OBJECTIVE

Indian Oil Corporation is the leading company in the field of Oil, Petroleum distribution in

the country. My objective for getting internship at Indian Oil Corporation is to study in

details the functioning of the company and the processes involved in supply distribution

of the Oil & Petroleum products by the company. It is worth mentioning here that

pumps are the very important and integral part any production and distribution system

involved in the field of oil industries. The main objective of the study is to understand

the selection process that is followed by IOCL for various purchases.

In 1st part of the report we shall study various types of pumps that are used in India

and further study in depth the centrifugal pumps which are generally used in oil

industries. Indian Oil Corporation Limited uses centrifugal pump for various processes

like pumping crude oil from offshore tankers to the port, pumping crude oil to oil

segregation plants , pumping final product to various location all over the country .

As we move further in the report we shall discuss the main characteristics that are

considered while selection of pumps. To understand the main characteristics we need

to know the working of centrifugal pumps and the physical aspects that it changes

(pressure , velocity , head). The main characteristics are used to plot various graphs

which help us in selection pumps while keeping our costs low and efficiency high . the

final selection is done via pump data sheet which is available in API-610 .

CHAPTER -1

1.0.0 INTRODUCTION TO IOCL

1.1.0 Indian Oil Corporation (IOCL) is India's largest commercial enterprise, with a sales

turnover of Rs. 4,50,756 crore and profits of Rs. 5,273 crore for the year 2014-15. It is also

the leading Indian corporate in Fortune's prestigious 'Global 500' listing of the world's

largest corporates, ranked at the 96th position for the year 2014. As India's flagship

national oil company, with a 33,000-strong workforce , Indian Oil has been meeting India’s

energy demands for over half a century. With a corporate vision to be 'The Energy of

India' and to become 'A globally admired company,' Indian Oil's business interests

straddle the entire hydrocarbon value-chain – from refining, pipeline transportation and

marketing of petroleum products to exploration & production of crude oil & gas, marketing

of natural gas and petrochemicals, besides forays into alternative energy and globalization

of downstream operations. Having set up subsidiaries in Sri Lanka, Mauritius and the UAE,

the Corporation is simultaneously scouting for new business opportunities in the energy

markets of Asia and Africa. It has also formed about 20 joint ventures with reputed

business partners from India and abroad to pursue diverse business interests.

1.1.2 BUSINESS

Indian Oil is India’s flagship Maharatna national oil company with business interests

straddling the entire hydrocarbon value chain – from refining, pipeline transportation and

marketing of petroleum products to Research & Development, Exploration & Production,

marketing of natural gas and petrochemicals. By venturing into the Renewables and the

Nuclear Energy, the company has grown and evolved itself from a pure petroleum refining

and marketing company to a full-fledged energy company.

Having set up subsidiaries in Sri Lanka, Mauritius and the United Arab Emirates, Indian

Oil is simultaneously scouting for new business opportunities in the energy markets of

Asia and Africa.

Born out of the vision of achieving self-reliance in oil refining and marketing for the nation,

Indian Oil Corporation Ltd. has the proud possession of the world’s oldest running refinery

at Digboi with a luminous legacy of more than 110 years and also the upcoming Paradip

refinery, which when commissioned would be one of the most modern and complex

refineries.

Indian Oil Group (including two refineries of its subsidiary company Chennai Petroleum

Corporation Ltd. (CPCL)) owns and operates 10 of India’s 22 refineries. The group refining

capacity of 65.7 million metric tons per annum (MMTPA) or 1.31 million barrels per day

(mb/d) is the largest among refining companies in India. It accounts for 30.5% share of

national refining capacity. On a stand-alone basis, the company owns and operates eight

refineries with a capacity of 54.2 MMTPA (1.1 mb/d).

Indian Oil Corporation Ltd.. reaches millions of people every day through an unmatched

countrywide massive and ever-expanding infrastructure network to deliver Petroleum

products. The network, comprising over 42,600 touch points as on 30.11.2014, was

strengthened from 41,640 touches. Largest and most extensive network of retail outlets,

numbering 24,403 (including 6,194 Kisan Seva Kendras), 136 depots and 6,376

consumer pumps for the convenience of large consumers, are some of the vital

components of this network, ensuring availability of products and inventory at the doorstep

of customers. The needs of domestic fuel (LPG) are fulfilled through 91 Bottling plants and

7,626 LPG distributors, serving over 86 million customers.

