Beruflich Dokumente
Kultur Dokumente
and
Donald G. Coppins
President
Lube-Power, Inc.
Shelby Township, Michigan
Vinod
Patel
is
a
Senior Principal Engineer
Machinery Technology, for
the M.W. Kellogg Company, in
Houston,
Texas.
In
this
assignment, he is responsible
in the preparation and
auditing of specifications,
equipment
evaluation,
engineering
coordination, and testing
and installation startup of
rotating
and
special
equipment. He has worked in
the various application of
rotating machinery in the
petrochemical and refinery
processes including ammonia,
LNG, olefins, cat cracking, and hydrotreating for
domestic and international projects.
Mr. Patel received B.S. and M.S. degrees in
Mechanical and Metallurgical Engineering from
M.S. University, and Youngstown University,
respectively. He is a registered Professional
Engineer in the State of Texas.
Donald
G.
(Don)
Coppins
designs
and
manufactures oil lubrication
systems, seal oil systems,
seal buffer systems, heat
exchangers, and hydraulic
systems
for
the
petrochemical,
refining,
power
generating,
and
process industries. He has
29 years experience
in
the oil hydraulic and
lubrication systems business.
Mr. Coppins started and
INTRODUCTION
The pump user's objective is to maximize revenue
from his process. In order to meet this objective, it is
extremely important to have safe and reliable operation
of pumps and auxiliaries.
Larger process pumps and drivers often use
hydrodynamic bearings, due to required bearing load
and their noted reliability over antifriction bearings at
higher bearing surface velocity. The oil iflm that forms in
the hydrodynamic bearings provides the needed
separation between shaft and bearing. This
continuously replenished oil film removes bearing heat
and wear particles.
The oil film properties are a function of many things
including oil viscosity, bearing/shaft clearance, bearing
load, etc. Constant oil supply within the acceptable
temperature and pressure range is required to keep the
bearing system in balance. A loss of oil supply means a
External Factors
Ambient temperature range
Tropical area
Electrical area
Seaside or platform location
Local codes (CSAJCRN, IEC, country codes)
Operational Factors
Lube oil supply pressure higher than cooling water
Vertical process pump with dual AC motor
driven lube oil pumps
Equipment coastdown time
Synthetic versus mineral base lube oil systems
140
SYMPOSIUM
API 610,
EIGHTH
EDITION
LUBE OIL
SYSTEM
SCHEMATIC
ST
R
AI
N
E
R
LEGEND
Fi
Flow IndIcelor
(Wove Indinal. funclfonl
71
Temper.. Inbicaiot
valve
Pi
Pressure kglula
PD1
PSLA
Low-Plee..
PSLB
Low-PmeN. e+Alef,
(alstml
PELL
Low-peeseure
Ins ..nem
NENN valve
AIR PASSAGE
*WOW
1.) isladl
WO)
OIL RETURN
Om
2,
Pleasure
control valve
IA' Check vale
W
Block and
bleed valve
r
I (TI
II I
Rdlidx.lype
Loll indicalor
(Ion
SIZED
3
TIMES AREA
OF
COMBINED
PUMP
SUCTION
LINES
VIEW AA
OIL
PASSAG
E
Provide
for
temperature
fluctuations,
expansion
volumes,
location for heating, and oil purifier
connections.
SELECTION OF LUBE OIL SYSTEMS COMPONENTS FOR PROCESS PUMPS AND AUXILIARIES
(EXTERNAL, PRESSURIZED) 141
Reservoir Sizing
System flowrate.
Retention time.
Height of return line from process
equipment.
Required working capacity.
Rundown capacity.
Location of auxiliary pump (internal or
external of.reservoir). Refer to Figure 2 for
baffle design and location. Figure 3 shows
suction and return locations in the
reservoir as well as reservoir capacities.
OIL RETURN
SUCTION
CONNECTION TO
INTERNALLY
MOUNTED PUMP
MAN WAY (TYP)
SUCTION OF TANK
T
OP MOUNTED PUMP OIL RETURN
F
ROM
TANK
TOP
FILLER/BREATHER
CAPACITY
D
R
A
I
N
2.0'
W
I
T
H
SUCTION LOSS
SUCTION CONNECTION HORIZONTAL MOUNTED
PUMP OR FLOODED SUCTION
STRAINER
RUNDOWN LEVEL
P
L
U
G
T
3 0"
MIN.
