Okafor, Winston CHURCHILL

Instructor: Pumps 1
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Okafor, Winston Churchill Instructor’s profile

Assistant Manager Operations – (Refining – 8yrs., Gas - 4yrs.)

+234(0)7031694142, LinkedIn – Engr. Winston Churchill Okafor

• Education
–[Link]. (Chemical Engineering - Catalysis)
–[Link]. (Chemical Engineering - Basic)
–Honeywell-UOP (General Engineering Technology Training)

• Experiences / Work history

– Assistant Manager.- Dangote Petroleum and Petro. Project (6yrs)
– Process Engr. Bharat Petroleum corp. India (6 months)
– Process Engr.- NGC– NNPC (4yrs.)
– Process Engr.- Astrid Offshores Ltd. (3yrs.)
– Grad. Ass. - Federal Uni. of Pet. Resources (1yr.)
– Process Engr. ETSD-WRPC-NNPC (1yr.)
 Target Audience

• Field and Panel Operators

• Maintenance Engineers

• Technical Services

• Instrumentation
Technicians

• Artisans

3
 • Section 1
COURSE CONTENTS
• Introduction to oil and gas equipment
• Introduction to pumps and types

• Section 2
• Pump performance (Pump curves)
• Pump operating curve
• Pump resistance curve

• Section 3
• Cavitation
• NPSH of pumps

• Section 4
• Pump utilities (sealing, flushing and cooling system)
• Pump commissioning
• Pump troubleshooting
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Class Decorum

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COURSE CONTENTS • Section 1
• Introduction to oil and gas equipment
• Introduction to pumps and types

• Section 2
• Pump performance (Pump curves)
• Pump operating curve
• Pump resistance curve

• Section 3
• Cavitation
• NPSH of pumps

• Section 4
• Pump utilities (sealing, flushing and cooling system)
• Pump commissioning
• Pump troubleshooting
6
 Classification of Oil and Gas equipment

Non-
Proprietary
proprietary
Static
Equipment

proprietary

Pumps, compressors,
Rotating Fans, turbines, blowers
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Proprietary Non-proprietary

Pumps Reactors
Proprietary
equipment are Non - Proprietary
designed and Compressors Columns equipment are
manufactured by designed as
specialists and Centrifuge Heat exchangers special, one-off
displayed for items for
shopping. (i.e., particular
Dryers Separators
the engineer processes. (i.e. to
specifies the meet specific goal
parameters of Mixers Scrubbers such as reaction
interest to the or separation)
vendor and Filters
delivery is made) Evaporators

Valves Cooling towers

A Typical Centrifugal Pump

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 Definition of Key terms
• A Pump is a device that adds energy of flow to fluids (liquids)

• Any device that increases the pressure and velocity of a fluid (liquid) by the
conversion of mechanical energy into pressure in a flowing system

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P &ID Symbols

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Life-Cycle Cost of a Pump

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Pumping System

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Parts of a Pump

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Parts of a Pump Cont…

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Pump Classification

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Pump Classification

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Pump Classification

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Pump Classification

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Pump Classification

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Pump Classification

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Pump Classification

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Pump Classification

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Pump Classification

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Pump Classification

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Pump Classification

Suction

Discharge

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Pump Classification

Suction Discharge

Diaphragm

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Pump Classification/Selection

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29
 • Section 1
COURSE CONTENTS
• Introduction to oil and gas equipment
• Introduction to pumps and types

• Section 2
• Pump performance (Pump curves)
• Pump operating curve
• Pump resistance curve

• Section 3
• Cavitation
• NPSH of pumps

• Section 4
• Pump utilities (sealing, flushing and cooling system)
• Pump commissioning
• Pump troubleshooting
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Pump Performance: Head and Capacity

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 Pressure Head & Height Calculations
Difference between head and height of liquid

• P1 = Rho. g. H1,
heights
• P2 = Rho. g. H2

Conversion factors
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Discharge Pressure and S.G Variation

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NPSH – Net Positive Suction Head

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 Pump Performance Curve

Performance Curve
Head

Pump Flow Rate

• Most pump performance curves slope from left to right 35
 Pump Performance Curve

Shut-off Head
Head

Pump Flow Rate

• Shut-off Head is the maximum pressure or head the pump can produce
• No flow is produced 36
 Pump Performance Curve

