Oil & Gas Processing Plants Design and Operation Training Course

DGEP/SCR/ED/ECP - 24th March-4th April 2003

ROTATING EQUIPMENT

DGEP/SCR/ED/ECP - 24th March-4th April 2003

CONTENT

Pumps

DGEP/SCR/ED/ECP

PUMPS

Pumps classification Centrifugal pumps performance Centrifugal pumps in operation

DGEP/SCR/ED/ECP

PUMPS CLASSIFICATION

Volumetric (Positive Displacement)

- Reciprocating (Chemical lnj : TEG Circulation, ...)
- Rotating (Lube oil, Viscous fluids, ...)

Dynamic (Variable Head)

- Centrifugal (General Process, Liquid Exports, ...)

- Axial (Very high flowrate : Cooling water, ...)

DGEP/SCR/ED/ECP

PUMPS

DGEP/SCR/ED/ECP

GEAR PUMPS

DGEP/SCR/ED/ECP

SCREW PUMPS

DGEP/SCR/ED/ECP

PUMPS

DGEP/SCR/ED/ECP

HORIZONTAL IN-LINE PUMPS

DGEP/SCR/ED/ECP

10

MULTISTAGE - AXIALLY SPLIT ALONG THE HORIZONTAL CENTER LINE

(HORIZONTAL JOINT SURFACE)

DGEP/SCR/ED/ECP

11

 LIGHT PROCESS - PUMP - API

DGEP/SCR/ED/ECP

12

MULTISTAGE - AXIALLY SPLIT ALONG THE VERTICAL CENTER LINE

(VERTICAL JOINT SURFACE)

DGEP/SCR/ED/ECP

13

VERTICAL IN - LINE PUMP

DGEP/SCR/ED/ECP

14

 LIGHT PROCESS - PUMP - EUROPEAN

DGEP/SCR/ED/ECP

15

 HEAVY PROCESS - PUMP -

DGEP/SCR/ED/ECP

16

VERTICAL SUMP PUMP

DGEP/SCR/ED/ECP

17

VERTICAL BARREL OR CANNED PUMP

DGEP/SCR/ED/ECP

18

LIQUID HYDRAULIC PATH IN A CENTRIFUGAL PUMP

DGEP/SCR/ED/ECP

19

PRESSURE VELOCITY EVOLUTION IN A CENTRIFUGAL PUMP

DGEP/SCR/ED/ECP

20

PUMPS

The logical steps in the initial selection of a pump are as follows : Determine the flowrate Design the piping system Determine the differential head = static + dynamic Flow & head = the pump duty point Net positive suction head available Select a pump Flowrate Determined by No of pumps operated simultaneously. No of pumps : Plants reliability and the criticality of the service. In critical service : 2 x 100% or 3 x 50%

DGEP/SCR/ED/ECP

21

DIFFERENTIAL HEAD

Static Head difference : the difference in levels between the starting point of the system.
Pressure Head difference : the difference in static pressure between the starting point and the finishing point of the system.

Frictional Resistance : the head due to the resistance to flow as the liquid moves through the system.

DGEP/SCR/ED/ECP

22

STEPS FOR ESTIMATING PRESSURE DIFFERENTIAL

Calculate system resistance (Conservatism : high static level and pressure differential, and the highest expected pipe friction). Calculate system resistance (best case : low of static level and pressure differential and the lowest pipe). Plot these curves as the extremes expected from the behaviour of the system.

Select pumping equipment that successfully meets all reasonably expected operating conditions.

DGEP/SCR/ED/ECP

23

SYSTEM RESISTANCE CURVE

DIFFERENTIAL HEAD (Pr - Pa) Hmt = ---------------------- + (Zr - Za) + Hfa + Hfr

g
DGEP/SCR/ED/ECP

@ P,T

24

CENTRIFUGAL PUMP - SINGLE STAGE PERFORMANCE

Qv = d UR

2 3

d p NR Qv = --------------30 W=mU
2 2

DP m (pNR) W = -------- = ---------- (30) 2 where : d : flow coefficient m : manometric coefficient Qv : volumetric flowrate (m3/s) U : peripheral speed (m/s) R : impeller external radius (m) N : rotational speed (RPM) W : massic energy to fluid (J/kg)
DGEP/SCR/ED/ECP 25

DIFFERENTIAL HEAD

DGEP/SCR/ED/ECP

26

RELATIONSHIP HEAD - FLOW

DGEP/SCR/ED/ECP

27

PUMP AND SYSTEM CURVE

DGEP/SCR/ED/ECP

28

HEAD-CAPACITY AND PIPING SYSTEM RESISTANCE CURVE

DGEP/SCR/ED/ECP

29

RELATIONSHIP POWER - FLOW

DGEP/SCR/ED/ECP

30

ANALYSIS OF MAXIMUM FLOW

WHEN HALF CAPACITY PUMPS ARE IN PARALLEL SERVICE

QR1 = Rated capacity of each half capcity s pump Qmax1 = Maximum capicity of single pump Qmax2 = Maximum operating flow obtained by two half capcitys pumps in service
DGEP/SCR/ED/ECP 31

