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1 SCOPE
2 PROPERTIES OF FLUID
3 CALCULATION OF DUTY
6 RECOMMENDED LAYOUT
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8 VERTICAL PUMPS
8.1 General
8.2 Pressure Casing
8.3 Bolting
8.4 Flanges and Connections
8.5 Rotating Element
8.6 Packed Glands
8.7 Bearings and Bearing Housings
8.8 Pump Head
8.9 Column Pipes
8.10 Line Shaft and Couplings
8.11 Reverse Rotation
8.12 Gearboxes
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9.1 Castings
9.2 Casings
9.3 Impellers
9.4 Shafts
9.5 Shaft Sleeves
9.6 Bolts and Nuts
10 DRIVERS
11 BIBLIOGRAPHY
APPENDICES:
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TABLES
GRAPHS
This Process Engineering Design Guide covers the following pumps and allied
systems, typical of petrochemical plants:
Section One: covers the integration of pumps into the process and should be
read in conjunction with GBHE-EDG-MAC-1014.
2 PROPERTIES OF FLUID
Cooling water will vary from plant to plant affected by the quality of water
treatment, process fluid ingress and local atmospheric conditions. See
typical analyses, Appendix A.
2.2 Brine
In general brine used will be saturated sodium chloride (NaCI) –for sample
analysis of fully saturated brine see Appendix B. Freezing point for fully
saturated brine is -21°C. (Reference Perry's Chemical Engineering
Handbook 4th Edition).
Estuary water will vary mainly dependent upon the location, which in
general, is in a tidal river estuary. Typical analysis – see Appendix C
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Do not assume that pump construction and materials suitable for sea
water are also suitable for harbor water. The latter may contain more
debris and be contaminated. Look for reference installations for each
individual case.
3 CALCULATION OF DUTY
Brine pumps usually draw from a reservoir which has varying levels. The
differential head should be calculated on the maximum draw down level. A
minimum start level is required for vertical pumps to cover first stage
impeller - Fig 3.2.
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For vertical bell mouths the intake should be more closely matched to the
normal flow lines to cater for the flow coming from behind the bellmouth.
4. 1 Type of Pump
(a) For line booster pumps for duties less than 100 l/s choose BS 4082
inline pump within the limits of GBHE-EDG-MAC-1014.
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When choosing the pump type the following points should be considered:
(a) Vertical immersed pumps should be used on essential or auto start duties.
(b) Pump wells/pits may be used for horizontal pump installations where
economically justifiable and should be provided with a reliable drainage
system with non-return facilities. To eliminate the possibility of flooding,
avoid using a well/pit, or at least, arrange any equipment liable to water
damage to be l50 mm above the finished ground level. Pits of 1 m depth
and greater are not permitted on plants handling flammable or toxic gas as
the area is liable to become the subject of a Chemical Works Regulation 7
entry certificate; also the Area Classification will be Zone 2 if not Zone l.
(c) Pumps operating in series from the main cooling water main to boost
pressure for localized high pressure systems.
(d) Power recovery from high pressure source let down to cooling water
return line pressure. This would take the form of a centrifugal pump
operating as a hydraulic turbine in accordance with GBHE-EDG-MAC-
1014, providing power via a double ended motor to the cooling water
pump.
(e) Jet educt or/centrifugal pump combination should be used when the
suction lift is too great for an ordinary horizontal centrifugal pump or a self-
priming unit.
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(b) Main cooling water pumps are normally high powered; consequently the
power supply of the electric motors may have a step change in cost
corresponding to 415 Volts, 660 Volts, 3.3 kV and II kV steps in electricity
supply voltage.
(c) Account should be taken of existing pumps in use on the same Works/Site
with the view of using common spares.
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Note that the inlet NPSH often determines pump speed. The chart should then
be re-entered after converting the duty into the equivalent duty at the speed
given in the table, see GBHE-EDG-MAC-1014, Fig. B.2.3.2.
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(a) Permanent inlet strainer made from perforated plate BS 1669 Class A
12.5 mm. dia. holes: 3 mm. thick plate: the fine 20 mesh used for start up
on pumps with less than 6" inlets will be removed as soon as possible.
