Centrifugal Pumps

EPT 07-T-06C October 1992 Draft

Scope
This Engineering Practice Tutorial (EPT) is part of a series, starting with EPT 07-T-06A and continuing in EPT 07-T-06B. This EPT provides the project engineer with a basic understanding of centrifugal pump selection. Refer to EPT 07-T-05A, EPT 07-T-05B and EPT 07-T-05C for information on Reciprocating Pumps.

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Table of Contents
Scope................................................................................................................................................... 1 Table of Figures ................................................................................................................................ 4 1. References.................................................................................................................................. 5 1.1. 1.2. 1.3. 1.4. 2. 3. Mobil Tutorials ................................................................................................................. 5 APIAmerican Petroleum Institute ............................................................................... 5 ASME American Society of Mechanical Engineers ................................................. 5 NACENational Association of Corrosion Engineers ............................................... 5

General ........................................................................................................................................ 6 Materials of Construction .......................................................................................................6 3.1. 3.2. 3.3. 3.4. 3.5. Materials Selection Factors........................................................................................... 6 Types of Corrosion ......................................................................................................... 7 Abrasive Wear ...............................................................................................................13 Material For Centrifugal Pump Parts .........................................................................14 Selection of Materials of Construction .......................................................................17

4.

Standards..................................................................................................................................18 4.1. 4.2. 4.3. 4.4. API STD 610 (Centrifugal Pumps for General Refinery Service) .........................18 Chemical Pump Standards..........................................................................................18 Comparison of API and ANSI Pump Standards ......................................................18 Data Sheets ...................................................................................................................20

5.

Selecting a Centrifugal Pump..............................................................................................20 5.1. 5.2. Number of Pumps Required........................................................................................22 Additional Considerations ............................................................................................22

Appendix A: Nomenclature ........................................................................................................23

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Appendix B: Example Problem (Metric)..................................................................................25 Appendix C: Example Problem (Customary).........................................................................29 Appendix D: Generic Types of Centrifugal Pumps ..............................................................33 1. 2. 3. 4. 5. 6. 7. 8. ANSI Pump ...............................................................................................................................33 Single Stage API Pump.........................................................................................................35 Vertical In-Line Pump ............................................................................................................37 API Multistage Split Case Pumps.......................................................................................39 API Barrel Pumps ...................................................................................................................41 Sump Pump..............................................................................................................................42 API Vertical Turbine or Can Pump .....................................................................................44 Submersible Pump.................................................................................................................46

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Table of Figures
Figure 1: Pumping Head Vs. Flow Rate for Different Types of Pumps (Use as a Guide for Selecting the Most Economical Pump)..............................................21 Figure D-1: Schematic Diagram of an ANSI Pump (Courtesy of Gould Pumps) ......... 33 Figure D-2: Example of an API single-stage pump (Courtesy of Gould Pumps)......... 35 Figure D-3: Schematic Diagram of an In-Line Pump (Courtesy of Gould Pumps)......37 Figure D-4: Example of an API Multistage Split Case Pump (Courtesy of Gould Pumps).......................................................................................................................... 39 Figure D-5: Example of a Barrel Pump....................................................................................41 Figure D-6: Example of a Sump Pump (Courtesy of Gould Pumps) ............................... 42 Figure D-7: Schematic Diagram of a Vertical Turbine or Can Pump............................... 44 Figure D-8: Schematic Diagram of a Submersible Pump...................................................46

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1.

References
The following Mobil EPTs and industry publications shall be considered a part of this EPT. Refer to the latest editions unless otherwise specified herein.

1.1.

Mobil Tutorials
Reciprocating Pumps Reciprocating Pumps Reciprocating Pumps Centrifugal Pumps Centrifugal Pumps

EPT 07-T-05A EPT 07-T-05B EPT 07-T-05C EPT 07-T-06A EPT 07-T-06B

1.2.

APIAmerican Petroleum Institute

Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and Gas Industry Services Eighth Edition

API STD 610

1.3.

ASMEAmerican Society of Mechanical Engineers

Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process Errata - August 1992 Specification for Vertical In-Line Centrifugal Pumps for Chemical Process Boiler and Pressure Vessel Codes

ASME B73.1M ASME B73.2M ASME SEC VIII

1.4.

NACENational Association of Corrosion Engineers

Selection of Metallic Materials to Be Used in All Phases of Water Handling for Injection into Oil-Bearing Formations

NACE RP0475

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2.

General
Centrifugal pump selectio n shall be in accordance with requirements of this EPT, unless superceded by more stringent local regulations. Pumps serve many purposes in production facilities. The largest pumps are usually shipping or sales pumps which increase the pressure of oil or condensate so that it can flow into a sales pipeline or be loaded into tankers, barges, railroad cars, or trucks. Other large pumps are used with water injection systems for disposing of produced water or for water flooding. Smaller pumps are used to pump liquids from low to higher pressure vessels, to pump liquids from tanks at a low elevation to tanks at a higher elevation, or to transfer liquids for further processing. A facility's utility system often has many pumps, which may be used for firewater wash down and utility water, heat medium, fuel oil or diesel, and hydraulic systems. The project engineer shall be able to select the proper pump for each application, determine horsepower requirements, design the piping system associated with the pump, and specify materials and details of construction for bearings, seals, etc. On standard applications the project engineer may allow the vendor to specify materials and construction details for the specified service conditions. Even then, the project engineer shall be familiar with different alternatives so that he or she can better evaluate proposals and alternate proposals of vendors.

3.

Materials of Construction
3.1. Materials Selection Factors
Factors that affect selection of pump construction materials are: 1. Service condition 2. Safety 3. Service Life 4. Maintenance Pump service conditions shall be reviewed to determine if pump liquid properties and operating conditions can be handled with standard materials of construction offered by the pump manufacturer or if more expensive materials of construction will be required to handle service conditions related to corrosion, erosion, or abrasion wear. For safety reasons, pressure-containing parts of pumps that handle flammable or toxic liquids need steel or alloy steel construction. Cast iron construction may be suitable for other services. Aluminum bronze or other corrosion-resistant alloys often are used in

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water handling/injection services for longer service life and ease of maintenance. These factors, as well as economic factors of construction and design that are often based on experience with an application, shall enter into the design selection process. In the final analysis, there is no substitute for engineering judgement in making design decisions.

