5.

16 PEG FOR PUMPS

CONTENTS

5.7.1 BASIS OF DESIGN..................................................................................2

5.7.2 DESIGN PHILOSOPHY.............................................................................2
5.7.3 LEGENDS............................................................................................4
5.7.4 STANDARDS........................................................................................4
5.7.5 SPECIFICATIONS...................................................................................4
5.7.6 EXPECTED MINIMUM PERFORMANCE............................................................4
5.7.7 DELIVERABLES INTERFACE (MATRIX)...........................................................4
5.7.8 SURVEYS AND STUDIES...........................................................................4
5.7.9 CALCULATIONS....................................................................................4
5.7.10 DATA SHEETS......................................................................................7
5.7.11 STANDARD DRAWINGS............................................................................7
5.7.12 CHECKLISTIS.......................................................................................8
5.7.13 DESIGN VALIDATION..............................................................................8
5.16 INTRODUCTION

Refer to the PETROFAC PROCESS DESIGN MANUAL – Vol. 3 Equipment, eBMS Document
No. PEC-BMS-EN-STN-P-5853 for a detailed description of the types of pumps and
general information on sizing of pumps typically used in the oil and gas industry.

CAUTION: This guideline gives the concept for pump calculations. The EPC Process
Design Engineer shall refer to the Project Design Basis, Project Design Philosophy and
any Client Philosophies or Gudelinesto establish the detailed design requirements.

Pump Types:

There are various classifications based on the number of applications and the liquids
handled. Broadly there are mainly two types of pumps centrifugal pumps and positive
displacement type pumps. Centrifugal pumps can be horizontal and vertical type.
Positive displacement can be rotary and reciprocating type.

Classification of Pumps

Mode of Operation:
Pumps can be operated in series i.e. one after the other. Mainly series operation is
used when boosting of the pressure is required. Parallel is used when the throughput of
the system is high and load sharing is good way of selecting the pump models.
 General
Process information for pump specification requires the engineer to provide
information sufficient to allow for the proper selection of the pump for the service.
The primary information required by the mechanical department is capacity,
differential head and NPSHA (Net Positive Suction Head Available). In addition to the
main sizing characteristics for a pump it is necessary to provide information regarding
the potential factors that may affect the operation or startup of the pump. It is the
responsibility of the process engineer to ensure that all relevant cases and potential
operating conditions are reviewed with respect to the pump and to provide sufficient
data such that the vendor will provide a ‘fit for purpose’ pump.
Pump calculations should consider the entire system from the fixed pressure point at
the suction to the fixed pressure point at the discharge. The fixed pressure is
determined by the piece of equipment which has a set pressure and is typically a vessel
or a pump. This may include additional pieces of equipment within the pumped system
including heat exchangers and control valves.
Upon receiving information from the vendor (pump curves) the process engineer is
required to review the vendor information to ensure the pump is fit for purpose.

CAPACITY

Case selection

Capacity of the pump is typically determined from the system requirements provided in
the H&MB and the requirements of the downstream system. It is important that all
relevant cases are reviewed including start-up, turndown, winter and summer
operation as a minimum. Where additional cases may be necessary for the operation
of the facility it is important to review the potential impact on the operation of the
pump.
For utility units such as drain system, flare knock out drum pumps and make up pumps
basis for pump capacity needs to discussed and agreed with client.