AIR
GAP
R
UNDOWN CAPACITY OIL
RETURN
WORKING
A minimum 1.5
gpm extra must be
available on systems
in the 5 gpm to 12
gpm range for proper
valve
sizing and
maintaining head.
The
pressure
control valve is sized
along with the pump
and
it
should be
sized
so
that
the
excess flow
of
2.64
gpm will
pass over
the
RETENTION
CAPACITY
SUCTION LOSS
142
SYMPOSIUM
Vertically
mounted pumps
(with
pumps
installed
inside
the
reservoir)
require the tank be
opened only if a
pump
maintenance
or
replacement
is
necessary.
Opening
the
reservoir presents
an opportunity for
contamination to
enter the tank.
Due to improved
auxiliary pump suction
conditions and the
COUPLING
pump's proximity to the
reservoir heater, a vertically mounted
pump will be available
sooner for cold starting
than a horizontally
BELL
Horizontal pump mounts
HOUSING
MANWA
Y
COVER
MANWA
Y
GASKET
PUMP
MANWA
Y RISER
RES
ERV
OIR
RESERVOIR
COUPLING
GUARD
GATE
VALVE
Maintenance Considerations
I
STRAINER
Y-
PUMP
mounted pump.
SHIM
OUNTING PLATE
S
p
e
e
d
:
3
0
0
0
r
p
m
F
l
o
w
r
a
t
e
g
p
m
Viscosity
SSU
33
Pressure - PSI
25
125
50
150
75
100
16.7
13.3
15.6
12.8
14.7
14.0
65
17.5
14.7
16.7
16.0
15.5
15.1
100
17.8
15.6
17.2
16.7
16.3
15.9
150
18.1
16.3
17.6
17.2
16.9
650
18.8
17.9
18.5
18.3
1000
18.9
18.2
18.7
5000
19.2
18.9
10000
19.2
19.0
25
125
50
150
75
100
33
.6
1.7
.9
2.0
1.1
1.4
16.6
65
.6
1.7
.9
2.0
1.1
1.4
18.2
18.0
100
.6
1.7
.9
2.0
1.1
1.4
18.5
18.4
18.3
150
.6
1.7
.9
2.0
1.1
1.4
19.1
19.0
19.0
18.9
650
1.0
2.1
1.3
2.4
1.6
1.9
19.2
19.1
19.1
19.0
1000
1.2
2.4
1.5
2.7
1.8
2.1
5000
2.9
4.0
3.2
4.3
3.4
3.7
BHP - hp
Viscosity
SSU
Pressure - PSI
SHIM
COUPLING
10000
4.3
5.4
4.5
5.7
4.8
5.1
SELECTION OF LURE OIL SYSTEMS COMPONENTS FOR PROCESS PUMPS AND AUXILIARIES
(EXTERNAL, PRESSURIZED) 143
Table 2.
Screw Pump Discharge
Capacity and Input Power Chart.
S
p
e
e
d
:
Viscosity
- PSI
SSU
3
0
0
0
r
p
m
F
l
o
w
r
a
t
e
g
p
m
Viscosity
PSI
SSU
Pressure 25
100
50
125
75
150
33
22.6
19.3
21.2
18.6
20.2
17.9
65
23.5
21.2
22.5
20.6
21.8
20.1
100
23.9
22.1
23.2
21.6
22.6
21.2
150
24.3
22.8
23.6
22.4
23.2
22.1
650
25.1
24.3
24.8
24.2
24.5
24.0
1000
25.2
24.6
25.0
24.5
24.8
24.4
5000
25.5
25.3
25.4
25.2
25.3
25.2
10000
25.6
25.4
25.5
25.4
25.2
25.3
BHP - hp
Pressure
25
100
50
125
75
150
33
.9
2.0
1.3
2.4
1.7
2.8
65
.9
2.0
1.3
2.4
1.7
2.8
100
.9
2.0
1.3
2.4
1.7
2.8
150
.9
2.0
1.3
2.4
1.7
2.8
650
1.7
2.8
2.1
3.2
2.4
3.6
1000
2.1
3.2
2.5
3.6
2.8
4.0
5000
5.0
6.1
5.4
6.5
5.7
6.9
10000
7.4
8.6
7.8
8.9
8.2
9.3
materials
Sim
RAnge
pm
0
12
5 -15
125 250
512,000 1,024,000
15 -25
22
44
91,000
10
500
1000
2000
4000
8000
16,000
32,000
64,000
89
178
182,400
356
712
1425
2850
5700
11,400
22,800
45,600
128,000 256,000
25 - 50
4
8
16
16,200 32,400
32
63
126
253
506
1012
2025
4050
8100
50 - 100
1
2
3
2880 5760
11
22
45
90
180
360
720
1440
64
128
256
8
over 100
16
512
32
1024
144
SYMPOSIUM
Given that API 610 requires the non bypass filter, and only a
CONNECT TO
pressure differential indicator is provided
ELEMENT HOUSING
to visually determine f i lter condition,
specific considerations should be made in
the filter selection process.
