Training Services

Pumps
n Introduction
= Pump Curves
- Head versus Capacity
- WSH
- EBciency
u Single-Stage Centrifugal Pwmp Design
- Pump Components
- Shaft SeaXing
Pumps
(continued)
m Reliability
8 Fan Laws
a Hydraalics
8 Pump Control
i..
r S d e s s h p s
r h p Selection and PerEomance
r Doizble Suction, Mujti-Stage, and Sundyne funips
" pd46"S" phq?!
This is a typical pump curve. The pump curve gives information on how
the pump will perform, the NPSH required by the pump, and the impeller
size mg e for the casing. AH p m p manufacturer's c me s are similar so, if
you can read one nnanufiictwer's curve, you can read anybodys.
0 400 800 1200 I W 2000 2400
Gallons Per Minme
Head-capacity curve. Once this curve is established based on the impeller
diameter and speed, the pump wig1 always operate on this curve. Note how
the curve rises as the Row goes down. This is a charactexistic of d l
centrifugal pumps.
Single Stage Centrifagal Pump
Mechanical Seal
Shaft f ~ k l i n ~ Deflector ' L 03 Levef BoHe
Sleeve Met Ring
Single stage centrifugd pump. As the centrifugil force of the impeller
throws the fluid out towards the cstsing, the velocity of the fluid goes up.
-4s the fluid leaves the p m p , this velociQ energy is changed to pressure
energy.
I
L Identical Pumps Handling Liquids
of Dgferent Specific
CrasoEioc. S.G. = 0.75 Waxer, S.G. = f .O Brine, S.G = 1.2
Pump perfomance is measured in feet or meters of head. Head i s the
height of the column that the pump cm move the fluid. Pump head is a
function of impeller diameter and sped. It is not a function of the density
or specific gravity of &e pumped fluid. Here are three identical. pumps
pumping out of three identical tanks. Note that the head or column height is
identical even though the specific gravity of the Ruid is different.
Galbns Per ,Minute
Each pump casing size can handle more than one size impeller. This pump
' casing can handle impeller diameters between 9 and J 1 inches. Also, the
impeller can be trimmed to any size between 9 and 11 inches to meet the
sated opemxing point. The impeller diaeter does not have to be a whale
inch size.
-
0
L2
E;
. -
z
cr?
2
o 400 aw 1200 ISOO 2000 ~rl.00
CaXlons Per Minute
The pump m e also gives the NPSH required by the pump. Note how %he
,WE required curve rises with increasing flow.
A B
Puhc Along Liquid Pit&
The fluid loses pressure in the pump before the pressure starts to rise. As
the fluid enters the pump, these are entrance and friction losses. As the
ff aid enters the rotating impeller, $here are turbulence and friction Iosses at
the vane tips. If this pmssure drop is enough to drop the pressure of the
fluid below its vapor pressure point, flashing will occur. This phenomena,
called caviation, will quickly destroy an impeller and a pump. The h?SH
ava3lable must be greater than the WSH required.
The NPSH avaifable is a function of the pumping sysxem. WSW avail able
is the pressure at the pump suction minus the fluid vapor presswe. Xt is the
pressure thaz can be lost in the pump inlet area before Washing or catritaeon
begins. For a bubble point or vapor pressure point fluid, the &iSH
avaitfabje is gained with vessel. elevation.
0 300 800 1200 1600 2000 2400
Galtoas Per &ate
The pump curve shows the efficiency of tfxe pump at any operating point.
Note that the efficiencies rise with rising Bow to the best efficiency point
(BEP), and then quickly drop off. Optimum pump operation is at or near
best efficiency point.
0 - \ I d -
0 400 800 lGZOO 1600 2000 2300
Gallons Per Minute
Pwnp curves also show the FP requirement for the pump. Do not use these
curves. CAU3UX,AE W. These FP cwes only appfy if the specific
gravity of the fluid is 1.0. Also, it i s difficult to get a good, accurate
reading. EEP is a simple calculation shown later in this talk.
Pump Selection
Y
60 Cycle C m n t
3550 rlmn
I
Two Sage Prmss
Singk Sxcion Uoubit. Suction
35% r/min S550 r h n I
Double Sumon
Pump Cap~ciry, gpm
This chart shows the approximate head-capacity ranges of single stage fuX1
and half speed pumps, doable suction pumps, and two and &ti-stage
pumps. Low Bow, high head applications are Sundynes.
AE API pumps today are centerline mounted. The centerline mounx allows
the pump casing to p w both up and down as the casing hears up. This
keeps the shaft in the horizontal plane and helps prevents seal leaks and
shaft mis-alignment.
Impellers
All API pumps today have closed impellers with covers or shrouds on both
sides of the vanes. This gives the fluid a more defined path through the
pump and raises efficiency. The flow splitter in the outlet or double volute
equalizes the radial forces around the impeller and minimizes the load on
the radial bearings.
Single Suetion Enclosed Impeller
Single suction enclosed impefier.
Siagle Suction impeller
Large single suction impeller. Note tee impeller vanes at the inlet md
outIet, This is a half speed impeller. Full speed impellers are only allowed
up to 15 inches in diameter to control tip speeds,
Suction Specific Speed
PV*P
J.
S = rpm ( g ~ r n ) ~ / frvPSItr)3J4
r Can range between 3000 - 20000
The suction specific speed relates rpm, gpm, and NPSH required. UOP
' limits the suction specific speed to 11000. If a pump manufacturer w a s to
reduce the NPSH required of a certain pump, he can increase the impeller
eye m a to reduce fiction drop and reduce IWSW required. This increased
eye area increases the internal circulation in rhe suction area of the pump.
This can buitd up heat which can also flash the fluid and reduce pump
reliability. This also reduces the sable operating range of the pump. As the
flow is reduced, the p mp becomes less efficient and more heat is built up
in the pump. At higher suction,. specific speeds this can promute cavitation.
Model 3735 High TmperatuteMigh Pressure Process Pumps
Heavy Duty Design Features to Meet the Total Range
of Process Indu:stries
Intpetier Sealing Renewable Stuffing Box
Wearing Rings Refiability Froat Bushing
b 1 ,- Heavy Cast
t Y Large Cooling
Duaf IWfficient
Jacket
Voiate Mechanical
Casing Sealcooijng
This is a single stage (one impeller), single suction (one entry into the
impeller), overhung (impeller is cantilevered on one set of bearings) pump.
This is cdkd a Process pump. The metdfwgy is as follows:
Casing Carbon Steel
Impeller Carbon Steel <50QF, 1 1-13% Cr >50O0F
Shaft Carbon Steel
Wearing rings 11-1.396 Cr
Throat bushing il-13% Cr
Throttle bushing Bronze or non-sparking ma ha 3
1
Single Stage Overhung Pump
Single stage, single suction, overhung pmp. Note the vent connection on
the top of the casing.
Single Stage Pump
Single stage, single suction, overhung pump. This pump is self-venting as
the dischsge is at the high point of the casing. This design is typic$.
Before there were mechanical seals, pumps were sealed by "stuffing" an
absorbent material caned packing wound Ehe shaft. Since the process fluid
had to lubricate &e surface between the stu%h,a and the shaft, the packing
had to leak, typically abut 200 cchr for a new application. Over time, &e
packing would become sitmated with fluid and the leakage would increase
until the pump had to be shut down md &e packing replaced. Today, UOP
does not specify any pumps with packing.
Single Mechanical Seal
I
Single mechanical seal. Mlost A H pumps today have single mechanical
seals. The single mechanical pusher type seal has two members, a rotating
member md a stationary member. The main sealing takes place due to the
friction between the rotating seal face and the stationary seal face. Since
the pumped fluid lubricated this seal face, the si-qle mechanical seal does
leak. Typical leak rates are about 2 ccfhr or about f 00 p p of emissions in
the air sumunding the se& As the seal faces wear, springs in the rotating
member keep a t i a t fit between %he two seal faces. O-rings prevent
X&age between the seal and the shaft and between she seal and the pump
casing.
Connection A (refer to appropriate Connection B (refer io appropriate
primary seal piping arrangement) \xiliary seal piping mge mc nt )
Seal Box -
Sleeve
-.-w-
Rotatiag
Seal .Member
Seal
End Plate
/ sealing device
Single mechanical seal. Used for most non-hazardous services.
