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Sulzer PumpsSulzer ISO 13709 (API 610) Type BB5 Barrel Pumps
The Heart of Your Process
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 2
Sulzer PumpsLong History of Barrel Pumps
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 3
Sulzer PumpsBarrel Pumps: Diffuser Style
45 MW SuperCriticalBoiler Feed
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 4
Sulzer PumpsTypes of Horizontal Multistage Pumps
Volute - Horizontal Split
BB3
Diffuser Barrel CasingBB5
Volute Barrel
BB5
Diffuser - Segmental Ring
BB4 – Not used on H.C.
High Speed Diffuser Barrel
BB5
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 5
Sulzer Pumps
Single Volute Casing
Volute vs. Diffuser Casings
FR
Radial loads increase at lower flow, and at flow rates beyond best efficiency point.
The result is an unbalanced radial load on the rotating element.
Small, low flow pumps have relatively small radial loads.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 6
Sulzer Pumps
Dual Volute Casing
Volute vs. Diffuser
FR~ 0
A dual volute casing has an additional passageway 180º from the main throat area which will almost balance the generated radial force.
Horizontally split, dual Volute Multistage Pumps have 1 throat are in the top half, 1 in the bottom half - to balance radial forces.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 7
Sulzer PumpsMultiStage Dual (MSD) Volute
Volute throat in top half of casing.
Bottom Half Casing
Top Half Casing
Volute throat in bottom half is on opposite side for radial force balance.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 8
Sulzer PumpsVolute vs. Diffuser
Diffuser Casing
FR= 0
A diffuser has multiple discharge passageways with equal area distributed throughout the circumference -resulting in radial load balance.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 9
Sulzer PumpsDiffusers
Diffuser – Discharge Side
Impeller runs in center
Stage casings
Diffuser – Suction Side
Return Channels feed next stage
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 10
Sulzer Pumps
Opposed Impeller Design
X X
Fr xst
Pd xst Pd xstPd 1stPd 1st
Fr 1st
X X
Unbalanced pressure distribution on impellers results in a thrust in the direction of suction.
Fr Total = 0
Opposed impeller design offsets the unbalanced pressure distribution (thrust) effectively balancing axial thrust. When there are odd number of stages, thrust is handled by adjusting the diameter of the throttle bushing with residual handled by a thrust bearing.
Axial Thrust Development
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 11
Sulzer Pumps
Inline Rotor Stack
FDrum ~ 85% Fr TotalFr Total = Fr 1st+Fr xst
Stacked impeller design results in adding thrust in the direction of suction.
Fr 1st
X X X X
Fr xst
Unbalanced pressure distribution on impellers results in thrust in the direction of suction.
Ps
FDrum
Developed thrust must be compensated by a hydraulic balancing device. Residual thrust is handled by a thrust bearing.
Pd xst
Pd 1stPd 1st Pd xst
Axial Thrust Development
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 12
Sulzer Pumps
Balances 85 - 90% of generated thrust. Residual thrust handled by a thrust bearing.
With inline rotor stack, this is most reliable design for transient conditions (start up and run down, temperature changes, daily starts and stops).
Easy and safe axial rotor setting due to radial gap as compared to axial gap (explained on next slide).
Rotor is fixed in the axially position by thrust bearing.
Higher amount of leakage - less efficient.
Axial Thrust CompensationBalance Drum
PSuction PDischarge
Close clearance pressure breakdown
Balance Drum Balance Drum Liner
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 13
Sulzer Pumps
Balances 100% of the generated thrust.
No thrust bearing required.
Rotor floats axially for proper operation.
Least amount of leakage - higher efficiency.
Disc lift off device required for frequent starts and stops
ISO 13709 (API 610) Para. 5.7.1 requires radial running clearance be used for axial thrust balance. That precludes the use of this device.