Collapse pressure of the element
should exceed the pump's relief settings.
If the element gets very dirty, oil will pass
over the pump relief and the lube oil
supply pressure will decrease until oil
pressure at the header drops, causing an
alarm condition. This alerts the operator
to look at filter condition and transfer to
the clean element. A bypass design or a
low collapse pressure element will allow
dirt to flow into the bearing when the
element clogs and the bypass works or the
element fails. Bypass design elements are
equipped with a relief valve poppet.
Any time the differential across the
element exceeds the bypass valve
setting, the bypass opens and allows
unfiltered oil downstream.
A better solution is the addition of a
pressure differential switch across the
filter housing to alarm at a dirty filter
condition. Presetting the alarm at 25
psid to 30 psid will give the operator
plenty of time to schedule the element
change. A filter element that is properly
sized will be contaminated/clogged 60
percent to 70 percent of its capacity, at a
pressure drop of 30 psid.
ASME code stamped filters should be
considered based on size, pressure, volume,
and geographic locations where code
vessels are mandated.
Filter transfer valves should be open in
the neutral position. Inlet port of the
transfer valve should be open to the
inlet of both elements. The outlet of the
transfer valve should be open to the
outlets of both elements. This will guarantee
continuous flow when transferring from one
filter to another.
Maintenance Considerations
The single component expected to be
maintained is frequently the filter element.
The old saying "cleanliness is next to
godliness"
certainly
applies
here.
Replacing the element regularly increases
bearing life.
1. Consideration should be given to
locating the filter at the outside edge of
the skid for ease of maintenance.
2. Equip the filter with individual
canister vents and drain valves. The
filter and all maintenance valves shall be
located in an accessible location on the
skid.
BA
LA
NC
E
LI
NE
GA
TE
VA
LV
E
OIL IN
2 POSITION
6WAY
TRANSFER
VALVE
OIL OUT
k
li
t
U
VENT
GLOBE
VALVE
WITH PLUG
DRAIN
GATE
VALVE
WITH
PLUG
Heat Exchangers
API 610, Eighth Edition, requirements for
heat exchangers are:
TypeShell and tube
MaterialTubes inhibited admiralty
(fresh water service), shell steel (pressure
retaining)
0
4:0
Cad.,
tee NM I
ilo Nob,
Soo /CO 1
13e NoN 1
N
o
r
m
a
n
AP.
011In
Notes:
1. Opslan
hTe purchases insy specify sighs shoat recuaing spectafeature of she dims-wins sernparcle blinds.
purdaser may specify valve wish
2. 00011 A.17.11.4 purchaser may specify high-tesnpeszions swilch
frSli) and/or low-seinpersasee swisch (73L).
specify const..teleperl./V Nree7.0ption A-17c: 71. purchaser may specify bypass oil line and
con-
110I
ocuptabk. thc
SELECTION OF LUBE OIL SYSTEMS COMPONENTS FOR PROCESS PUMPS AND AUXILIARIES
(EXTERNAL, PRESSURIZED) 145
Ans
nutfi
ve
arra
nas
msnt
(2.
Not
e 2)
Nero,
See Note 2
Soe Notes
Soo Nan
Sane
L
Cooler
I
N
0it
Oil In
Duplex
heat
exchanger
arrangements are necessary on
unspared equipment. In the case of
duplexed heat exchangers, a balance
valve, vents and drain valves on the
L LL
PRESSURE
REDUCING
VALVE
L
U
B
E
OI
L
S
U
P
P
L
Y
PRESSURE
CONTROL
VALVE
"
jf
146
SYMPOSIUM
Instrument Isolation
Table 4. Requirements for Piping Materials.