Continuing its thrust on reaching rural masses through Kisan Seva Kendras (KSKs) and

LPG distributorships under Rajiv Gandhi Gramin LPG Vitaran Yojana (RGGLVY), Indian

Oil Corporation Ltd. has continuously extended its reach to the rural India, with 6,194

KSKs and 1,867 RGGLVYs as on 31st November 2014. The KSKs and RGGLVs also

represent a success story for Indian Oil Corporation Ltd. in its efforts towards inclusive

development in the rural hinterlands of India. The facilities at KSKs inter-alia include

availability of seeds, pesticides, fertilizers, provisions, farm equipment, medicines, Nutan

stoves, banking help including rural ATMs, communication etc, and all under one roof.

Indian Oil Corporation Ltd. places significant thrust on knowledge and research based

growth and has a dedicated world class R&D center. The R&D center has 320 active

patents to its credit as on 30th November 2014, of which 173 are active international

patents. In the context of vagaries of the international crude oil prices and changing

domestic pricing regime, Indian Oil Corporation Ltd. R&D is viewed as a key competitive

advantage driver. Investment in proprietary research in lubricants, catalyst, refinery and

pipelines operations, and product offerings are key thrust areas for Indian Oil. Research in

new businesses, especially, petrochemicals and alternative energy is emerging a major

focus area for Indian Oil Corporation Ltd..

Indian Oil Corporation Ltd. has established itself as a key player in petrochemicals with

good market acceptability and occupies the second largest player in the domestic

petrochemical market. Under the umbrella brand PROPEL, it offers a full products slate

covering all the major segments of petrochemicals Viz. Linear Alkyl Benzene (LAB),

Purified Terephthalic Acid (PTA), Paraxylene (PX), Mono Ethylene Glycol (MEG) & other

glycols (DEG & TEG), Butene-1, Butadiene, Polypropylene (PP), Linear Low Density

Polyethylene (LLDPE), High Density Polyethylene (HDPE) etc. Indian Oil has a market

share of 22% in LAB, 16% in Polymers and 16% in Glycols. The company has also taken

a lead in expanding petrochemicals business globally with exports to 21 new countries

during 2013-14 taking the total to 66 countries with Indian Oil’s footprint.

The gas business of the Corporation is intent upon leveraging the sizeable opportunities

being presented by the country’s growing demand for gas. The company also plans to

exploit the increased international gas sourcing opportunities brought on by the

international unconventional gas revolution. The company also operates a unique concept

of supplying LNG to small customers located away from the pipelines through ‘LNG at the

Doorstep’, which has been highly successful. Indian Oil’s 5 MMTPA LNG import terminal

at Ennore will be the first such terminal on the east coast and a gateway for the

corporation to enter southern Indian gas market. This Terminal will be set up through a

Joint Venture Company led by IndianOil. The Corporation is a partner in two joint ventures,

namely, GSPL India Gasnet Ltd. And GSPL India Transco Ltd. with 26% equity

participation for building of Mehsana-Bhatinda & Bhatinda- Jammu-Srinagar gas pipelines

and Mallavaram-Bhopal-Bhilwara-Vijaypur gas pipeline, respectively.

Indian Oil Corporation Ltd. has been making continuous efforts to expand its E&P

portfolio, both in domestic as well as overseas market. Indian Oil Corporation Ltd.

presently has Participating Interest (PI) in 10 domestic and 7 overseas blocks. These

blocks are in different stages of operations. Out of the 10 domestic blocks, Indian Oil

Corporation Ltd. is operator with 100% PI in 2 onshore exploration blocks in Cambay

basin. In the remaining 8 domestic blocks, it holds non-operating participating interest

ranging from 20% to over 43%. Further, Indian Oil Corporation Ltd. holds non-operating

participating interest ranging from 3.5% to 50% in the 7 overseas blocks located in 7

countries namely Libya, Gabon, Nigeria, Yemen, Venezuela, USA and Canada.