(b) Suction isolation valve for horizontal pumps with flooded suction: the valve
should be anchored.
(c) Pump casing drain valve if pump is not self-draining through pipework
(d) Pump casing vent: this should be automatic on vertical pumps or pumps
on auto standby
(f) Non-return valve should be damped action with a short stroke, slam free
(i.e. Mannesmann, Demag or similar): the valve should be anchored to
withstand transient pressure load
(j) Suction lines generally of 20" diameter or greater should be provided with
two Viking Johnson couplings for flexibility
(k) initial coarse straining of sea/river water and open sumps require double
suction screens made from galvanized mild steel floor grating or mesh to
BS 4483, 049.
(l) Sea and river estuaries water require a full width band screen or rotary
drum screen.
(m) Any baffles in the sump should be made of stainless steel plate.
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For the rights and wrongs of suction pipework for horizontal pumps see Fig 6.
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The casing should have the inlet and discharge nozzles in the lower half to
ensure maintenance can be carried out without disturbing the pipework.
The casing joint should only be allowed to overlap on the casing half
opposite to the direction of flow, see Fig 7.la.
Mis-matching of the two halves of the casing and failure to remove excess
metal from the slit joint can result in "spreading" of the volute and loss of
efficiency.
The casing joint should be metal to metal sealed with a jointing compound.
When jacking screws are used to part joints one of the faces should be
relieved to prevent marring.
7.2 Bolting
Tapped holes in the pressure parts are permitted providing that sufficient
metal in addition to the metal allowance for corrosion is left around and
below the bottom of the tapped holes to enable hole to be redrilled and
tapped to the next larger standard size.
Fastenings materials should have low galling and seizing tendency with
the mating material.
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All flanges should be to BS 1560. Cast iron flanges should be flat faced for
full face gaskets. Flange sealing surfaces should be machined by a tool
rotating about the axis of the branch, the final cut being in the form of a
single spiral groove.
Flanges should be spot faced on the back and should be designed for
through bolting.
All pumps should be provided with a vent connection. Pumps on auto start
should be fitted with an automatic air release valve.
The impeller diameter fitted for the rated duty should be capable of being
changed to give a 5% increase or a 20% reduction in head.
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Axial flow impellers generated head can be reduced by cutting down the
outside diameter but is rarely done in practice as it requires a new casing
on a liner. Varying the speed is the better solution.
(a) Underfiling the trailing edge of the vane. This can give a 3%
increase in head at BEP, the higher the speed the more
pronounced the effect. Fig 7.4d.
Two stage pumps should have the impellers mounted back to back to give
balanced hydraulic thrust loadings.
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The shaft diameter and distance between shaft ends should be limited to
Zone B of Appendix H.
Shaft sleeves should be sealed at one end, and the shaft-sleeve assembly
(or nut) should extend beyond the outer face of the packing gland or the
seal end plate. Leakage between the shaft and the sleeve thus cannot be
confused with leakage through the stuffing box packing or the mechanical
seal faces.
24, 28, 33, 38, 43, 45, 50, 55, 60, 65, 70, 80, 90, 100, 110, 120, 130, 140,
150, 160, 180, 200.
A mechanical seal having direct contact with the shaft (i.e. no sleeve)
should be stationary relative to the shaft at the point of contact (e.g. a
bellows type seal).
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If screwed sleeves are unavoidable, the thread length should be not more
than 10 mm to reduce the chances of binding during maintenance.
Sleeve bore should be relieved for the major portion of its length but not
under the seal clamping position.
Any sleeves that directly clamp the impeller should be the same diameter
as the impeller hub at the intersection to ensure smooth entry flow.
Tack welding is not permitted for the retention of wear rings. Locking
devices should not protrude into the wear allowance and should remain
effective when worn.
Casing wear rings which direct the leakage radially are preferred for
pumps with a suction specific speed greater than 0.4, to reduce the
unfavorable disturbance of the inlet flow into the eye of the impeller, see
Fig 7.5a.
The axial thrust balance arrangement should ensure that residual thrust
direction is unilateral over the operating capacity range. For this purpose
the nominal wear ring diameters may be different on opposite sides of a
double entry impeller.
