reciprocating pump presentation

7/23/2019 Reciprocating Pump Presentation

http://slidepdf.com/reader/full/reciprocating-pump-presentation 1/86

One company … unlimited solutions

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RECIPROCATING PUMP TRAINING




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Agenda

Introduction

Characteristics of Multiplex Pumps

NOI Multiplex Pump Product Line and Nomenclature

Applications- Oilfield, Mining & Industrial

Selection Criteria Of Multiplex Pumps

Multiplex Pumps Accessories Design and Fabrication of Pump Packages

Reciprocation Pumps versus Multistage Centrifugals




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What is a Reciprocating Pump

A reciprocating pump is positive displacementmechanism where the liquid discharge pressure is

limited only by the strength of structural parts. The

liquid volume capacity is delivered regardless of

pressure and varied only by driver speed or

plunger/piston size changes




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Characteristics of Multiplex Pumps

Positive Liquid Displacement

High Volumetric Efficiency

High Mechanical Efficiency

High Pressures Obtainable

Low Pump Maintenance Cost

Higher Capital Cost




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Volumetric Efficiency

Volumetric Efficiency is the ratio of the actual

displacement of liquid to the calculated theoretical

(100%VE) displacement based on pump speed, stroke

and plunger/piston diameter on a percentage basis

95% is typically used for multiplex pumps

(API-674 maximum)




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Mechanical Efficiency

Mechanical Efficiency of a pump is thepercentage of input power (kW) or energy

imparted to the liquid being pumped.

Single Acting Pumps 90%

Double Acting Pumps 85%




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National-Oilwell Pump History

1874 Wilson Snyder Pumps Founded

1912 Steam Duplex Piston Pump1927 Steam Triplex Plunger Pump1944 “O” Series Triplex Power Plunger Pumps

1950 “O” Series Quintuplex Power Plunger Pumps

1956 Invented First Slurry Diaphragm Pump1959 Triplex Pumps Over 500 Hp1959 (4) “J” Series Pumps Introduced

1962 All “J” Pumps Hp Upgraded By 20%1967 Savage River Iron Ore Pipeline1972 Black Mesa Coal Pipeline

1984 “J” Series Included 14 Input Hp1976 “O” Series Expanded To 83 Models

1985 Electro-hydraulic Diaphragm Pumps1987 National Supply and Oilwell Supply merged.

1989 TRW Mission purchased

2001 Wheatley Gaso purchased

2003 Mono-Pumps purchased




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Continuous Duty “Simplex / Duplex / Quintuplex” Plunger

Pumps National “J” Series

Oilwell

Wheatley

Gaso

Continuous Duty Double Acting Duplex Piston Pumps

Gaso

Oilwell

Emsco

Intermittent Duty Well Service Plunger / Piston Pumps National “JWS” Series

Oilwell “SA” Series

Omega

Gaso

NOI Pump Trade Names




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SIMPLEX

DUPLEX

DOUBLE

ACTING

QUINTUPLEX

TRIPLEX

Multiplex Pumps




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W 2250

Intermittent Duty & Continuous Duty 185 to 2250 Horsepower Ranges

Plunger and Liner Pumps available

High Pressure Pumping




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NATIONAL-OILWELL PUMP NOMENCLATURE

100 T P – 4 L

Rated Input

Horsepower

Pump Type

“S” - Simplex

“D” - Duplex

“T” - Triplex

“Q” - Quintuplex

Fluid End Pressure Rating

“XL”- Extra Low Pressure

“L” - Low Pressure

“LS” - Low Special Pressure

“M” - Medium Pressure

“MS” - Medium Special Pressure

“H” - High Pressure

Nominal Stroke Length [in]

Internal Pinion




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Horizontal Boring of Power Frame




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Assembly of Small Pumps




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Assembly of Mid Sized Pump




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Test Stand




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Skid Base




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Package Assembly




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Typical Industries / Applications

Oilfield

Mining

Industrial




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Typical Oilfield Applications

Waterflood ServiceSalt Water Disposal

Enhance Oil Recovery

Condensate & Crude Oil TransportationClosed Drain

Amine / Glycol Treatment

Well Servicing

Work-Over




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29T-3M Condensate Pumps




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Model 2652 Duplex Piston Pump




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APACHE 160TP-6M




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Specialty Applications

Low NPSH

High Temperature

API 674




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Reverse OsmosisReverse Osmosis

Water BlastWater Blast

RefineryRefinery

Crude Oil PipelineCrude Oil Pipeline

Chemical InjectionChemical Injection

CO2CO2

Water cuttingWater cutting

Car washCar washSteelSteel

De-bark Timber De-bark Timber

INDUSTRIAL




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Horizontal Drilling Rig




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Reverse Osmosis Installation




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GASO 2562 Refinery Service




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Fluid End Expendables (for most pump lines)

Fluid End Valves including:

Ball and Seat

Disc type

Bottom Guided type

Spherical type (patented design)

Plungers (threaded or clamp type):

Tungsten Carbide (Colmonoy 88)

Premium Tungsten Carbide (Colmonoy 730)Ceramic

HardCoat type

Fluid King Expendables

Fl id Ki E d bl




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Precision machining and

manufacturing facilities allow

National Oilwell to produce aversatile offering of high quality

plunger pump fluid end

expendables for all major

pump manufactures.

