1- Pumps operations and troublshooting.pptx

Bearing and pumps

1. CNPC Niger Petroleum S.A. CNPC Niger Petroleum S.A. Production, Gathering & Transportation Operations Lecture-1: Pumps, Bearings & sealings

2. Contents 2

3. Learning objectives Learning objectives 3

4. Check that the valve body is intact, the valve parts should be complete and in good condition, bolts and nuts should be tightened to prevent loosening, stuffing box gland bolts should be tightened promptly, and all connecting bolts on the valve should be present with bolts protruding 2 to 3 threads beyond the nut as appropriate. Missing parts should be replaced or completed in a timely manner. Additionally, the valve should not be subjected to hammering, heavy objects should not be placed on it, nor should people stand on it to avoid damage to the valve. 4

5. A wide variety of pumps are used in petroleum industry. A pump is used to increase the total energy content of a liquid in the form of pressure increase. -Move liquids from low level to high level -Move liquids from low pressure location to high pressure location -Hydraulic Systems -To increase the flow rate of a liquid 1- FUNCTION OF PUMPS The pumps are used to perform one of the following jobs:

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7. Pump is used to convert Mechanical Power into Hydraulic Power Definition ( Mech. Energy ) ( Hyd. Energy ) P

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9. Pumps Turbine MOTION HYDRAULIC ENERGY HYDRAULIC ENERGY MOTION

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11. Pump Drives The source of power for a pump could be an electric motor, a gas or diesel internal combustion engine, a gas, water, or steam turbine, a steam engine, or a steam operated piston. Small pumps may be operated by hand or foot, by air pressure or another fluid pressure, or an electromagnet.

12. 12 35 psi S.G.- 1.2 S.G.- 1.0 S.G.- 0.7 H=115ft H=115ft 50 psi 60 psi H=115ft Head is totally independent of (specific gravity) of the liquid Pressure is dependent on the (specific gravity) of the liquid

13. CENTRIFUGAL POSITIVE DISPLACEMENT DIAPHRAGM 2- Pumps Classification ROTARY GEAR VANE LOBE SCREW OTHERS RECIPROCATING PISTON PLUNGER OTHERS JET LIQUID RING MANY TYPES

14. Main Types Pumps HIGH LOW V. HIGH NO NO YES LOW HIGH V. HIGH YES NO NO Pressure P Flow Rate Q S .R .V Efficiency Maint . cost Pulsation Positive D.P. Centrifugal Axial Flow V. HIGH LOW LOW HIGH MEDIUM V. HIGH

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16. 100 1000 10,000 20 50 200 500 2000 5000 2 5 20 50 200 500 1000 2000 5000 10000 100 1000 10,000 20 50 200 500 2000 5000 100 10 Centrifugal multistage Centrifugal double suct . Axial flow Screw Gear Multi cylinder plunger GPM Ft of Liquid PSIg Centrifugal single stage

17. Centrifugal Pumps API 610 ASME B73.1 & B73.2 Most common pumps API 685 Seal less Pumps Liquid Ring Vacuum Pumps API 681 Positive Displacement Pumps API 674 Reciprocating API 675 Controlled volume API 676 Rotary Firewater Pumps NFPA 20 3- Code and Standards

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19. Centrifugal pumps Ball Valve Ball Valve Check Valve Strainer

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21. Horizontal Split Case Feed Pump 13000 gpm 7000 ft

22. Vertical Sump Pumps Single Stage Vertical Shaft 5000 gpm 300 ft

23. Vertical Cantilever Pump Slurry Applications 1000 GPM 110 ft Head 11 Ft Length

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25. Vertical Inline Centrifugal API 610, ASME B73.2 Motor

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27. Volute casing

28. Closed impeller

29. Open impeller Semi open impeller Closed impeller

30. Very high Head Very Low Flow Impellers Classification High Head High Flow Very high Flow Very Low Head

31. SOME TYPES OF CENTRIFUGAL PUMPS DOUBLE SUCTION IMPELLER SINGLE IMPELLER OPPOSITE IMPELLERS MULTI STAGE P P0 P4 P 4 Balancing Drum MULTI STAGE

