Multistage Centrifugal Pump Assessment

Provision of Water Injection Pump Rental
Pump Assessment and Inspection Report
PROVISION OF WATER
INJECTION PUMP RENTAL
NOVEMBER 15, 2019

PETROENIM
Jl Tebet Barat Dalam Raya No.126A, Jakarta Selatan 12810
Issued fo Review | Rev 0 | November 2019

Page 1 of 16
Client
Petroenim
Document Title
Reference Client Reference Number (if applicable)
Issued fo Review
Contact
Teguh Ariffriadi, Project Manager

Teguh_ariffriadi@yahoo.co.id
Tel: +62 822 1314 1668
Engineering Consultant
Pelita Air Service Blok H No.8
Depok 16434, Indonesia
Revision Date Reason for Issue Prepared Checked Approved Client
0 18/11/19 Issuer For Use TA TA TA
A 15/11/19 Issued for Review TA TA TA

Page 2 of 16
Executive Summary
Pump assessment and inspection is performed to ensure reliability of the pump when delivering and
injecting produced water from water storage pond which is located at Processing Station – SP Betun
to Betun-05 injection well with an approximate distance of 2.5 km.
Based on the pump catalogue attached in Appendix A, the following parameters for the Water
Injection Pump (DG 25-50 x 10) have been summarize as follow:
 Design Flowrate Q : 25 m3/h ~ 3777 BWPD
 Pump discharge pressure Pdischarge : 710.9 psig
 Pump discharge head Hdischarge : 500 m
 Net positive head required NPSHr : 2.8 m
 Pump Shaft Speed Rpm : 2950
 Pump Estimated Efficiency E : 54 %
 Brake horse power P : 75 kW
Based on the pump assessment and inspection attached in Appendix B, the following results for the
Water Injection Pump (DG 25-50 x 10) have been summarize as follow:
 Required Flowrate Q : 3000 bpd
 Pump discharge pressure Pdischarge : 420 psig
 Pump discharge head Hdischarge : 309 m
 Net positive suction head available NPSHA : 6.5 m
 Net positive head required NPSHR : 2.8 m
 Pump Shaft Speed Rpm : 2950
 Pump Estimated Efficiency E : 32 %
 Brake horse power : P : 75 kW
NPSHa value is bigger than NPSHr, this conclude that the pump will not having problem with
cavitation for suction head to minus 2 m (pump suction is 2 m lower than the pump center line). The
maximum suction head as per calculation is minus 5 m
To deliver continuous flowrate on 3,000 bwpd the pump shall have discharge pressure on 420 psig.
This pressure could be achieved by throttling the discharge valve and/or might be effected by the
injection well restriction characteristic. Hence, pressure class rating #300 is required. It is not
recommended to run the pump with flowrate more than 3,600 bwpd, since cavitation might occur.
The pump’s efficiency decreases because of required power stay the same but pump head is
smaller. However, It conclude that pump is ready to be operated while it will consump a slightly more
power than it should have.

Page 3 of 16
Table of Contents
1.0 Project Background 5
1.1 General 5
1.2 Goal and Objective 6
1.3 Scope of Work 6
1.4 Definitions 6
1.5 Abbreviations 7
2.0 Pump Assessment and Requirement 8
2.1 Assessment of New Water Injection Pump 8
2.2 Requirement 8
2.3 NPSHa Calculation 9
3.0 INSPECTION TEST at PT KASANIAGA PLANT 12
3.1 Performance Test of New Water Injection Pump 12
3.2 NPSH Test of New Water Injection Pump 12
3.3 Mechanical Run Test of New Water Injection Pump 13
4.0 RESULTS & RECOMMENDATION 14
4.1 Result of Assessments & Inspection of New Water Injection Pump 14
4.2 Recommendation 15
5.0 References 16

Page 4 of 16
1.0 Project Background

1.1 General
Petroenim Betun Selo (COMPANY) is an exploration and production company operating in

Sumatra Island, Indonesia. Company currently operates BETUN Field and producing crude
oil with associated produced water.
Figure 1 Betun Field Water Transport/Injection System Map
The produce fluids from wells are delivered via pipeline to Betun Production Station (SP
Betun) for futher processing. The oil production are delivered to Pertamina tank farm via
pipeline whilst the produced water from the field which is approximately 3,000 bwpd injected
to BTN-05 well via 2.5 km of pipeline from SP Betun by water injection pumps.
Since water production rate increases and soon will exceed the capacity of the existing water
injection pump, therefore an additional water injection pump will be added.
The new pump will have capacity around 3,000 bwpd and will be located adjacent to the
existing water injection pump at SP Betun.

