used to uniformly warm
the pump, or maintain hot standby.
Barrel RTD’s can provide

indication of uniform
temperatures.

GSG Cross Section and Features Sulzer Pumps
Radial split Interstage bleed

identical stage connections Low NPSH 1st stage
casings, diffusers available impeller. Double
and impellers suction available.
Thrust bearing - anti-

friction or double acting
tilting pad.
Radial bearing - sleeve
or anti-friction. Bearings
protected by
Labyrinth type
oil seals
Studs & Nuts,

Radial Split barrel
Super-nuts or Twist
casing with confined
Lock barrel closure
gasket. Either casting
on Back-to-Back
Stacked rotor design with or forging available.
only
Hydraulic balance staggered keyways to
device is Drum type provide positive torque to
impellers

Pictures Sulzer Pumps
GSG Boiler Feed pump with speed increasing gearbox, lube system,
suction strainer and automatic recirculation control valve

GSG portion of
hydrotreater train (GSG
pump, clutch, MSD-T
power recovery turbine)
with full instrumentation
and insulation.
Sleeve bearing RTD,

Active Thrust RTD,
Inactive thrust RTD,
X-Y vibration probes,
Key phasor.

10 stage GSG on 0.4

Sp.Gr. cold Ethylene
VFD driven at > 4,000
RPM with fan cooled
antifriction bearings

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Sulzer ISO 13709 (API 610) Sulzer Pumps

Type BB5 Barrel Pumps

The Heart of Your Process

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 2

Volute - Horizontal Split Diffuser - Segmental Ring Volute Barrel

Diffuser Barrel Casing High Speed Diffuser Barrel

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 4

Radial loads increase at Single Volute Casing

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 5

A dual volute casing has Dual Volute Casing

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 6

Volute throat in top

Bottom Half Casing

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 7

A diffuser has multiple Diffuser Casing

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 8

Diffuser – Discharge Side Diffuser – Suction Side

Impeller runs in center

Opposed Impeller Design

Pd 1st X X Pd 1st Pd xst

 Unbalanced pressure distribution on impellers results in a thrust in the

Inline Rotor Stack

Fr Total = Fr 1st+Fr xst FDrum ~ 85% Fr Total

Fr 1st Fr xst FDrum

Pd 1st Pd 1st Pd xst

 Unbalanced pressure distribution on impellers results in thrust in the

 Balances 85 - 90% of generated

Balance Drum Liner  Higher amount of leakage - less

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 12

 Balances 100% of the generated

GSG Back-to-Back diffuser Barrel Pump

Direct drive, inline diffuser barrel pumps are the

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 15

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 16

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 17

Non-galling material selection is important. Sulzer uses a stellite coated, or

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 18

Back to Back (Opposed impeller)

Back to Back (Opposed impeller)

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 19

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 20

A “Cartridge” design barrel pump allows

On small pump sizes this is impractical

On smaller pumps, a “Non-Cartridge”

To accommodate axial growth due The discharge end is equipped with a

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 22

 Studs & Nuts – Most common – requires stretching or torquing

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 23

GSG: SMALLER SIZES

 Gray or white are inline

 Light blue are only

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 24

GSG: LARGER SIZES

 Gray or white are inline

 Light blue are only

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 25

GSG: SMALLER SIZES

 Gray or white are inline

 Light blue are only

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 26

GSG: LARGER SIZES

 Gray or white are inline

 Light blue are only

Unbalanced pressure distribution on impellers results in a thrust in the

Unbalanced pressure distribution on impellers results in thrust in the

Balances 85 - 90% of generated

Balance Drum Liner Higher amount of leakage - less

Balances 100% of the generated

Studs & Nuts – Most common – requires stretching or torquing

Gray or white are inline

Light blue are only

Gray or white are inline

Light blue are only

Gray or white are inline

Light blue are only

Gray or white are inline

Light blue are only