For standard materials of rubbing pairs the clearances should not be less
than the values given in the following table.
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Select a rubber bellows type, e.g. Crane 502 and 521, Sized from the
range given in Clause 7.4. Inch sizes, type 4 and 5 are acceptable.
The use of seals with split carbon seats should be considered for large
seals where down time is critical and replacement of conventional seats
would involve a major strip down of the bearings housing and lube oil
system.
The seal face materials have traditionally been ni-resist and carbon 387A
(formerly BR171) but silicon carbide has proved successful on
contaminated water duties. For brine and seawater use 379A (formerly
BRMCM).
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A lantern ring with a clean water flush is preferred for brine and sea water
duties. The clean water flush pressure will be 1 bar above stuffing box
pressure.
The sleeve under the gland packing should be hard coated by fusion
welded surface deposits of nickel cobalt or nickel-boron-tungsten alloys
e.g. Stellite or Colomonoy.
The gland surface finish should be better than 0.4 micron Ra.
If water cooling is required it should be designed to cool the oil not the
bearing housing. The cooling system should be self draining to protect
against frost damage.
7.10 Lubrication
7.11 Couplings
7 .12 Guards
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7.13 Baseplates
All mounting pads should be fully machined flat and parallel to receive the
equipment. Corresponding surfaces should be in the same plane within
0.17 mm per meter of distance between pads, as machined to allow for
installation of shims 1.5 mm minimum thickness under the driver train.
When the pump vendor provides the driver, a set of stainless steel shim
packs 3.0 mm minimum thickness should be included. When the pump
vendor does not mount the driver, the pads for the driver should be
machined but not drilled, and shim packs should not be provided. All
shims should straddle hold-down bolts.
Baseplate and pump supports should be constructed and the pumping unit
mounted to minimize misalignment. The underside of fabricated
baseplates beneath the pump and driver supports should be welded in
order to reinforce cross-members and should have members shaped to
lock positively into the grout to resist upward movement of the baseplate.
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The height of the pump shaft centerline above the baseplate should be
minimized. Adequate clearance should be provided between the case
drain connection and the baseplate for installation of drain piping the same
size as the connection.
All pumps and drivers should be fully assembled and aligned within 50
micron total indicator reading in accordance with the cold alignment
diagram on their baseplate at the vendor's works. The baseplate should
be left free standing for this. Motor dowelling may be left until site
installation.
7.14 Flywheels
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8.1 General
Additional features required for vertical pumps are covered in the following
clauses.
(a) Wet sump: suspended column type where the impeller and pump
bowl is immersed in the water and any major overhaul requires the
whole unit to be withdrawn, see Fig 8.la.
(b) Dry sump: where all the parts of the pump are accessible in a dry
chamber, which allows maintenance to be carried out or impellers
changed to alter the duty. They can either be the suspended
column type see Fig 8.lb or the volute casing mixed flow, driven by
a remote driver, Fig 8.lc.
The bell mouth intakes should closely match the normal flow lines.
Elliptical cross-sectional dimensions are shown in Fig 8.2.
8.3 Bolting
The pumps will have a vent connection fitted with an automatic air release
valve which will also act as a vacuum breaker.
The pump should have its own thrust bearing designed for an LIO life
greater than 40,000 hrs with a self-contain lubrication system. This
precludes the use of NEMA hollow shaft motors.
The design should permit replacement of the thrust bearing in situ without
moving the driver.
The line shaft bearings should be stainless steel shelled nitrite lined
(cutless rubber) lubricated by the pumped liquid, supported by spigoted
spiders, clamped between the flanges of the column pipes. The maximum
spacing between bearings is given in graph Fig 8.7.
The pump will have a separate base mounting flange (sole plate) and this
should be grouted with epoxy grout.
The column pipes should have cast integral flanges or fabricated with
machined faces and spigots to accurately align/position the bearing
spider.
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Cone couplings should be used and sealed against liquid ingress, see Fig
8.10a.
If the system cannot be provided with a non return valve in the discharge
then a reverse rotation clutch should be used: Borg Warner, Morse,
Stuber Cluteh type RS/BF.