Single Mechanical Seal
Here is another view of the single mechanical seal. Note the yellow process
fluid coming from rhe pump discharge to the process side seal face. The
mbbing seat faces generate heat. If the pumped Ruid is at vapor pressure or
bubble point and. heat is added, the fluid could Aash around the sea$ and the
seal faces codd b e their lubricant- Process fluid flows fron the discharge
of the p mp &-ou& an usifice. The pmsswe is kept high enough momd
the seal to stay above the vapor pressure point even though with the seal
faces are adding heat.
Welded
Carbon or Tungsten Carbide
Puller
Metal Betitows
vs. SteIlite Sealing Faces
Croove
Solid &.eel Rotating
Stationary
Wv e Lags Sestf
seat
]Bellows seals are specified for high temperature applications, above 5S0F.
Bellows seals have two members9 a rotating member and a stationary
member, similar to &e pusher type seal.
f
Cap S
-
X*FICOZI
When the seal face wears on a bellows seal, the metal beljlows expands like
an accordion. The o-rings bemeen the seal and the shaft do not move dong
Ehe shaft as they do in a pusher type seal. Since the xing material starts to
break down at higher temperatures, pusher type seak are temperame
limited due to h e dynamic o-ring. Since the o-ring on the bellows seal is
sattic, the bellows seal cca operate effecgvely at temperatures up to 800F.
m ~1000 ppm (Most <I00 ppm)
m Comply wigh Regulations in Most Cases
8 3+ Years Life
Liquid Taadem Seals
(Unpressarized Dual Seals)
= c50 ppm (Most <I0 ppm)
r Vent to Flare
1
r Diesel Buffer Liquid
8 3+ Years Life
Tandem seals are now referred to as mpxessurized dual seals. The buffer
between the two seals is vented to flare and is unpressurized. Leakage of
process fluid is greatly reduced from the single mechanical seal. Any
process fluid that leaks across &e inner seal is contained by the outer seal.
Refease of process fluid to the atmosphere is under 10 ppm.
Unpressurized Dual Seals
Connection C (refer to appropriate
randem seal piping mngemnt )
fe Bushing (mechaaical seal
Seal Member
shing) or auxiliary s eahg device
Unpressusized dud mechanicd sed. Used for following:
- Light hydrocarbons - Vapor pressure over 30 psig
* 1 wt % Benzene
25 wt % C6-c9 ~O-CS
5 mol% H,S
* Other environmentally hazardous materials
Buffer fluid is circulated from the seal pot to the buffer area and back to the
seal pot with pumping rings on the shaft. Leakage of process fluid is into
the buffer area. The seal pot has a pressure dann for Bashing fluids and a
level aIann fur non-flashing, fluids to warn of an inner seal leak.
Photo_wph of actual API Plan 52.
Mufti-stage pump with unpressurized dual sears. Note the two seal pots the
' the API Plan 52.
Disc
Suction
.tion Tube
Sealless canned motor pump. Zero fugitive emissions. The motor windings
turn a magnet on the pump shaft across a containment barrier. The process
fluid lubricate the bearings on the pump shaft and remove heat from the
mom windings. Therefore, %he pump cannot be run dry (bearings will not
be lubric&ed] or be fun blacked in (heat will not be removed from a e
motor). UOP specifies insmmentation (alarm and shutdowns) to prevent
pump damage En the event of mis-opefatiom.
Sealless canned pump. Yote the process fluid circulating from the pump
discharge to the back end of the pump. The nuid rhen travels though the
pmp, Iszbricafing the shaft bearings and removing heat from the motor
windings.
. If &e process fluid is comsivc, ( EF acid) the bearing fluid could be from
an external source. s&
Sedfess canned pump. For this type, the process fluid i s circulating back
through the shaft instead of externally.
Magnetic Drive Pamp
Sedless magnetic drive pump. Magnets on the motor shaft twn mapets on
the pump shaft across a contaiment barrier. This is an altemte design to
the canned motor p m p . Process ffuid still Iubpicates the p u p sha&
bearings. Zero fugitive emissions.
Magnoseal "
Standard Features
i ASMWANSI 13'mensions
Magnetic Coupiings to
100 IfP
Engineered Composite
andMetal
Containment SkUs
m Precision Cast Semi-
Open Impeller
Wear Resistant Silicon
Carbide Bearing System
Sealless magnetic (Mag) drive pump. Note that the magnetic couplings are
good only to 100 HP.
Reliability and Maintenance
What is ReliabiXitv?
The main objective of reliability is to achieve the
highest plant availability at the lowest possible cost
in order to maximize prof~t,
The goal is t o achieve f i e World Ciuss target
of 95+% plant availability!
Reliability and Maintenance
; .Critical Equipment - Centrifugal
Compressors, Some pumps - Unspared
- Continuous Monitoring System
.Pumps, Reciprocating Compressors - Spared
- Periodic Monitoring of Vibration b t a -
CoIleci and Analyze
- Root Cause Analysis
Reliability and Maintenance
Equipment Specs and Standards
Vendor Selection
Design and Testing
Process Considerations
Operations and Monitoring
Reliability and Maintenance
95% on-kne availability for pumps, 5 year MTBR
1. Reactive - Run to failure
2. Preventative - Time-based maintenance
3. Proactive - Condition-based mainhnance
t
Reliability and Maintenance
1
Reactive - Run %o Failure
Process Interruption
m No Opportunity for Diagnosis
Frequent failures
r Other Pasts are Effected
Replace Good PUT%
Reliability and Maintenance
Pre'ventative - Time-based Maintenance
r No UppurtuniSy f or Diagnosis
i deplace 600d parts
Reliability and Maintenance
Proactive - Condition-based Maintenance
m Repair Before Pump Fails
m Replace Only Bad Parts
u Diagnostics and Root Cause Anavsis
Portable Vibration Monitor
.Reliability and Maintenance
Unbalance RPMx 1 Steady
Bent Shaft WM x I. or 2, Axial high
Cavitation Random Fluctuating
Misalignment R3PN x 1 and 2
Pardlel Radial
Angular High Axial
Foundatioffi, Unsteac3y XUPM,
Reliability and Maintenance
Prucuremerzt
EPC during vendor/contractor proposal review
"I am concerned with 3 things:
Price, price and price"
Reliability and Maintenance
1. Price
2. Functionality
Reliability and Maintenance
Procurement
Main Air Blower quits
Cost up to $500,0001day in
lost production
1. Functionality
2. Reliability
3. Utilities
4. Price
Reliability and Maintenance
Procurement
Reliability and Maintenance
Life Cycle Costs
i
1 Reliability and Maintenance
I
E
Besi Psactices - Pump and Sys?ern Design
Suction Specific Speed 4 11000
m L3/b4 < 60 (inches) -6b rj~-k+ 1%
m Design system for operation at or near BEP
m 5 faot NPSH margin
Mi n i m 5 pipe diameters shvtight pipe on
r 1mtafl APX Flush ?Ian 23 if pumping
temperatwe > 30O0F (14g0C)
Reliability and Maintenance
, Best Practices - Pump Operation
= Do not start and stop often Check cooling water and seal
-
Do not nm pump dry
flush temps
1
Operate at or near BEP
B Inspect and change bearing
m V i i y iinhpect pump often
0.2 (3-6 months)
(once per shift)
r Do not "hose down'' pumps
r M;easummd record D Report problems immed.iately
brati ions r Training
Reliability and Maintenance
Best Pmtices - Pump Reliabifitv
r Alignment -
~ 8 k e e
8 Bearings
w b b e oil
Mudtoring - $rend analysis
Reliability and Maintenance
I
Reliable Reciprocating Compressor Design
Limit Piston Speed
m Lianit 3Pis;tonRPM
, .' Limit CyHnder Size
8 LMt Discharge Temp (250F)
H
f
i
r Lubricate Cylinders
i = coat ~isttyx R U ~
m Vibration and Temperature Moni^tor
FPD.%XWPD-M
Relkbility and Maintenance
Reliable Centrifugal Compressor Design
I
m Limit b4axi.m- Impeller Yield Strength
! r ~q as Seals
i
r Report all Operating Cases
r Voting Type Sha*down
r An$i-surge c;oatrok (where required)
Affinity Relationships
Q = Capacity, gpm
N = Rotative Speed, rpm
H = Head, feet
]HIP = Horsepower
D = Impeller Diameter
Affinity relationships or fan laws.