Page 5 of 16
1.2 Goal and Objective
The objective of this document is to perform assessment and inspection of new Water
Injection Pump.
1.3 Scope of Work
This document presents the pump NPSH analysis, performance and durability to deliver
water from open water pond at SP Betun to BTN-05 Injection well.
1.4 Definitions
In and throughout this document, unless the context otherwise requires, the following
definitions apply:
COMPANY : Petroenim Betun Selo
CONSULTANT : Engineering Consultant
PROJECT : Provision of Water Injection Pump Rental

Page 6 of 16
1.5 Abbreviations
API American Petroleum Institutes
ASME American Society of Mechanial Engineers
ANSI American National Standards Institute
BHP Brake Horse Power
BWPD Barrel Water per Day
CL Centre Line
SF Safety Factor
ID Internal Diameter
LLL Low Liquid Level
MW Molecular Weight
NPS Nominal Pipe Size
NPSH Net Positive Suction Head
NPSHA Net Positive Suction Head Available
NPSHR Net Positive Suction Head Required
OD Outside Diameter
USgpm USgallon per minute
WT Wall Thickness

Page 7 of 16
2.0 Pump Assessment and Requirement

2.1 Assessment of New Water Injection Pump
There following parameters are considered as a key input for pump assessment as shown in
Table 2-1 2.1 below:
Table 2-1 Pump data (DG 25-50x10) based on Catalogue
Description Value
Multistage
Type
Centrifugal Pump
Capacity (bwpd) , (m3/h) 3,770 (25)
Head (m) 500
NPSHr (m) 2.8
Shaft speed (rpm) 2950
Power (kW) 75
Efficiency (%) 54
Pump curve and structural drawing of DG Pump model
2.2 Requirement
The pump requirement are presented in table 2.2 below:

Table 2.2 Pump Performance Requirement
Description Value
Capacity (bwpd) 3,000

Head ,psig (m) 300*
Pump suction to Pump CL (m) (-)2**
Note:
* based on current pressure data at BTN-05 wellhead

** suction line is 2 m under the pump centre line

Page 8 of 16
The properties of water are presented in table 2.3 below:

Table 2.3 Water Properties at Site
Description Value
Specific Gravity 0.998

Vapour Pressure at 75.2 oF (psia) 12
2.3 NPSHa Calculation
The NPSH is supplied from the system and is solely a function of the system design on the
suction side of the pump. Consequently it‘s controlled by the system designer.
To avoid Cavitation, the NPSH available (NPSHa) from the system must be greater than the
NPSH required (NPSHr) by the pump.
NPSHa = Ha + Hs – Hvp – Hf
Where
Ha = Atmospheric Head
Hs = Static Head
Hvp = Vapor Head
Hf = Friction Head
The schematic diagram below is presenting the actual installation on site:
Figure 2 Water Injection Pump System Sketch

Page 9 of 16
Pump Operating Parameters System Inlet Height Configuration

Open System:
Fluid Temperature (through the pump): (32 - 212 F) 45 deg. F

Total Pump Volumetric Flow Rate: 87.5 gpm liquid level
14.7 PSI
Atmospheric Pressure: (can't change) (Positive) Height
33.957 ft. Water
h
Fluid Vapor Pressure: 0.7516 (ft. Water)
inlet
Surface Pressure
Water Vapor Pressure Reference Table 0 PSIG
Water Temp. Vapor Pressure
(Deg. F) (ft. Water) inlet
80 1 -h
100 2 (Negative) Height
liquid level
120 4
140 7
180 18
200 28
212 33.96
Static Head
Water Vapor Pres. @ Sea Level Height: -6.6 ft.
40
Vapor Pres.(ft. Water)
y = 7.1929E-06x 3 - 9.8352E-04x 2 + 4.6395E-02x

35
30
25
20
15
10
5
0
0 50 100 150 200 250
Temperature Deg. F
System Piping Configuration

1 Pipe Type Schedule 40
Pipe Size (Nominal) 3 inch
Pipe Length 30 ft
Flow Rate 87.5 gpm
Fittings Qt. Eq. Length Total

90 Ells 5 20 100
45 Ell 5 16 80
Globe Valve 0 340 0
Angle Valve 0 150 0
Ball Valve 1 8 8
BF-Valve 0 29.9 0
Ck-Valve 1 55 55
Stand. Tee - flow through run 1 20 20
Stand. Tee - flow through branch 1 60 60
- 0 0 0
Total Eq. Length 323

