Process Engg - Design Guide - Pumps
Process Engg - Design Guide - Pumps
Process Engg - Design Guide - Pumps
GUIDE DOCUMENT
Issued
Book N
Chapter N
312
1.1.2.
VIII
CONTENTS
1.
PUMP SELECTION
1.1.
1.2.
2.
Pump selection
Flow control
CENTRIFUGAL PUMPS
2.1.
2.2.
2.3.
2.4.
Shaft power
Pump efficiency
Viscosity correction factor
Electrical motor efficiency
Criteria for motor selection
Power at reduced capacity
Pump suction specific speed Nss
3.
4.
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PUMP SELECTION
1.1.
Flow control
Whatever the type of pump is, the flow can always be controlled by adjusting the
speed ; at a fixed speed, flow can be often adjusted through control valve, throttling
valve, etc.
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CENTRIFUGAL PUMPS
2.1.
2.1.1.
2.1.2.
At a given speed
The Impeller shape offers a constant cross sectional area (exit velocity triangles
remain similar) :
- The flowrate is directly proportional to D
- The head H is directly proportional to D2
- The power P is directly proportional to D3 (at fixed efficiency).
The cross sectional area through the impeller increases with the diameter :
2.1.3.
NPSH
It is directly proportional to n2, but does not vary with the diameter of the impeller
(provided that the diameter reduction is less than 20%). The use of inducers allows to
decrease the NPSH required.
n : Impeller speed (revolution per minute, rpm).
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2.2.
2.2.1.
Rating point
The pump rating point shall be located as close as possible from the maximum
efficiency, but should not go beyond in terms of flowrate.
2.2.3.
Minimum flow
A minimum flow shall always be maintained in a centrifugal pump. This may require
a manual or automatic recirculation by-pass (restriction orifice, valve or "schroeder"
check valve).
The minimum flow is specified by the pump supplier. It is usually 20 to 30% of the
nominal flow, excepted for high-speed pumps, for which performance curves are
bell-shaped and the minimum flow can be up to 50% of normal flow.
2.2.4.
Materials of construction
The main characteristics of various types of centrifugal pumps are summarized in the
following table :
Centrifugal
pumps
Flowrate
Viscosity
(%)
NPSH
Required
(m)
Flow
control
(m3/h)
Single-stage pump
Single-stage pump
1500
10 to 80
1 to 4
Valve
Low
3000
10 to 80
1 to 5
Valve
Low
180
20000 max.
20 to 60
1 to 5
Valve
Moderate
< 500
35
3000
10 to 75
2 to 5
Valve
Moderate
< 500
140
3000
10 to 80
3 to 8
Valve
Moderate
Current
speed
(rpm.)
Efficiency
(cSt)
Differential
pressure
(bar)
2000
< 500
15
1500
< 500
35
Single-stage Sundyne
pump
90
< 500
Double-stage pump
250
Multi-stage pump
1500
Sensitivity
to solid impurities
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H-3
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2.4.
Power estimation
2.4.1.
Shaft power
P (kW ) =
2.4.2.
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Q (m3 / h x P (bar)
36 x (pump ' s efficiency )
Pump efficiency
A standard nominal power shall be selected for the motor. The nominal power will be the
standard nominal power immediately above the absorbed power at design conditions.
API 610 selection criteria shall be followed, i.e. the ratio of motor nominal power and
pump shaft power at rating point shall not be less than :
1.25 if the shaft power at rating point is < 22 kW
1.15 if the shaft power at rating point is from 22 to 55 kW
1.1 if the shaft power at rating point is > 55 kW.
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When the pump is specified for open-valve start-up, the absorbed power at maximum
flow (end of the curve flow / head) shall be considered to select the motor, excepted for
high specific velocity pumps for which the maximum absorbed power corresponds to
minimum flow.
Practically, to calculate the power at maximum flow (end of the curve flow / head), the
Mechanical Department will consider 125% of the flow at B.E.P. (Best Efficiency Point).
The standard nominal powers of electric motors are given alongside with motor
efficiency values in the table enclosed further on.
Generally, low voltage motors (380 V) are used so long as the nominal power does not
exceed 132 kW and high voltage motors (5500 V) for higher values. However, the limit
between low and high voltage tends to increase, and a limit of 160 or even 200 kW may
be considered. This is usually defined in a Project general specification.