32. SINGLE IMPELLER PUMP MECHANICAL SEAL HANGED BEAM IMPELLER

33. MECHANICAL SEAL BEARING HOUSING

34. SPLIT TYPE PUMPS 1- Horizontally Split High Flow Medium pressure

35. 2- Vertically Split (Double Barrel) high pressure and medium Flow

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37. Hanged Beam Impeller Wearing rings A B

38. Pumps arrangement

39. P d = P 1 + P Centrifugal pumps in series Q Q Q P 1 P d P P 1 P

40. Centrifugal pumps in parallel Q = 2 Q 1 Q 1 P 1 P 1 Q 1 P Q P P

41. Mechanical Seal Wearing rings Wearing rings Volute function

42. FLUIDS FLOW KINAMATIC ENERGY v 2 < v 1 P 2 > P 1 P1 P2 + 2 g V 2 2 P 2 + 2 g V 1 2 P 1 CONSTANT Thermal energy Plus

43. TOTAL ENERGY DIMENTIONS 2 V 2g ft 2 sec 2 ft 2 sec = ( ft ) = ft 2 sec ft 2 sec = P density ft 3 2 ft = ( ft ) = Lb Lb 2 ft 3 ft =

44. Discharge Volute Discharge

45. Impeller velocity diagrams Velocity of liquid (effect of impeller rotation) Velocity of liquid (effect of flow tangential to the blade trim) Velocity of liquid Result Diffuser

46. Volute Volute function is to convert most of the Velocity energy to pressure P = ( v 2 / 2 g) 8/30/2024 50

47. pressure velocity velocity volute suction Impeller shroud pressure + 2 g V 2 P FLOW KINAMATIC ENERGY 8/30/2024 51

48. IMPELLERS IN ROW MULTI-STAGE

49. OPPOSITE IMPELLERS MULTI-STAGE Pump outlet

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51. 2- Pumps Specific speed 1- Centrifugal pumps Performance curve 3- Pumps Horse Power

52. CENTRIFUGAL PUMP PERFORMANCE CURVE (Q-H)

53. Q - H CENTRIFUGAL PUMP PERFORMANCE CURVE (Q-H) H ft 10 20 30 40 50 Q gpm. 100 200 300 400 500 30 40 50 60 70 ξ KW 30 40 50 60 RPM = 3000 IMP.DIA = 10 Inch

54. Q - H CENTRIFUGAL PUMP PERFORMANCE CURVE (Q-H) a . b . Q gpm. 100 200 300 400 500 H ft 10 20 30 40 50 KW 10 20 30 30 40 50 60 70 ξ PUMP RPM = 3000 IMP. DIA. 10 . C 230 OPERATING POINT

55. Q gpm. 100 200 300 400 500 H ft 10 20 30 40 50 60 50 N1 N3 N2 . 70 40 ISO- EFFICIENCY CURVES

56. ISO- EFFICIENCY CURVES Q gpm. 100 200 300 400 500 H ft 10 20 30 40 50 60 70 30 40 50 60 70 N1 N3 N2 60 50 . 70 N1 N2 N3 Pump ( RPM ) N1 > N2 > N3

57. 1 ( PSI) = 2.31 ( Ft) Pressure = Head (Ft ) x (SG) / 2.31 (PSI) Water 231 Ft x 1.0 / 2.31 = 100 PSI HCL 231 Ft x 1.2 / 2.31 = 120 PSI Gas oil 231 Ft x 0.80 / 2.31 = 80 PSI Gas oil For water

58. FRANCES RADIAL CAPLAN MIXED FLOW PROPELLER N S = 500 800 1200 2000 3000 N S = Q 1 / 2 H 3 / 4 N Q = FLOW RATE (GALLONS. PER MIN). H = HEAD PER IMPELLER (FEET ) N = RPM PUMPS SPECIFIC SPEED N S