3.2.

Types of Corrosion
Corrosion is the destructive attack of a metal by either a chemical or electrochemical reaction. Types of corrosion are: 1. Uniform Corrosion 2. Erosion Corrosion 3. Stress Corrosion 4. Intergranular Corrosion 5. Cavitation Erosion 6. Graphitization 7. Galvanic Corrosion 8. Pitting Corrosion 9. Crevice or Concentration Cell Corrosion

3.2.1.

Material Selection
As a general rule, pump materials shall be selected primarily on the basis of corrosion resistance to the liquid being pumped. If the liquid contains abrasive solids, the construction material shall be selected primarily for abrasive -wear resistance, provided the corrosion resistance characteristics are acceptable.

3.2.2.

Description and Impact of Corrosion Types

A brief description of each type of corrosion and its impact on pump design follows: 1. Uniform Corrosion a) Uniform corrosion is the overall attack on a metal by a corroding liquid resulting in a relatively uniform metal loss over the exposed surface. This is the most common type of corrosion; it can be minimized through the selection of a material that offers resistance to the corroding liquid. b) The pH of a liquid is an indication of its corrosive qualities, either acidic or alkaline. It is a measure of the hydrogen or hydroxide ion concentration in gram equivalents per liter. The pH value is

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expressed as the logarithm to the base 10 of the reciprocal of the hydrogen ion concentration. The scale of pH values is from zero to 14, with 7 as a neutral point. From 7 to zero denotes increasing hydrogen ion concentration and increasing acid ity; from 7 to 14 denotes increasing hydroxide ion concentration and increasing alkalinity. c) Table 1 outlines materials of construction usually recommended for pumps handling liquids of known pH value. The pH value shall only be used as a guide. For more corrosive solutions, temperature and chemical composition shall be carefully evaluated in the selection of construction materials.

Table 1: Materials for Pumps Handling

Liquids of Known pH pH Value 10 to 14 8 to 10 6 to 8 4 to 6 0 to 4 Material of Construction Corrosion Resistant Alloys All Iron Bronze Fitted or Standard Fitted All Bronze Corrosion Resistant Alloy Steels

3.2.3.

Erosion-Corrosion
1. Erosion-corrosion results when a metal's protective film is destroyed by high velocity liquid. It is distinguished from abrasion, which is the destruction of the base metal by liquids containing abrasives. 2. In centrifugal pumps the impeller is particularly susceptible to erosioncorrosion. Diffuser-type casings, with their many vanes, are more susceptible to erosion-corrosion than are volute-type casings. 3. Wear rings also are susceptible to erosion-corrosion and shall receive special consideration in material selection. The high fluid velocities through the small clearance annulus can result in high rates of wear unless the proper material is selected. 4. Most pump components of standard designs are limited to a hardness of approximately 350 Brinell. Above 350 Brinell the standard machining operations of turning, boring, drilling, and tapping become uneconomical. Stuffing box sleeves and wear rings of greater hardness can be provided, and the finishing operation of cylindrical components can be accomplished by grinding.

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3.2.4.

Stress Corrosion
1. Stress corrosion (corrosion fatigue) is the failure of a material due to a combination of stress and a corrosive environment. 2. When material for a pump component that is subjected to a cyclic stress is evaluated, the endurance limit of the material shall be considered. The endurance limit is the maximum cyclic stress that the material can be subjected to and still not fail after an infinite number of cyclic stress reversals. The endurance limit of steel, for example, is approximately 50 percent of its tensile strength. A 690,000 kPa (100,000 psi) tensile steel can be subjected to a static load in tension to produce 690,000 kPa (100,000 psi) stress, but the same steel subjected to a cyclic stress of 690,000 kPa (100,000 psi) would fail in a short period of time. If the stress were reduced to 345,000 kPa (50,000 psi), however, the endurance limit would not be exceeded; the metal could be subjected to 345,000 kPa (50,000 psi) stress reversals and not fail. If the same steel were subjected to a cyclic stress of 345,000 kPa (50,000 psi) in a corrosive environment, however, failure could occur quite rapidly. 3. In corrosion fatigue, minute cracks develop at the surface. In a corrosive environment the surface of the metal exposed by the cracks corrodes rapidly. The crack then penetrates deeper, corrosion develops further and the piece will ultimately fail. 4. Since the corrosion fatigue strength of any metal is dependent more on the corrosion resistance of the metal than on its tensile strength, the life of any pump component subjected to cyclic loading can only be estimated. A pump shaft, for example, is subjected to a complete stress reversal for each revolution; it will have some definite life based on the rotational speed of the pump and the corrosion fatigue strength of the material in the particular application. The best way to guard against short shaft life is to protect the shaft against exposure to the liquid by means of sleeves.

3.2.5.

Intergranular Corrosion
1. Intergranular corrosion results in the complete destruction of the mechanical properties of the steel for the depth of the attack. Solution annealing or using extra-low-carbon stainless steels will minimize intergranular corrosion. It may be necessary to use special metallurgy for severe cases. 2. Intergranular corrosion of austenitic stainless steels occurs as a result of carbides precipitating out at the grain boundaries during the slow cooling of the casting. When exposed to a corrosive environment, the carbides are preferentially attacked, and the strongly bonded matrix of the metal grains is destroyed. The precipitation of carbides can be controlled by heating the casting to 1100 C (2000F) and then quenching. At 1100C (2000F) the carbides are held in solution, and the rapid quench prevents their precipitation.

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3. Susceptibility to intergranular corrosion in austenitic stainless steels also can be reduced by controlling the carbon content of the alloy. Standard austenitic stainless steels of the 300 series have a carbon content in excess of 0.08 percent. Without proper heat treatment, these steels are susceptible to intergranular corrosion. Extra-low-carbon steels are available in the 300 series and are identified by the suffix letter L. These steels have a carbon content of less than 0.03 percent and are much less susceptible to intergranular corrosion. 4. The possibility of intergranular corrosion shall be considered when castings of austenitic stainless steels are indicated for impellers and casings of centrifugal pumps or for the liquid ends of reciprocating pumps.

3.2.6.