The flow varies proportionaI to the speed variation md the head varies
pfoportionaI to the square of the speed. These laws explain why high flows
and low heads are achieved wjth law speed pmgs and low flows and high
heads ate achieved with high speed (Sundym) pumps.
d
I
GP.M x Head x $13. CR -
-
Ib / nin x Head
BHP =
- -
GPM x PSI
3960 x Eg 33,000 x E# 1714 x Efl
When using pump curves for 60 cycle and the pumps wi3I be in a mn t y
with 50 cycle power, &e Row, head, md NPSH required must be corrected
before a pump can be selected,
Horsepower in Field
Measure imp draw of motor
Watts = b p s x Volts
BHP=1.73 x Amps x VoRs x motor eff x motor power factor
i 746
Motor eff = 0.95 (Approx)
Motor power factor = 0.90 (Approx)
For si~gfe phase mot& don't mdtip3y by 1.73 (3y")
Horsepower in Field
Power Factor
Power factor is the ratio between the KW and the
KVA drawn by an electricat load where the KW is
the actual load power and the KVA is the apparent
load power.
Xt is a measure of how effectively the current is
being converted into usem work output and more
partZculariy is a good indicawr of the effect: of the
load cmsent on &e eMicienty of the supply system*
I
Horsepower in Field
i
ExayXe
~ n r ~ s ' = 30
Volts = 360
BKP = 1.73 ( 30) (360) (0.95) (090)/746
i
BHP = 21.4
GPM = 300
P2 = 170
Eff = (300) (1'70-95)/(1714)(21.(t)
Head = psi *2.31/S.G.
System Resistance Curve
Flow, gpm IPP.WDR
q3 ~ s i g
200 GPM, 33 % Flow
I
30 psig mH = i& &
-
1.5 psi
> - a - 05 psi
0.5 psi
I 1 psi 1 psi
70 psig
7
System Resistance Curve
RUW~ gpm E P W
System Resistance Curve
Pump Performance Curve
F~ow, gpm IP&203Wpn78
Twu Centrifgal Pumps in Parallel
Capacity gpm
When pumps s e operated in parallel, the combined performance curve is
obtaiaed by adding horizontally the capacities of the same heads. it is
preferred that the head-capacity curves rise to shtrtoff: If the curves droop
and if the second pump comes on-line at low flow, the pruryi, cuufd "hunt"
between two flows at ate s me head.
Two Centr?ugaI Pumps in Series
Capacity gpm
t P D WD B i
P D M Y
For series opesation, the combined performance curve is abtained by adding
vertically the heads at the same capacities. Note that the maximum suction
pressme of the &wnswem p a p is the shutoff pressure of the upstream
PUW'.
Typical Mo.tor/Motor Spare Pump
Amge me at
Discharge
9
Typically, there are nxro pumps insQlled, one operating and one spare. If a
pump goes out of service, an operator has to corne out and srart up the spare
pump. Pumps are typiaEy started with the &scharee valve closed or
pinched open. The bast amount, of starting torque req&red by the motor to
stm the pump is with the discharge valve closed.
Typical Motor-Auto Cut-In Turbine
Spare Pamp Arrangement
Discharge
.-----.-----.--
"I
Slow Roll
:
I
I
i , EZY-P~SS
! h7 i / Control
Exhaust Steam
3.5 Kg/m2g
Critical service pumps are on mtomaric start. Examples of critical service
pumps are Boiler Feedwater, Surface Condenser Condensate, Compressor
Lube Oil, and HI? Add pumps. If a critical service pump goes out of
service, equipment, personnel, or caalysr codd be damaged before an
operator corxld get the spare p m p in opedon. Therefore, the spare pump
must come on-line automaticidly when the operating p a p goes down,
Rolling Element (Ball) Bearings
Double Axial
Radjd Vent Thrust Bearings
Rolling Element Bearings
Ring Oil Bearing Lubrication
Rolling Element Bearings
r Per APX 610 Minimum Requirements
r 23M0 horn (3 yrs) at rated capacity
m 16000 hours (2 yrs) at nzax radial & axial loads
Bearings Enemies
rr Wrong 02 level
Wa$er
a Sotids
Bearings Oil Level
8 Just Right - Half way up bottom bearing
Too Low - Inadequate Lubrication
f" -!+
bq
Too High - Excessive Heat -+ k9 +& -*Q w-
8 Per SKI", oil has useful life of 30 yrs @ 30C (80F)
Cug in half for every 1 0C ( 1 8 "F) rise
.rr At 100C (2 EF) usefuf life is 90 days
Bearings Water
Where Does It Come From?
fCiq,.&, A h b a i . ?LAC)
a House Cleaning
Seal Gland Quench
i- Aspiration
N Open Oil Cans
m Other
Bearings Water What Are Problems?
i fitting and Corresion increase fatigue
Free a t d e X.f, camas hydrogen exnbnittlexnent
acce~eralhg fatigue
Water/oil emulsion is poor fabricant
rt 01002 % H20 can reduce bearing life 48 %
Bearings Solids
Where Do They Come From?
Seal Cage and Bearing Box Seal Wear
m Oil Flinger Ring
r, Soofids in contamhated 02
1 Air borne partides
m Entrodaced during assembly
Oil Mist
Wrong 03 Ievds, water eontamination, solid
abrasion all go away with oil mist lubrication
I Pure Oil Mist
Pure Oil M-ist
Pure Oil M'st
Engineered for large Process units:
rn Serve up to 80 Pumps with Drivers
Required Maimum of 30 SCFM of
Air
m Consume Less than 2 Gallons of
Oil per Day
. . ,justifying use of Synthetic Oils
for Mzulimm Benefits
r I pm oil per 200,000 parts a b
Oil Mist Benefits
a The Proper Amount of Clean Oil is Applied
Continuously
a Clean Oace Thfough Lubrication
B e a ~ g Housings are Pressurized Preventing
External Contamination
m Internal Metal Surfaces are Always Coated 114th
oil which Prevents Corrosion (Important For
Stand-by Eqni pat )
n L,, Bearing Life $3 Extended by a Factw of 6
Source: Texas A&M Unrivemity Research
Oil Mist BeneJits
~ekring fdures reduced up to 90%
Dirt particles are not delivered to the bearings
m Dirt pantides do not accumulate in the oil sump
Wyr particles are carried away
m hearings operate 18 to 27F cooler
m Bearings see onjly fresh oil
r Seal failures m y be reduced up to 30%
Double Suction
Single stage, double suction between bearing pump.
.- irdJfl + *-fLdv2.te .an 6. 6y.f \p,-.l
ha% *" /pep
Single Stage Double Stlction
Single stage, double suction pump. Note the between bearing design.
Two Stage Single Suction
Between Bearing
Two stage, single suction pump.
HofizontaEly (axially) spiit multi-stage pump.
8 Stage Centrtyugal P a q
Opposed linpellers
Mechanical Wear
Cross
Seal
Quench 7
J ~ z & s Over f m
Discharge
4th Stage Discharge to 5& Stage Suction
Inside of hurizontal11y split mufti-stage pump. The impeXlers are opposed to
each other. The first stage is on the far left of &e pump. The fluid travels
to f$e left for the first four stages. me r the fourth stage, the fluid crossed
over ta the far right and travels to fhe right for the 5th through 8th stages.
This is to balance the axid thrust on the bearings.
1
Horizontally Split Multi-Stage
Six stage, axidly split pump. Note the cf.ossover piping internal to the
casing.
Double Case Ceatr~ugal Pamps
Radially split multi-stee pump. Radially split .multi-stage pumps are more
expensive and take longer to repair &an axidly split multi-stage pumps.
The axidZy split rnuki-stage pump has a large casing split. Therefore, to
reduce &e possibility of process fluid Je&age, APT 610 does not allow the
use of axidly split muki-stage pimps if the panping temperature is over
400F, the discharge pressure is over 1450 psig or the specific gravity is
under 0.7.