Potential for contact causes this design to be considered less forgiving than balancing drum
Axial Thrust Compensation balance disk - Not allowed by ISO 13709 (API 610)
PSuction PDischarge
Balance DiskCounter Disk
Axial gap will adjust in response to thrust changes
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 14
Sulzer PumpsInline Impellers vs. Opposed Impellers
Note: All are ISO 13709 (API 610) type BB5
Sulzer GSG:
Inline diffuser Barrel Pump
Sulzer CP:
Opposed Impeller Volute Barrel Pump
GSG Back-to-Back diffuser Barrel Pump
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 15
Sulzer PumpsInline vs. Opposed Rotor Stack
Direct drive, inline diffuser barrel pumps are the least expensive barrel pumps to build.
High Speed inline pumps require tilting pad thrust bearings and lube system, high speed seals, VFD or gear speed increaser, etc. which add to the cost.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 16
Sulzer Pumps
ISO 13709 (API 610) requires stable rotordynamics with 2 times normal ISO 13709 (API 610) specified wear ring clearances.
Inline vs. Opposed Rotor Stack
Back to back diffuser stack is often used on smaller pumps or high energy pumps with many stages where rotordynamics require a midspan bearing. The Sulzer Thunderhorse 650 Bar, 13MW injectionpumps are designed in this manner.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 17
Sulzer PumpsThe “K” factor – large barrel pumps
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Inline 3.38 Inline 4.25 B-B 3.380
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“K factor”
• Rotor Wt. in lbs.
• Shaft Span, in.
• Shaft Dia. in.
K=(W*L^3/D^4)^0.5
Lower “K” factor is generally better. It can be achieved either with fewer stages & large high speed shaft on inline rotor, or back-to-back rotor and direct drive
Back to Back GSG, HPCP or CP
Type / shaft size, inches
Some say K factor of </= 1200 is good; “Semi-stiff shaft” is another term they use
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 18
Sulzer Pumps
For small pumps with many stages, the rotor will rest on center bushing. When the pump starts, Lomakin effect lifts rotor for non-contact running.
Non-galling material selection is important. Sulzer uses a stellite coated, or nitrided throttle bushing and center bushing on opposed impeller pumps.
Rotor Sag
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 19
Sulzer PumpsInline vs. Opposed Rotor Stack
Back to Back (Opposed impeller) diffuser or volute design is also used in remote locations where customers prefer not to have a lube system to maintain. Opposed impellers balance axial thrust and may allow use of an antifriction thrust bearing.
Back to Back (Opposed impeller) volute multistage barrel pumps are used in abrasive services where 2large throat diameters are preferred in lieu of many smaller diffuser throats. The inner volute casing is larger in diameter than diffusers so volute style barrel pumps often cost more than diffuser style
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 20
Sulzer PumpsDirect Drive vs. High SpeedFlow of a centrifugal pump varies directly with RPM. Head produced by a stage varies as the square of the RPM.
In other words, to make the same head, operating a smaller pump 42% faster would make the same head with half the number of stages.
However, some customers prefer direct drive 2 pole pumps for reliability and reduced items to maintain. Direct drive pumps often do not require these costly accessories:
- lube system & sleeve/pivot shoe bearings
- more extensive instrumentation
- gear increaser
- special mechanical seals
High Speed, VFD or Gear; fewer stages
Low Speed, Direct Drive; more stages
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 21
Sulzer PumpsCartridge vs Non-cartridge designs
A “Cartridge” design barrel pump allows the inboard bearing housing and seal chamber to be withdrawn from the barrel with the bundle.
On small pump sizes this is impractical because the IB bearing housing is larger than the barrel opening on the IB end.
On smaller pumps, a “Non-Cartridge”design barrel pump requires the inboard bearing housing and seal chamber to be removed before withdrawal of the bundle from the outboard end. That adds a little time to disassembly/reassembly but parts are relatively small and can often be handled by hand
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 22
Sulzer PumpsHigh Temperature – Thermal Expansion
To accommodate axial growth due to high temperature operation the suction end of the barrel is equipped with a pin which fixes the Drive End of the pump.