Indian Oil Corporation Ltd foray into renewable energy is aimed not only towards

diversification through inclusion of cleaner forms of energy in its portfolio but also for

alleviating energy poverty and improving energy access at the 'base of the pyramid' in

India. In its quest towards a greener world by offering sustainable and environment-

friendly energy options, Indian Oil Corporation Ltd. is geared up to tap alternate energy

sources such as wind, solar, hydrogen and bio-fuels. Indian Oil Corporation Ltd. aims to

reduce the eco-footprints (carbon, water and waste) of its operations by exploiting these

renewable energy resources.

With a view to expanding its cleaner energy portfolio, the company has set up a Joint

Venture with NPCIL, namely, M/s NPCIL – Indian Oil Nuclear Energy Corporation Limited

(NINECL) for 2*700 MW Rajasthan Atomic Power Project 7&8 where Indian Oil has 26%

equity stake.

1.1.3 PIPELINES

Indian Oil Corporation Ltd. operates a network of 11,214 km long crude oil, petroleum

product and gas pipelines with a capacity of 77.258 million metric tons per annum of oil

and 10 million metric standard cubic meter per day of gas. Cross-country pipelines are

globally recognized as the safest, cost-effective, energy-efficient and environment-

friendly mode for transportation of crude oil and petroleum products.

The operational throughput of pipelines was recorded at 74.20 million metric tons during

2013-14. The offshore terminals of Indian Oil at Vadinar, Mundra and Paradip have

handled 218 tankers including 128 VLCCs during the year. The multi-product pipelines

successfully prepared to transport Euro IV grade fuels from refineries to marketing

centers maintaining the high quality standards of products during transportation.

Beginning with the first batch of Euro-IV MS grade quality fuel to National Capital Region

in January, 2010, Euro IV grade quality fuels have been transported through the

pipelines from refinery locations to the major metros for supply of these environment

friendly products to the consumers as per the new emission norms.

Indian Oil Corporation completed and commissioned the 290-km long Chennai-

Bangalore Pipeline to position the petroleum products from Chennai Petroleum

Corporation’s Manali refinery to Bangalore and surrounding areas in a cost-effective

manner. Crude oil feed for the expansion of Panipat refinery to 15 million tons was

arranged through the augmented Mundra-Panipat Pipeline. The augmentation project

was commissioned during the year at a cost of Rs. 165 crore against approved cost of

Rs. 205 crore.

Integrated crude oil handling facilities being provided at Paradip involves setting up of a

second and third Single Point Mooring (SPM) and concomitant subsea pipelines. Crude

oil blending application installed at Mundra has been an attractive solution for refineries

with the ability to blend different crude types to provide a consistent and optimal

feedstock to refinery operations. The online integrated crude oil blender facility is now

being implemented at Vadinar crude oil terminal to enable the maximization of yields of

higher value products.

Implementation of Paradip-Sambalpur-Raipur-Ranchi Pipeline, branch pipeline from

Koyali-Sanganer Pipeline at Viramgam to Kandla will further strengthen the petroleum

product delivery in central and western India in the coming years.

Nearly 14 pipeline projects are under implementation at an approved cost of over Rs.

6,700 Crore. Upon completion, these projects would result in additional length of over

3,600 km and added capacity of 16 MMTPA. These include the 700 km Paradip-Haldia-

Budge Budge-Kalyani-Durgapur LPG Pipeline, 295 km Sanganer-Bijwasan Naphtha

Pipeline, Augmentation of PHBPL and five additional tanks at Paradip, 270 km branch

pipeline from Patna to Motihari and Baitalpur, 120 km Cauvery Basin Refinery to Trichy

Pipeline and 400 km Ennore-Trichy-Pondicherry LPG Pipeline.

