Professional Documents
Culture Documents
By
Dheerendra Dubey
1.Pump
2 Control Valve-Pump Discharge Circuits
1.0 Pump
1.1 Introduction
The common types of pumps used in oil & gas industry are
centrifugal and positive displacement.
CENTRIFUGAL PUMP
1.2.2 Service
Name of pump as given in Equipment List / PFD
1.2.3 Type Centrifugal / Metering / Reciprocating / Screw /
Vertical submerged centrifugal , etc
Metering pumps are small reciprocating pumps which can
deliver variable capacity by stroke adjustment.
Large reciprocating pumps ( generally flow above 5 m3/ hr or
high discharge pressures ) are constant capacity pumps and
any requirement of variation in flow will have to be handled
outside the pump by spill back control.
Where to use metering or reciprocating pump
Metering pump is specified where variable capacity is required
and reciprocating type is specified where fixed capacity is
required.
1.2.4 Liquid handled
If service indicates type of fluid like naphtha/diesel/sour water
then hydrocarbon / water should be mentioned.
If service does not indicate type of fluid but mentions main
fractionators reflux / Debutanizer reflux / Absorber reflux then
Naphtha / LPG/Light hydrocarbon are mentioned.
Information on internals / type of seal is required by rotating /
vendor to decide type of pump.
1.2.5 Pumping Temperature
The normal temperature is to be indicated.
Range needs to be indicated when there is wide variation.
Process engineer to review start up, shut down, pump out
cases w. r. to change in temp, fluid, and source/destination.
A note indicating name of fluid, temp, properties, vapor
pressure, capacity, discharge pressure, suction pressure,
NPSH, and duration envisaged is to be provided by process
engineer.
Capacity or pump discharge pressure is left to be decided by
rotating group / vendor because various cases to be considered
are not rigid case of operation e.g. pump out can take longer
time hence discharge pressure is must but capacity can be
less or during start up, capacity requirement is rigid but
discharge pressure can be low due to lower circuit pressure
drop.
However requirement of both capacity and discharge pressure
as judged by process engineer should be mentioned with note
that “Rotating Equipment to confirm”.
1.2.6 Viscosity at pumping temperature
Range (if variation is wide) / viscosity at pumping
temperature from simulation / curves.
For highly viscous fluids where screw pumps have been
specified, lowest viscosity envisaged is very important as
problems of low efficiency, slippage, etc occur.
2.3 Procedure
Control valves in pump discharge circuits broadly fall under the
following categories:
(Types A to G, and J, K are on centrifugal pump discharge while
H & I are on positive displacement pump discharge)
A -Control valve in the governing circuit (from pump
differential pressure requirement angle) e.g. FV-1203 in Fig-1.
B -Control valve in parallel circuit to a different destination i.e.
not in governing circuit e.g. FV-1202 in Fig 1.
C Control valve in a parallel circuit i.e. not in the governing
circuit, but to same destination. e. g. FV-1401 in Fig 2.
D Control valve in series with main control valve in
the governing circuit. e. g., FV-1502 A in Fig 3.
E Control valve in parallel in a part of the circuit. e. g.,
FV-1502 B in Fig 3.
F Pump minimum flow control valve for centrifugal pump.
e.g. FV-1201 in Fig.1.
G 3-way valve. e.g., TV-1701 in Fig 4.
H Control valve at positive displacement (constant flow)
pump discharge. e. g., FV-1601 in Fig 5, LV-1601 in Fig 5.
I Spill back control valve for positive displacement pump.
e. g., PV-1601 in Fig 5.
J Pressure control valve for fuel oil to furnace
K Back pressure control valve in fuel oil circulation line
L Control valve at pre heat inlet like FV-1801/ HV-1801
in Fig 6
M Control valve at heater pass inlet like FV-1901 Fig 6
N Pressure control valve on pump discharge as in
pipeline application. e. g., PV-2001 in Fig 7.
O Mixing valves e. g., at desalter / caustic wash inlet
2.4 Estimation of del PCV min
del PCV min is estimated as part of pump hydraulic calculations.
del PCV min is taken as 0.7 kg/cm2 as an initial estimate.
NOTE:- del PCV min for any control valve shall be 0.7 kg/cm2
minimum. However this may be relaxed for special cases, like
revamp jobs if pump discharge rating increases only due to
control valve del P. Engineering confirmation on availability
of control valve needs to be obtained before finalizing pump in
such cases.
Step-1:
del Pckt is proportional to Q2 ---------------1
del Pckt + del PCV = constant -----------------2
From equations 1 and 2 above, since del Pckt max and del Pcv min
are known from pump hydraulic calculations, del Pckt min , del
PCVmax , del Pckt nor and del P CV nor can be calculated.
Step 2:
However above equation-2 does not consider that pump
discharge pressure increases with decrease in flow for a
centrifugal pump. Hence del PCV max and del PCV nor calculated
in step1 above is to be corrected for this extra head developed
by the pump.