The discharge end is equipped with a key slot which will allows the barrel to expand in the direction of the NDE end. The barrel to pedestal bolts are torqued to a specific value to accommodate the axial growth.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 23
Sulzer PumpsBarrel Head Closure Methods
Studs & Nuts – Most common – requires stretching or torquingSupernuts – more expensive, no stretching; hand tool torquingorSulzer’s Patented Twist LockOn lower temperature services, to speed overhaul, some customers preferSulzer’s patented Twist Lock barrel end cover design – no studs/nuts and notorquing required.
Head Installed Head partially rotated
Head Rotated & Locked
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 24
Sulzer Pumps
GSG: SMALLER SIZES 50 Hz, 2 pole motor speed
Gray or white are inline rotor
Light blue are only available in back-to-back rotor
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 25
Sulzer Pumps
GSG: LARGER SIZES 50 Hz, 2 pole motor speed
Gray or white are inline rotor
Light blue are only available in back-to-back rotor
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 26
Sulzer Pumps
GSG: SMALLER SIZES 60 Hz, 2 pole motor speed
Gray or white are inline rotor
Light blue are only available in back-to-back rotor
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 27
Sulzer Pumps
GSG: LARGER SIZES 60 Hz, 2 pole motor speed
Gray or white are inline rotor
Light blue are only available in back-to-back rotor
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 28
Sulzer PumpsHydraulics
Double suction first stage available on larger sizes
A double suction impeller reduces the NPSHr by about 30%
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 29
Sulzer Pumps
Hydraulic layoutMultiple hydraulic impeller & diffuser sets per pump sizeMixing of impeller / diffuser hydraulics in single pump is possibleDouble suction first stage is available in larger size pumpsDynamic balanced impellers & rotor > 3 stagesRadial load is balanced
Impellers and Diffusers
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 30
Sulzer Pumps
Pumped Medium : Boiler Feed Water Speed : 3570 rpm MD 100-300 / 8 Density : 909.2 kg/m³ Stage Number : 8 Temperature : 318 °F nq : 20.0 kinem. Viscosity : 0.19 mm²/s Impeller Set : B / B / B Tender : /1Head (design) : 4,600 ft Basis 4335.11.11/2 & 4335.11.11/2 Characteristic : TS/1Capacity (design) : 900 gpm & 4335.11.11/2 Impeller diameter : 11.1 inchTotal efficiency : 75.8 % Extraction head : 1,268 ft Impeller dia. (max) : 11.8 inchPump Power : 1,350 HP Extraction capacity : 250 gpm NPSHR : 19 ft
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H [
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Mixing of Impeller Hydraulics with Interstage Bleed Off
By mixing impeller hydraulics efficiency and power can be optimized
Note the all “B”impeller hydraulics
Note efficiency = 75.8% and power is 1,350 hp
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 31
Sulzer Pumps
Pumped Medium : Boiler Feed Water Speed : 3570 rpm MD 100-300 / 9 Density : 909.2 kg/m³ Stage Number : 9 Temperature : 318 °F nq : 20.0 kinem. Viscosity : 0.19 mm²/s Impeller Set : B / B / S Tender : /1Head (design) : 4,600 ft Basis 4335.11.11/2 & 4335.11.11/2 Characteristic : TS/1Capacity (design) : 900 gpm & 4335.11.21/1 Impeller diameter : 10.9 inchTotal efficiency : 78.7 % Extraction head : 1,268 ft Impeller dia. (max) : 11.0 inchPump Power : 1,301 HP Extraction capacity : 250 gpm NPSHR : 19 ft
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H [
ft ] By mixing impeller
hydraulics efficiency and power can be optimized
Efficiency now = 78.7% and power is 1,301 hp (49 hp reduction)
Now the “B” hydraulics have been replaced with “S” after the interstage bleed off.
Mixing of Impeller Hydraulics with Interstage Bleed Off
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 32
Sulzer Pumps
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Pump Flow - % of BEP
Pow
er @
BEP
- H
P (3
600
rpm
)Bearing Type Selection
Anti-Friction Thrust & Sleeve Radial – Ring Oil Lube
Pivot Shoe Thrust & Sleeve Radial – Lube System required
Anti-Friction Thrust & Radial –Ring Oil Lubrication
Exact bearing system will depend upon application
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 33
Sulzer PumpsAnti-Friction with Ring Oil Lubrication
Ring Oil Lubrication – Oil rings rotate with shaft, dip down into an oil reservoir and “throw” oil onto bearings. Grooves or channels are located in the bearing housing to distribute oil throughout the bearing(s). Shaft mounted cooling fans provide cooling up to a liquid temperature of 177o C (350° F).