Fluid King Expendables




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General service valve

Abrasion resistant valve

Plate Type Valves




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Provide positive sealing

surface

Reduces valve and seat

wear Severe duty valves

available with replaceable

sealing element

Improved NPSH pressurerequirements

Cage Style Spherical Valves




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Spherical Valves - Features Spherical Surfaces - Reliable sealing

More bearing area

Less Weight - Easier to handle Full Open Bore - Low pressure loss

Better flow characteristics

Better volumetric efficiency

Reduced NPSHR

Eliminates cavitation

Quick Twist Lock Spring Retainer - Easy installation and maintenance

No threads to corrode and fuse

NACE Compliance - Broadens applications (even withH

2S)

Severe Duty Valve Insert Lip - Positive sealing eliminates internal

leakage Snap-On Insert - Quick material change and

replacement

Wave Ring - Protects valve integrity




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Provide positive sealing

surface

Reduces valve and seat

wear Severe duty valves

available with replaceable

sealing element

Improved NPSH pressurerequirements

Spherical Valve




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Superior Surface Finish

Spray Metal Plungers Precision Ground

Ceramic Plungers

Clamped and

Threaded IntermediateRods

Wide Variety of Packing

Styles

Complete Offering of

Stuffing Box Brass and

Gaskets

Plungers and Packing




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Fluid End Expendable Test Area




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Pump Accessories

Suction Dampeners

Discharge Dampeners

Relief valves set at 110 to 125% of pump

discharge pressure




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Dampener Manufacturers

Blacoh Fluid Control, Inc.CoorsTek (Pulsation Engineers, Larkin, UltraMax)CoorsTek (Nixco)Fluid KineticsHydacHydril Company LP (White Rock Eng PASAFE™)

Performance Pulsations IncPulseGuard Ltd & Inc (Liquid Dynamics)Pump Mates

Status FlowYoung Engineering (Greer Hydraulics Style)




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Incorrect Dampener Setup




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Retrofit Dampeners




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HYDRIL DAMPENERS

National-Oilwell Mission Products

currently has standardized on Hydril

Dampeners for majority of applications

Hydril Selection Program is simple and

provides documentation of selection

Hydril purchased White Rock Eng

PASAFE™dampeners

Multiplex Pump Unitizations Experience




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Multiplex Pump Unitizations-Experience

Complete Packaged Units pre-assembled and tested

ready for Installation at a customers site

Hazardous Area / Non Hazardous Area Classifications

Drivers Electric Motor

Variable Voltage Variable Frequency Drives (VVVF’s)

Diesel Engine

Gas Engine

Hydraulic Motors

Multiplex Pump Unitizations Experience




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Multiplex Pump Unitizations-Experience

Transmission Systems

Belt Drive Gear Reducer Driven

Manual Transmission

Hydraulic Coupling

Control Systems PLC

Local / Remote Designed Systems

Accessories Suction and Discharge Pulsation Dampeners

Maintenance Free Nitrogen Pre-charged Units

Pressure Relief Valves

Isolation Valves

Mission Centrifugal Charging Pumps




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Multiplex Pump Unitization




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Highly engineered custom

multiplex unitization services

Leading manufacturer of

multiplex pumps

Wide performance range

offering

Multiplex Pump Unitization

Critical Factors in Pump Sizing




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Volume

– HP, Capacity DeterminationPressure

– HP Determination, Component Ratings

Pump Speed

– In relation to proper operation, pump andexpendable life

Type of Duty – Continuous duty = 8-24 hrs. day fully

loaded – Intermittent Duty = (Well Service) Not

more than 4 hrs. in a 24 hour period

Critical Factors in Pump Sizing

Critical Factors in Pump Sizing Cont




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Fluid Volume – To determine the correct pump, a key component is

the amount of fluid to be pumped.

– The pump catalog lists flows at 100% volumetric

efficiency and 90% mechanical efficiency.

– Due to pump design and API 674 a 95% volumetric

efficiency is used for most applications.