Cavitation Erosion
1. Cavitation erosion is the removal of metal as a result of high localized stresses produced in the metal surface from the collapse of cavitation vapor bubbles. In a corrosive environment the rate of damage is accelerated as the corrosion products are continuously removed, and the corrosion proceeds unabated. 2. While every effort shall be made in the design and application of centrifugal pumps to prevent cavitation, some is possible if the NPSHA is less than or equal to the NPSHR. In addition, it is not always possible to assume that the NPSHA is always greater than the NPSHR at capacities other than the rated maximum efficiency capacity of the pump. Therefore, cavitation shall be considered in any evaluation of the material for impellers. 3. Open-type mixed-flow impellers that produce heads in excess of 10.7 m (35 ft) are particularly susceptible to cavitation erosion in the clearance space between the rotating vanes and the stationary housing. Any evaluation of the impeller and housing material for a pump of this type shall include the possibility of vanetip cavitation. 4. Laboratory tests of the resistance of a wide range of materials to cavitation erosion have produced the following tabulation of the cavitation resistance properties of pump materials, listed in order of increasing cavitation resistance: a) Cast iron b) Bronze c) Cast steel d) Manganese bronze e) Monel f) 400 series stainless steel g) 300 series stainless steel

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Centrifugal Pumps h) Nickel-aluminum bronze

October 1992 Draft

3.2.7.

Graphitization
1. Gray iron consists of a matrix of iron and graphite. The graphite exists as flakes and produces the characteristic gray appearance of cast iron. The presence of the graphite also provides a lubricant during machining. This property, plus the fragility of the chips, accounts for the excellent machining qualities of cast iron. 2. These characteristics, in addition to low foundry costs, combine to make gray iron the most widely used metal in the pump industry. Aside from the low tensile strength and ductility of cast iron relative to the steels, the corrosion- resistance properties of cast iron shall be carefully considered. The presence of graphite in the matrix of cast iron produces the unique corrosion effect known as graphitic corrosion or, more simply, graphitization. 3. In the presence of an electrolyte, a galvanic cell exists between the iron and the graphite particles. In the combination of iron and graphite, iron becomes the anode and the graphite becomes the cathode. A galvanic current flows from the iron to the graphite, and the iron goes into solution. The result is a gradual depletion of the iron in the matrix until only the graphite remains. The original casting in iron now has been reduced to a porous graphite structure interspersed with the corrosion products of iron. The physical properties of the graphite structure are greatly inferior to those of cast iron, and the structure fails rapidly. In fact, the effect is so dramatic that, while the casting appears sound from outward appearances, pieces may be broken off with the fingers. 4. The effect of graphitization on a cast iron impeller pumping seawater has been observed many times. The result is a rapid deterioration of the impeller vanes as the soft graphite structure is scoured away, progressively exposing new metal to further attack. The same impeller pumping a nonelectrolyte, such as fresh water, shows no effect of graphitization. Experience has shown that a cast iron impeller shall never be used on brackish water or seawater; the result is inevitably destruction by graphitization. 5. Experience also has shown that cast iron casings are much more resistant to destructive graphitization than are cast iron impellers. While it is true that examination of the inside surface of the casing may reveal a layer of graphite, the velocities encountered in the casing very often are not sufficient to scour away the graphite, and the base material is protected against further attack. This is true, however, only for pumps producing 30 m (100 ft) of head or less. For heads in excess of 30 m (100 ft), alternate casing materials shall be considered for brackish water or seawater services.

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3.2.8.

Galvanic Corrosion
1. Galvanic corrosion is the electrochemical action produced when one metal is in electrical contact with another more noble metal, with both being immersed in the same corroding medium, called the ele ctrolyte. A galvanic cell is formed, and current flows between the two materials. The less noble material, called the anode, will corrode, while the more noble cathode will be protected. It is important that the smaller wearing parts in a pump be of a more noble material than the larger, more massive parts, as in an iron pump with bronze or stainless steel trim. 2. The following is a galvanic series listing the more common metals and alloys: a) Corroded End (Anodic, or least noble) b) Magnesium c) Magnesium Alloys d) Zinc e) Aluminum 2S f) Cadmium g) Aluminum 17ST h) Steel or Iron i) j) Cast Iron Stainless Steel, 400 Series (Active)

k) Stainless Steel, Type 304 (Active) l) Stainless Steel, Type 316 (Active)

m) Lead-tin Solders n) Lead o) Tin p) Nickel q) Nickel Base Alloy (active) r) Brasses s) Copper t) Bronzes u) Copper-Nickel Alloy v) Monel

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Centrifugal Pumps w) Silver Solder x) Nickel (Passive) y) Nickel Base Alloy (Passive) z) Stainless Steel, 400 Series (Passive) aa) Stainless Steel, Type 304 (Passive) bb) Stainless Steel, Type 316 (Passive) cc) Silver dd) Graphite ee) Gold ff) Platinum gg) Protected End (Cathodic or most noble)

October 1992 Draft

3.2.9.

Pitting Corrosion
Pitting corrosion is a localized, rather than uniform, type of attack. It is caused by a breakdown of a protective film, and it results in rapid pit formation at random locations on the surface.

3.2.10.

Crevice or Concentration Cell Corrosion

Crevice or concentration cell corrosion occurs in joints or small surface imperfections. Portions of the liquid become trapped, and a difference in potential is established due to the oxygen concentration difference in these cells. The resulting corrosion may progress rapidly, leaving the surrounding area unaffected.

3.3.

Abrasive Wear
Abrasive wear is the mechanical removal of metal from the cutting or abrading action of solids carried in suspension in the pumped liquid. An undulating matte-finish wear pattern can usually be identified as abrasive wear. The rate of wear for any material is dependent upon the following characteristics of the suspended solids: 1. Solids concentration 2. Solids size and mass 3. Solids shape: spherical, angular, or sharp fractured surfaces 4. Solids hardness 5. Relative velocity between solids and metal surface 6. Angle of impingement Mobil Oil,1998 13 of 47

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3.3.1.

Rate of Wear
The rate of wear depends on the materials selected for the rotating and stationary components of a centrifugal pump. Although metal hardness is not the sole criterion of resistance to abrasive wear, hardness does provide a convenient index in the selection of ductile materials normally used in centrifugal pumps.

3.3.2.