Flowrate classification

Pump calculations will require minimum, normal and rated conditions to enable proper
selection of the pump.
Minimum flow rate: In a pump design there are two kinds of minimum flowrates. The
pump minimum flowrate and process minimum flow. The pump minimum flowrate is
number provided by vendor for safe operation of the pump. Process minimum flowrate
is result process constraints and it is generally referred as turndown flow. On process
datasheet process minimum flowrate should be specified.
Normal Flow rate - is defined as the flowrate required during normal operating
conditions. Additional operating conditions may be provided in notes if required.
Rated (Maximum) Flow rate – the rated flow will typically be determined by the design
margin required for the specific service of the pump. These can be found in the design
margin guidelines. In some cases the rated flowrate may be significantly different due
to other operating considerations and should be reviewed on a case by case basis.
Where continuous minimum flow protection is provided the minimum flow rate must be
added to the actual normal flowrate to determine the normal flow of the pump.
I.e. Normal flow to destination + pump minimum flow = pump normal capacity.
Where pumps are operated as on/off (intermittent) a rated flow is not normally
provided. However, there may be some instances where two operating points are
required.
 The basis for capacity and the margin taken over the flow should be covered with a
note in the Process Datasheet.
Once the capacity of the pump is determined it is possible to determine the
differential pressure and therefore the differential head of the pump.

DIFFERENTIAL HEAD

Differential pressure = Pump Discharge pressure – Pump Suction Pressure

A sketch of the system should be produced to aid in providing a clear understanding of

the system. The sketch should include all equipment, design pressures, elevations
(actual or estimated), suction and delivery pressures, estimated or actual line lengths,
any changes in pipe diameter and any changes in conditions. Sketch is necessary to
understand the controlling route for pump design in case of multiple destinations.

Line lengths should either be determined from the plot plan allowing for a suitable
margin for fittings, etc. Or determined from piping isometric and/or General
Arrangement drawings providing an accurate straight line length and including all
fittings. It is important to include the elevations in the line length calculations.

Process datasheet should include the differential pressure as well as differential head.
If there is any other operating mode, designer should calculate the differential head
for the same and mention in the notes, explaining the basis in brief.

PUMP SUCTION CONSIDERATIONS

Please refer to DOC XXX for general guidelines related to pressure drop calculations.

Suction Lines
Line loss for the suction line should be determined based on the rated flow to ensure
minimum line loss as specified in the line sizing criteria.

It is important when determining the pump suction pressure that any equipment losses
are accounted for this includes suction strainers and heat exchangers.

(Caution: Allowable pressure drop given in suction strainer datasheet should be either
less or same as used in pump calculations)

The pressure drop is determined based on the rated flow. Where vendor information is
available this should be used and normal and min flow rates pro-rated. Where vendor
information is not available standard pressure drops should be used and again pro-rated
for normal and min flowrates.

As with the capacity all operating cases should be considered particularly where
density and/or viscosity changes occur.

Pump inlet piping size and rating needs to go into the process datasheet.

In case any line size is changed for pressure drop or velocity limits, this needs to be
informed to the P&ID team.
Pump Suction Pressure

Pump suction pressure is calculated from the originating pressure plus the static head
minus the line and/or equipment loss such as strainer etc. (strainer pressure drop
generally varies between 0.05 bar to 0.075 bar.

The static head should be calculated from the lowest liquid level or the tan line/
bottom of the vessel to the pump centre-line to ensure that sufficient static head is
available. Static head is critical in determining if sufficient NPSH is available.

In case of the pump suction from vacuum tower, suction side elevation should not be
less than 1 atm.

Generally during the initial phase designer may not have the data for pump centre line
elevation. Mechanical dpt and process lead engineer/ immediate supervisor needs to
be consulted for high capacity and high head pumps with low available NPSH.
(Generally less than 5 m). This basis needs to into the process datasheet.

In case the pump suction is from another pump, suction pressure should be mentioned
with proper reference, e.g. pump suction flange.
A proper note for pulsation dampener is needed in consultation with Mechanical
Engineer.

NPSH

NPSH (Net Positive Suction Head) is the suction head requirement to ensure that the
pump does not cavitate.

NPSHA= Suction Operating pressure – Vapour Pressure (at max op. temp) – suction
side frictional/ equipment pressure drops + Static Head- Process Safety Margin

Suction Operating pressure:

This is normal operating pressure same as taken for pump suction calculation.

Vapour Pressure:

It is necessary for all operating cases to be reviewed to ensure that NPSH available is
acceptable for all cases.