Oil RingsOil Reservoir
Thrust Bearing Radial Bearing
Cooling Fan
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 34
Sulzer Pumps
Anti-Friction Thrust & Sleeve Radial Bearingswith Ring Oil Lubrication (GSG Back-to-Back only)
Ring Oil Lubrication – Oil rings rotate with shaft, dip down into an oil reservoir and “throw”oil onto bearings. Grooves or channels are located in the bearing housing to distribute oil throughout the bearing(s). Shaft mounted cooling fans provide cooling up to a liquid temperature of 177o C (350° F). Optional water cooled finned tubing is available.
Oil RingsOil Reservoir
Thrust BearingRadial Bearings
Cooling Fan
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 35
Sulzer Pumps
Double Acting Tilting Pad Thrust & Sleeve Radial Bearings with Force Feed Oil Lubrication
Forced Feed Lubrication – Bearing lubrication is provided by an external lube oil system. Depending on specification requirements lube oil systems can be very basic or very elaborate. Standard lube system could cost < 20,000 Euro/USD. ISO 13709 (API 610) Lube system is typically 40,000 Euro/USD. ISO 10438 (API 614) could be 3 to 4 times that cost. If customers specify lube systems, they often specify bearing RTD’s and vibration measurement instrumentation which adds further cost.
Double Acting, Tilting Pad Thrust Bearing Sleeve Radial Bearings
Shaft Driven Oil Pump
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 36
Sulzer PumpsJournal and Thrust Bearing Arrangement
Sleeve Bearings
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 37
Sulzer Pumps
Thrust Bearing Lubrication
Tilting Pad Thrust Bearing Arrangement
An “oil wedge” builds up between each stationary thrust pad and the rotating collar, and no metal-to-metal contact occurs during normal operation.
The babbit lining of the pads is designed to be tolerant of any minute particles of grit that may get through.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 38
Sulzer Pumps
Double Acting “Pivot Shoe” or “Tilting Pad” Thrust Bearing
Journal and Thrust Bearing Arrangement
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 39
Sulzer PumpsForced Feed Lube Oil Systems
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 40
Sulzer PumpsSeal Chambers & Jackets
Seal Chambers are designed to ISO 13709 (API 610) Table 6 dimensions and features.
ISO 21049 (API 682) single, double or tandem seals are available
Seal Chamber cooling or heating jackets are available on this model pump.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 41
Sulzer Pumps
Q/DFIFO
TI
Seal Flush Plans
A variety of seal flush plans are available
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 42
Sulzer Pumps
NDE Bearing temperature
DE Bearing temperature
NDE X-Y Shaft vibration DE Shaft vibrationBalance Leakoff flow
Instrumentation - options
Barrel Temperature, Bottom & Top (for hot standby)
In lieu of more expensive X-Y probes & proximitors, normally bearing bracket velocity is adequate for direct drive pumps
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 43
Sulzer Pumps
With anti-friction bearings the shaft is firmly connected to the bearing frame via the bearings.
Any vibration of the rotating element will be transferred from the shaft to the bearings to the bearing housings and there will not be any relative movement of the shaft to the bearing housings.
Vibration is measured by the relative RMS velocity or acceleration of the bearing frame - by either velomitors or accelerometers.
Firm contact from shaft to bearing frame
Velomitors
Vibration Instrumentation
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 44
Sulzer Pumps
With sleeve bearings, the shaft “floats” on a film of oil and is free to move within the clearance of the sleeve bearings.
This allows the rotating element to vibrate within the sleeve bearings while the actual bearing frame may not vibrate at all.
Vibration is the relative movement of the shaft within the bearing frame. Probes are mounted with very close proximity to the shaft (Bently Nevada type systems) to detect displacement movement.