Material Selection Guide

While it is not normally possible to establish any direct relation between the life of pump components and the quantity and characteristics of abrasive particles pumped, the following tabulation can be used as a guide in material selection, listed in order of increasing abrasive -wear resistance: 1. Cast iron 2. Bronze 3. Manganese bronze 4. Nickel-aluminum bronze 5. Cast steel 6. 300 series stainless steel 7. 400 series stainless steel

3.4.

Material For Centrifugal Pump Parts

3.4.1. Impellers
1. The following criteria shall be considered in the selection of the material for the impeller: a) Corrosion resistance b) Abrasive-wear resistance c) Cavitation resistance d) Casting and machining properties e) Cost 2. For most water and other noncorrosive services, bronze satisfies these criteria and, as a result, is the most widely used impeller material for these services. Bronze impellers, however, shall not be used for pumping temperatures above 120C (250F). This limitation exists primarily because of the different expansion rates of the bronze impeller and the steel shaft. Above 120C (250F), this difference produces an

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unacceptable clearance between impeller and shaft. The result is a loose impeller on the shaft. 3. Cast iron impellers are used to a limited extent in small, low -cost pumps. Since cast iron is inferior to bronze in corrosion, erosion and cavitation resistance, low initial cost would be the only justification for a cast iron impeller. 4. Stainless steel impellers of the 400 series are widely used when bronze does not satisfy the requirements for corrosion, erosion or cavitation resistance. The 400 series of stainless steels is not used for seawater, since pitting will limit their performance life. Nevertheless, the 400 series shall be used when pumping temperatures exceed 120C (250F), since the differential expansion problem no longer exists with a steel impelle r on a steel shaft. 5. The austenitic stainless steels of the 300 series are the next step up on the corrosion and cavitation-resistance scale. Initial cost is a factor here that shall be evaluated against the increased life.

3.4.2.

Casings
1. The following criteria shall be considered in the selection of material for centrifugal pump casings: a) Strength b) Corrosion resistance c) Abrasive-wear resistance d) Casting and machining properties e) Cost 2. For most pumping applications, cast iron is the preferred material for pump casings when evaluated against initial cost. For single -stage pumps, cast iron is usually of sufficient strength for the pressures developed. For corrosive liquids and hydrocarbons it may be necessary to specify ductile iron, cast steel, or cast stainless steels of the 400 or 300 series. 3. Cast iron casings for multistage pumps are limited to approximately 6900 kPa (1000 psi) discharge pressure and 177C (350F). For temperatures above 177 C (350F) and pressures above 13,800 kPa (2000 psi) discharge pressure, cast or forged steel is usually specified. 4. In any evaluation of cast iron versus steel casings, consideration shall be given to the probability of casing erosion during operation. Erosion can occur either from abrasive particles in the fluid or from wire drawing across the flange of a split-case pump. (Wire drawing is the condition in which, at high pressures, the fluid may begin to leak at the flanges. The fluid causes erosion of small channels in the flange surfaces. Cast iron

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casings are very susceptible to wire drawing because it is very difficult to obtain a perfect seal on a split-case pump.) 5. While the initial cost of a steel casing is higher than that of a cast iron casing, a steel casing often can be salvaged by welding the eroded portions and then re-machining. Salvaging a cast iron casing by welding is not practical, and the casing usually shall be replaced. 6. The ductile irons are useful casing materials for pressure and temperature ratings between cast iron and the steels. While the modulus of ela sticity for the ductile irons is essentially the same as that for cast iron, the tensile strength of the former is approximately double that of the latter. In any evaluation of the ductile irons as a substitute for the steels in the intermediate pressure and temperature range, it shall be remembered that ductile iron casings cannot be effectively repair-welded in the field. Some companies specify ductile iron for hydrocarbon service even in temperature and pressure ranges at which other companies accept cast iron.

3.4.3.

Shafts
1. The following criteria shall be considered in the selection of the material for a centrifugal pump shaft. a) Endurance limit b) Corrosion resistance c) Notch sensitivity 2. The endurance limit is the stress below which the shaft will withstand an infinite number of stress reversals without failure. Since one stress reversal occurs for each revolution of the shaft, the shaft ideally will never fail if the maximum bending stress in the shaft is less than the endurance limit of the shaft material. 3. In practice, however, the endurance limit is substantially reduced because of corrosion and stress raisers such as threads, keyways and shoulders on the shaft. In the selection of shaft material, consideration shall be given to the corrosion resistance of the material in the fluid being pumped as well as the notch sensitivity. 4. Often the shaft (and wear rings) is made of a less corrosion resistant material, and corrosion control material is added to the critical areas of the shaft. This process is called overlaying or facing. It is usually done by weld metal deposition and machining to tolerance; but it can be done using metal sprays, electrostatic deposition, diffusion and so on. Proper use of this technique can result in longer service life or more economic investment decisions.

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3.4.4.

Wear Rings
1. The following criteria shall be considered in the selection of the material for the wear rings: a) Corrosion resistance b) Abrasive-water resistance c) Galling characteristics d) Casting and machining properties 2. Since the purpose of wear rings is to provide a close running clearance to minimize leakage from the discharge to the suction of the impeller, an increase in leakage as a result of wear in the rings has a direct effect on the head, capacity, and efficiency of the pump. 3. To reduce the wear rate of the wear rings and thereby increase the life of the pump, special consideration shall be given to the corrosion and abrasive-wear characteristics of the ring material in any evaluation of wear ring selection. 4. Bronze is the most widely used material for wear rings because it exhibits good corrosion resistance for a wide range of water services and good wear characteristics in clear liquids. The bronzes also are low on the galling scale if metal-to-metal contact occurs. This is especially true for the 8 to 12 percent leaded bronzes, and they shall be used whenever possible. The casting and machining properties of most grades of bronze are excellent. However, bronze wears rapidly when abrasive particles are present. 5. In applications where bronze is not suitable because of either corrosion or abrasive-wear limitations, or where pumping temperatures exceed 250F (120C), stainless steel rings are required. Unlike bronze, the stainless steels of the 300 and 400 series exhibit a great tendency to gall. The risk of wear ring seizure can be minimized by increasing the clearance between the rings, specifying a difference in hardness of at least 125 to 150 Brinell between the two rings, or providing separations in one of the wear ring surfaces. It is apparent that increasing the clearance between the wear rings is the least costly procedure to reduce the risk of galling or seizure, but increasing the wear ring clearance reduces the output and efficiency of the pump.