In case the pump suction vessel is operating at equilibrium between vapour and liquid
then operating and vapour pressure will be same. (e.g. knock drums)

In case there is no equilibrium condition, the vapour pressure should be taken at

maximum operating temperature.

Suction Side frictional /equipment pressure drop

Please refer above section.

Static Head

The static head should be measured from the low low liquid level or the Vessel bottom
or tan line to the pump suction centreline. Since the vessel elevation is measured from
grade it is necessary to subtract the elevation from grade to the pump centreline. If
the pump centreline elevation from grade is not available 0.5-1 m is typically
assumed.

It is the responsibility of the process engineer to determine the NPSH available to set
the minimum elevation required for the originating equipment.

Process Safety margin

During the pump calculation phase we have uncertainties like suction piping isometrics,
pump centre-line elevation etc. Thus a designer may keep some process safety margin
on NPSHA (generally ≤ 1m). This margin should be clearly stated in process datasheet.

NPSHA and NPSHR

For getting a preliminary value of the NPSHR, mechanical engineer should be

contacted. Alternatively woking manual can be referred for estimating the NPSHr for
preliminary calculations. The NPSHR (Net Positive Suction Head Required) is provided
by the vendor, this should be reviewed with the calculated NPSHA to ensure that the
NPSHA is higher than the NPSHR. (Mechanical Engineer has to ensure the margin
between NPSHA and NPSHR is met as per project specifications). In the event that
NPSHA is lower than the NPSHR than a review should be carried out in conjunction with
mechanical and the vendor.

Margins between NPSHA and NPSHR generally is 1 m but varies on case to case basis
(sub-atmospheric pump suction, dissolved gases in pump suction). Project
specifications has to be referred for the same.

Where it is not possible to provide sufficient NPSHA (as is possible when pumping Light
HC liquids from storage) alternative pumps types should be considered (i.e. vertical
canned pumps)

Reciprocating pumps:

Other than frictional and vapor pressure losses there is also head loss due to
acceleration, which should be calculated as per API 674 Appendix G:
 Following are some of the measures which can improve the NPSHA:

- Increase the suction line size.

- Place the pump as close as possible to the source vessel/tank etc. or
minimize the bends/fittings, reduce the equivalent length to minimize the
suction pressure drop.
- Elevate the source vessel.
- Increase the pump trip level in the suction vessel / tank.
- If possible increase the blanketing pressure, in case of sub-cooled liquid at
operating conditions.
- Wrt to flare pumps, if possible, use the difference in site elevation to gain
some static head in pump suction.
- If NPSHA is very low and no further improvement is possible, use of the
canned pump is one of the options.

PUMP DISCHARGE SIDE CONSIDERATIONS

Discharge Lines

Please refer to DOC XXX for general guidelines related to pressure drop calculations.
Line loss for the discharge line should be determined based on the rated flow to ensure
minimum line loss as specified in the line sizing criteria. All operating cases should be
reviewed to determine the maximum line loss at rated flow.
 In case any line size is changed for pressure drop or velocity limits, this needs to be
informed to the P&ID team.

Pump Discharge Pressure

Pump discharge pressure is calculated by the sum of all the losses and the destination
pressure. Losses on the discharge should include line losses, all equipment, control
valve losses, and static head. In the event that the elevation of the destination
equipment is lower than the pump the static head becomes a negative.
Each destination for the pump should be looked at separately to determine the
required discharge pressure. It is important when determining the pump discharge
pressure that any equipment losses are accounted for. The pressure drop is
determined based on the rated flow. Where vendor information is available this should
be used and normal and min flow rates pro-rated. Where vendor information is not
available standard pressure drops should be used and again pro-rated for normal and
min flowrates.
Static head for discharge side will be from pump centreline elevation to nozzle
elevation. If there is low capacity / low head pump such as chemical injection pump or
make up pump then static head should be highest point in the pump circuit. As an
alternative if possible, a note can be included on P&ID asking piping to route the pipe
for such pumps in the lowest possible elevation. Design of the pump should take care of
the start-up case also.
In the absence of control valve data, a typical pressure drop of 0.7 bar (at rated flow)
or 30% of the hydraulic line loss (at normal flow) whichever is higher should be used. In
absence of any data for exchanger pressure drop it is safe to consider 1 bar pressure
drop, however assumptions needs to be captured in holds.
For vertical submersible pumps discharge pressure reference should be given in the
datasheet (e.g. pump mounting flange)
It is an engineering practice to consider contingency in discharge pressure to account
for changes in later stages of the project. There are various thumb rules