– The amount of fluid is a critical component of the

horsepower calculation

Hydraulic Horsepower = Flow (gpm)X Pressure

1714

kW = L/sec x MPa

Critical Factors in Pump Sizing Cont.





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Pressure Discharge Pressure

– The positive displacement aspect of the plunger

pump will allow it to pump fluid regardless of the

downstream pressure resistance. The ratings of the

of piping and other components should be beequivalent or greater than the pump ratings.

– Pressure is the another main component in

determining the horsepower required to move a

specific amount fluid.

Hydraulic Horsepower = Flow(gpm) X Pressure(psi)1714

kW = L/sec x MPa






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Pressure

– To determine input horsepower: – Input Horsepower = Hydraulic Horsepower

90%

Rod Load

– Reciprocating pump ratings include the determination of the rod or plunger load. This loading is the force placed

on the end of the plunger and transmitted to the power

end components.

– Rod load = Discharge Pressure (psi) X Plunger Area (in2)

Example: 2500 psi X 2-3/8” or 4.4301(in2) = 11,075 psi






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Fluid Type And Composition – Pump component material selection

– Effect on expendable products

Temperature – Effect on Vapor Pressure, Pump

– Components/Expendables






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Fluid Type And Composition

Standard fluid end and stuffing box material isnickel aluminum bronze.

– Forged steel fluid ends are available for crude oil

services or services where the melting point of the

material is a concern. This material is also standard

for the National-Oilwell “Well Service” fluid ends. – Cast Ductile iron material.

– 316 stainless steel material is for fluids containing

corrosive agents. 316 stainless steel can be used for

fluids containing small amounts of chloride.

– Higher grades of stainless steels are becoming more

popular. Duplex stainless steels are suitable for

corrosive fluids containing high concentrations of

chloride.






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SEAL AND PACKINGMATERIAL

SEALS AND PACKING

– There many types of elastomers and packing stylesused in

plunger pump applications.

– UTEX 838, 843 & 858

– Garlock Kevlar

– Spring Loaded, Non Adjustable

– Leak Detection design






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Temperature

– Fluid temperature is important to keep in mind whenselecting a pump due to the effect high or low

temperatures have on various components of the

pump such as seals and packing.

– Fluid temperature can also be a factor when

determining the vapor pressure in NPSH

calculations. As temperature increases the vapor

pressure increases. This means more pressure must

be applied above the vapor pressure to keep the

fluid from becoming a vapor or flashing.






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NPSH

– What is NPSH? – NPSHR for National-Oilwell pumps

– Available head

– Accelerated head loss

– Vapor Pressure

– Suction Dampener effect on NPSHA

Suction System Design for proper operation

High Suction pressure conditions

Solids Content Effect on Expendables

– Minimizing






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Pump speed Pumps should be sized to offer maximum

competitiveness BUT consider….

– Wear on pump components and expendables

– Flexibility to meet changing operating conditions.

– NPSHR to allows for optimal filling of pump suction. – Pump should run slower with fluids having high

viscosity's.

– Speed in conjunction with API 674 requirements.

.






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Pumping Requirements

What type of fluid? How much? Discharge Pressure?What are the suction conditions? NPSHA?

– Calculate

• Hydraulic Horsepower

• Input Horsepower

Find the right pump

– Locate the pump closest to the calculated HP

– Determine

• Plunger size

• RPM

• RPM Vs. pump Max. RPM

• Iterate to best solution


Production Solutions




COMPARASION

Reciprocating Pumps

Versus

Multistage Centrifugal Pumps

Introduction




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Introduction

Operating Principles

Energy Consumption

Efficiency

System ParametersOperation and Maintenance issues

1 Operating Principals




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1. Operating Principals

Centrifugal Pumps

A. Fast rotating

B. Convert kinetic energy to pressure head.

C. Direct coupled driver

Typical Centrifugal Pump




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Typical Centrifugal Pump

Multi Stage Centrifugal




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Multi-Stage Centrifugal

1 Operating Principles




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1. Operating Principles

Reciprocating Pumps Linear movement

Exert force to overcome system resistance

(pressure)

Speed reduction needed

Reciprocating Plunger Pump




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Reciprocating Plunger Pump

2 Efficiency




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2. Efficiency

Centrifugal Pumps

Efficiency loss: hydraulic, volumetric, and mechanical.

Normal operating efficiency 30-60%, best efficiency point

<80%.

Goulds Pumps, ITT Industries - the actual average pump is

operated below 40% efficiency from a 17th Dec 2004 article for

World Pumps .

Efficiency Decreases over time with wear

Efficiency varies as flow rate or system head changes.

