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Understanding Centrifugal and Reciprocating Pumps for Chemical Plants

The types of pumps most often encountered in a refinery or chemical plant can be classified as kinetic or positive displacement pumps.

Kinetic Pumps

In a kinetic pump energy is added continuously to increase the fluid’s velocity within the pump to values over those in the discharge pipe. Passageways within the pump then reduce the velocity until it matches that in the discharge pipe. Bernoulli’s law states that as the velocity head of the fluid is reduced, the pressure head must increase. Therefore, in a kinetic pump, the fluid’s kinetic energy or velocity energy is increased and then converted to potential or pressure energy. Most of the pumps used in plants are centrifugal pumps, in which the kinetic energy is imparted to the fluid by a rotating impeller, which generates centrifugal force.

Positive Displacement Pumps

In a positive displacement pump the volume containing the liquid is decreased until the resulting liquid pressure is equal to the pressure in the discharge system. That is, the liquid is compressed mechanically, causing a direct increase in potential energy. Most positive displacement pumps are reciprocating pumps, where the displacement is accomplished by the linear motion of a piston in a cylinder. Rotary pumps are another common type of positive displacement pump. In these pumps, displacement is caused by circular motion.

Centrifugal Pumps

This type of pump is used almost exclusively in refineries and chemical plants. Centrifugal pumps have few moving parts and therefore tend to have greater reliability and lower maintenance costs than positive displacement pumps. A centrifugal pump generally has a spare unless the plant can run without it.
Design Considerations:

  • Pressure rise is dependent on density because velocity is converted to static head in feet of fluid.
  • Head developed is determined by speed (RPM), impeller diameter, and number of impellers
    (stages).
  • Multistage pumps can develop head up to 6000 ft (1800m), about 1300 – 2500 psi (90-175 kg/cm2)
    for hydrocarbons.
  • Minimum capacity without recirculation is usually limited to 15 – 20 gpm (4 m3/h)
  • Centrifugal pumps lose efficiency as viscosity increases.

Reciprocating Pumps

Reciprocating pumps are often used to handle viscous fluids and in sludge and slurry service. Compared to centrifugal pumps, reciprocating pumps: are more efficient are poorer at handling liquids containing solids that erode valves and seals have higher maintenance costs and lower availability because of pulsating flows and the large number of moving parts.
Design Considerations:

  • Its performance curve is constant capacity, variable head.
  • It produces a pulsating flow. Pulsations are minimized by use of multiple plungers (duplex, triplex,
    etc).
  • Pressure rise is independent of fluid density, so these pumps are used where a wide range of
    fluids must be handled.
  • Reciprocating pumps are used for low capacities and high heads. They need safety valve
    protection.

Centrifugal Pumps Design

When designing a system utilizing a centrifugal pump, keep in mind that centrifugal pump performance
changes with operating conditions, as illustrated by the pump curves on this screen. This is a typical centrifugal pump curve at a constant speed (rotational velocity). As the flow rate through the pump increases, the generated head decreases. The efficiency curve reaches a maximum, hopefully near
the design point. The brake horsepower curve increases continuously with the flow rate.

Centrifugal Pumps Impeller Change

If the pump speed is changed (i.e. variable speed drive or larger impeller), the head and flow rate will also
change.

impeller

Centrifugal Pumps Design

This curve shows how a control valve affects flow through a pumped system. The control valve pressure drop decreases the flow rate through the system. When the control valve opens fully, the flow rate increases from the “operating flow rate” to the “maximum flow rate” the point where the system pressure drop equals the pump discharge pressure.

Pump Affinity Laws

Relationships called “Pump affinity laws” show the effect of changing speed or impeller diameter on pump performance.
Pump affinity laws are useful when looking at a new service for an existing pump.
FLOW Q ∼ (Peripheral Speed)
{Q2=Q1(N2/N1) or Q2=Q1 (D2/D1)} important
HEAD H ~ (Peripheral Speed) 2
{H2=H1 (N2/N1) 2 or H2=H1 (D2/D1) 2} important
POWER HP ~ (Peripheral Speed) 3
{HP2=HP1 (N2/N1)3 or HP2=HP1 (D2/D1) 3 important
Where D=impeller diameter and N=impeller RPM

Centrifugal Pump Design Factors

Five major factors affect the design of centrifugal pumps:
– Fluid properties
– Pump differential pressure
– Net positive suction head
– Pump casing design pressure
– Driver and utility requirements

These factors are described in the following pages.