3.5.

Selection of Materials of Construction

The selection of the materials for pumps is a compromise between the cost of manufacture and the anticipated maintenance costs. Many pump installations start out with a low service factor and, through operating experience, are gradually upgraded in materials until an acceptable and scheduled replacement program is achieved. It shall be anticipated that, for the more corrosive services, modification and replacement of the wetted parts is necessary during the life of the pumps.

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API STD 610 includes tables that can help in the selection of materials for centrifugal pump applications. Another useful source of material selection guidelines is NACE RP0475.

4.

Standards
4.1. API STD 610 (Centrifugal Pumps for General Refinery Service)
API STD 610 for centrifugal pumps was first issued in 1954 and since then has been updated several times. Its intent is to outline minimum design and mechanical requirements, standards, and quality control to limit maintenance and insure reliability in critical services. The standa rd states that equipment furnished to this standard is designed and constructed for a minimum service life of 20 years and at least three years of uninterrupted operation.

4.2.

Chemical Pump Standards

In 1962, a committee of the Manufacturing Chemists Association (MCA) reached agreement with a special committee of the Hydraulic Institute on a proposed American Standards Association (ASA) standard for chemical process pumps. This document was referred to as the American Voluntary Standard or the Manufacturing Chemists Association Standard. In 1971 it was accepted by the American National Standards Institute (ANSI) and issued as ANSI Standard B123.1. In 1974, it was renumbered as ANSI B73.1. (Currently, information can be found in ASME B73.1M.) Many pump manufacturers in the United States and a few in foreign countries are building pumps that meet these dimensional and design criteria. This standard assumes that pumps of similar size from all sources of supply are dimensionally interchangeable with respect to mounting dimensions, size, and location of suction and discharge nozzles, input shafts, base plates, and foundation bolts. It also outlines certain design features. The standard states that the minimum bearing life, under the most adverse operating conditions, shall be not less than two years.

A similar document, ASME B73.2M, covers vertical in-line centrifugal pumps for chemical process.

4.3.

Comparison of API and ANSI Pump Standards

Table 7 compares some of the major requirements of these two standards.

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The API standard is more stringent in design requirements and quality control. The pump is normally used for critical services where reliability is important. Information found in ANSI B73.1 is currently found in ASME B73.1M. ANSI pumps for pressure ratings of ANSI Class 150 are less expensive and much more readily available. Some manufacturers make an ANSI-type pump for higher pressure ratings. Whenever service conditions allow, considerable time and cost savings are possible when an ANSI pump is specified.

Table 2: Comparison of API and ANSI Pump Standards

API 610 Pump Casings Rating Pump casings All pressures and temperatures normally encountered ASME SEC VIII, Div. 1 ANSI B73.1 ANSI class 150 and temperatures up to 500F Ductile iron, carbons steel, or alloy steel required for flammable or toxic service

Carbon or alloy steel required in flammable or toxic service Impellers Single piece castings Secured to shaft with a key Wear Rings Mechanical Seals Shaft Critical Speed Minimum hardness of 400 BHN or hardness difference of 50 Required Lateral critical speed greater than 120 percent of maximum pump speed Three-year life for ball bearings Hydrodynamic and thrust bearings where bearing diameter (mm) x pump rpm > 300,000, or pump rated hp x pump rpm > 2.7x10 6 Baseplates Drip lip or drain pan required Adequate to limit shaft displacement at coupling to 0.005 in Testing Hydrostatic test to 1.5 items allowable casing pressure for 30 minutes Performance test required Hydrostatic test to 1.5 times allowable casing pressure for 10 minutes No performance test required No requirements No requirements No requirements No requirements May be keyed or threaded to shaft

Bearings

Ball bearings with two-year life

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4.4.

Data Sheets
Many companies provide detailed data sheets for specifying centrifugal pumps. If no data sheets are available, the following items shall be considered. 1. Information Required by Pump Manufacturer for Setting Pump Size; Flow, head, NPSH Available, liquid pumped and its corrosivity, pumping temperature. 2. Construction grade: API STD 610, ASME B73.1M, other 3. Pump type (if there is a preference); See Appendix D of this EPT 4. Preferred major construction features if appropriate a) Materials of construction: Case, shaft, impeller, packing gland/mechanical seal, gland b) Sealing system: Mechanical seal or packing and, for a mechanical seal, API seal code seal piping plan. c) Bearing type: Rolling contact or hydrodynamic d) Pump baseplate and skid: Drain pan, skid material, skid leveling screws e) Coupling type 5. Required testing: Performance test, hydrostatic test, NPSH test. Which tests will be witnessed? 6. Driver type

5.

Selecting a Centrifugal Pump

To select the pump required for a specific installation it is necessary first to determine the desired flow rate or head. The NPSH available shall be determined, and if a centrifugal selection is possible, a system head/flow rate curve shall be developed. Generally, positive displacement pumps are better suited for high head and low flow rate applications. Figure 59 is a guide for the type of pump that will probably be most economical. Naturally, the economics and thus the choice of pump type vary from installation to installation. Figure 1 shall be used merely to provide guidance and not to justify any one specific decision.

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

Figure 1: Pumping Head vs. Flow Rate for Different Types of Pumps (Use as a Guide for Selecting the Most Economical Pump)
Generally, select centrifugal pumps unless:

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

1. Capacity at pumping head files within area labeled "positive displacement pumps." 2. Viscosity is greater than 1000 cp at pumping temperature. 3. Percentage of undissolved gas by volume is greater than 5 percent, or gas is not well dispersed. 4. The percentage of solids by volume is greater than 50 percent, or solids are not well dispersed. 5. The pump is expected to run dry without automatic shutdown provisions, e.g., pumpout pumps. In choosing a pump type it is necessary to consider the system's physical constraints. Space available or weight limitations may dictate a centrifugal or rotary pump; the need to pump solids may dictate a centrifugal or diaphragm pump, and the need to run dry may dictate a diaphragm pump. When discharge pressures vary over a large range but flow shall remain constant, a positive displacement pump is probably a good choice.

5.1.