59. Radial flow 60 Mixed flow 45 Mixed flow 45 60 90

60. . 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 1 . ξ 50 30 10 GPM 3000 500 300 200 100 1000 10000 GPM Q 500 1000 1500 2000 2500 3000 N S N Q H 3 / 4 IF N = 2000 RPM Q = 1600 GPM H = 256 FT / Impeller N S 2000 1600 256 3 / 4 N S 64 80000 1250 0.84 1250 IF N = 1500 RPM Q = 100 GPM H = 81 FT / Impeller N S 1500 100 81 3 / 4 N S 27 15000 555 0.68 555

61. H P W = H Q ρ H P B = H Q ξ ρ H P W = WATER HORSEPOWER ρ = LIQUID DENSITY P = PUMP DIFF. PRESSURE Q = PUMP FLOW RATE ξ = PUMP EFFICINCY = BREAK HORSEPOWER B H P WHERE MOTOR PUMPS POWER

62. H P W = P Q 0.00058 P = p s i Q = GPM H P W = P Q 0.037 P = bar Q = M 3 hr H P B = P Q ξ 0.037 H P B = P Q ξ 0.00058 HOW TO ESTIMATE PUMP POWER 1 HP = 75 kg. m / sec 1 HP = 550 Ib. ft /sec WHP = Q.P 75 WHP = 75 Kg / cm2 M3 /hr WHP = 75 Kg m3 sec *3600 * 100*100 m2 WHP = 75 Kg 3600 * 100*100 m sec * WHP = Kg 0.037 m sec

63. FOR BOTH PUMPS WATER. HP. = 0.00058 * 20*2000 HP. = 23.2 HP EXAMPLE CALCULATE MOTOR HP. FOR 1-PUMP (A) HAS D.P = 20 PSI Q = 2000 GPM 2-PUMP (B) HAS D.P = 400 PSI Q = 100 GPM 69

64. 500 1000 1500 2000 2500 3000 . 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 1 . ξ 50 30 10 GPM 3000 500 300 200 100 1000 10000 GPM Q 0.85 NS Q = 2000 GPM H / Imp = 20 * 2.31 = 46.2 ft 3800 N S 1000 2000 46.2 3 / 4 N S 3800 PUMP ( A ) 70 5 GPM

65. BRAKE HP = 23.2/0.85 = 27 HP. Motor HP = 27 * 1.2 = 33 HP PUMP A N S = Q 1 / 2 H 3 / 4 N N = 1500 RPM D.P / impeller = 2O*2.31 = 46.2 ft Q = 2000 GPM N S = 1500 * 2000 1/2 46.2 3/4 = 1500 * 44.7 17.66 3800 = ξ = 0.85 71

66. N S 1000 100 924 3 / 4 500 1000 1500 2000 2500 3000 . 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 1 . ξ 50 30 10 GPM 5 GPM 3000 500 300 200 100 1000 10000 GPM Q 0.25 NS Q = 100 GPM H/ Imp = 400 * 2.31 = 924 ft N S 60 60 PUMP ( B )

67. BRAKE HP = 23.2 /0.24 = 97 HP . Motor HP = 97 * 1.2 = 116 HP PUMP B N S = Q 1 / 2 H 3 / 4 N N = 1500 RPM D.P / impeller = 400 * 2.31 = 924 ft Q = 100 GPM N S = 1500 * 100 1/2 924 3/4 = 1500 * 10 117 90 = ξ = 0.24 73

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69. NET POSITIVE SUCTION HEAD NPSH

70. 76 Examples of Cavitation Damage Increase of noise and vibration, resulting in shorter seal and bearing life. Erosion of surfaces, especially when pumping water-based liquids.