- 1 bara as contingency or 10% of the line losses whichever is higher.

- If there is calculation for any pump for which there are uncertainties with
P&ID and plot plan, then higher contingency such as 2 bara may be taken, in
consultation with supervisor or lead engineer.
- 5% of the differential head (for preliminary/initial head calculation)
PUMP SHUT-IN PRESSURE

Where vendor information is available this is the point on the curve at no flow and
provides the maximum head of the pump. Project specification generally gives
guidelines on calculation of estimated shut in pressure. Estimated shut-in pressure is
based on the maximum suction pressure plus 1.25 times the pump differential head.
The maximum suction pressure is typically calculated as the suction vessel (or
equipment) design pressure plus the static head from HHLL. This is the conservative
design. (However, other options are taking the normal operating suction pressure and
suction static head wrt to HHLL or taking the design suction pressure and normal
operating level.)
If the pump handles a range of densities, the highest density needs to be considered for
the differential head.
PUMP POWER

The pump hydraulic horsepower should be calculated for all cases. The highest
hydraulic horsepower should be specified to ensure the correct size motor is provided.
Pump efficiency should be estimated between 60-75% depending on the pump. It is
worth discussing the pump efficiency with mechanical to come to a reasonable
estimate. If no information is available then a conservative estimate of 65% may be
used until vendor information is provided. It is usually up to the mechanical engineer
to determine the installed power for the pump motor as specific efficiencies and
corrections for viscosity may need to be factored into the installed pump motor duty.
Therefore, where high viscosities or startup conditions are present the process
engineer is responsible for providing this information on the data sheet.

PUMP PERFORMANCE AND SYSTEM CURVES

Pump performance is shown on Head Vs Flow curve. This curve is given by the pump
vendor. This curve is important for the following:

- For finding the shut in pressure

- For finding the pump discharge pressure at various flow
- For finding the pump minimum circulation flow and pump preferred and
allowable operating flows.

Pump operating point is dependent on where the system curve i.e. Pressure drop Vs
Flow curve intersects the performance curve, as shown below.

For further details refer Perry`s section 10.25.

DENSITY CONCEPT

In an oil and gas industry there are many design cases, consisting of large changes in
compositional data over summer and winter conditions. Thus engineer may encounter
varying difference in densities. The main aim in using the density data is to get the
conservative pump design.
Head Calculation should be done at lower density and fix the head. Then for the power
& shut in pressure calculation, convert the head in meters into bar with maximum
density.

A proper note should be included in the pump datasheet for maximum density to be
used for motor rating.

PUMP SEALS/ EFFICIENCY/ POWER

Pump seal type will be given by the mechanical engineer. Refer API 682 for details
regarding seals categories / types /arrangements and various seal plans.

For pump efficiency and installed power contact mechanical engineer.

Estimated power at a given efficiency can be calculated as
Power = (Differential Pressure x Rated Flowrate) / Pump Efficiency

For critical services below are some relevant process data.

Past projects Database:

Oil export /Hydrocarbon Service

Project Project Rated Head Pump NPSHr

Code Name Capacity m C/L
m3/hr m

Water Service

Project Project Rated Head Pump NPSHr

Code Name Capacity m C/L
m3/hr m

Sweetening Unit

Project Project Rated Head Pump NPSHr

Code Name Capacity m C/L m
m3/hr