Number of Pumps Required

The number of pumps required for a given installation depends on a balance of capital cost and operating flexibility. For most sma ll installations a choice shall be made whether the cost of a standby pump is justified by the potential lost income if the pump shall be maintained. On larger installations several other alternatives shall be investigated. These can include: 1. One pump rated at 100 percent throughput. 2. Two pumps rated at 100 percent throughput each (one pump is standby). 3. Two pumps rated at 50 percent throughput each (if one pump is down, throughput is decreased to 50 percent of design). 4. Three pumps rated at 50 percent throughput each (two operate, one is standby). 5. Three pumps rated at 33 percent throughput each.

5.2.

Additional Considerations
In making the selection it is important to consider the actual throughput requirements over the life of the installation and not merely the peak design throughputs. Finally, the ability to obtain spare parts and service at the location and the desires of operating personnel shall be considered.

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Appendix A: Nomenclature
BHP BHPvis C CE CH CQ D EM Evis EW g H HHP HA HEV Hf Hp HSH HVH HVIS Hvpa HW Ln N NPSH NPSHA NPSHR Ns Brake horsepower, kW (HP) Viscous brake horsepower - the horsepower required by the pump for the viscous conditions, kW (HP) Bearing constant Efficiency correction factor Head correction factor Capacity correction factor Diameter of impeller, mm (in) Pump mechanical efficiency Viscous efficiency in percent Water efficiency - the efficiency when pumping water, percent Acceleration due to gravity, 9.81 m/sec2 (32.2 ft/sec 2 ) Total head, m (ft) Hydraulic horsepower, kW (HP) The head on the surface of the liquid supply level, m (ft) Potential head, m (ft) Pipe friction loss, m (ft) Total head required for pump, m (ft) Static pressure head, m (ft) Velocity head, m (ft) Viscous head - the head when pumping a viscous fluid, m (ft) The vapor pressure head, m (ft) Water head - the head when pumping water, m (ft) Life of bearing, millions of revolutions Pump speed, rps (rpm) Net positive suction head, m (ft) Net positive suction head available, m (ft) Net positive suction head required, m (ft) Pump specific speed

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EPT 07-T-06C

Centrifugal Pumps Static pressure, kPa (psi) Flow rate, m3 /hr (ft 3 /sec) Flow rate, m3 /hr (BPD) Flow rate, m3 /hr (gpm)

October 1992 Draft

P Q Q q qvis qw Rp SG V W Z

Viscous capacity - the capacity when pumping a viscous liquid, m3 /hr (gpm) Water capacity of pump, m3 /hr (gpm) Pump speed, rps (rpm) Specific gravity of liquid relative to water Average liquid velocity, m/sec (ft/sec) Bearing load, N (lb) Elevation above or below pump centerline datum, m (ft) Density of liquid, kg/m3 (lb/ft 3 )

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Appendix B: Example Problem (Metric)

Given:
An offshore production facility processes 400 m3 /hr of a 0.94 specific gravity crude oil. A charge pump pumps produced oil from a storage tank and delivers it through a metering skid to the main shipping pumps. The inlet pressure to the shipping pump is 1415 kPa (g). Crude oil pumping temperature is 27 C. The shipping pump for the above facility shall be centrifugal. This pump shall meet the followin g criteria: 1. The maximum size motor that can be installed on the pump is 150 kW. (The platform generator is not capable of starting a larger motor.) 2. The pump's discharge pressure is to be 4035 kPa. 3. Platform space is at a premium. 4. The pump is to be direct-driven by an electric motor turning at 3600 rpm. 5. Pump components and auxiliaries are to be in accordance with safe practices for off shore platforms.

Steps to Solve:
1. Approximate number of pumps. 2. Pump configuration. 3. Head and flow for each pump. 4. Pump type. 5. Mechanical features of the pump: a) Seal system with API code b) Bearings c) Material by ASTM number for this application, as recommended by API STD 610, for the following parts: i. ii. iii. Pressure Casing Impeller Shaft

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

Step 1: Determine Approximate Number of Pumps

Total Hydraulic Power Required

HP =

q P 3600

q = 400 m3 /hr 4035 - 1415 = 2620 kPa

(400 )(2620 ) = 291 kW

3600
Number of pumps required at 150 kW each is

416 kW = 2.8, Use 3 Pumps 150 kW / pump

Assuming pumps are selected with an average efficiency of 0.7.

291 = 416 kW 0.7

Step 2: Determine Pump Configuration

Since three pumps are required, the basic pumping configuration shall be established. Option I: Three Pumps Operating in Parallel This configuration requires three identical pumps. Thus, if one pump is down, pump capacity will be reduced by approximately 33 percent. Additionally, spare parts for each pump are identical. Option II: Two Pumps Operating in Parallel with 1 Pump in Series This configuration requires two different pumps. The final pump will have larger impellers and casing than the first stage pumps. This will require additional spare parts. Additionally, if one pump is down, pump capacity is reduced by 50 to 100 percent. Option III: Three Pumps Operating in Series This configuration requires three identical pumps. Each will be selected with the capability to pump the design flow rate at 33 percent of the rated differential pressure. If one pump is down,

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

two pumps operating in series will be able to reach the required discharge pressure, but the flow rate will be reduced considerably. Spare parts for each pump will be identical. Option IV: Four Pumps Operating in Series or Parallel This is similar to Options I and III as far as pump selections is concerned. The only difference is that one standby pump is provided, so capacity can be maintained if one pump is out of service. Selection Only Options I and III will be considered. The selection will depend on pump system interaction curves.