Page 10 of 16
Date: 14/11/2019 14:10 NPSH Calculation

Job Name: Water Injection Pump Address: Jakarta, Indonesia
Client Petroenim
Max GPM: 87.5
Edit NPSH Parameters View Flow Calculations
Constants / Assumptions:
Mean Operating Fluid Temperature: 45 ºF Total Flow Through Pump: 87.5 gpm Atmospheric Pressure: 14.70 PSIA 33.96 ft. Water
Pumped Fluid: WATER Vapor Pressure of Liquid: 0.75 ft. water Surface Pressure: 0 PSIG (if exposed to air surface pressure = 0)
Piping Configuration:
Pipe
Sub System#: 1 2 3 4 5 6
Pipe Diam. (Nom): 3 inch 1 inch 1 inch 1 inch 1 inch 1 inch
Pipe Length: 30 feet 0 feet 0 feet 0 feet 0 feet 0 feet
Flow Rate: 87.5 gpm 0 gpm 0 gpm 0 gpm 0 gpm 0 gpm
Total
Pipe Pressure Drop: 0.5 ft. Water 0.0 ft. Water 0.0 ft. Water 0.0 ft. Water 0.0 ft. Water 0.0 ft. Water 0.5
0.2 psi 0.0 psi 0.0 psi 0.0 psi 0.0 psi 0.0 psi 0.2
Valves (Fully Open) / Fittings
1 2 3 4 5 6
Eq. Eq. Eq. Eq. Eq. Eq.
Qt. Length Total Qt. Length Total Qt. Length Total Qt. Length Total Qt. Length Total Qt. Length Total
90 Ells 5 20 100 0 20 0 0 20 0 0 20 0 0 20 0 0 20 0
45 Ell 5 16 80 0 16 0 0 16 0 0 16 0 0 16 0 0 16 0
Globe Valve 1 340 340 0 340 0 0 340 0 0 340 0 0 340 0 0 340 0
Angle Valve 1 150 150 0 150 0 0 150 0 0 150 0 0 150 0 0 150 0
Ball Valve 1 8 8 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0
BF-Valve 1 29.9 29.9 0 29.9 0 0 29.9 0 0 29.9 0 0 29.9 0 0 29.9 0
Ck-Valve 1 55 55 0 55 0 0 55 0 0 55 0 0 55 0 0 55 0
Stand. Tee - flow through run 0 20 0 0 20 0 0 20 0 0 20 0 0 20 0 0 20 0
Stand. Tee - flow through branch 0 60 0 0 60 0 0 60 0 0 60 0 0 60 0 0 60 0
- 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Total
Eq. Length Total: 762.9 0 0 0 0 0 762.9
Fitting Pressure Drop: 3.5 ft. water 0.0 ft. water 0.0 ft. water 0.0 ft. water 0.0 ft. water 0.0 ft. water 3.5
1.5 psi 0.0 psi 0.0 psi 0.0 psi 0.0 psi 0.0 psi 1.5
Description
Additonal Pressure Drops: input here 0.0 ft. water
input here 0.0 ft. water
Total: 0.0 ft. water Total Head Loss (Pipe + Fittings + Additional Drops) : 763.4
Results
(Static Head) (Vapor Pressure) (Loss in Fittings) NPSHA

NPSHA = 34.0 + -6.6 + 0.0 - 0.8 - 0.5 - 3.5 - 0.0 = 22.52 ft. Water
(Atmospheric Pressure) (Surface Pressure) (Loss in Pipe Length) (Additonal Loss)
Net Positive Suction Head Available
NPSHR 9.18 ft. Water
Net Positive Suction Head Required
(From Pump Curve)
Safety Factor 2.45

Page 11 of 16
3.0 INSPECTION TEST at PT KASANIAGA PLANT

A Pump test normally devided in to three kind of tests refer to API 610 and ANSI/HI 14.6,
which are performance test, NPSH test and mechanical run test. All the tests are used to
determine that the head and flow produced by a pump as well as the power required to
operate a pump match the project requirements and durability of the pump it self
3.1 Performance Test of New Water Injection Pump
The new water injection pump perfirmance test result is shown in Table 3.1 below:
Pump Performance Test

DG 25-50 x 10
Rated Flowrate 87.5 gpm (3000 bpd) Suct ID : 3"

Rated Head 1640 ft (500 m) Disch ID : 2"
Rated Speed 2950 rpm
API 610 requirement (technically equal to ANSI/HI 14.6)
Suction Spec Discharge Total Temp Power Speed Eff