71. 77 Cavitation

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73. CAVITATION CAN OCCUR in CENTRIFUGAL PUMPS POSITIVE DISPLACEMENT PUMPS AND NPSHA < NPSHR WHEN

74. It is an action of fluid vapor attack on the parts of equipment which produce: Suction pressure less than Vapor pressure of the pumped fluid. What is cavitations phenomenon

75. loss of the weakest component element of suction parts material due to bubble explosion on the surface of suction parts causing cavities . Vapor bubble explosion on the parts surface could be 60,000 psi. This action will cause:

76. Water Vapor Pressure Graph P Kg/Cm 2 T F 14.7 Psi Liquid Vapor 200 150 250 300 212 20 40 60 80 Add Temp Lower Pressure Vapor

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78. Liquid Flow A B

79. Vapor Pressure Graph through pump the impeller P Kg/Cm 2 Cavitations start Vapor pressure limit Impeller length

80. Pump suction parts FLUID VAPOR BUBBLES Pump suction parts After attack cavities

81. CARBON STEEL CAST IRON STIANLESS STEEL BRONZ BRASS THE WEAKEST ELEMENT ( LOST ELEMENT ) SUCTION PARTS MATERIAL CARBON ZINC LOST ELEMENTS IN SUCTION PARTS

82. What is Cavitations Effect Impeller deterioration Decrease discharge pressure Decrease pump flow rate Increase vibration level Bearings & M/S failure 1- CENTRIFUGAL PUMPS 2- RECIPROCATING PUMPS Suction valve deteriorations Spring Rupture Decrease discharge pressure Decrease pump flow rate Piston Damage Cylinder Head Damage

83. YOU CAN GET FROM PUMP MANUAL 1- NET POSITIVE SUCTION HEAD REQUIRED NPSH 2- NET POSITIVE SUCTION HEAD AVAILABLE YOU CAN CALCULATE FROM PUMP SITE TO AVOID SUCTION CAVITATION AND FOR SAFE OPERATION NPSHA > NPSHR

84. What is the parameters affecting NPSHA SUCTION PIPE LENGTH LIQUID SPECIFIC GRAVITY LIQUID VISCOCITY INTERNAL SURFACE OF SUCTION PIPE LIQUID SURFACE ALTITUDE VAPOR CONTAMINATION SUCTION PIPE LEAKS SUCTION PRESSURE LIQUID TEMPERATURE SUCTION PIPE DIAMETER LIQUID VAPOR PRESURE ATMOSPHERIC PRESSURE

85. HOW TO IMPROVE NPSHA SHORTEN THE SUCTION PIPE LENGTH INCREASE SUCTION PIPE SIZE DECREASE SUCTION LIQUID TEMP. DECREASE SUCTION NEGATIVE ALTITUDE INCREASE SUCTION POSITIVE ALTITUDE STOP THE PIPING SUCTION LEAKS RENEW THE SUCTION PIPE

86. liquid specific gravity S p.gr Z liquid surface height ft P S Pump suction pressure psig V liquid velocity ft/sec P f Friction Pressure drop psi P a Atm. Pressure psi V p Vapor pressure psia g 32.2 ft/sec.sec h L Suction head loss ft Vessel pressure psig P SV P VS Z P S v NET POSITIVE (+) SUCTION HEAD

87. NPSHA IS NOT OR P S THE SUCTION GAUGE PRESSURE P VS Z LIQUID LEVEL IN THE SUCTION VESSEL

88. V 1 Z + V 2g 2 { (P vs +Pa) – Vp } 2.31 + Sp.gr - h L NPSHA = General Equation P VS Z

89. IF The Suction pressure is known - h L = Z + P s Sp.gr P sva Sp.gr Z + V 2g 2 { – V p } 2.31 + Sp.gr - h L P sva P sa NPSHA =