Mrclti-Stage Pump with Balancing Drum
Suction
Inside a radially split multi-stage pmp. Note that the impellers are all
facing the same direction. This is because the design of she forged, barrel
type casing does not allow for the cross over piping. To bdance the axial
thrusts, a balance d m atmched to a line at suction pressure is installed on
the discharge side. This drum absorbs the axial thrust. Also, this enables
both seals to sed against suction pressure.
RadtizlZy Split Multi-Stage
Six stage radial1 y spjitjt pump. Note the double suction suction erst stage for
reduced -WSH. Also note .the balance piston discharge.
Power
lini t
Gearbox
Integral
Centrifugal Separator
Diffuser
Pump Casing
Mbdel LiMV-
21 Sundyne
Process
Pump
Mechanicai Seal
Sundyne pump. This is a high speed, integrally geared pump used for low
flow, high head appXica~ions. Sundyne is the only manufacturer having
good success with this design of p m q . This pump is built to MI 610
standards. It can achieve high heads using high speed rather than multiple
impellers.
Sundyne with single gem between motor shafl and impeller shaft. This type
gear box is good to 50 hp.
Purchasing Pumps
Technical Evalaation
Does it meet flow and head?
Check completed API data sheets line by
line. Does it meet the spec?
96 of BEP
Parchasing Pumps
Technical Evaluation
5. Suction Specific Speed
6. Seals
7. Materials
8- Efficiency
9 Exceptions to Specs and Standards
lo. Experience
PROBLEMS "
Problem I
I
I
Liquid is at bubble point. Friction loss is 2 psig. (6 feet)
npsha = (26 - 3) - 6 = 17 feet
Two existing pumps (operating and spare) Byron Jackson 4 x 6 x 13 j$ L (curve attached)
Present pump duty Flow 600 gpm
Head 500 ft
npshr 14 ft
Sp Gr 0.80
Temperature 150F
60 Cycle
New conditions require flow to be increased to 780 gpm.
Now need 18 R npsh. What can be done?
PROBLEM I - MSWER
Methods to increase available npsh:
I
Raise minimum liquid level
Modify piping to reduce friction loss
Reduce pump centerline elevation
Operate both pumps in parallel
Purchase new pump with lower npsh required
Cool vessel liquid to reduce vapor pressure
Note that increasing flow will increase friction loss in piping about 1 psig or 3 feet.
Problem I11
1. Make the best pump selection fiom the attached curves.
P/IM/J;~:@& 4 x 6 ~ - T OC
2. How many stages?
6 d + F
3. What is the efficiency?
*%
s/fjQ -- C X
4. What is the horsepower? %
3F
5. What is the required npsh?
d\lfS"tW\> 12 FJc
Effective FEE. 65
Byron United
WGp w/lP hternational, hc. Jacksonm Centrifugalm
Pwnp Divisim Pumps Pumps
---.
Senion 1-130
Paoe 1.730-4s
-
Byron United
Effective FEB. 65 Pumps Pumps
Page 1-730-47
r
Effective FEB. 65
Byron United
wGP w/IP International, Inc. Jackson@ CentrifugalN
, Pump Division Pumps Pumps
Section 1-730 '
Page 1-730-49
Effective May 65
Supersedes February 6!
Byron United
WGInY BWIIP ~niernatbnal, IN. Jacksona centrifugalm
Pmp Division Pumps Pumps
Secti on 73 0
Page 1-730-51
Section 1-73 Byron United
, PumpDivlslon Pumps Pumps
I
. .
Effective February 65
Effective February 65
Byron United
wqIF BWN) lntemtional, inc Jackson@ Centrifugal"
Pllmp oivision Pumps Pumps
Se ~ t i 0 n 730
Page 1-730-53
Effective Februarv 65
Byron United
w*p m p Internatbnal, Inc. Jackson* CentrifugaP
Pump Oivision Pumps Pumps
Sectia n 73 0
J
Page 1-730-55
Best pump selection - 4 x 6 x 9D 2604-2
Stages
I
- 7
Efficiency - 80%
Horsepower - 750HP
Required npsh - 17 feet
Types of Co~npressors
- ., , 0 .< %
Posj tive Displacement
Reciprocating
(Centrifugal) I
--
As with pumps, there are dynamic md positive displacement compressors.
Compfessor $law is measuted in ACFM, Actual Cubic Feet per Minute, or
inlet Ms/hr. ACT34 is the flow rate at atmospheric conditions (standard)
correcxed for inlet gempernure and pxessme.
Compressors
r Basic Theory
Hardware
i Case studies
i
3
Large, 10 cylinder reciprocating compressor.
Receiver
cieAnce
Volume
1
Discharge
Iniet
Reciprocating Cornpressor Compression Cycfe
Compression (1 -2)
The piston compresses the gas inside the cylinder. When the pressure
exceeds the suction pressure, the inlet valves close so the gas cannot escape
h c k to the suction side. The piston continues to compress the gas until the
discha-ge pressure is reached. At this point, the discharge vdves open.
Ex haust (2-3)
The piston continues in its forward stroke, pushing the gas out at discharge
pressure.
Expansion
1 Pressure
f k-) Stroke ,-A
Discharge .:,.. 1 I . 0 '
Inlet
Expansion (3-4)
The piston completes its forward stroke. Some gas is left inside the
cylinder. The piston moves back toward the crankcase. The gas inside the
cylinder expands and the pressure drops. When the presswe inside the
cylinder drops below discharge pressure, the discharge valves cXose. When
the gas &ups bdow suction pressure, the suction valves open.
Receiver
I .f Pressure
Discharge
Inlet
Iritake (4-1)
As the piston .travels back toward the crankcase, the cylinder continues to
fiE with gas.
Compressor Valves
The compressor valves are nothing more than check valves designed to open
or close based on the differeaiaf pressure across the vafve. Since most of
the maintenmce of reciprocating .compressors have to do with the valves,
there 'has been much research and imprmmenw; in vdve types and
mdexids. Channel valves have been used fox- a long time. ' he channels
move up and down 300-500 dxnes a nziau%e ad&nst the valve sptings. If any
liquid gets between the channel md spring, the spring could break as liquid
is inconrpressjble, h is important that the gas is kept clean and dry.
Ring valve. Tday the i n s are made out of a high temperawre
themzopliassic, PEEK.
Plate valve with PEEK plate.
Poppet vaive with PEEK poppets. One size poppet fits valve sizes.
Two Stage Compression
Volume -
Staging
Reciprocating compressors have a discharge temperature constraint. Due so
mechanical considerations, the discharge temperature of a gas compressor
should not exceed 27SF. Discharge temperamre is a function of
compression ratio and sucGozl temperature. Xf the process demands a
compression ratio resulting in an unacceptable discharge temperature, the
compression can be staged. The compressor shown above has a suction
pressure of 15 psia and a discharge pressme of 115 psia. This coxnpsession
ratio of 7.7 will resub in an unacceptably high discharge temperature.
Therefore, the compression is divided into two stages with intercoofing.
The first-stase cylinder(& raise the pressme up to 40 psia. The gas is then
cooled back down to XOOF. The second-stage cylinder(s) then raise the
pressure up FO If5 psia. At no time does the gas temperature exceed
limitations.
Staging also saves power consu3nption. Cooling the gas after partial
compression to a temperature equal to the original intake temperature
reduces the power required in the second stage. (HP is a function of mas
flow times differential head. Head is a function of temperature.)
Occasional! y. even if discharge temperature is not a consideration,
intercooling is used to save power. The power savings has to offset the
utility consumption of the intercooler.
Reciprocating Compressor Control
r Saction Valve Unfoaders
r Cyfinder Pockets
w Bypass
Capacity is controlled with suction valve unfoadefs, cylinder cIearance
pockexs, and bypass.
Finger Type Unlouder
Unloaders hold fie suction valves open so no compression can take place.
If one side of a double acting cylinder is unloaded, the capacity goes down
by 50% for that cylinder. A one cylinder cornpressor can unload to 50% and
0% capacity. A two cylinder compressor can unload to 75%, 50%- 25% and
0%. A four cylinder compre~j,sor can unIoad in steps of 12.5% and so on.
Clearance Pocket
In addition to suction valve unloaden, head end fixed cleaance pockets are
also used for capacity controI. The head end of the cylinder has a pocket
that can be opened. When opmed, the total cylinder clearance increases.