No Flowrate (gpm)
Head (ft) Gravity Head (ft) Head (ft) (Deg F) (kW) (rpm) (%)
1 0 0.998 1268 1268 95 shutoff 0 75 2800 0
2 0 0.998 1037 1037 95 95% * Rated 83.125 75 3000 28.97%
3 0 0.998 1014 1014 95 99% * Rated 86.625 75 2800 29.52%
4 0 0.998 1014 1014 95 100 * Rated 87.5 75 2900 29.81%
5 0 0.998 968 968 95 105% * Rated 91.875 75 2900 29.88%
6 0 0.998 922 922 95 120% * Rated 105 75 2950 32.53%
Note
1 Eff = (flowrate x Total Head x Spec Gravity)/(Power x 3960)
3.2 NPSH Test of New Water Injection Pump
NPSH Test
DG 25-50 x 10

Discharg
Suction Head Spec Total Temp Flowrate Power Speed
No e Head
(ft) Gravity Head (ft) (Deg F) (gpm) (bhp) (rpm)
(ft)
1 Full open 0 0.998 1014 1014 95 87.5 75 2950
2 80% open 0 0.998 1014 1014 95 87.5 75 2950
3 50% open 0 0.998 1014 1014 95 87.5 75 2950
4 25% open 0 0.998 922 922 95 87.5 75 2950
Note
1 Suction valve throttling methode
2 Total Head developed is monitored which total 3% drop

Page 12 of 16
3.3 Mechanical Run Test of New Water Injection Pump
Pump Mechanical Run Test
DG 25-50 x 10

Bearing
Time Speed Disharge
No Temp Leakage Remark
(minutes) (rpm) Head (st)
(Deg F)
Gland Packing Seal Type requires
1 Start shutoff Water drips
drips for cooling
2 15 2710 1150 ft 104 No leakage
3 30 2710 1151 ft 104 No leakage
4 45 2710 1152 ft 104 No leakage
5 60 2710 1153 ft 104 No leakage
6 75 2710 1154 ft 104 No leakage
7 90 2710 1155 ft 104 No leakage
8 105 2710 1156 ft 104 No leakage
9 120 2710 1157 ft 104 No leakage
10 135 2970 920 ft 104 No leakage Engine exhaust vibrate heavily
11 150 2970 920 ft 104 No leakage tightened exhaust U-Bolt
12 165 2970 920 ft 104 No leakage No execsise vibration occur
13 180 2970 920 ft 104 No leakage
14 195 2970 920 ft 104 No leakage
15 210 2970 920 ft 104 No leakage
16 225 2970 920 ft 104 No leakage
17 240 2970 920 ft 104 No leakage
Note
1 discharge head 500 psig change to ft
1 discharge head 400 psig change to ft

Page 13 of 16
4.0 RESULTS & RECOMMENDATION

4.1 Result of Assessments & Inspection of New Water Injection Pump
The new water injection pump assessment & inspection result is shown in Table 4.1 below:
Table 34.1 New Water Injection Pump (DG 25-50 x 10) Result
Case
Parameter Unit
Pump Data Pump Test Pump Required
Discharge Flowrate m3/h (bwpd) 25 (3,777) 19.87 (3,000) 19.87 (3,000)
Discharge Pressure psig 711 420 300
(Note-1)
Discharge Head ft (m) 1640 (500) 1014 (309) 689 (210)
Suction Head ft (m) - -6.5 (-2) -6.5 (-2)
NPSHa (Note-2) ft (m) - 22.52 (6.86) 22.52 (6.86)
NPSHr ft (m) 9.2 (2.8) 9.2 (2.8) 9.2 (2.8)
Shaft speed rpm 2950 2950 -
Pump efficiency % 54 32 -
Brake Horse Power (Note-3) kW 75 75 -
Note:
1. The Disharge Head is calculated from: Discharge Head = (Discharge Pressure / (2.31 x Specific Gravity))
2. The NPSHA is calculated from test condition refer to actual condition at site
3. BHP is measured from engine shaft rotation plotted to engine curve
Pump installation elevation system of -2 m pump suction line to pump centre line will produce
NPSHa value = 6.86 m with SF 2.5, the required NPSH (NPSHr) is smaller than the NPSHa
value, hence the pump will be working properly without having cavitation issue when
discharge flowrate on 3,000 bwpd and discharge pressure on 420 psig.
The minimum of NPSHa value is at least 1 m bigger than NPSHr, which is maximum depth
of pump suction for this pump might installed -5m to pump centre line.
The maximum discharge flowrate for this pump may reach 3,600 bwpd, whilst discharge
pressure will decrease to circa 390 psig
Finally, the pump is capable to operate at required condition whilst power consumption is
slightly more than what the requirement need.
Figure 3 Pump Operating Curve