Examples of calculations :
The shaft power required for a pump at design conditions is equal to 7 kW. From the
table given further on, we obtain :
Motor efficiency : 85% for a 7.5 kW motor
Motor efficiency : 86% for a 11 kW motor.
For the 7.5 kW motor, the absorbed power is 7 / 0.85 = 8.2 kW. This motor is not
acceptable because the absorbed power (8.2) exceeds the nominal power (7.5).
For the 11 kW motor, the absorbed power is 7 / 0.86 = 8.1 kW. This motor is acceptable
because the absorbed power (8.1) is lower than the nominal power (11).
Checking of the API 610 criteria
For the 11 kW motor, the ratio (motor nominal power / pump shaft power) equals 11 / 7
i.e. 1.57 > 1.25. The criteria is met.
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Example n 2
The shaft power required for a pump at design conditions is equal to 12.2 kW. From the
table given further on, we obtain :
Motor efficiency : 87 % for a 15 kW motor
Motor efficiency : 88 % for a 18.5 kW motor.
For the 15 kW motor, the absorbed power is 12.2 / 0.87 = 14 kW. This motor is
acceptable because the absorbed power (14) is lower than the nominal power (15).
For the 18.5 kW motor, the absorbed power is 12.2 / 0.88 = 13.9 kW. This motor is
acceptable because the absorbed power (13.9) is lower than the nominal power (18.5).
Checking of the API 610 criteria
For the 15 kW motor, the ratio (motor nominal power / pump shaft power) equals
5 / 12.2 = 1.22 < 1.25. The criteria is not met.
For the 18.5 kW motor, the ratio (motor nominal power / pump shaft power) equals
18.5 / 12.2 = 1.5 > 1.25. The criteria is met.
2.4.6.
w
w
2Y
2.4.7.
N
Q
NPSHreq
rpm.
m3/h
m
This criteria is used by the Mechanical Department for pump selection when a maximum
value is imposed by the Client ; If not, it is only used as a guideline.
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The Nss is calculated for the flow giving the best efficiency with the impeller maximum
diameter. This means that for a same service, two pump suppliers will usually provide
different Nss depending on the position of the operating point.
In some particular cases, an increase of the NPSH required (consequently of the NPSH
available) can be desirable to get an acceptable Nss value. But this case is uncommon
because few suppliers can propose two NPSH for a same pump model (different wheels
for a same pump casing).
The Process Department does not have to verify this criteria ; It has to be done by the
Mechanical Department.
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380 V
Nominal P
kW
5500 V
Efficiency
%
0.75
1.1
1.5
2.2
3
4
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
70
73
74
77
79
80
85
86
87
88
89
90
90.5
91
91.5
92
92.5
93
93.5
Nominal P
kW
160
200
290
400
500
750
1 000
1 500
2 000
3 500
5 000
> 5000
Efficiency
%
91
92
93
93.5
94
94.5
95
95.5
96
96.5
97
97
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HA and HB
PA
TV
g
r
D PAB
HAB
( PA TV
(PAB )2 + (H AB )2
5
g x x 10
0.5
: Height in m
: Suction pressure in bar a
: Vapour pressure of the pumped liquid in bar a
: Gravity factor in m / s2
: Density in kg / m3
: Pressure drop due to friction in m
: Acceleration head
Equation 1 (Note 1)
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For centrifugal pumps, HAB is nil and DPAB does not depend on the pump. The NPSHa is
independent of the selected pump.
For a reciprocating pump, HAB and DPAB depend on the pump, the NPSH available is
dependent on the selected pump :
D PAB : Pressure drop due to friction, is calculated for the maximum liquid velocity
HAB : Acceleration head, depends on the pumping rate.
During the preparation of the process specification, the characteristics of the pump are
unknown and the NPSHa (from equation 1) cannot be calculated. The NPSH given in the
process specification is the NPSHa for a non-pulsed flow, i.e. :
The NPSH available calculated is the one calculated as for a centrifugal pump, (HAB nil
and D PAB calculated for an average velocity which corresponds to the average flow
indicated in the specification).
Only after pump selection, provided that the piping layout at pump suction is defined, the
NPSH available for the selected pump can be given. Subsequently, the following note is
written on the process specification :
"The Mechanical Department must check with the supplier that the NPSH available
corresponding to the pump is compatible with its NPSH required."