Head

Max. flow

Pump Flow Rate

• Maximum Flow is the largest flow the pump can produce
• Min Head is produced 37
 System / Operating Curve

• Operating Curve is a mapping of the head required to produce flow in a

given system

• A system includes all the pipe, fittings and devices the fluid must flow
through, and represents the friction loss the fluid experiences

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 System/Operating Curve

Head

Operating curve

Static Head {
Pump Flow Rate
• The friction loss is mapped onto the graph
• The amount of friction loss varies with flow through the system 39
 Operating Point of a pump

Operating point
Head

Pump Flow Rate

The point on the operating curve that intersects the pump curve is known as the
operating point. 40
System Resistance Curve

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System Resistance Curve

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System Resistance Curve

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 Performance Curve

Varied by throttling the discharge valve 44

Altering the Curve: More flow

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Altering the Curve: More pressure

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Pressure Head Plots (Pump Curves)

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 Affinity Laws
• It is used to relate pump performance with power

• It shows the relationship between pump performance variables

Q1 D1 N1
= =
Q2 D2 N 2
1 1
2 2 Q1 H1 2 BHP1 3
H 1 D1 N1
= = Therefore = =
H2 D2 N2 Q2 H2 BHP2
3 3
BHP1 D1 N1
= =
BHP2 D2 N2

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EXERCISE 1

• A centrifugal pump rotating at 1200rpm delivers flow of 55l/s to 27m head.

If the rotating speed is increased to 1500rpm, and the impeller diameter is
increased 10%. Compute the new flow and head

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 Pump Performance : Terminology

• BEP: Best Efficiency Point; it is the point

maximum efficiency. Also at this point
maximum allowable flow is achieved.

• BHP: Brake Horse Power, it is simply the

power required to drive a pump.

• Shutoff Head: This is the maximum head

when the flow is zero or discharge valve
is closed fully.

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Exercise 3
• Process requirements are 800 gpm of 0.75 SG oil and 2400 ft head.

Use the pump curve to determine

• Impeller size

• Efficiency

• NPSH
• Power requirement (in hp)

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29
 • Section 1
COURSE CONTENTS
• Introduction to oil and gas equipment
• Introduction to pumps and types

• Section 2
• Pump performance (Pump curves)
• Pump operating curve
• Pump resistance curve

• Section 3
• Cavitation
• NPSH of pumps

• Section 4
• Pump utilities (sealing, flushing and cooling system)
• Pump commissioning
• Pump troubleshooting
54
 Understanding Cavitation

• Cavitation is an unwanted phenomenon in

Prevention of Cavitation
pump operation.

• It occurs when the suction pressure • Increase suction head

becomes less than the vapor pressure of
the liquid. • Prime the pump

• It leads to the formation of bubbles which • Reduce suction temperature if higher

collapse when returning to liquid phase
and applies a force that can damage the than design
impeller or casing.

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 Understanding Cavitation

Operated under cavitating conditions for sufficient length of time:

• Pitting of impeller vanes and pump volute
• Short bearing life and heavy loading
• Shaft breakage and other fatigue failures in the pump
• Short seal life

Damages to mechanical seals can be:

• worn pins and pin slots
• Broken springs
• shaft fretting
• Chipping of carbon faces

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Cavitation: Inlet Pressure Profile

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Cavitation: Temperature and Pressure effect

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 Cavitation in Pumps and Valves

• [Link]
• [Link]

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 Net Positive Suction Head (NPSH)

• In other to curtail cavitation during operation, the suction head must be greater
than the vapor pressure of the liquid at that temperature.
• Net Positive Suction Head (NPSH) is a measure that pump designers and
operation engineers use to evaluate cavitation of a pump.
• NPSH can be defined as the difference between the suction head and vapor
pressure head of the liquid.

NPSH = hs −hv Where hs is Suction head and

hv is liquid vapor pressure head

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 NPSHR VS NPSHA

• The operating window in which

cavitation will occur is when
NPSHR > NPSHA.
• NPSHA is improved to moved it to
a cavitation free region.