FLOW OR TWO IDENTICAL PUMPS IN SERIES OPERATION

DGEP/SCR/ED/ECP

32

FLOW CONTROL BY VARYING PUMP SPEED

DGEP/SCR/ED/ECP

33

ESTIMATION OF CENTRIFUGAL PUMPS EFFICIENCY

DGEP/SCR/ED/ECP

34

PROCESS DATA SHEET PUMP

DGEP/SCR/ED/ECP

35

PUMP CALCULATION DATA SHEET

DGEP/SCR/ED/ECP

36

THE EFFECT OF VAPORIZATION ON THE HEAD-FLOW CURVE

DGEP/SCR/ED/ECP

37

THE DIFFERENCE BETWEEN REAL AND APPARENT CAVITATION

DGEP/SCR/ED/ECP

38

THE DIFFERENCE BETWEEN NPSH absolute AND NPSHR MEASURED USING AERATED WATER

DGEP/SCR/ED/ECP

39

NPSH available

2 Po Co PVt NPRHA = ------ + -------- - ------- 2g

(Pa - PVt) NPRHA = ----------------------------- + Za - Hfa

@ P,T

DGEP/SCR/ED/ECP

40

CENTRIFUGAL PUMP - SUCTION CAPACITY

NPSH Required
NPRHR = From Pump vendor NPSH Available

NPRHA =

P0 --------

C0 -------2g

- --------
+ Za Hfa

PVt

(Pa - PVt) NPRHA = ----------------------

@ P,T

NPRHA = NPRHR + 1 m

DGEP/SCR/ED/ECP

41

CENTRIFUGAL PUMP - SUCTION CAPACITY

Where: Po = Dynamic press. at pump inlet Co = Fluid velocity at pump inlet P1 = Minimum pressure in pump Pa = Pressure in upstream vessel (bar) PVt = Vapor pressure of fluid @ T (bar)

= density

G = gravity constant Za = Liquid level elevation in upstream vessel (m) Hfa = Suction pressure losses (m)

P, T = Pumping conditions

DGEP/SCR/ED/ECP

42

TYPICAL CENTRIFUGAL PUMP PERFORMANCE CURVES

DGEP/SCR/ED/ECP

43

CENTRIFUGAL PUMP - CHARACTERISTICS

TOTAL MANOMETRIC HEAD DP.10.2 Hmt = -----------------SpGr@P,T SHAFT POWER DPQv Ps = ----------36 h
g

Hmt Qv SpGr@P,T Ps = ---------------------------367 h g

DGEP/SCR/ED/ECP

44

CENTRIFUGAL PUMP - CHARACTERISTICS

where : Hmt : manometric head (m) DP : pressure increase (bar) SpGr : specific gravity (no unit) Ps : shaft power (kW) Qv : actual volumetric flowrate (m3/h) h g : overall efficiency P,T : pumping conditions

DGEP/SCR/ED/ECP

45

NPSH

Will cavitation occur at pump suction ? The NPSH (available) : NPSH(a) = Hs + hs - DPs - Pv Hs = absolute pressure head (in suction vessel) hs = minimum liquid level above pump suction centreline DPs = friction losses in suction piping Pv = vapour head NPSHA > NPSHR
(NPSHR obtained from the pump manufacturer)
46

DGEP/SCR/ED/ECP

SUCTION PIPING

The pump should be installed as close as practical to the liquid source. Inlet piping should be as short and as simple as possible. Minimise friction losses and maintain Net Positive Suction Head at adequate levels at all intended flow rates. Avoid potential air or vapors traps ; eg : use flat-top reduces, avoid inverted loops, etc Avoid swirl or uneven flow-avoid elbows, bends and other devices that change flow directions close to the pump. If unavoidable, it may be necessary to install flow straighteners.
DGEP/SCR/ED/ECP 47

AFFINITY LAWS

DGEP/SCR/ED/ECP

48

LOW FLOW RECIRCULATION BY FIC

DGEP/SCR/ED/ECP

49

LOW FLOW RECIRCULATION BY OUTLET CHECK VALVE

DGEP/SCR/ED/ECP

50

DGEP/SCR/ED/ECP

51

DGEP/SCR/ED/ECP

52

NAUTILUS PROJECT

Nautilus is a subsea 1.3 MW electrically driven multiphase booster station.

The development of this project is being led by TOTAL with Sulzer having overall responsibility for thepump/motor unit. Nautilus has been designed for installation up to about 60 km (37 miles) from the receiving platform which is therefore expected to improve significantly the economic viability of subsea satellite or remote fields.

DGEP/SCR/ED/ECP

53

PUMP PACKAGE FEATURES AND BENEFITS

DGEP/SCR/ED/ECP

54

DGEP/SCR/ED/ECP

55

Centrifugal pump with inducer

DGEP/SCR/ED/ECP

56

Performance correction chart for viscous flow

DGEP/SCR/ED/ECP

57

DGEP/SCR/ED/ECP

58