CHAPTER 2 2.0.0 CLASSIFICATION OF PUMPS

2.1.0 Classification of the pumps can be done based on different parameters such as

2.1.1 On the basis of Flow Pattern

a) Centrifugal Pumps

b) Reciprocating Pumps

Plunger Pumps

Diaphragm Pumps

Piston Pumps

Radial Piston Pumps

2.1.2 Classification of the basis of Service Liquid

2.1.4 Classification on the basis of Impeller type

2.1.5 Classification on the basis of the Mounting

2.1.6 Classification on the basis of different type of construction

2.1.7 Classification on the basis of different Position of Bearing

2.1.8 Classification on the basis of No. of stages

2.1.9 Classification on the basis of Position of Pump with respect to the Fluid

2.1.10 Classification on the basis of Splitting of casing

2.1.11 Types of centrifugal pump

2.1.12 Types of pumps available in the industry.

2.2.0` Classification on the basis of Flow Pattern

2.2.1 Intermittent-Positive Displacement Pumps.

2.2.2 Continuous-Roto-Dynamic or Turbo Pumps.

2.3.0 The two basic type of pumps are :-

1 Centrifugal pumps

2. Reciprocating pumps

2.3.1 Centrifugal Pumps

Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic

energy to the hydrodynamic energy of the fluid flow. The rotational energy typically

comes from an engine or electric motor. The fluid enters the pump impeller along or near

to the rotating axis and is accelerated by the impeller, flowing radially outward into a

diffuser or volute chamber (casing), from where it exits.

Some properties of centrifugal pumps

1. The discharge is continuous and smooth.

2. It can handle large quantity of fluid.

3. It is used for large discharge through small heads.

4. Runs at high speed.

2.3.2 Reciprocating pumps

A reciprocating pump is a class of positive-displacement pumps which includes the

piston pump, plunger pump and diaphragm pumps . It is often used where a relatively

small quantity of liquid is to be handled and where delivery pressure is quite large. In

reciprocating pumps, the chamber in which the liquid is trapped, is a stationary cylinder

that contains the piston or plunger.

Some properties of reciprocating pumps:-

The discharge is fluctuating and pulsating.

Handles small quantity of liquid.

It is meant for small discharge at high heads.

Runs at low speed .

Types of reciprocating pumps

1. Plunger pumps

2. Diaphragm pumps

3. Piston pumps

4. Radial piston pumps

.

2.4.0 Classification of Pumps on the basis of service liquid

Pumps can be classified as under on the basis of service liquid

Oil

Water

Mud, Slurry

2.5.0 Classification of Pumps can be classified on the basis of type of impeller

Pumps can be classified as under on the basis of type of impeller

Open

Semi open

Closed

2.6.0 Classification of pumps on the basis of mounting

Pumps can be classified as under on the basis of mounting

Vertical

Horizontal

1.7 Classification of pumps based on different type of construction

1. Mono block-where motor is attached to shaft and the motor shaft is attached to the

impeller.

2. Other types are where the motor and pump and coupled .

1.8 Classification based on position of bearing

1. OVERHELP -On one side of the pump there is the bearing and shaft . The other side is

free unattached .

2. BETWEEN BEARING PUMPS - On both the sides of the pump there are bearings.

1.9 Classification on the basis of no. of stages

5. Single Stage (1 impeller)

6. Multi Stage (more than 1 impeller)

1.10 Classification based on the position of pump with respect to fluid

7. Submerged pumps

8. Externally placed pumps

1.11 Classification based on the type of splitting of casing

9. Axially split

10. Radially

CHAPTER 3

3.0.0 Types of pumps used in oil industry

There are various types of pumps available in the market but only centrifugal pumps are

usually used in the oil industry. Pumps can be used to pump oil, Slurry, Mud .

Centrifugal pumps are also classified into various types of pumps they are given in the

table below. The process of pump selection is a rigorous one . The API 610 is used for

the process . API-610 is a document which has the standardized rules and regulations

for the production of pumps. A Document called Pump Data sheet is used for the

purchase of pumps by various companies. Pump data sheet consists of various different

aspects of pump required by the purchaser .

3.1.0 Types of Centrifugal Pumps

3.1.1 OH1 :- Foot-mounted single-stage overhung pumps shall be designated pump type OH1.

(This type does not meet all the requirements of this International Standard)

3.1.2 OH2 :-Centreline-mounted single-stage overhung pumps shall be designated pump type

OH2. They have a single bearing housing to absorb all forces imposed upon the pump

shaft and maintain rotor position during operation. The pumps are mounted on a base

plate and are flexibly coupled to their drivers.