Typical Curve Centrifugal Pump




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Efficiency




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Efficiency

Reciprocating Pumps

Efficiency loss: Volumetric and Mechanical.

Nominal efficiency used for Power Consumption : 90%

Constant Mechanical Efficiency

Mechanical Efficiency Test Data




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Mechanical Efficiency Test Data

NATIONAL OILWELL 12-P-160

PISTON ROD LOAD vs MECHANICAL EFFICIENCY - 100 SPM

82

84

86

88

90

92

94

96

98

100

0 20000 40000 60000 80000 100000 120000 140000

PISTON ROD LOAD (LBS)

M E C H A N I C A L E F F

I C I E N C Y (

Prepared 11-10-99

Typical Multiplex Pump Curve




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Typical Multiplex Pump Curve

3 Effects of Viscosity




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3. Effects of Viscosity

Centrifugal Pumps

High viscosity decreases head and flow rate.

High viscosity reduces efficiency further and

increases power requirement.

Effects Of Viscosity




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Effects Of Viscosity





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Reciprocating Pumps

High viscosity has little effect on pressure and flow rate.

High viscosity has little effect on efficiency.

Comparison CP versus PD




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Comparison CP versus PD

4. Energy Consumption




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4. Energy Consumption

Mechanical

Efficiency

Discharge

Flow

[BPD]

Discharge

Pressure

[psi]

Pump

Annual

Utilisation

Power Consumed

[kW]

Plunger Pump 90.0% 30000 1015 90.0% 518

Centrifugal Pump 65.0% 30000 1015 90.0% 718

Additional Power Requirement 199.34 kW

Power Cost $0.04 kW/hr

Additional Electrical Energy Cost $69,847.06 per year





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5. Performance At Constant Speed




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Centrifugal Pumps

A. Head drops as flow rate increases.

B. Loss of flow rate if system head higher than design point.

C. Needs a regulator valve and consumes more energy than

needed if system head lower than design point.

D. Needs a regulator valve and consumes more energy than

needed if design point has a safety margin on head and flowrate.





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Reciprocating Pump Constant flow rate even if pressure increases.

Constant flow rate if system is head higher than design point.

Constant flow rate and consumes less energy if system headlower than design point.

Needs a bypass valve and consumes less energy if design point

has a safety margin on head and flow rate.

7. Pump Characteristics




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7. Pump Characteristics

Centrifugal Pumps

Steady Flow

Reciprocating Pumps Flow variation

Pulsation suppression device is needed in suction/discharge to avoid

excessive vibration on piping.

7. Maintenance




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7. Maintenance

Centrifugal Pumps Bearing and packing field repairable.

Not suited for fluids with solid contents.

Shop repair needed if pump fails.

7. Maintenance




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7. Maintenance

Reciprocating Pumps

A. Field repairable.

B. Available expendable components for handling solid

contents.

Energy Costs Over Time




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Operating Cost Comparison

Qunituplex Plunger vs Multi-Stage Centrifugal Pump

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Year

C o s t : P a r t s & M

a i n t e n a n c e

$0

$1,000,000

$2,000,000

$3,000,000

$4,000,000

$5,000,000

$6,000,000

$7,000,000

$8,000,000

$9,000,000

$10,000,000

C u m u l a

t i v e C o s t s

625Q- Parts Cost

625Q- Labour. Cost

HPP4-80.- Parts Cost

HPP4-80.- Labor Cost

625Q- Cumulative Costs

Multi-Stage.- Cumulative Costs

Energy Costs Over Time

Comparative Summary




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Comparative SummaryReciprocating Pump vs. Multi-Stage Centrifugals

Centrifugal Pump Reciprocating Pump

1. OperatingPrinciples a. fast rotating

b. convert kinetic energy to pressure head.

c. direct coupled driver

a. linear movement

b. exert force to overcome systemresistance (pressure).

c. speed reduction needed

2. Efficiency a. efficiency loss: hydraulic, volumetric, andmechanical.

b. normal efficiency 30-60%, best efficiencypoint <80%.

c. efficiency changes as flow rate or headchanges.

a. efficiency loss: volumetric andmechanical.

b. normal efficiency 90%

c. efficiency keeps constant

3. Effect of Viscosity

a. high viscosity drops head and flow rate.

b. high viscosity reduces efficiency further and increases power requirement.

a. high viscosity has little effect onpressure and flow rate.

b. High viscosity has little effect on

efficiency.

4. EnergyConsumption

1.40-1.90 of reciprocating pump, up to a max. of 2-3 times if operated below 30%-40% efficiency.

Comparative Summary



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C p S y

reciprocating pump presentation

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