90. NPSHA = P S v 2 V 2g 2 { P sa – V p } 2.31 + Sp.gr ( ft ) If The Suction pressure is known

91. Z < h L P S Positive Reading Boiled water CAVITATION OCCURED Z

92. P S P VS P S ATMS Negative Pressure NO CAVITATION Z < 6m

93. Practically PS - Z = 6 mt of water ATMS SUCTION NEGATIVE ALTIDUDE NOT MORE THAN 6 METERS FOR ANY TYPE OF PUMPS

94. 76 Cm MERCURY ATMOSPHERIC PRESSURE 10,033 mt OF WATER ATMS ATMS SPACE

95. v P S v VACUUM P S P S ATMS 10,033 mt If Pump Eff. = 100% Practically 6 mt

96. CENTRIFUGAL PUMPS LOSSES Q g.p.m. 100 200 300 400 500 H ft 10 20 30 40 50 60 ACTUAL CURVE FRICTION LOSS EDDY LOSS LEAK LOSS HEAT LOSS THEORITICAL CURVE

97. 1 T P FIG-2 WHAT IS VAPOR PRESSURE FIG-1 1 P T 1 - Heat up a little of water in a pot up to boiling point 100 C ( valve 1 is opened) 2 - Take off the heating source, simultaneously close valve 1.

98. Closed T P Gauge 3- During cooling down, Start to record the P Gauge relevant to T emp. 4- Apply Absolute pressure Equation . P Absolute P gauge + 1 (bar) Cool Down

99. 5- Record the Absolute Liquid vapor pressure . 100 1 15 - 0.98 0.02 80 - 0.5 0.5 - 0.7 70 0.3 - 0.3 0.7 90 95 - 0.1 0.9 V apor P ressure P Gauge Temp C P Gauge + 1 ( bar ) absolute V apor P ressure

100. Solution Examples Crude oil level is 8 feet above center line of a pump , Vessel pressure is Atmospheric Vp is 4 psia Sp gr. is 0.8 Friction loss : 12 ft of liquid Atmospheric pressure is 14.7 psia ( Neglect velocity head ( NPSHA Z + { ( P sv + P a) – V p } 2.31 Sp.gr - h L = 8 + { (0 +14.7 ) – 4 } 2.31 0.8 - 12 = = 8 + 31 - 12 = + 27 ( ft ) Compare with NPSHR

101. Crude oil level is 8 feet above center line of a pump , Vessel pressure is Atmospheric Vp is 14 psia Sp gr. is 0.85 Friction loss : 2 ft of liquid Atmospheric pressure is 14.7 psia Solution NPSHA Z + { (Psv+ Pa) – Vp } 2.31 + Sp.gr - h L = 8 + { (0 +14.7) – 14 } 2.31 0.85 - 2 = = 8 + 2 - 2 = + 8 ( ft ) ( Neglect velocity head ( Compare with NPSHR

102. Crude pump Suction pressure is – 5 psig Vp. is 4 psia Sp gr. is 0.8 , Atmospheric pressure is 14.7 psia. Solution FIND NPSHA ( Neglect velocity head ( = + 16 . 46 ( ft ) + ( ft ) = { ( ( 0 + 14.7) - 5 )) – 4 } 2.31 0.8 NPSHA ( ft ) = Sp.gr { (P s + Pa) – V p } 2.31

103. If the liquid is butane and level is Z = - 8 ft System pressure is 60 psia. Temperature is 90 F Vp = 44 psia at 90 F, butane sp.gr is 0.58 Friction loss : 12 ft of liquid, Compare with NPSHR Solution = + 43.7 ft NPSHA ( Psva – Vp ) 2.31 h L Sp gr . Z ( ft ) = + ( 60 – 44 ) 2.31 h L 0.58 . - 8 ( ft ) = + ( Neglect velocity head ( FIND NPSHA

104. THE FLOW RATE WILL BE Q 2 Q 1 N 2 1 N IF THE PUMP SPEED CHANGES FROM N 1 TO N 2 PUMPS AFFINITY LAWS THE DISCH PRESS. WILL BE 2 P 2 P 1 N 2 1 N THE HORSEPWER WILL BE 3 N 2 1 N 2 1 P H P H