3.1.3 OH3 :- Vertical in-line single-stage overhung pumps with separate bearing brackets shall

be designated pump type OH3. They have a bearing housing integral with the pump to

absorb all pump loads. The driver is mounted on a support integral to the pump. The

pumps and their drivers are flexibly coupled.

3.1.4 OH4 :- Rigidly coupled vertical in-line single-stage overhung pumps shall be designated

pump type OH4. Rigidly coupled pumps have their shaft rigidly coupled to the driver

shaft. (This type does not meet all the requirements of this International Standard.)

3.1.5 OH5 :- Close-coupled vertical in-line single-stage overhung pumps shall be designated

pump type OH5. Close coupled pumps have their impellers mounted directly on the

driver shaft. (This type does not meet all the requirements of this International Standard)

3.1.5 OH6 :- High-speed integral gear-driven single-stage overhung pumps shall be

designated pump type OH6. These pumps have a speed increasing gearbox integral

with the pump. The impeller is mounted directly to the gearbox output shaft. There is no

coupling between the gearbox and pump; however, the gearbox is flexibly coupled to its

driver. The pumps may be oriented vertically or horizontally.

3.1.6 BB1 :- Axially split one- and two-stage between-bearings pumps shall be designated

pump type BB1.

BB2 :- Radially split one- and two-stage between-bearings pumps shall be designated

pump type BB2.

3.1.7 BB3 :- Axially split multistage between-bearings pumps shall be designated pump type

BB3.

3.1.8 BB4 :- Single-casing radially split multistage between-bearings pumps shall be

designated pump type BB4. These pumps are also called ring-section pumps,

segmental-ring pumps or tie-rod pumps. These pumps have a potential leakage path

between each segment. (This type does not meet all the requirements of this

International Standard.)

3.1.9 BB5 :- Double-casing radially split multistage between-bearings pumps (barrel pumps)

shall be designated pump type BB5.

3.1.10 VS1 :- Wet pit, vertically suspended, single-casing diffuser pumps with discharge

through the column shall be designated pump type VS1.

3.1.11 VS2 :- Wet pit, vertically suspended single-casing volute pumps with discharge through

the column shall be designated pump type VS2.

3.1.12 VS3 :- Wet pit, vertically suspended, single-casing axial-flow pumps with discharge

through the column shall be designated pump type VS3

3.1.13 S4 :-Vertically suspended, single-casing volute line-shaft driven sump pumps shall be

designated pump type VS4.

3.1.14 VS5 :- Vertically suspended cantilever sump pumps shall be designated pump type VS5.

3.1.15 VS6 :- Double-casing diffuser vertically suspended pumps shall be designated pump

type VS6.

3.1.16 VS7 :- Double-casing volute vertically suspended pumps shall be designated pump type

VS7.

CHAPTER 4

4.1.0 PARTS Of CENTRIFUGAL PUMPS Following are the parts of the Centrifugal Pumps

4.1.1 Casing:- The casing of a centrifugal pump serves to house the impeller and

create a chamber for liquid to be pumped through. The drive pieces of a

centrifugal pump also are housed in the casing.

4.1.2 Suction and Discharge Nozzles :-Built into the casing itself, the suction and

discharge nozzles serve as ports for water to enter and exit from, respectively.

Typically, suction nozzles are placed on the end of the pump and discharge

nozzles are located on the top.

4.1.3 Seal Chamber and Stuffing Box :-Both seal chamber and stuffing box refer to

the portion of the pump between the shaft and casing where the sealing

mechanism of the pump is housed. Seal chambers utilize a mechanical seal,

whereas stuffing boxes achieve the sealing purpose through some form of

packing. Regardless of the method used, the chamber is used to prevent liquid

from exiting the pump.

4.1.4 Bearing Housing:-The bearing housing is used to enclose and protect the shaft

bearings, ensuring proper alignment. The housing will also include some type of

method for lubricating the bearings and cooling the pump.

4.1.5 Impeller :-The main moving portion of the centrifugal pump. An impeller is a

specially designed component critical for proper functioning of the pump.