On the intake part of the stroke, the gas thax fifills the clearance pocket
expands and less gas enters fie cylinder. When the pocket is opened, the
capacity DECREASB. Typically, the pocket is sized for 10% capacity.
With the pockex closed. the compressor is at rated capacity of 110% nonnal
pmcess requirement. with the pocket opened, the compressor is a XOO%
process capacity.
Variable capacity pockets are not recommended. The plunger in the
variable pocket tends to leak, making the pocket useless.
Clearance Pocket
I
Here is a manual clearance pocket on the heid end of a cylinder.
Nore 2 compartment disrance piece, piston packing, piston sings, and rider
rings. Also note clearance pocket on head end of cylinder.
Cut-away of tbe two cylinder compressor. Note how the connecting rod
between the crankshaft and the piston rod is connected to the piston sod at
the crosshead. Tfne piston rod screws i ~ t o the crosshead. A pin attaches the
connecting rod to the crosshead.
Single Cylinder Reciprocating
Compressor 250 BHP Frame Rating
Single cylinder compressor. Double acting with one hlet md oudet vdve
on each side. The box mounted on the f m e is the crankshaft driven
cylinder ~ubxicatur. The oif lines from tbe f~brkti t~r to the cyiinder can be
seen. Typically, tfie packing box is dso lubricated by this lubricator.
Two Cylinder Balanced- Opposed
Reciprocating Compressor 400 BHP
Frame Rating
Two cylinder, two-stage compressor. The larger first-stage cylinder is an
the right. The fist-stage cylinder has 92 valves total, the second-stage
cylinder has four vdves total. Again, note the cylinder a d packing
lubricator mounted on the crankcase-
Pump to Point Cylinder Lubricator
Two cylinder, two-stage compressor. The larger first-stage cyXinder i s on
the right. The first-stage cylinder fits 12 valves roM. the second-stage
cylinder has four vaEves t ad. Again, note &e cylinder and packing
lubricator mowted on the crankcase.
Cut-away of the two cylinder compressor. Note how the connecting rod
between the crankshafi and tEre pistun rod is connected to the piston rod at
the crosshead. The piston rod screws into the crosshead. A pin attaches the
connecting rod to the crossbead.
Crankshaft
Cut-away of the two cylinder compressor. Note how the connecting rod
between the crankshaft and the piston rod i s connected to the piston rod at
the crosshead. The pism rod screws into the crosshead. A pin attaches the
connecting rod ro the crosshead.
Connecting Rod
Cut-away of the two cylinder compressor. Xote how the connecting rod
between the crankshaft and the piston rod is connected to the piston rod at
the crosshead. The piston rod screws into the crosshead. A pin attaches the
connecting rod to the crosshead,
Cms Head
Cut-away of the two cylinder compressor. Note how the connecting rod
between the crankshdt and the piston rod is connected to the piston rod at
the crosshead. Tfae piston md screws into the crosshead. A pin attaches the
connecting rod to the crosshead.
Cut-away of the two cyfinder compressor. Note how the connecting rod
between the crankshaft and the piston rod is connected to the piston rod at
the crosshead. The piston rod screws into the crosshead, A pin attaches the
connecting rod to the crosshead.
Paeking Box
Cut-away of the two cylinder compressor. Note how the comecting rod
between the crankshaft and the piston rod is connected to the piston rod at
the crosshead. The piston rod screws into the crosshead. A pin attaches the
connecting rod to the crosshead.
Four cylinder, two-stage compressor. The smaller second-stase cylinders
are on the right.
Fow cyhder, two-stage, compressor in field. Note the suction pulsation
bottles on top of the cylinders. There are also dischaage pulsation bottles
under the cylinders. The pulsation butdes danpen the pulses caused by rhe
reciprocating action of the pistons and ease the pulsations on the piping and
fuu~dation,
Large, eight cylinder, two-stage compressor. The four first-stage cylinders
' are on the right. Note Be total number of valves. Each first stage cylinder
has eight suction and eight discharge vafves. Each second-mge cylinder
has six suction arnd six discharge valves. The total number of valves is 112!
If one vdve bm&, the compressor is down.
Recip.rocating Compressor Piston Rod, Two
Compariement Distance Piece
Two compartment distance piece and crosshead connecting piston rod to
connecting rod.
. Reciprocating Compressor
Frame Oil System Lubricator
Crankcase wl& shaft driven f m e oil pump. Note the motor driven
cylinder lubricators located on top of the crankcase.
ReeQroeah'ng Compressor Piston
Piston Rings, Rider Rings
After the $-hour shop mechanical run, the piston nod is disconnected from
the cross head and the piston is pulled .From the cyginder for inspection.
Note the piston and rider rings
Recerocating Compressor Advantages
$ High Compression Ratios
i Constant VolmeIWide Pressure Range
m Molecdar Weight Flexibility
r Fairly Basic Evolved Teclunology
A Mcieney
Reciprocating Compressor Disadvantages
r Foundation and Piping Requirements
Pufsatin;:Fiow
r Vulnerable to Dirt and Liquid
t Maintenance
r Plot Area
n Large Volumes Constraints
r Lurbsieticta: Contamhating Process
Torsional Xmplia.bions
The foundation and piping have to be designed to handle the pulsating Bow.
Niaintenance is higher than far centrif~tgaf compressors due to the parts with
close clearances. Reciprocating compressors are typically spared.
Reciprocating compressors take up a lot more space &an centrifugal
compressozs.
The cylinder lube oiE can con2runinare downstream catalyst or molecular
sieve absorbents.
A reciprocating compressor driven by a steam turbine though a speed
reducing gear is not recommended.
i
High presswe barze1 type centrifugal compressor.
Di aphaps guide the gas from the discharge of one impeller to the suction
of t he next impeller.
Recycle Gas Compressor
5 Stage CePttrifugZ Compressor
Five-stage centrifugal compfessos. Note the seal md lube oil piping
connections. The labyrinth seals minimize the flow of gas back to a lower
pressure impeller.
Compressor Impeller.
Stress Corrosion Crack
Riveted impeller. This is an old manufacturing technique, now obsolete.
Today, most impellers are machined. The cover is $hen welded in place.
The stronger wheds result in higher achievable perfonnif~ce per stage.
Stress Corrosion Crack
Riveted impeller. Thi s is an old manufacturing technique, now obsolete.
Today, most impellers are machined. The cover is %en welded in place.
The stronger wheels resuft in higher achievable performance per stage.
Cen&i!ugal Compressor Control
= Variablte Speed
r Suction Throttle Valve
Centrifusal compressors are controlled with variable speed or for a singXe
speed driver, suction tkxottling.
Centrifuga E Compressor Typical Variable
Speed Performance Curves
30
30 40 50 60 70 80 90 100 110 120 130
Percent Inlet Volume
IPD21k14/CD45
cD.RCc-12
For a variable speed driver, steam tusbine, or variable speed motor, the
compressor speed can be varied to meet the head requirements along the
system resistance curve. Most variable speed compression trains can
opesate between 70% md 105% of the design speed.
Centrifugal Compressor Typical Constant
Speed Performance Curve
Percent Inlet Volume
When a compressor is motor driven, there is only one head-capacity curve.
When operating at off-design cases, pressure must be thjrotzled over a
conbraf valve.
Centrifugal Compressor Typical Constant
Speed Performance Curve
The throztle valve can go upstream or downstream of the compressor. If the
valve goes on the discharge, the voJurnetric Row rate, A m , is directly
proportional to the mass flow, lbslh~. 808 Ibshr will be achieved at 80%
ACEM. Note that a% 80% ACFM, almost half the head pmduced by the
compressor is ti~oa1ed across the control valve. Since HP is a Emction of
mass fiow time heasl, almost half &e El? requirement of the compsessox is
wasted across the control valve.
Centri@gal Compressor Typical Constant
Speed Performance Curve
I n~ surge ~ i n e I val ve5 ; 9
I J' Suction
I
w
Percent Inlet VoEume
If the throttle valve is on the compressor suction, not only does the mass
flow decrease as the vabe is dxrottjed, but the suction pressure also
decreases. ACW is inversely proposticmal $0 suction pressure. With $he
valve on the suction, 80% mass flow can be achieved at abut 90% ACI.'M.