Fluid Properties & Differential Pressure

The fluid properties most important to pump design are fluid density and viscosity:

  • For a fixed speed pump and a fixed capacity, the pump will develop the same head regardless of the density. However, pressure rise is directly related to fluid density.
  • The performance of centrifugal pumps deteriorates with increased viscosity.

Differential pressure is the difference between the discharge and suction pressures and is a measure of the amount of energy that the pump must supply.

Cavitation & NPSH

  • Cavitation refers to the formation and subsequent implosion of vapor bubbles.
  • Cavitation occurs when the static pressure of the liquid falls to or below the vapor pressure in a moving liquid system. The vapor bubbles formed in the cavitation are subsequently imploded by increasing static pressure. Cavitation commonly occurs in and around the impeller of a centrifugal pump.
  • For satisfactory pump operation, the liquid must flow without vaporizing from the pump inlet to a point within the impeller eye where the vanes begin to impart energy to the liquid. The force tending to suppress cavitation is the margin by which the local static pressure of the liquid exceeds the liquid vapor pressure at that temperature. When converted to terms of head of liquid, this pressure margin is termed the net positive suction head, or NPSH. To avoid cavitation, the available net positive suction head (NPSH) must be greater than that required by the pump.

Calculating and Approximating NPSH

NPSH is calculated by the following equation:
NPSH = hp -hvpa – hst -his

Where: hp = Pressure in suction vessel vapor phase.
hvpa = Vapor pressure of the liquid.
hst = Height of liquid above pump suction.
his = All suction line pressure losses.
NPSH is a characteristic individual to each pump and is determined by vendor testing. Pump specifications must include the available NPSH. Apply a 10% safety factor on the calculated NPSH. If the available NPSH is less than the required NPSH, consider increasing the elevation of the suction drum. If the available NPSH is greater than 25 ft (7.6m), specify NPSH = 25 ft (7.6m).

Mechanical Seals

  • A seal is required to prevent process fluid from leaking past the pump shaft.
  • Mechanical seals have many advantages over packed stuffing boxes. Typical stuffing box and mechanical seal configurations are shown below.
  • A single mechanical seal is sufficient for many pump shaft sealing services. Sometimes two mechanical seals are required, with some sealant injected between the seals. When two seals are constructed in a single assembly with some common parts, the combination is termed a double mechanical seal. When the two seals are separated and oriented in the same direction, they are termed tandem mechanical seals.
mechanical seal

Flushing Mechanical Seals

Mechanical seals must be flushed to maintain “sealage”. Mechanical seals are usually flushed with some of the process fluid; i.e., they are “self flushed”. When the process fluid is too dirty for self-flushing, however, an external liquid is employed.
Recently a new technology which flushes the seals with gas has been used for
difficult services.

Sealless Pumps

Most pump leaks and fires are caused by seal failures. Sealless pumps are becoming popular because of their environmental and safety advantages, although they are somewhat less efficient and more expensive than other types of pumps. Their use is expected to grow, especially for handling toxic material and for sites from environmentally sensitive areas.
Three basic types of sealless pumps are available:
Magnetically driven pumps
The drive shaft is connected to the pump impeller through magnetic couplings located at the inner wall of a metal container.
Canned pumps
A electric motor sheathed in metal serves as the impeller shaft, with the stator located outside the metal can.
Sealless diaphragm pumps
These are reciprocating machines with a flex diaphram to cause pumping action due to check valves on the inlet or outlet.

Important points

Remember: pumps produce head, not pressure
– Lower fluid density will reduce pressure
– Size pump differential pressure for minimum density fluid
– Size motor for maximum density fluid
– Check downstream equipment design pressure based on maximum density fluid
Always use ACTUAL fluid rate, not standard
Account for extra flows
– Constant low flow recycles
– Warm-up lines
– Seal flush using pump discharge fluid

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