(Used with permission of API)
Valves/Root Valve
API 610, Eighth
Edition, requirements
Away Me al .
fos s
1 . . . s a u r y. 4
Nol lora
3...
are:
flo .
.1*
i I
.
MS
a 71 pm,
, ..............,,
.
57..31
1
{.
C
NIL .211.
wsno A M
KI M . )
,,,, ..................
Ow SW
Om NO
ma . .
TAB MG
.11. 316
ns. 3 14
Ons NO
Om KO
AVM ...IM
magas
Tlle M
Type P
111. 1 *
hT . M.
Om 200
wt .
011.
Ow
Cuyan .1
bo l a
iliagad
1.1.1
AM. AI D
WM .1611
mas s
s maY s
TM 114
Or OW
cm . s e
cliat CO
a. . O w /
AVM U M
. 0
Y
1
11.1
8.14.1..8
CI
Om MOO
141.1 ...................
. . , . . , , , ..............
a*
maim
TY*
ISO
m .o
CM000,
Came
010 *
an *
ConnectionEach
pressure
instrument must have its own pressure
tap.
1M
Nessaa
il ./.1
S ad o *SW
711
..
i IP
ha
P
l
a
l
.
.
.
.
D
.
0
.
1
3
1
...,,,,
su n.
. . ; ; ; , ..............
Two
Ittro
ASIM AIN
sped *
45114 AIN
04
211
Or
LI
cy,
.
...,
106.01
oe
SpolNuAls,
AIM IM A M
1N
BLEED
110
: '"".4 0. 1 .
S*11.
40*
. . . nu n X s
,31,1,734,
V
M
OM ea 1,11111.. . .. 40 1 / an
a mo u r d NM VA* 10
slows . . 1
1
.
O
a
d
e
2
.
eg
A
BLO
CK
V
E
BLEED
BLEED
TEST
PORT
B
L
O
C
K
R
O
O
T
laws ar
le 30
OrOt
ua *
. . . I
r
rPX r
am*
on
&Ow v
am
well
1.411.
0.1011
H
y LUKE OIL SUPPLY
d Considerations
r
o
p
e
r
A
P
I
6
1
4
Figure
10.
ANSI-A194-2H nuts
Instru
ment
Valving
Mainte
nance
Consid
eration
s
Always install a union at the
electrical connection of the instrument,
so it can be removed without cutting the
conduit.
Always install a pipe union or
tube union between the isolation valve
and the instrument, so the switch can be
removed without having to shut the system
down.
Consider the use of stainless steel
for gauge boards; less galvanic action
occurs.
Lube Oil Piping
API 610, Eighth Edition, requirements are:
Type of piping connections and fittings
Socketweld flanged connection
upstream of filter
Buttweld flanged connection
downstream of filter
Ranges
150# RF, socketweld or slip on
upstream of filter
150# RF, slip on or buttweld
downstream of filter
SELECTION OF LUBE OIL SYSTEMS COMPONENTS FOR PROCESS PUMPS AND AUXILIARIES
(EXTERNAL, PRESSURIZED) 147
148
SYMPOSIUM
PPL
Y
T
EM
PE
RA
TU
RE
CO
NT
RO
L
VA
LV
E
T
O
P
O
F
R
E
S
E
R
V
O
I
R
L
U
B
E
O
IL
S
U
Instrumentation
Figures 10 (a) or 10 (b) can be used.
Tropical Area/Seaside or Platform Locations
Tropical areas
Reservoir should be carbon steel with epoxy
paint interior or stainless steel.
Duplex filters should include stainless
steel internal fasteners and polyester elements.
The paper elements tend to absorb more water and
this causes premature clogging.
Use stainless steel shim stock under pumps and
motors.
Seaside or platform location
Special coating efforts should be made for all
components. Galvanized skid, frame, supports,
conduit, pipe flange bolting, etc.
Stainless steel or galvanized gauge boards
Eliminate aluminum materials typically
found in pump motor couplings, pump seat retainers,
and instruments.
If sea water is used for cooling, change
cooler tubes to 20/30 copper, nickel, or titanium.
Where air to oil coolers are required, choose
phonelic coatings.
Electrical Area Class/CSA, CRN, JEC, Country Codes
Electrical area class
Select electric motors, reservoir heaters, and
instruments to meet electrical code class.
Conduit, conduit fittings, and conduit seals
should be selected to meet local codes, customer's
standards, and National Electrical Code (NEC) area
classifications.