Compared to discharge throttling, less pressure is taken across the control
valve and less WP is rqai red for the same mass flow. Therefore, most
centrihgstl compressus with singie sped drivers have suetion throttle
valves.
Rated TD Turb TD Disch TD Suct
SCFL) 6 0 W 48 48 48
ELECXEUC MOTORS
SSM vsm
STEAM TURBI1LXS
Cond Back Pressure
i
Gas turbines, Gas engines
Mechanical Shafi Seal
(TSO-Carbon Seal)
Sucfrnn G a Chantbcr
I. llvtatinif Carbon King
2. Robting Scsf King
3. SCz2ronarySlecvc
I ----" -"#------A
7. C h and Contanimtcd Oit #>rain
1- h b'ta;ttrng Babbitt-Faced Steel Kin::
9. Sea1 f Y i ~ r King
i I*. &a! 08 Drab L*
1 I. Sccontisry \Vi;'ia? Ring m ~ i n t h
12. ikaring Oil Drain Lint
12. Gzaring Wiper Kin%
Like the pump seal, the contact type compressor seal has a rotating member
and a stationary member. A floating carbon bushing is between the two
members. Process gas leaks across the ltab*nth on the right side of the seal
and fills ii gas chamber. This gas is at a lower pressure t h n the process
because of &e pressure drop across the labyrinth. Seal oil is i.n.troduc& on
&e bearing side of the seal faces. Most of &e oil goes around the seal back
to the reservoizt The 03 pressure is maintained higher than the gas pressure
in the gas chamber. The oil lubricates the sea3 and about 10 liters per day of
oi2 leaks into the gas chamber. This sow: oil is drained. Note that most of
the UOP processes contain some H,S or HCI. IE the sour oil is put back in
the oil reservoir, the lube oil can become co&minated at b&ng or seal
problems can result.
. Liquid Film Sleeve Seal
(TSO-Sleeve Seal)
i . .U.monar). &al S1csi.w
2. Kot3trag .%I.& Slt.~.v~.cvc
3 Spring
4. ,%a1 C~%:n;t r%s:trtion
9. tk.;l?rf%g Olf t>rsr;t [.me
6. and Cnn:.ztnmatcd Oil h r n
7. Ftaatrng fL~bbrtc-Fae~d St*.*! King
S. .%A Oit ifran ttnc
9. Wrwr Km,:
30 %.srir$ Wiper Kinf
Bushing type seal. Oil leakage is greater &an contact type but: there i s no
normal seal wear.
Thncst Bearing
'Rxust bearings are designed to withstand rhe axial forces on the shaft. The
'
thrust pads are designed to pivot to the contour of %he shaft.
Thmst bearing. The bearing pads ride against the thmsr disc and absorb
force in ei&ex axial drrection.
Journal Bearing
The journal hasings are de s i ~e d to withstand the radial forces on the shaft.
The bearing pads can tilt to fit the contour of the shaft. Note the
temperature mani tors on the back side of the pads.
' \
Compressor Lube Oil System
Centrifugal compressor bearings are rypicdly Iubricabd by an external
pressurized oil system. Oil is sroted in a large reservoir. These we two
pumps, one operating and one ;spare. On low oiI pressure, the spare p mp
comes on-line autoxnatidly. The two pumps should be driven by diffetenr
power supplies, wi edl y dectt-ic mozor and steam twhine, to insme a
supply of oil to the compressor. The spare pump must be motor driven. A
st em turbine will rake $00 kmg0 come on-line. Note &e twin coolers and
fiIters. Also note Ffie three separate low oil pressure shutdown switches.
The shutdown is two of three voting. Two of the switches ~ u s t vote to
shutdown before the drives is tripped- This avoids spurious shutdowns and
insures a shutdown i f one is needed-
Compressor Seal Oil System
E Xfe compsessor has an oil lubricated sed, the seal must be suppIied with
pressurized oil. The sea9 oil system is very similar to the lube oiXsystem
Compressor Lube and Seal Oil System
There are many common components between the lube and seal oil systems,
such as pumps, coolers, filters, ezc. Mmy compressors have combined lube
and seal oil systems. Ody one reservoir and one sez of p e coolers,
fiften, etc., is required. If the compressor has a high sztction pressure or
contains a large pantity of EX2$ fNydromackip1g Units), the oil systems are
kept separate. OtherwiseJ UOP specified combined lube sfnd seal oil
system. Today, UUP specifies dry S ~ & S SO only the lube oil system is
required.
Mechanical ShaJt Seal
(TW-Carbon Seal)
1. R~tati Ft:! Carhon Rirtfi
2. I<ol;tting %:1l Bin:!
3. Ststrmsv S$ccw
4. Spring Ketaincr
5 Snring
11. kcondclt): \\'ID?: HlnC I&-rin:b
I?. I l wr i ng Oi l I f r ~ i ! i ].he
13. licaring \\'ipcr Rin::
Like the pump seal, the contact type compresses: seal has a rotating mernber
and a stationary member. A floating carbon bushing is between the two
members. 3Psocess gas leaks across the fabyx5nf.h on the right side of the seal
and fills a gas chamber. 33% gas is at a lower pressure than the process
because of the pressure drop across the Tabykith. Seal oil is introduced on.
the bearing side of the seal faces. Most of the oil goes wound the seal back
to the reservoir. The oil pressme is maintained higher than the gas pressure
in the gas chamber. The oil lubricates the seal and about 10 liters per day of
oil leaks into &e gas chamber. 'This sum oil is drained. Note that most of
the UOP processes contain some H2S or MC1. If the sour oil is put back in
the oil reservoir, the lube oil can k o me contaminated at bearing or seal
problems can result.
Li pi d Film Sleeve Seal
(TSO-Sleeve S e a
Bushing type sed. 011 leakage is g e m than contact type but there i s no
nonnd seal wear..
Dry Gas Seal Spiral Groove Arrangement
Rotation
to Prim
Rotating face of dry gas s d . The se&ng face is attached to the compressor
shaft and rotates against a solid stationary face. With rotation, gas is
pumped from the 0.D. inward toward the root of the grooves where a
sealing dam is defined. The sealing d m provides resistance to flow,
increasing the pressme. The pressure genefated separates the carbon ring
surface out of contact with the tungsten carbide x-ing by about 0.0001 to
0.UW inches. This allows less &an 2 c h of gas to leak across the wal
faces.
Single Dry Gas Seal
SingIe dry gas seal cartridge.
Principle of Operation
Gas i s Compressed and
Pressure is Increased
As the grooved face rotates with the shaft, gas is~pmped towards &e center
and, after a few rotations, lift off occurs.
Design Comparisons
f Bidirec80natl
I
t Spiral Groove Spiral Groove
i p D . mD - GP
CfMOc-21
Some seals are bidirectional. With the spiral groove design, the seals on.
either side of the compressor shaft are minor images of each other. Idet
side and ouder side seals are not interchangeable. The bidirectional grooved
seal is syamesric so both seals on either end of the shaft are identical.
Dynamic Test Leakage
fur a 4.937" L)iameter Seal
2.5
g 2.0
C
0
V)
V
a> 5.5
C35
a3
x
nr
@ 1.0
A
0.5
0
1000 1,200
Pressure (pig)
FD-2OWCD-65
COa0522
Typical seal leakage rates. As can be seen from the tests, leakage is
primarily a function of speed and pressure. Nfolecular weight and
temperature can d s o affect the leakage rate to a lesser degree.
Control System
m P rovjdes three main Xiunctions
- IF&&-ation of buffer gas
- Replation of buffer gas
- Monitoring of seal performance
r Ugem 1-1 indication; of fEtw amd seal performance
m Design is simple $0 operate and user friendly with
minimnm maintenance requireme~&ts
The control system filters and regdates tho gas and monitor seal
performance.
Dry Gus Seal
To Rare
The seal buffer gas is typically process gas from the discharge of the
' compressor. The process gas is filtered and coalescecl, down to one micron
liquid and three microns solids. Note that it is critical to supply the seals
with a clean, dry baffer gas. The gas is injected on the process side of the
seal about 20 psi above the conrpessos suction pressure. Most %he the gas
goes across a labyrinth back into the compressor. Under two cfm leaks
across the seal. This gas is routed to 8are,
. Type 28 Seal Arrangements
Single Seal Tandem Seal
Double Opposed Seal Triple Seal
UOP specifies tandm dry gas seals for process gas applicadons.