Depending on the suction type and mechanical construction of the pump, the

actual design of the impeller may vary.

4.1.6 Shaft:- The shaft transfers the electrical or mechanical energy powering the pump directly to the impeller. In addition, the shaft is responsible for supporting any other moving parts on the pump. The shaft is responsible for a great deal of both energy transfer and structural support and therefore must be carefully machined.

4.1.7 Oil ring :- The bearings are most frequently oil bath or oil ring lubricated.

CHAPTER 5

5.0.0 IMPORTANT CHARACTERISTICS

Objective of understanding the characteristics of the pumps is to understand the

functioning of the pump as a whole based on following parameters:-

Working of Pumps

Head of a Pump

Importance of Head

Total Head

NPSHR

NPSHA

Volume Flow Rate

5.1.0 Working of a Pump

Centrifugal pumps are used to induce flow or raise pressure of a liquid. Its working is

simple. At the heart of the system lies impeller. It has a series of curved vanes fitted

inside the shroud plates. The impeller is always immersed in the water. When the

impeller is made to rotate, it makes the fluid surrounding it also rotate. This imparts

centrifugal force to the water particles, and water moves radially out. Since the rotational

mechanical energy is transferred to the fluid, at the discharge side of the impeller, both

the pressure and kinetic energy of the water will rise. At the suction side, water is getting

displaced, so a negative pressure will be induced at the eye. Such a low pressure helps

to suck fresh water stream into the system again, and this process continues. A

rotodynamic or centrifugal pump is a dynamic device for increasing the pressure of liquid.

In passing through the pump, the liquid receives energy from the rotating impeller. The

liquid is accelerated circumferentially in the impeller, discharging into the casing at high

velocity which is converted into pressure as effectively as possible.

5.2.0 Head of a Pump

It is assumed that a pump designed to move water clamped into a process line. There is

a suction line and a discharge line, both running horizontally. Assuming that we are able

to “move” the discharge line so it pumps straight up into the air. The pump is then turned

on. Once the pump is running, it will move the fluid to some height measured in feet.

That height to which the pump can raise the water to is its head.

5.3.0 Importance of Head

As the manufacturers do not know for what kind of fluid the purchaser requires the

pump .The pump manufacturer's want to tell you how much head their pump's will

produce but they don't know what type of water supply will be available, so how can they

get around this. Ingeniously simple, they subtract the head available at the suction from

the head produced at the discharge, they call this Total Head. Then it doesn't matter

what the suction tank level is, they are telling you only what the pump can do regardless

of the water supply pressure at the suction head is it is independent of the type of fluid

being pumped (assuming the viscosity is relatively low and similar to water). Whether

you’re pumping water or a heavy caustic solution, the head achieved will be the same.

The pressure at the discharge of the pump, however, will be higher for the heavier

solution. The relationship between head and pressure can be characterized by the

following formula.

5.4.0 Total Head

Total Dynamic Head (TDH) is the total equivalent height that a fluid is to be pumped,

taking into account friction losses in the pipe.

TDH = Static Height + Static Lift + Friction Loss

Static Height is the maximum height reached by the pipe after the pump (also known as

the 'discharge head').

Static Lift is the height the water will rise before arriving at the pump (also known as the

suction head).

Friction Loss (or Head Loss).- this depends on the length of pipes and their diameter and

the flow rate . Friction losses are different for different flow rates .

The relationship of head to pressure is expressed as

h=2.31p/SG

where

h = height of the fluid column above a reference point

p = pressure.

SG= Specific gravity

Net positive Suction head

NPSH is defined as the total suction head in feet of liquid (absolute at the pump centerline

or impeller eye) less the vapor pressure (in feet) of the liquid being pumped.

5.5.0 Net positive suction head required

Net positive suction head required (NPSHR) is defined as the amount of NPSH required to

move and accelerate the liquid from the pump suction into the pump itself. It is determined

either by test or calculation by the pump manufacturer for the specific pump under

consideration. NPSHR is a function of liquid geometry and the smoothness of the surface

areas. For centrifugal pumps, other factors that control NPSHR are:

Type of Impeller

Design of impeller

Rotational Speed

5.6.0 Net positive suction head available

NPSHA must be equal to or greater than NPSHR. If this is not the case, cavitation or

flashing may occur in the pump suction. Cavitation occurs when small vapor bubbles

appear in the liquid because of a drop in pressure and then collapse rapidly with

explosive force when the pressure is increased in the pump. Cavitation results in

decreased efficiency, capacity, and head and can cause serious erosion of pump parts.