A 20 % higher head is considered to be developed at shut off
i. e., at zero flow, del P developed at normal /minimum flow
can be estimated as given below assuming linear relation
between flow vs head developed.
del Pnor = del Pnor+ 0.2 x del P rated (Qrated – Qnormal)/Qrated
If there are multiple cases, del PCV min reported in data sheet
shall be corresponding to that case which gives max Cv max .and
del PCV max reported in data sheet shall be corresponding to that
case which gives the minimum C v min. del PCV nor reported shall
be that corresponding to the case which is a more probable
normal operating case.
Caution: If flashing occurs at control valve outlet, the
following data are to be included in process data sheet:
Weight % vapor at outlet, temperature at outlet, vapor
properties at outlet, vapor pressure and liquid critical
pressure.
sample calculations for pump discharge control valve circuit-
Case-II
del PCVmin = 0.7 (initial estimate)
del Pckt rated =1.88(LL) + 0.60 (3 FE ) + 6.00 (3 HE) = 8.48
del Pckt nor = 8.48 x (86.1/94.7)2 =7.0
del PCvnor =8.48+ 0.7-7.0 =2.18 or 2.2
del Pckt min = 8.48 x (43/94.7)2 =1.75
del PCvmax = 8.48+ 0.7- 1.75 =7.43 or 7.4
The del PCV min for main port shall be specified as 0.7
kg/cm2. The variation in dynamic losses for the rest of the
circuit is outside points C and D (i.e. other than E-1,FE-
1701and line loss between points C and D) shall be taken care
in the main control valve i.e., in FV-1702.
The remaining steps for estimation of del PCv max, del PCV nor
and del PCV min for main port are same as for type A control
valves.
The rated flow for both main and bypass ports shall be the
available rated flow for the exchanger circuit (to take care of
total exchanger bypass). For the bypass port normal flow and del
PCV nor need not be furnished.
The frictional losses through the exchanger circuit and
bypass circuits across points C and D are always equal
irrespective of flow.
del PCV min bypass port or del PCV max bypass port
= del P ckt max + del PCVmin main port
assuming negligible line losses in the bypass circuit.
Type H control Valves: Positive displacement pumps
develop a discharge pressure equivalent to the back
pressure at its rated (constant) flow.
Caution: Positive displacement pumps are fixed capacity
machines unless provided with auto capacity control like
stroke adjustment. If a control valve is envisaged in the
positive displacement pump discharge (either through a FIC or
LIC or both) a spill back control valve (normally a PIC)
should be provided to prevent pump PSV from lifting. The
spill back control is provided upstream of any control
valve in the pump discharge circuit. This spill back control
valve should be capable of pumping back the flow equivalent
to rated flow of the pump.
a. For control valve where the pump discharges to a single
destination:-
The del P through the control valve for all flows is to be
specified as 0.7 kg/cm2 and the same 0.7 kg/cm2 should be used
in pump hydraulic calculations.
b. For two different control valves in two different circuits
discharging to two different destinations: e.g., FV-1601and
LV-1601 in Fig-5.
---For the control valve in the governing circuit
del Pcv min / nor / rated shall be 0.7kg/cm2
---For the control valve in the not governing circuit
the del Pcv min / nor / rated shall be 0.7 +Difference in
(destination pressures + frictional losses + static
heads in the two circuits)
If there is a possibility of only one circuit being in operation
at a time, then since the pump would develop only the back
pressure, the del Pcv min for the control valve in each circuit
shall be 0.7 kg/cm2.
Warning: There have been instances of vibration problems
when control valve has been provided in positive displacement
pump discharge, and hence should be avoided if the system
design permits.
Type I control valves: The spill back control valve for
reciprocating pumps is a pressure control valve.
The maximum flow shall be indicated equal to the pump rated
flow rate in the control valve data sheet and a note -“this
control valve shall be normally in closed position“ shall be
added. No normal flow/ delP shall be indicated.
The circuit frictional loss is only the line loss.
del Pcv = pressure upstream of control valve –line loss in spill
back line - (source pressure at suction vessel + static head as in
pump suction pressure calculation)
Pressure upstream of control valve is the pump discharge
pressure less FE loss, if any , upstream of the control valve.
Suction line loss is not considered as it can be negligible
during turn down etc.
Pdischarge rated = Destination pressure + del Pckt max +discharge
side static head + contingency
Pdischarge min = Destination pressure + del Pckt min+ discharge side
static
head
Pressure upstream of control valve shall be estimated based on
both Pdischarge rated and Pdischarge min and two del Pcv figures shall
be reported for both rated and min flows.
Type J control valves: Since pressure control valve for fuel oil
to furnace involves pressure requirements at burner during
turndown, etc.
Type K control valves: Procedure shall be similar as for type B
and C control valves given above.
Type L control valves: Procedure shall be similar as for type A
control valves given above but Pckt shall be frictional
dynamic losses up to FV-1901 inlet only as it is intended to
ensure a fixed pressure of 2-3 kg/cm2 above bubble pressure
of liquid at FV-1901 inlet to prevent 2-phase at control valve
inlet which is not desirable for control.
Type M control valves: Procedure shall be similar as for type
A control valves given above but del Pckt shall be the
frictional dynamic losses downstream of FV-1901 only. But
control valve upstream pressure is constant and variation in
pressure with pumped flow is not to be compensated as it will
be absorbed in FV-1801/HV-1801.