A time delay should be built into the motor started circuit to ensure that the
pump is not started against reverse flow.
8.12 Gearboxes
For concrete volute pumps where the speed is generally less than 8 rps
epicyclic gearbox in accordance with GBHE-EDS-MAC-1806 should be
used.
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9.1 Castings
9.2 Casings
Cooling water pump casings should be grey cast iron. Casings with 6"
branch sizes and greater should be coated in accordance with Appendix
E.
For a pump where Q = 450 l/s and Ns = 0.08 the long-term efficiency
reduction was 8%. For the same pump the hydraulic effect of applying the
coating was to raise the new pump efficiency by 2% over the untreated
casing. The same improvement was measured on Project A.2S68 -
Harland 6"/S" Uniglide Q = 104 l/s, Ns = 0.063. The on-site tests carried
out on a European Olefins Plant, cooling water pumps indicated a 1%
increase after coating. These are SPP pumps type BR24A with a flow of
IS60 l/s, Ns = 0.076.
These rises reflect the effect both of the treatment of the cast surfaces in
preparation for the coating and the smoothness of the coating itself.
Brine and sea water casings should be flake graphite austenitic cast iron
(ni-resist) or 'grey cast iron, coated in accordance with Appendix E.
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9.3 Impellers
Cooling water impellers should be grey cast iron for acid free systems with
a suction specific speed of less than 0.4 and austenitic corrosion resisting
steel above this limit or if there is a possibility of acid contamination.
Brine and sea water impellers should have flake graphite austenitic cast
iron impellers for suction specific speeds of less than 0.4 and austenitic
corrosion resisting steel for greater suction specific speeds.
9.4 Shafts
Brine and sea water pump shafts should be to BS 970 - Part 4, 416 S21 or
Monel.
Brine and sea water pumps should have stainless steel studs/bolts to BS
970 Part 4 304 SIS or 321 S12 used with free machinery nuts material 303
S21 or 325 S21 with the alternative of bronze.
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10 DRIVERS
The motor should be sized to cover end of curve conditions for pump sets
operating in parallel.
If the pump has a pressurized lube oil system then the motor bearings
should be supplied from the same system.
If the motor does not have its own thrust bearing then a limited end float
coupling should be used.
When a flywheel is provided the motor should be designed to cater for the
higher starting torque.
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A. 1 European Site
These include the large open evaporative systems and some smaller open
systems.
These include some coolers on Sulfuric Acid Plants and coolers on some
Methanol plants.
Note:
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Pressure surges in long pipe lines are usually initiated from two sources:-
2 Loss of power from the driver causing down surge. The effects can be
limited by introducing a flywheel into the pumpset to increase the stored
kinetic energy available to maintain pumping for a short period.
The inertia of a modern pump and motor is relatively small and causes the
pumpset to reduce speed and head, rapidly. The addition of a flywheel of
sufficient inertia will extend the rundown time beyond the pipe line period of the
first reflection, preventing void formation in the delivery line by continuing to
generate pressure. Whilst a flywheel will prevent water hammer and valve slam it
has very little effect in reducing the peak pressures.
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The difference between 6 and 5 gives the approximate value of the moment of
inertia of the flywheel. If the difference is less than 20% of the total then do NOT
specify a flywheel but check further at the ordering stage with a detailed
investigation, involving the selected Vendor/ Vendors.
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D.1 SCOPE
This Appendix covers the requirements and the method of resin coating
pump casing internal surfaces of cast iron, axially split, single stage
pumps with branch sizes 6" nb and greater.
D.2 COATING
Casings of pumps whose rated head is less than 40 m should have all
sharp edges and internal corners ground to a minimum radius of 3 rom.
This includes all the termination points such as the split joint, wear ring,
and flange bores, etc. For pumps with greater heads the minimum radius
at the split joint and flange bore should be 5 rom. See Figures 9 to 11.
The volute cut water point and any vane trailing edges should have a
minimum radius of 5 mm.
Any machined surfaces that need protecting against grit blasting should
be clearly identified to the Supplier.
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After blasting the surfaces shall be cleaned from dust and abrasive
residue by dry air blast or vacuum.