Probes and Proximitors
Film contact from shaft to bearing frame
Vibration Instrumentation
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 45
Sulzer Pumps
AISI 4140AISI 4140AISI 4140AISI 4140Case and Gland Studs
12% Chrome Hardened
12% Chrome Hardened
12% Chrome HardenedCast IronInterstage Bushings
12% Chrome Hardened
12% Chrome Hardened
12% Chrome HardenedCast IronInterstage Sleeves
12% Chrome Hardened
12% Chrome Hardened
12% Chrome HardenedCast IronThroat Bushings
12% ChromeAISI 4140AISI 4140Carbon SteelShaft
12% Chrome Hardened
12% Chrome Hardened
12% Chrome HardenedCast IronImpeller Wear Rings
12% Chrome Hardened
12% Chrome Hardened
12% Chrome HardenedCast IronCase Wear Rings
12% Chrome12% ChromeCarbon SteelCast IronImpeller
12% Chrome12% ChromeCarbon SteelCast IronInner Case
12% ChromeCarbon SteelCarbon SteelCarbon SteelPressure Casing
12% Chrome/ 12% ChromeCS/12% ChromeCS/CSCS/Cast Iron
C-6S-6S-5S-1
Material classes and abbreviations
Part
API Material Classes
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 46
Sulzer Pumps
AISI 4140AISI 4140AISI 4140Case and Gland Studs
S.D.Duplex316L SS HFInterstage Bushings
S.D.Duplex316L SSInterstage Sleeves
S.D.Duplex316L SS HFThroat Bushings
S.D.DuplexDuplex SSShaft
S.D.Duplex316l SS HFImpeller Wear Rings
S.D.DuplexDuplex SSCase Wear Rings
S.D.Duplex316L SSImpeller
S.D.Duplex316L SSInner Case
S.D.Duplex316L SSPressure Casing
Super DuplexDuplex SS316SS/316SS
D-2D-1A-8
Material classes – cont’d.
Part
API Material Classes
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 47
Sulzer Pumps
Pre-warming of this style pump is required. Maximum ramp-up temperature is 10º C (20ºF) per minute and 110ºC (200 ºF) instantaneous thermal shock
On Horizontally split multistage pumps, the casing is not uniformly thick. It has very heavy cross sections that take time to reach operating temperature.
The rotor & lower half casing gets hot and expands quickly.
Pre-Warming
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 48
Sulzer Pumps
The Sulzer GSG Pumps are designed with uniform thicknesses and clearances on the inner case components to minimize distortion. Warmup is not required on many applications < 260oC (500oF).
Above that temperature, the barrel drains can be used to uniformly warm the pump, or maintain hot standby.
Pre-Warming
Barrel RTD’s can provide indication of uniform temperatures.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 49
Sulzer Pumps
Thrust bearing - anti-friction or double acting tilting pad.
Radial bearing - sleeve or anti-friction.
Radial split identical stage casings, diffusers and impellers
Interstage bleed connections available
Low NPSH 1st stage impeller. Double suction available.
Radial Split barrel casing with confined gasket. Either casting or forging available.Stacked rotor design with
staggered keyways to provide positive torque to impellers
Hydraulic balance device is Drum type
GSG Cross Section and Features
Bearings protected by Labyrinth type oil seals
Studs & Nuts, Super-nuts or Twist Lock barrel closure on Back-to-Back only
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 50
Sulzer PumpsPictures
GSG Boiler Feed pump with speed increasing gearbox, lube system,suction strainer and automatic recirculation control valve
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 51
Sulzer PumpsPictures
GSG portion of hydrotreater train (GSG pump, clutch, MSD-T power recovery turbine) with full instrumentation and insulation.
Sleeve bearing RTD, Active Thrust RTD, Inactive thrust RTD, X-Y vibration probes, Key phasor.
GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 52
Sulzer PumpsPictures
10 stage GSG on 0.4 Sp.Gr. cold Ethylene
VFD driven at > 4,000 RPM with fan cooled antifriction bearings