CSA/CRN, UL, FM
Canadian electrical standards require that
all electrical components require Canadian Standards
SELECTION OF LURE OIL SYSTEMS COMPONENTS FOR PROCESS PUMPS AND AUXILIARIES
(EXTERNAL, PRESSURIZED) 149
ce-e 1(fd40'76
VrA117.
wam
e
s
e
r
v
o
i
r
7 I See Note 1
See Note 2
o
r
P
e
r
m
i
s
s
i
v
e
d
r
a
i
n
s
t
a
r
t
h
e
a
d
e
r
HI
Drilled
check valve
To equipment
T
o
r
Notes:
1. Option A-13a: The purchaser may specify an atmospheric
breather valve.
2. This tank shall be located at an elevation
such that the static head is less than the
equipment lube-oil trip pressure.
3. This valve is normally closed; it is opened only
to fill the tank before the equipment is started.
Figure
14.
Emergency
Lube
Oil
Atmospheric Rundown Tank. (Used with
permission of API)
For vertical process pumps, a coastdown
tank is used because the main lube oil pump
is AC motor driven, not shaft driven and on
loss of power, the AC motor driven pump
stalls.
A coastdown
tank
bypass
is
recommended for all applications to
maintain a warm slug of oil in the
150
SYMPOSIUM
All fluids should
be mentioned for
chemical makeup,
particulate count, pH
(TAN), and
kinematic
viscosity.
Oil
samples should
be
drawn
during operations
from the reservoir
and the lube oil
supply and return
lines. The National
Fire
Protection
Association
(NFPA) sampling
method is applied
to result in quality
analysis.
Many
service companies
provide
a
spectrographic
analysis of oils
where
12
elements
are
measured
in
parts per million
(Table 5).
II
Elements
Normal
Oil Change
ange
Required
Aluminum
1.0
4.75
Copper
5.0
10.0
Chromium
4.5
7.75
Lead
3.25
6.75
Iron
3.5
7.75
Magnesium
1.25
4.75
Lube-oil supply
To equipment
To reservoir or
drain
header
throughout
a
constant
temperature range. Note that
the design should consider a
coalescing filter element and an
oil
purifier when
selecting
synthetic oils. The addition of
water to the synthetic oil can
result in plating out (coking)
onto hot elements, such as
immersion heaters, rendering them
inefficient.
Maintenance
Molybdenum
3.0
6.75
Nickel
3.0
6.75
Tin
13.5
22.0
Silver
1.0
4.0
Silicon
17
22.0
0-3
6.75
Titanium
measured TAN
>1.0 Mg KOH/g
SELECTION OF LUBE OIL SYSTEMS COMPONENTS FOR PROCESS PUMPS AND AUXILIARIES
(EXTERNAL, PRESSURIZED) 151
Coolers:
hem No.
04nn
Staple.
I
Pqe
2
of
MO:
0 Type:
0 Lo L.O. Pros.
pig
0 ANNE DelignOtsmp
0 HI L.O. Temp.
deg F
Duty (B111/hr):
Surface Arat(112):
0 Lo L.O. Level:
0 Temp. Cont. VI,. R.od
mg,:
0 HI Fin. DP:
MI
0 Single
0 Duel
0 TEMA C
0 TEMA R Terbleet Mfr.
0 kern No:
Design/Hydra Prat (pap: Shell: /
Tubes:
I
0 Stay Conde.
In/Out:
(Prig. den F)
Dimensions (inches): Shell OD:
0 Rating(HP):
0 Speed (RPM)
Tubes OD:
BWO:
Meter: MR:
Water Flow (gmn):
Temp. In/Out ( F):
/
0 Voltsge/Plasekl
:
/
I
Speed:
0 Fouling Factor:
0 Tube ael. (May
Rating Mg
0 Service Factor:
0 Max delta P (psi):
Inspect. a Testing:
Required
Witness
Test Log
Accumulator: 0 Mfr:
Canonry (pl):
0 Cleanliness
O Required.
ASME Code Design/Stamp:
0 I Hour Tea
Run
Typo.
Designniydro Press. (pap
/
0 Cheek Cootrols
Mounting: 0 On equimeau skid
0 Seprate hotplate 0 Chengeoven
Dimenuons:
R.
lob No.
Client
Loudon
Unit
Item No
Service
Requisition No.
Switches/Truk:
I Shutdown
Piaght:
152
SYMPOSIUM