Page 14 of 16
4.2 Recommendation
Discharge flowrate shall not be set more than 3,600 bwpd because it can cause heavy
cavitation then consequently will damage the pump
Piping system rating on pump upstream shall be design on class #300
The pump is a non self priming type, therefore several important point shall be considered;
a. Ensure the foot valve is not passing
b. Ensure filter is not blocking the pump inlet suction

c. Ensure gland packing is replaced within maximum 2 months operation
Y-strainer shall be installed at pump downstream to catch solid particle entering the pump
4.2.5 Flowmeter shall be installed at pump upstream to check pump performance continously

Page 15 of 16
5.0 References
 API 610 Centrifugal pumps for petroleum, petrochemical and natural gas industries
 ANSI/HI 14.6 Rotodynamic Pumps for Hydraulic Performance Acceptance Tests
 ASME B 31.3 Process Piping
 DG Pump Catalogue Boiler Water Supply Pump

Page 16 of 16
DG PUMP CATALOGUE

Appendix

Appendix

Appendix

Appendix

Appendix

Appendix

Appendix

Appendix

Appendix

Appendix

Appendix

Appendix
FUNCTION ACCEPTANCE TEST PHOTOS

Appendix

Appendix

Multistage Centrifugal Pump Assessment

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Provision of Water Injection Pump Rental

Pump Assessment and Inspection Report

NOVEMBER 15, 2019

Issued fo Review | Rev 0 | November 2019

Pump Assessment and Inspection Report

Reference Client Reference Number (if applicable)

Teguh Ariffriadi, Project Manager

Revision Date Reason for Issue Prepared Checked Approved Client

0 18/11/19 Issuer For Use TA TA TA

A 15/11/19 Issued for Review TA TA TA

Issued fo Review | Rev 0 | November 2019

Issued fo Review | Rev 0 | November 2019

1.0 Project Background 5

1.2 Goal and Objective 6

1.3 Scope of Work 6

2.0 Pump Assessment and Requirement 8

2.1 Assessment of New Water Injection Pump 8

2.3 NPSHa Calculation 9

3.0 INSPECTION TEST at PT KASANIAGA PLANT 12

3.1 Performance Test of New Water Injection Pump 12

3.2 NPSH Test of New Water Injection Pump 12

3.3 Mechanical Run Test of New Water Injection Pump 13

4.0 RESULTS & RECOMMENDATION 14

4.1 Result of Assessments & Inspection of New Water Injection Pump 14

Issued fo Review | Rev 0 | November 2019

1.0 Project Background

Petroenim Betun Selo (COMPANY) is an exploration and production company operating in

Figure 1 Betun Field Water Transport/Injection System Map

Issued fo Review | Rev 0 | November 2019

1.2 Goal and Objective

1.3 Scope of Work

Issued fo Review | Rev 0 | November 2019

API American Petroleum Institutes

ASME American Society of Mechanial Engineers

ANSI American National Standards Institute

BHP Brake Horse Power

BWPD Barrel Water per Day

LLL Low Liquid Level

NPS Nominal Pipe Size

NPSH Net Positive Suction Head

NPSHA Net Positive Suction Head Available

NPSHR Net Positive Suction Head Required

USgpm USgallon per minute

Issued fo Review | Rev 0 | November 2019

2.0 Pump Assessment and Requirement

Pump curve and structural drawing of DG Pump model

The pump requirement are presented in table 2.2 below:

Capacity (bwpd) 3,000

* based on current pressure data at BTN-05 wellhead

Issued fo Review | Rev 0 | November 2019

The properties of water are presented in table 2.3 below:

Specific Gravity 0.998

2.3 NPSHa Calculation

The schematic diagram below is presenting the actual installation on site:

Figure 2 Water Injection Pump System Sketch

Issued fo Review | Rev 0 | November 2019

Pump Operating Parameters System Inlet Height Configuration

Fluid Temperature (through the pump): (32 - 212 F) 45 deg. F

y = 7.1929E-06x 3 - 9.8352E-04x 2 + 4.6395E-02x

System Piping Configuration

Fittings Qt. Eq. Length Total

Issued fo Review | Rev 0 | November 2019

Date: 14/11/2019 14:10 NPSH Calculation

(Static Head) (Vapor Pressure) (Loss in Fittings) NPSHA