Single &y gas seat. The grooved silcar rotor is attached to the shaft.
Tandem dry gas seal. Most of the gas which Eeaks across the primary seal is
vented to flare. Under 0.5 cfm leaks across the secondary seal. A nitrogen
separation gas prevents the process gas from migrating to the lube oil in the
bearing box. The gas that escapes across b& seals is routed to atmosphere
outside the compressor shelter.
If zero fugitive emissions is &sired, rhe nitrogen separation gas can be
routed between the two seal faces. This will force dl of the gas that teaks
across the primary seal our the vent to flare, Only inert nitrogen will leak
across the secondary seal to atmosphere.
d
I
I
Comparison of Wet Seal vs, Dry Gas Seal
Wet Oil Seals Dry Gas S d
I I
Pumps, ~t:semoirs, filters I None
traps. coofers. consoles
Sed oil consu&tjon 1-100 gaXfonslday j NO sea1 oil
Maintneance cost A major ex nditsue over NegIigibIe
/ equipment Ke
I Energy costs SgaI Rper loss: 10-30 MP
ZImt &ven pumps: 20-100 HP
1 Process gasj~&age 1 Gas Leakage: 25 scfm & higher ) Less than 2 scfm
I
Today dmost d1 process gas compressors axe specified with dry gas seaIs.
Dry Gas Seal Console
Dry Gas Seal Console
Compressor Dry Gas Seal System
vet to
Rcl*Im&f
t I
UOP dry seal schematic. A 2 of 3 voting high-high pressure shutdown
is specified on each primary seal vent to shut down in the event of a primary
seal leak. A low flow d m across the primary seal vent warns of a
secondafy sed leak. If more gas is leaking across the secondq seal, less
gas will be tmveEing out &e primary seal vent.
A Model of Sarge
m Surge DelEi~ritioa
Surge is self-osc~~ions of pressure and fbw, including a flow
reverkaL Tlxe surge flow reversal is the only point of the curve when
pressure and flow drop simulbneously.
Characteristic Curve of42 Typical C&rrtnjCugaZ Compressor
- BtoCin24lto50mSec
- Cycle B to B at 0.33 to 3 Hertz
IPPZGWC076
CD-RW29
All centrifugal compressors can and surge. If the compressor rides up its
curve due to rising discharge pressure or decreasing gas rno~ecalax weight,
the compressor will physically not be able to overcome the downsueam
pressure requirements. Since gas is eompsessible, pressure and energy ~ $ 1 1
build up downs@eam. When the compressor curve reaches point B, the
cornpressor will no Ionger be able to push the gas out the discharge. The
gas will then reverse Bow through the compressor. Row & point C is
negative. Now that the downstream presswe has been relieved through the
compressor, the compressor cstn start pushing gas out the &sctnage again.
When the pressure builds up and the compressor em no Xonger keep up with
the demand, the gas once again goes back through the compressor to the
suction. This can happen multiple .times per second.
The Surge Phenomena
1 Rapid flow osciIfations
3
0
6 r Thmt reversals
r Potentialdamage
w
e
1
(0
k r Rapid pressure oscilfations
with smess instabilitv
4 -
r Rising tempmbres inside
c. cowressar
Time
The consequences of surge are severe. The thrust reversds on the shaft wilI
damage seals, bearings, md open up critical internal clearances. Since the
same gas is passing throagh the compressor multiple t i ms a second, the
temperatwe in the compressor rises rapidly.
Surge Description
FXQW reverses -in 20 to 50 milJiseconds
Surge cycles at a rate of 113 to 3 hertz
r Compressor vibrates
8 "CWJhoosbijng" noise
8 Trips may wcur
I Conventioad btmrnents and hmm operators
m y fail to rec~~anize surge
Some Stlrge Conseqrcences
r Umbbie flow and pressure
Damage h sequence with increasing severity to
s 4 s , bearings, impeEEers, shaft
r Increased seal c1eat.mces and leakage
r Lower energy efficiency
i Redaced compressor fife
PlatJorming Recycle Gas Circuit
This is a VOP Piatforming recycle gas circuit. Note that this i s a circulating
loop circuit. The compressor discharges into the comprressor suction. There
are no automatic conxols on compressor speed and no ausoxnazic control
valves. Assuming no blockages occur in the exchangers or reactor, which
will only happen slowly over time, there is nothing in tkis circuit &a% can
put the cornpressor into sage. Therefore, UOP recycle gas circaits do not
require anti-surge control.
FCC Muin Air Blower
Regenerator
a
This is a FCC Main Air Blower. There are automatic valves which if not
operating properly can put the blower into surge. Therefore, anti-surge
equipment is specified-
Antisurge Controller Operation
S e e limit Line (SU)
The anti-surge con.trolIes measures gas pressure, temperature, and flow a
' minimum of 40 ~ me s per second. E the operating point hits &e surge
controf line, the anti-surge co~trolfer smds a signal. to open the spillback
valve. This allows tbe gas downstream of the comp~msor an alternate path
around the compressor instead of back through fhe compressor. A margin7
b2, i s left between the surge con&ol Ene and the actual surge line. This
ensures that the spillback valve will open in time to prevent the compressor
from surging.
Antisurge Controller Operation
Surge Limit Line (SLL)
APc
0 0 0 0
Surge Control Equarion:
KA PC + bX = APo minimum
!
I Aattslcrge ControIZer Operation
I
S&ge Limit Line (SLZ)
Antisurge Controller Recycle Trip Circait
Operation
Recycle Trip Line (RTIL)
swge ~i n-i t ~ i e (SLL) /
\
.---- Surge Control Line (SCL)
Activates open loop
0 0 0
control
m Reven& surge in all
$he most severe
disturbance
APo
but
The surge controller is also progmmmed with a recycle trip h e . If the
opera%ing point hits the surge control line, the spilgback valve opens slowly.
Xt is not desirable for &e spillback valve %o go wide open because catalyst in
the circuit cadd be starved of hydrogen.
K -the opefating pi nt hits the recycle trip line, now the compressor is in
danger of surging.. The spillback valve wiIl step open quickly to avoid
surge.
Simple Antisurge System
r Flow measured in suction
(@o)
Suction and discharge
pressure transmitters for
pressure differential
calculation
r Control strategy is
proportional plus integral
control to maniprrEate recycle
valve
I Increase flow through
compressor and reduce
discharge resistance when
required to prevent surge
h a simple amisurge system, flow and pressure measurements on the
suction and pressure measuremen% on the discharge me sent to rhe antisurge
contro31er7 'LTXC. The U C controls the recycle valve which is nonnaEXy
closed. If surge is approached, &e ZsyCopens the recycle valve.
FCC Axial Main Air Blower
with CCC Performance Controller
CCC Pctiomwicc Co~twl!c
6 2
8 ,
t ,
*-_-------*L-..--.?
8 ,
- - - - - " - - - - - C- - - - ,
t
t I
. '
This is an actual UOP FCC Main Air Blower P & XD. Note the flow,
pressure, a d ternpermre measurements transmitted to the perfommce
controfler which i s contxoIliag the flow of air to the regenerator. The
performance controller is adjursting the axid air blower guide vanes or the
tufbirte driver speed. The pdomance controller is also sendlag d&a to the
antisurge con~l l er , whicb is controlling the normally closed snort valve. If
the surge line i s appxoached, the antisurge contro1ler will open the snort
valve md uncouple the performance controUer from the Emp.
Occasionafly, in a surge event? the pedommce contrler could actually
push the compressor further towards swrge by speeding up or slowing down
the compressor. With the antisurge and perfommce cortrroflers '?taiking'!"' to
each other, this is pzvented fiom happening.