105. Exercise Find the flow rate, head and power for a centrifugal pump impeller that has reduced its diameter Given data: h h = 80 % P 1 = 123 kW D 1 = 0,5 m H 1 = 100 m D 2 = 0,45 m Q 1 = 1 m 3 /s

106. Exercise Find the flow rate, head and power for a centrifugal pump that has increased its speed Given data: h h = 80 % P 1 = 123 kW n 1 = 1000 rpm H 1 = 100 m n 2 = 1100 rpm Q 1 = 1 m 3 /s

107. C:\Documents and Settings\11030\Desktop\hydraulics.xls - 'Flow affinity law'!A1

108. GAS LIFT PUMPING JET PUMPING

109. submergence Total lift Nozzle Gas main Rising main Standing water level submergence Total lift = Ratio 1 300 1.3 200 1.6 100 Ratio Total lift ( ft) Gas lift Compressor Gas injected through the nozzle, mixed with the crude and forming a foam mixture with a very light density, that means long mixture column GAS LIFT PUMPING

110. Driving Fluid Throat Nozzle Venturi (Diffuser) Ejector JET PUMPING

111. Driving Fluid Ejected Fluid WELL JET PUMPING THE WELL

112. ROTARY PUMPS

113. Rotary pumps Relief Valve

114. Suction Discharge Rotary Vane Pump

115. Rotary Vane Pump

116. ROTARY PUMPS External Gear THE FLUID IS TRAPPED BETWEEN ROTOR AND CASING

117. THREE LOBE PUMPS

118. Rotary Twin-lobe Pump

119. TWO LOBE PUMPS

120. Diaphragm pump

121. GEAR PUMP

122. Internal Gear

123. Driving rotor Crest

124. TIMING GEAR GEAR PUMP TIMING GEAR

125. TIMING GEAR FUNCTION 2- KEEPS NO CONTACT BETWEEN ROTORS 1- TRANSMIT MOTION TO OTHER ROTOR 3- PREVENT WEAR BETWEEN ROTORS

126. Multiple-screw double-end arrangement

127. RECIPROCATING PUMPS

128. Pulsation Dampener P Accumulator Q Relief Valve KEEP ENOUGH QUANTITY IN SUCTION REDUCE PRESSURE FLUCTUATION

129. RIDER RINGS PRESSURE RINGS Reciprocating Piston

130. GLAND FOLLOWER PACKING LANTERN RING THROAT BUSH Reciprocating Plunger

131. PRESSURE 10 20 30 40 Bar T time 1 2 3 4 5 6 7 8 9 10 Single Plunger Pump

132. Reciprocating Plunger Duplex Pump

133. PRESSURE 10 20 30 40 Bar Mean discharge pressure T time 1 2 3 4 5 6 7 8 9 10 Duplex Pump

134. Reciprocating Plunger Triplex Pump

135. PRESSURE 10 20 30 40 Bar T time 1 2 3 4 5 6 7 8 9 10 Triplex Pump Mean discharge pressure

136. Vacuum Pump

137. LIQUID RING Compressors OR Vacuum PUMP

138. A A Side View Pump Cover

139. LIQUID Fill liquid volume According to manual instruction BEFORE STARTING

140. AFTER ROTATION This port is connected to pump discharge Due to centrifugal force, a liquid ring will be formed This port is connected to pump suction

141. Cooling water

142. WATER OXYGEN ATMOSPHERE VACUUM

143. SEAL LESS PUMPS

144. Electric motor Coupling Pump

145. Containment shell Outer magnet ring Rotor chamber air gap Liquid gap inner magnet sheathing Secondary pressure casing inner magnet ring

146. Magnetic Drive Pump, Separately Coupled.

147. A Better You, A Better Niger CNPC Niger Petroleum S.A