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Friction in Valves and Pipe Fittings

144 1 2
P1 − P2 + v1 − v22 = z2 − z1 + hL
ρ 2g
ρ = Density, lb/ft 3
P = Pressure, lbf /in2
v = Velocity, ft/sec
g = Gravitational Acceleration, 32.174ft / s2
z = Elevation, ft
hL = Head loss, ft

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Friction in Valves and Pipe Fittings
0.00259 (  K ) Q 2
hL =
d4
Q = Volumetric Flowrate, gpm
d = Pipe Diameter , in
 K = Sum of all fittings
L
K = f , straight pipe
D
2
 d  2
K = 1 −  , Sudden enlargement
1
2
 d  2

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Friction Loss Factors for Fittings

Fitting K

Standard 90o Elbow 30fT

Standard 45o Elbow 16fT

20fT Run
Standard Tee
60 fT Branch

Pipe Entrance 0.78

Pipe Exit 1.0

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Friction Loss Factors for Valves
Valve K
Gate valve 8fT

Globe Valve 340fT

Swing Check Valve 100fT

Lift Check Valve 600fT

Ball Valve 3fT

29.9d 2
K =
CV2
CV = Valve Coefficient 65
 Fanning Diagram

1 D
= 4.0 * log + 2.28
f 

  
1 D D/
= 4.0 * log + 2.28 − 4.0 * log4.67 + 1
f   Re f 
f =16/Re

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 Energy Loss in Valves

• Function of valve type and valve position

• The complex flow path through valves can

result in high head loss (of course, one of the
purposes of a valve is to create head loss
when it is not fully open)

• Ev are the loss in terms of velocity heads

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Centrifugal Pump Selection

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29
COURSE CONTENTS • Section 1
• Introduction to oil and gas equipment
• Introduction to pumps and types

• Section 2
• Pump performance (Pump curves)
• Pump operating curve
• Pump resistance curve

• Section 3
• Cavitation
• NPSH of pumps

• Section 4
• Pump utilities (sealing, flushing and cooling system)
• Pump commissioning
• Pump troubleshooting
 Lubrication System

• Friction generates heat and wears &

tear rotating parts like bearing.

• In order to remove this heat and

reduces wear and tear, these moving
parts must be lubricated with grease
or oil to mitigate these effects.

• It consist of the oil system and cooling

system

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 Lubrication System
Various types of Lubrication System

1. Grease Lubrication

2. Oil Flood

3. Oil Rings

4. Oil Mist

* Pure Mist
* Purge Mist

5. Oil Slinger

6. Force Feed
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 Sealing System

• Sealing system is used to separate the lube oil system from the fluid being
pumped.

• It can be used to prevent leakage of fluid from the pump to the

environment.

• Various types of seals are used for different purposes during operation.

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 Types of Sealing System

1. Packing

2. Mechanical Seals

3. Serrated Bushings

4. Floating Rings

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 Conventional Packing Glands

• These type are fast becoming obsolete for pump sealing.

• It is made up of Asbestos, Graphite Asbestos or synthetic materials

• Leakage is higher

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 Mechanical Seals

• Mechanical seals are devices to prevent leak between rotating parts

(shafts), and stationary parts (pump housing).

• There are two types of mechanical seals:

• Single mechanical seals

• Double mechanical seals

• Mechanical seals consist of gland, sleeve, secondary seals and two faces

which slide against each other.

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 Mechanical Seal

• The faces are pressed together by a

spring.

• Between these two faces a fluid film

prevents the heat generation between

seal faces.

• The absence of this fluid film will result

in frictional heat and the destruction of

the mechanical seal. 77

 Flushing Plans

• A flushing plan is implemented to extend the life of the mechanical seal.

• It circulates fluid to and fro the seal chamber to clean up the seal chamber.

• It maintain the temperature, pressure, proper lubrication and effective solid

management.

• Various types of flushing plans exist depending on the type of mechanical seal
used.

• It can be external or internal.

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Flushing Plan: Plan 11

Flushing fluid

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 Reasons for Seal Failure

• Poor installation

• Vibration

• Pipe strain

• Seal faces worn

• Wrong seal face or ring material

• Wrong seal design

• Flush cooler inoperative

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 Reasons for Seal Failure
• Mis-alignment

• Rotating assembly out of balance

• Seal flush inoperative

• Seal flush vaporization

• Cavitation

• Operation off best efficiency

• Particles or foreign objects from process or seal flush

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 Matching Pumps with Drivers

Various Driver types exist for pumps

• Electric motor

• Gas turbine

• Steam turbine
• Internal Combustion Engine

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 Commissioning of Centrifugal Pump

• After the suction and discharge line has been pre-commissioned then the pump and

motor is ready for commissioning.