Any cavities or fissures that remain shall be filled after blasting with epoxy
mortar (Devcon or Resocon) providing a margin to be finally ground back
to restore the correct profile.
D.5 COATING
The coating should be applied in several coats with brush or spray to give
a minimum total thickness of 350 µm.
The coating work should be scheduled so that following coats are applied
before a previous coat is fully cured. (The coating is fully cured when the
test piece is unaffected by a solvent swab -use methyl isobutyl ketone or
acetone).
If it is shown that full curing has occurred then the gloss should be
removed before applying the next coat.
D.6 INSPECTION
Coating should not start until the Inspectors have approved all preparatory
work including mortar filling and a surface finish check against a
comparator tablet (for ground finish textures).
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Patching of fault is permitted. The patch should extend the fault by 25 mm.
The gloss should be removed before the patch (in the same material as
originally used for the coating) is applied.
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E.1 Anderson conceived the parameter of the area ratio Y to relate the flow
conditions at the pump impeller outlet to those at the casing volute throat,
where:
The throat area ~ is the sum of the two corresponding areas for a double
volute or the Sum of the outlet areas between diffuser vanes defined as
for the impeller.
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(a) High efficiency pumps are being sought for clean liquids of low
viscosity, so that vane incidence angles and shapes are properly
matched to the flow conditions.
The efficiency does not vary strongly with Y but there is an advantage for
values of Y near unity.
REFERENCES
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In order to obtain the quality of castings required the following should be agreed
with the pump vendor and drafted into the sub-order on the casting manufacturer.
(a) Material Specification as agreed, taken from Table 8 of this Design Guide.
Typical mechanical and chemical material test certificates to DIN 50049 -
2.1 is the minimum requirement.
The thickness of the vane over its full length should be within + 12% of the
design thickness or 1 mm whichever is the greater.
(c) Surfaces left as cast should have a surface finish better than 25 micron Ra
and the waviness better than 1 mm in 50 mm.
(d) Any lumps caused by core shift should be removed and the correct inlet
angle retained. The vane tip should be rounded not knife edged, see
sketch.
(e) The eye of the impeller should be fully machined. Any steps between the
cast and machined surfaces should be blended by grinding.
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G. 1 FOREWORD
At the design point (BEP) the flows in the volute are fairly uniform and the
pressure distribution is uniform: consequently the steady-state radial load
applied to the shaft is very low.
At flows away from BEP the approximate radial load balance is disturbed,
with two effects:
There are grounds for assuming that these perturbing forces relate to the
function:
All the pumps considered have had either single volutes or double-volute
casings, dependent upon size. The magnitude of the cyclic forces appears to be
roughly the same for both casing configurations, despite the reduction in steady-
state force in double-volutes. This analysis does not apply to diffuser pumps.
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The two principal forces tending to restore the shaft to its initial position are:
Note that:
These arise from the effects of the process liquid films within the
clearances at impeller wear rings and at shaft bushings.
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The chart relates the perturbing and the restoring forces by displaying an
empirical boundary line between two zones.
(1) Pumps whose parametric values fall into Zone A are not
acceptable.
(2) Pumps whose parametric values fall into Zone B are acceptable on
this criterion but should be further reviewed for their critical speed
performance.
(3) Stiffer shafts are desirable to obtain the intrinsic life expectancies of
mechanical seals.
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Apart from designing the rising main for internal pressure and dead weight loads
the reverse bending moment of the main should be taken in account at the
connection flange of the main/pump head. (See sketch below).
This bending moment is due to a disturbing force at the first stage impeller and
shall be calculated in the order of:
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In the bid comparison for large cooling water pumps, cost compensation should
be applied to cover the variation in power absorbed by the Vendors against the
lowest power quoted amongst the technically acceptable offers.
The guarantee points tolerances bias the power absorbed in favor of the pump
manufacture when the overall accumulation of tolerances are added together, i.e.
The power penalty to be applied that will guarantee a definite benefit to the plant
operator is by using the minimum difference between best power absorbed figure
and the remaining vendors.
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ISO 281 Rolling Bearings - Dynamic Load Ratings and Rating Life Part 1.
Calculation Methods (referred to in Clause 7.9).
BRITISH STANDARDS
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