Option I: Step 3 (Option I): Determine Head and Flow for Each Pump
SG = .94

Head =

0.102 P 0.102 ( 4035 1415 ) = = 284 m / pump SG .94

Flow = 400 m3 /hr x 1/3 pumps = 133 m3 /hr

Step 4 (Option I): Determine Pump Type

A review of the centrifugal pump types shows that the following are available: 1. ANSI Pump 2. API Single Stage 3. In-line Pump 4. API Multistage Split Case 5. API Barrel Pump 6. Vertical Can Pump 7. Sump Pump 8. Submersible Pump Types 1-3 can be eliminated as they are single stage pumps and a multistage most likely will be required. Types 7 and 8 are not designed for applications such as this. Types 4-6 are all suitable for application. Types 4 and 5 are horizontal pumps with horizontal electric motors, while Type 6 is a vertical pump with a vertical motor. Since the vertical pump uses considerably less space than the horizontal pumps, it probably would be preferred for this offshore application. Mobil Oil,1998 27 of 47

EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

Step 5 (Option I): Determine Mechanical Features of the Pump

1. Seal system: Per seal usage guide, a balanced tandem seal shall be provided. Since the fluid pumped is not extremely hot and not sour, the o-ring material can be Teflon or Kelrez, fourth letter G or I. Since crude is liable to contain some sand or other abrasives (e.g., products of corrosion, the rubbing surfaces of the seal), the fifth letter shall be at least an L. The total seal system is thus BTTGL with API seal piping plan 12 or 13. 2. Bearings: Manufacturer's standard. Bearings shall have both a radial and thrust capacity. 3. The material class from API STD 610 is S-1. Therefore, the following material shall be specified: a) Pressure Casing = Carbon Steel b) Impeller = Cast Iron c) Shaft = Carbon Steel From API STD 610 the following conversions can be made: 1. Pressure Casing = ASTM A-216 Grade WCA or WCB 2. Impeller (Forging) = ASTM A-105 3. Shaft (bar stock) = ASTM A-576 Grade 1015

Option III: Step 3 (Option III): Determine Head and Flow

Head = (0.102 )( 4035 1415 ) 3x(.94 )

Flow = 400 m3 /hr

Step 4 (Option III): Determine Pump Type

This type of pump shall be identical to that of Option I.

Step 5 (Option III): Determine Mechanical Features

Mechanical features of this pump shall be id entical to those of Option I.

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Appendix C: Example Problem (Customary)

Given:
An offshore production facility processes 60,000 BOPD of a 0.94 specific gravity crude oil. A charge pump pumps produced oil from a storage tank and delivers it through a metering skid to the main shipping pumps. The inlet pressure to the shipping pump is 205 psig. Crude oil pumping temperature is 80 F. The shipping pump for the above facility shall be centrifugal. This pump shall meet the following criteria: 1. The maximum size motor that can be installed on the pump is 200 HP. (The platform generator is not capable of starting a larger motor.) 2. The pump's discharge pressure is to be 585 psig. 3. Platform space is at a premium. 4. The pump is to be direct-given by an electric motor turning at 3600 rpm. 5. Pump components and auxiliaries are to be in accordance with safe practices for offshore platforms.

Steps to Solve:
1. Approximate number of pumps. 2. Pump configuration. 3. Head and flow for each pump. 4. Pump type. 5. Mechanical features of the pump: a) Seal system with API code b) Bearings c) Material by ASTM number for this application, as recommended by API STD 610, for the following parts: i. ii. iii. Pressure Casing, Impeller Shaft

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

Step 1: Determine Approximate Number of Pumps

Total Hydraulic Horsepower Required

HP =

Q P 58,756

Q' = 60,000 BPD P = 585 - 205 = 380 psi

HP =

(60 ,000 )(380 ) = 388 HHP 58,756

Assuming pumps are selected with an average efficiency of .7 BHP/E = 388/.7 = 554 HP Number of pumps required at 200 HP each is:

554 HP = 2.7, Use 3 Pumps 200 HP / pump

Step 2: Determine Pump Configuration

Option I: Three Pumps Operating in Parallel This configuration requires three identical pumps. Thus, if one pump is down, pump capacity will be reduced by approximately 33 percent. Additionally, spare parts for each pump are identical. Option II: Two Pumps Operating in Parallel with 1 Pump in Series This configuration requires two different pumps. The final pump will have larger impellers and casing than the first stage pumps. This will require additional spare parts. Additionally, if one pump is down, pump capacity is reduced by 50 to 100 percent. Option III: Three Pumps Operating in Series This configuration requires three identical pumps. Each will be selected with the capability to pump the design flow rate at 33 percent of the rated differential pressure. If one pump is down, two pumps operating in series will be able to reach the required discharge pressure, but the flow rate will be reduced considerably. Spare parts for each pump will be identical. Option IV: Four Pumps Operating in Series or Parallel This is similar to Options I and III as far as pump selection is concerned. The only difference is that one standby pump is provided, so capacity can be maintained if one pump is out of service. Mobil Oil,1998 30 of 47

EPT 07-T-06C Selection

Centrifugal Pumps

October 1992 Draft

Only Options I and III will be considered. The selection will depend on pump system interaction curves.

Option I: Step 3 (Option I): Determine Head and Flow for Each Pump
SG = .94

Head =

2.31 P 2.31 (585 - 205 ) = = 933 ft / pump SG .94

1 gpm Flow = 60,000 BPD pumps 0.0292 = 582 gpm 3 BPD

Step 4 (Option I): Determine Pump Type

A review of the centrifugal pump types shows that the following are available: 1. ANSI Pump 2. API Single Stage 3. In-line Pump 4. API Multistage Split Case 5. API Barrel Pump 6. Vertical Can Pump 7. Sump Pump 8. Submersible Pump Types 1-3 can be eliminated as they are single stage pumps and a multistage most likely will be required. Types 7 and 8 are not designed for applications such as this. Types 4-6 are all suitable for application. Types 4 and 5 are horizontal pumps with horizontal electric motors, while type 6 is a vertical pump with a vertical motor. Since the vertical pump uses considerably less space than the horizontal pumps, it probably would be preferred for this offshore application.

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

Step 5 (Option I): Determine Mechanical Features of the Pump

1. Seal System: Per seal usage guide, a balanced tandem seal shall be provided. Since the fluid pumped is not extremely hot or not sour, the o-ring material can be Teflon or Kelrez, fourth letter G or I. Since crude is liable to contain some sand or other abrasives (e.g., products of corrosion, the rubbing surfaces of the seal), the fifth letter shall be at least an L. The total seal system is thus BTTGL with API seal piping plan 12 or 13. 2. Bearings: Manufacturer's standard. Bearings shall have both a radial and thrust capacity. 3. The material class from API STD 610 is S-1. Therefore, the following material shall be specified: a) Pressure Casing = Carbon Steel b) Impeller = Cast Iron c) Shaft = Carbon Steel From API STD 610 the following conversions can be made: 1. Pressure Casing = ASTM A-216, Grade WCA or WCB 2. Impeller (Forging) = ASTM A-105 3. Shaft (bar stock) = ASTM A-576 Grade 1015

Option III Step 3 (Option III): Determine Head and Flow

Head = 2.31 (585 - 205 ) = 311 ft / pump 3 (.94 ) gpm = 1746 gpm BPD

Flow = 60,000 BPD 0.0292

Step 4 (Option III): Determine Pump Type

This type of pump shall be identical to that of Option I.