• The following steps are taken during commissioning of a pump:

• Check Pump with updated P&ID to assess the completion(mechanical and instrumentation)

• Change storage oil used in the bearing housing and maintain required level.

• Checking rotation of the motor meet the design spec

• Performing of pre-alignment for motor shaft and coupling

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 Commissioning of Centrifugal Pump

•Mechanical Run Test(MRT) is done for the pump without load: Bearing Temperature, Lube

Oil Temperature and Pressure, Test Water Inlet and Outlet Temperature, Cooling Water in

and out Temperature and Pressure (if any), Bearing Housing Vibration (mm/s or in/s), Shaft

Vibration (μm or mil), Shaft Speed, Power consumption and mechanical Seal Leakage rate.

• MRT is done for 4hrs and usually without load.

• Perform final alignment for the coupling and shaft for pump

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 Commissioning of Centrifugal Pump

• Drain suction casing via the casing drain then close it.

• Line up casing vent while opening the suction valve to prime the pump

• The suction strainer is covered with commissioning mesh(100µm) prior to lining up suction valve

• Line up minimum circulation line prior start up and crack open the discharge valve.

• Get authorization from sub station before starting the pump to ensure that the motor is

energized.

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 Concept of Air or Gas Lock

• Air or gas pockets can form in the suction piping if pipe leveling is not properly attended

• Pumps can function with small stationary pockets, problems arise when the gas moves

and enters the pump.

• When the air or gas increases to about 6%, it can affect the performance of the pump.

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 Concept of Air or Gas Lock

• Horizontal eccentric reducers with the straight part at the top must be used
instead of concentric ones.

• The suction line must either be laid horizontal or with a steady rise towards the
pump to eliminate gas pockets. Vertical loops in suction lines should be avoided
as well.

• The pump must be primed during startup to eliminate air or gas pockets

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 Concept of Priming
Priming is used to removed trapped air or gas in the pump

Procedure For Priming

• Draining the casing via the casing drain valve then close it after draining

• Line up the Casing vent valve to remove trapped air or gas

• Line up the suction valve to fill the casing and displace air/gas pockets in the
pump.

• The activity can be confirmed by observing the floe via the vent using the
sight glass.
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 Failure Identification and Causes
TROUBLESHOOTING GUIDE
TROUBLE POSSIBLE CAUSES
Liquid not delivered Pumps not primed
Air or vapor pocket in suction line
Pump not up to rated speed
Wrong rotation
Impeller or passages clogged
Failure to deliver rated capacity and Available npsh not sufficient
pressure
Pump not up to rated speed
Wrong rotation
Impeller or passages partially clogged
Wear rings worn or impeller damaged
Air or gases in liquid
Viscosity or specific gravity not as specified
Air or vapor pocket in suction line
Air leak in stuffing box
Total head greater than head for which pump designed

Injection of low vapor pressure oil in lantern and ring of hot

pump
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 Failure Identification and Causes
TROUBLESHOOTING GUIDE
TROUBLE POSSIBLE CAUSES
Pump loses prime Air leak in suction line
Air leak in stuffing box
Air or gases in liquid
Pump overheats driver Speed too high
Specific gravity or viscosity too high
Packing too tight
Misalignment
Total head lower than rated head
Low voltage or other electrical trouble
Trouble with engine, turbine, gear or other allied equipment
Pump vibration Available npsh not sufficient
Air or gases in liquid
Misalignment
Worn bearings
Damaged rotating element
Foundation not rigid
Pump operating below minimum recommended capacity
Impeller clogged 90
 Failure Identification and Causes
TROUBLESHOOTING GUIDE
TROUBLE POSSIBLE CAUSES
Stuffing box overheats Packing too tight
Packing not lubricated
Incorrect type packing
Gland cocked
Bearings overheat or wear rapidly Incorrect oil level
Misalignment or piping strains
Insufficient cooling water
Bearings too tight or preleaded
Oil rings not functioning
Suction pressure appreciably different than specified
Improper lubrication
Vibration
Dirt or water in bearings

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