D PAB calculation :
The pressure drop due to friction is calculated as for a centrifugal pump, but the
maximum liquid velocity, corresponding to the maximum instantaneous flow of the liquid
in the suction pipe, has to be considered. Depending on the type of pump selected, the
maximum instantaneous flow can be calculated by multiplying the average design flow
by the following factor :
Double-acting pump
Single-acting pump
Simplex
Duplex
Triplex
Quadruplex
Others
3
2
2
1.5
1.3
2
1.5
1.3
1.3
1.3
Note - If a pulsation dampener is installed on the suction line, the factor to consider is 1.2
whatever the type of pump is.
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HAB Calculation :
H AB = 0.712 x K x
QxNxL
D2
Equation 2 (Note 2)
Where :
HAB
Q
N
D
L
K
:
:
:
:
:
:
In m
Average design flow in l/min
Number of rpm
Pipe diameter in mm
Pipe length in m
Factor depending on the type of the pump
Single-acting pump
Simplex
Duplex
Triplex
Quadruplex
Others
Double-acting pump
1.00
0.50
0.166
0.125
0.10
0.50
0.29
0.166
0.10
0.10
In case the suction line comprises several piping diameters, HAB must be calculated for
each section, and the results added.
The equation 2 above derives from the following assumptions :
The motion generated by the pump is assumed to be a harmonical one,
The fluid is assumed to be incompressible.
The first assumption is never realised. Usually, the motion generated by the connecting
rod-crank assembly exceeds the maximum values of the harmonic curve. This excess
depends on the ratio r = (length of the connecting rod / length of the stroke), which
commonly ranges from 1.5 to 2.
The maximum acceleration head must be increased by 25 to 35%.
The second assumption is checked when the suction pressure is close to the atmospheric
pressure, which is usually the case for reciprocating pumps.
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Remark : When a pulsation dampener is installed on the suction line, the acceleration
head between the pulsation dampener and the pump must be calculated from equation 2.
The acceleration head between the drum and the pulsation dampener will be taken as 10%
of the calculated value from equation 2. The two heads have to be added to obtain the
total acceleration head.
Notes
4.
1.
There is a phase shift between the pressure drop due to friction D PAB and the
pressure drop caused by acceleration HAB (acceleration is maximum when the
velocity is minimum).
This phenomenon is taken into account by the term [(PAB)2 + (HAB)2]05 in
equation 1.
2.
Some sources indicate equation 2 as being unrealistic when the suction line is
very long.
divide by 1.25
divide by 2 or consider liquid at bubble point.
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Type of
reciprocating pump
NPSH
Usual
Global
velocity efficiency required
%
m
rpm
Flow
Viscosity
m3/h
cSt
100 (simplex)
250 (duplex)
1800
20 to 350 usually
700 and more possible
0-70
45-80
3-4
Controlled piston
pump (or plunger)
300 (multiplex)
1800
20-450
55-85
4-5
20 by head
1000
350 usually
3000 possible (metal
diaphragm)
150-200
80
4-5
50
1800
0-40
250000
500
3000
Possible
50-200
Dosing pump :
Maxi range
Usual range
0-10
0-3
Differential
pressure ( )
bar
2 to 4
20
4-5
(
) the maximum values indicated for flow and differential head may not be simultaneous.
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Type of rotary
pump
Gear
Screw :
- 2 screws
- 3 screws
Vanes
Flow (1)
Viscosity
m3/h
cSt
Differential
pressure (1)
bar
Usual
velocity
rpm
Global
efficiency
%
NPSH
required
m
200
10 x 106
250
0-3000
50-90 (2)
3-4
1000-2000
1000
1 x 106
2 x 106
200
200
2000
up to 15000
50-90
50-90 (2)
3-4
3-4
400
1 x 106
25
0-1500
Remarks
Max. temperature : 3500C
Max. temperature : 3000C
Pistons
up to 50
(3)
up to 700
2000-3000
Deformable rotor
20
20000
2-4
200-1800
10 to 30
200
1 to 200000
50
0-1500
50
1-5
Lobes
200
1 to 200000
5-20
< 700
30-40
1-5
Deformable stator
20
25000
5-15
0-200
30-50
Mouvex
120
3-5
250-1400
45-50
(1)
(2)