Flashing causes the pump suction cavity to be filled with vapors and, as a result, the

pump becomes vapor locked. This usually results in the pump freezing up, which is

called pump seizure.

NPSHA is not a function of the pump itself but of the piping system for the pump. It can

be calculated from

pA = atmospheric pressure

pva = liquid vapor pressure at pumping temperature.

NPSHA decreases with increases in liquid temperature and pipe friction losses. Because

pipe friction losses vary as the square of the flow, NPSHA also varies as the square of

the flow. Thus, NPSHA will be the lowest at the maximum flow requirement.

5.7.0 Volume flow rate (Q)

Also referred to as capacity, is the volume of liquid that travels through the pump in a

given time (measured in gallons per minute or gpm). It defines the rate at which a pump

can push fluid through the system. In some cases, the mass flow rate (m) is also used,

which describes the mass through the pump over time.

CHAPTER 6

6.0.0 CHARACTERISTIC CURVES : The objective is to study characterstic curves i.e

Performance Curve

The System Curve

Following terms are used to understand the characterstics curves Terms Used

Shut off Head

Cut off Head

Pump Runout

BHP

Impeller Trim

6.1.0 The performance or characteristic curve of the pump

The pump characteristic is normally described graphically by the manufacturer as a

pump performance curve. The pump curve describes the relation between flow rate and

head for the actual pump. Other important information for proper pump selection is also

included - efficiency curves, NPSHr curve,pump curves for several impeller diameters

and different speeds, and power consumption.

During a test, the total head that a centrifugal pump can develop is a function of the

speed at which the impeller is turned and the diameter of the impeller. If a pump impeller

is being turned at its rated speed and a valve on the discharge side of the pump is

closed, it will develop a certain maximum head. Under these conditions, this head is

read on a pressure gauge. The gauge reading translated into feet registers the height to

which the pump is capable of elevating water. This is known as the “shut off head.” If the

valve is slowly opened, the pressure gauge reading will fall as the flow increases, and

this will continue until some point of maximum flow and minimum head is reached. If the

total head being developed at any given rate of flow is plotted against the quantity of

water being delivered, the result will be a performance curve for this particular pump at

this particular speed.

Each pump will have its own maximum efficiency point. The best efficiency point (BEP)

is the point of highest efficiency of the pump. All points to the right or left of the BEP

have a lower efficiency.

Increasing the impeller diameter or speed increases the head and flow rate capacity -

and the pump curve moves upwards.

The head capacity can be increased by connecting two or more pumps in series, or the

flow rate capacity can be increased by connecting two or morepumps in parallel.The

pump performance curves can made for trimmed impeller for same conditions

The units considered are different for different purposes . This curve is used to find the

head flow of a trimmed impeller for a specific efficiency and flow rate . The impeller is

trimmed to adjust to the requirement of a particular buyer.

6.2.0 The System Curve

A fluid flow system can in general be characterized with the System Curve - a graphical

presentation of the Energy Equation.

The system head visualized in the System Curve is a function of the elevation - the static

head in the system, and the major and minor losses and can be expressed as:

H=dh+h

where

H= System Head

dh= elevation (static) head - difference between inlet and outlet of the system

h= Head loss

Head loss = kq^2

Increasing the constant - k - by closing some valves, reducing the pipe size or similar - will

increase the head loss and move the system curve upwards. The starting point for the

curve - at no flow, will be the same.

Centrifugal pumps always pump somewhere on their curve, but should be selected to

pump as close to the best efficiency point (B.E.P.) as possible. The B.E.P. will fall some

where between 80% and 85% of the shut off head (maximum head).

6.3.0 Terms used

6.3.1 Shut off Head: The highest point the pump will lift liquid. At this point the pump will

pump 0 gallons per minute.