1
Purchasing Reciprocatiag Compressors
Technical Evahatiovc
1. Scope of Supply (Per Spec and API 618)
2. , Frame Loading
3. No. of Cylinders
5. Cylinder Diameter
P~crchasing Reciprocating Compressors
Technical Ifvaluation
6. Piston Speed
7. Piston R_PM
8. Exceptions to specs and standards
9. Power Requirement
la Experience
Purchasing CentPz?$ugal Compressors
Technical Evaluation
1. scope of Supply
2. Can it meet all,operatiag points (N2 start)
i-
3. Materials (Impeller yield strength)
4. 3Es proposal complete
5. Does proposal meet APE 617
IPtT1oae'CP$O
Purchasing Centm~uggal Compressors
Technical Evaluation
6. Efficiency of various operating points
7. Rotor: dynamic stability (How many wheels)
8. Exceptions to specs and standards
10. Experience similar casing sizes, rotor
sizes, pressufes, Bows
TRAXNlNG PROGUM - PROBLEMS A & 3 (Complete BBP Calculation Forms)
TYPE COMPRESSORS
XTEM NO.
PROBLEM A
t
/ SERVICE 1 RECYCLE GAS
1 1 (Lubricated)
Page No. 1 Date
Project I BY
f
I
PROBLEM B
MAXN AIR
BLOWER
D m TYPE I MOTOR I 1 Tt R3I ; NJ E I
c 1 1 6.35 1
ED-2004 uc)Ip Compressors- l
Atmospheric
c2
4-38 Air
SYMBOL
--
Subject: RECIPROCATING COMPRESSORS-BHP
and Suction Tmpemtufe
Date
For: Sample Problem A / BY
SYMBOL
Subject: CEhmFUGAL COMPRESSORS-BHP
For: Sample Problem B ,
tosses frictional Seal
Date
BY
Compressor Palytropic Efpclency
Basic bhp/mmfi3/d
Compression W o
SpeciJic Gravity Cowectiun
1
PLATFORMXNG WT GAS - PROBLEM C
1
Gentxifugd compressor (condensing steam turbine driven) vs. 3-50% reciprocating compressors
(motor driven). Which is better?
Cost of 2 body compsessor, condensing steam turbine including oif console and g s seal console:
Spare compressor and tmbine rotors: $1,065,000
Cost of 2 stage (6 cylinder) reciprocating compressor: $3,327,000
i '
Assumptions: Installation: Centrifugal - 20% of compressor cost
Reciprocating - 50% of compressor cost 4
Maisftenance: Centrifugal - Ohp/ y
Reciprocating - $35hp/yr
CEN'SJRWCAL COMPRESSORS PROJECT N W E R
RECfPROCATLNG COMPRESSORS PROSECT NZjmBER
SOLUTION - PROBLEM A
IPD-2004 UOP Compressors- 1
Subject: RECIPROCATING COMPRESSORS-BHP
For: Recycle Gas
Date
By
I
30.55
580
243
387
1.59
1.31 1
7.6
0.26
1.001
1.003
1.002
1433
0.237
187F
23
3
34.76
---
1.002
-
906
SYMBOL
Qb
T s
ps
p d
r
k
mol wi
SPgr
2s
z d
=avg
Qs
Td
( A)
( B )
( c)
( D)
( E )
( F )
BHP Req d
Million SCFD
OR
psia
psia
Pd1p.s
C ~ / C ~
Molecular Weight
Specific Gravity
ft3/min Q Suction
(sfd 1 ? ~ / d ) 7 4 . 7 ) ( ~ ~ ~ 1 ~ )
(1 440)(pS 1520)
k- 1
-
k
(TS (' 1r
BHP/mm @ 14.4 psia
and Suction Temperature
sp gr Correction
(Qb XI . 02 KTs )
520
Add 5 pct if N.L.
Zavg
Gear Loss 3 pct (if Gear is used)
( A + BXCXDXE) (F)
COMPRESSOR PROBLEM SOLUTIONS - PROBLEM B
-)
Centrifugal - Main Air Blower
std ft3/d 14.7 psia Ts " R
A ft3/min = x x-
minuteslday ps psia 520R X zs
Aft 3/min = 34.54x106 x- 14'7x555x1.0=26134fi3/min 63 Inlet
1440 14.4 520
34.54 x 1 D" 28.49 Ibllb mol = lb,min
Ib/min wt flow = x
7440
379.48 std ft 3/lb mol
0.546
--
M
- Beta = 1.590
Polflropic Head = ZavgRTs B = (1.0)(1545J28.49)(555)(1.590)= 47846 ft Ib f / l b m
Head x lblmin (48376)(1800.8)
GHP =
- -
33000 x Eh (33000X0.832)
= 3138
SOLUTION - PROBLEM B (cont.)
Subject: CENTRIFUGAL COMPRESSORS-BHP
For: Main Air Blower
Date
By
l
SYMBOL
Qb
7 s
ps
p d
r
mol wl
R
k
Qs
Iblmin wt flow
2 s
Zd
=avg
Eh
M
Beta
Head
Gas hp
Losses Frictional Seal
Gear
Total bhp
7d
--
Million SCFD
"R
psia
psia
PdIPs
Molecular Weigh1
1545
mol wi
C ~ / C v
ft3/min @ Suction
(Qb Xmol wt)
546000
Polytropic Efficiency
k - 1
-
k
k - 1
-
k Eh
(r)M - 1
(rl M - I
M
(zavg )@XTS )(Beta)
(Wt low X~ e a d )
( 33000) ( ~~ )
I pct of Gas hp
(If used) 3 pct of hp
(TS MM
34.54
555
14.4
51.2
3.556
28.49
54.23
1.4
26 1 34
1800.8
1 .o
1 .o
1.0
0.832
0.2857
0.343
0.546
1.590
47846
31 38
32
-
31 70
398
SOLUTION - PROBLEM C
Savings with centrifugal compressor - $8.78 million for first year
Capital Cost
Installation
UtilitiesNear
Maintenance
Total11 st Year
Centrifugal
$5.32
$0.85
$2.72
0
$8.89
Reciprocating
$9.98
$4.99
$2.44
$0.26
$1 7.67
CENTRIFUGAL COMPRESSORS PROJECT NUMBER
Qb
Ts
ps
pd
r
MW
R
k
Qs
#/Min
Wt. Flow
z s
z d
za v
Eh
M
Beta
Head
GHP
Losses
Frict.
Seal
Gear
Total BHP
Td
1 st
74.76
566
49.35
1 15.06
2.33
10.3
150.0
1.257
16832.556
1409.14
1 .ooo
1.002
1.001
0.83
0.204
0.246
0.232
0.941
79991.486
41 15.351
1.01
1
41 56.504
237.232
Million SCFD
OR
psia
psia
Pd/Ps
Mol. Wt.
1545/M W
CdCv
CFM @ Suct.
QbxMW
546000
Poly Eff.
k -7/k
k - l /kh
M
( r ) -1
M
( r ) - I
M
Zav R Ts Beta
wt Flow x Heaa
33000 x Eh
7% of GHP
3% of GHP
Ts ( r )
2nd
77.27
555
107.81
243.50
2.26
9.9
1 56.1
1.267
7824.635
1399.89
1.002
1.004
1.003
0.81
0.21 1
0.260
0.236
0.908
78840.783
41 29.01 7
1 .O1
1
41 70.307
226.041
I
RECIPROCATING COMPRESSORS PROJECT NUMBER
Q b
Ts
ps
pd
r
k
MW
S. G.
Zs
Zd
zave
Qs
Td
6.4)
(B)
(C)
(0)
(E)
(F)
BHP Req'd
2nd
38.64
555
107.81
243.50
2.26
1.267
9.9
0.3
1 .ooo
1.002
1.001
3905.01 4
0.21 1
198.960
4 1
3.5
42.07
1
1.001
1
1873.790
Million SCFD
OR
psia
psia
Pd/Ps
cp'cv
Mol. Wt.
Spec. Grav.
CFM Suct
k- l / k
k-l / k
r Ts
BHP/mm @ 14.4
psia & Suct T
Sp. Gr. Corr
Qb (1.02) Ts/520
Add 5% if N.L.
Zav
Gear loss 3%
(A+B) (C) (D) (E) (F) (G)
1 st
37.38
566
49.35
1 15.06
2.33
1.257
10.3
0.4
1 .ooo
1.002
1.001
841 6.278
0.204
21 2.948
41
3.5
41 -50
1
1.001
1
1848.61 6