Step 5 (Option III): Determine Mechanical Features

Mechanical features of this pump shall be identical to those of Option I.

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Appendix D: Generic Types of Centrifugal Pumps

1.

ANSI Pump

Figure D-1: Schematic Diagram of an ANSI Pump (Courtesy of Gould Pumps)

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EPT 07-T-06C DESCRIPTION: 1. Mounting = Horizontal 2. Casing Split = Radial 3. Impeller Type = Radial

Centrifugal Pumps

October 1992 Draft

4. Mounting Feet = Bottom of pump casing 5. Number of Stages = One APPLICATIONS: 1. Flow Conditions: 30 to 700 ft of head; 35 to 400 gpm 2. Service Rating: Non-Critical 3. Typical Uses: a) Service Water b) LACT Charge Pump c) Oil Transfer d) Cooling Tower Circulation Pumps NOTE: General processing and transfer service at temperatures below 350F

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

2.

Single Stage API Pump

Figure D-2: Example of an API single-stage pump (Courtesy of Gould Pumps)

DESCRIPTION: 1. Mounting = Horizontal 2. Casing Split = Radial 3. Impeller Type = Radial 4. Mounting Feet = Centerline of pump casing 5. Number of Stages = Single APPLICATIONS: 1. Flow Conditions: 100 to 20,000 ft of head; 40 to 900 gpm, high temperature 2. Service Rating: Critical 3. Typical Uses: a) Hot Oil Pumps

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EPT 07-T-06C b) Rich Oil Pumps c) Raw Products Pumps

Centrifugal Pumps

October 1992 Draft

d) Cooling Tower Circulation Pumps NOTE: Hydrocarbon in the low to moderate flow and moderate head ranges

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

3.

Vertical In-Line Pump

Figure D-3: Schematic Diagram of an In-Line Pump (Courtesy of Gould Pumps)

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EPT 07-T-06C DESCRIPTION:

Centrifugal Pumps

October 1992 Draft

1. Mounting = Vertically, in-line with piping 2. Casing Split = Radial 3. Impeller Type = Radial 4. Mounting Feet = None 5. Number of Stages = Single APPLICATIONS: 1. Flow Conditions: 15 to 600 ft head; 20 to 1200 gpm 2. Service Rating: Non-Critical 3. Typical Uses: a) Service Water b) LACT Charge Pump c) Oil Transfer NOTE: General processing and transfer service at temperature below 350F. Minimum space applications.

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

4.

API Multistage Split Case Pumps

Figure D-4: Example of an API Multistage Split Case Pump (Courtesy of Gould Pumps)
DESCRIPTION: 1. Mounting = Horizontal

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EPT 07-T-06C 2. Casing Split = Axial 3. Impeller Type = Radial

Centrifugal Pumps

October 1992 Draft

4. Mounting Feet = Centerline of pump casing 5. Number of Stages = Multiple APPLICATIONS: 1. Flow Conditions: 200 to 1500 ft of head; 200 to 4500 gpm, high specific gravity 2. Service Rating: Critical 3. Typical Uses: a) Pipeline Booster (Crudes and Refined Hydrocarbons) b) Water Flood c) Hot Oil Pumps d) High Pressure Boiler Feedwater

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

5.

API Barrel Pumps

Figure D-5: Example of a Barrel Pump

DESCRIPTION: 1. Mounting = Horizontal 2. Casing Split = Radial 3. Impeller Type = Radial 4. Mounting Feet = Centerline of pump casing 5. Number of Stages = Multiple APPLICATIONS: 1. Flow Conditions: 200 to 1700 ft of head; up to 900 gpm, all specific gravities 2. Service Rating: Critical 3. Typical Uses:

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EPT 07-T-06C a) Pipeline Booster b) Water Flood c) Lean Oil Pumps

Centrifugal Pumps

October 1992 Draft

6.

Sump Pump

Figure D-6: Example of a Sump Pump (Courtesy of Gould Pumps)

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EPT 07-T-06C DESCRIPTION: 1. Mounting = Vertical 2. Casing Split = Radial 3. Impeller Type = Radial 4. Mounting Feet = Mounting Plate 5. Number of Stages = One APPLICATIONS:

Centrifugal Pumps

October 1992 Draft

1. Flow Conditions: Low head and moderate flow rate 2. Service Rating: Non-Critical 3. Typical Uses : Primarily used to pump water or hydrocarbons from shallow pits or compartments.

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EPT 07-T-06C

Centrifugal Pumps

October 1992 Draft

7.

API Vertical Turbine or Can Pump

Figure D-7: Schematic Diagram of a Vertical Turbine or Can Pump

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EPT 07-T-06C DESCRIPTION: 1. Mounting = Vertical 2. Casing Split = Radial 3. Impeller Type = Mixed or Radial 4. Mounting Feet = Mounting Plate 5. Number of Stages = Multiple APPLICATIONS:

Centrifugal Pumps

October 1992 Draft

1. Flow Conditions: 100 to 30,000 ft of head; 10 to 1500 gpm, low NPSH available 2. Service Rating: Critical 3. Typical Uses: a) Firewater Pump (Offshore) b) Pipeline Pump

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EPT 07-T-06C

Centrifugal Pumps

Octobe r 1992 Draft

8.

Submersible Pump

Figure D-8: Schematic Diagram of a Submersible Pump

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EPT 07-T-06C DESCRIPTION: 1. Mounting = Vertical 2. Casing Split = Radial 3. Impeller Type = Radial 4. Mounting Feet = Mounting Plate 5. Number of Stages = Multiple APPLICATIONS:

Centrifugal Pumps

October 1992 Draft

1. Flow Conditions: 100 to 30,000 ft of head; 10 to 2000 gpm, low NPSH available 2. Service Rating: Critical 3. Typical Uses: a) Firewater Pump (Offshore) b) Downhole in Well (Crude lifting) c)

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