6.3.2 Cut-off Head: The head at which the energy supplied by a pump and the energy

required to move the liquid to a specified point are equal and no discharge at the desired

point will occur.

6.3.3 Pump run out: is the maximum flow that can be developed by a centrifugal pump

without damaging the pump. Centrifugal pumps must be designed and operated to be

protected from the conditions of pump runout or operating at shutoff head.

6.3.4 BHP : Break Horse Power . The pump performance curve will give information on the

brake horsepower (BHP) required to operate a pump (horsepower required at the pump

shaft) at a given point on the performance curve. The brake horsepower curves run

across the bottom of the pump performance curve usually sloping upward from left to

right. These lines correspond to the performance curves above them (the top

performance curve corresponds to the top BHP line and so on). Like the head-capacity

curve, there is a brake horsepower curve for each different impeller trim.

6.3.5 Impeller Trims : Impeller trims or impeller diameter is measured in either inches or

millimeters. Pump performance curves generally show performance for various impeller

diameters or trims. Manufacturers will put several different trim curves on a pump

performance curve to make pump specification easier, although this sometimes makes

the pump performance curve more difficult to read. It is good practice to select a pump

with an impeller that can be increased in size permitting a future increase in head and

capacity.

CHAPTER 7

7.0.0 FACTORS FOR PUMP SELECTION

7.1.0 Various factors considered while selecting the pumps are studied in this chapter: They

are broadly classified as under:-

7.1.1 Definition of the technological process outline and main process parameters, such as

flow, pressure and temperature.

7.1.2 Determination of the required pumping services.

7.1.3 Complete description of the fluid to be handled in each pumping operation (type of fluid,

temperature, density, viscosity, vapour pressure, solids in suspension, toxicity, volatility)

7.1.4 General layout of the plant and determination of available space in three dimensions;

7.1.5 General arrangement and dimension of the piping according to the recommended

velocities for each fluid and type of pipe;

7.1.6 Determination of elevation for suction and discharge points of vessels, relative to the

centre line of the pump;

7.1.7 Preliminary calculation of friction losses and plotting of system characteristic curves;

7.1.8 Definition of the working parameters of the pump, namely capacity, head, suction and

discharge pressures – taking into account any possibility of variations in pressure or

temperature at different pumping conditions;

7.1.9 Determination of any possible exceptional start, stop or running conditions;

7.1.10 Determination of available NPSH (Net Positive Suction Head);

7.1.11 Preliminary selection of the pump type, design, position, driver, type of sealing, and

cooling of seal and bearings – if required;

7.1.12 Establishing the type of drive unit (electric motor, steam turbine, etc) and its main

operating parameters

7.2.0 Factors to be discussed in the report

7.2.1 Primary Factors

Total Head

Flow Rate

Service

a) Head

The total head, suction lift and flow rate are dependent upon the piping system and the

pump’s characteristics. The piping system and the pump interact to determine the

operating point of the pump – flow rate and pressure.The pump cannot independently

control these parameters. As the flow rate is increased the work to move each unit of

water or total dynamic head the pump must produce increases.

Total head and flow are the main criteria that are used to compare one pump with

another or to select a centrifugal pump for an application. Total head is related to the

discharge pressure of the pump.

Steps are

Determine the static head

Determine the Friction Head

Calculate the total Head

Select the pump based on the pump manufacturer’s catalog information using the total

head and flow required as well as suitability to the application

B) Flow rate

Flow rate is directly proportional to speed or the velocity of the impeller . Changing the

impeller diameter gives a proportional change in peripheral velocity which thus causes a

change in the flow rate .

C) Services

By service it means whether it is operated continuously or weekly , quarterly , monthly

etc.This is required as the pipelines might get clogged if not operated continuously and

cleaning operations need to be done. For example In oil industry if a pipeline is not used

continuously then grease and other materials are clogged inside the pipeline . Thus to

reach the optimum flow warm crude oil is first transported through the pipes so that the

grease and other substances would melt within days.

7.2.2 Secondary Factors

NPSH

Purpose

Efficiency

Range

NPSH - Net positive suction head

For safe operation, NPSHA should exceed NPSHR (net positive suction head required)

by more than 1m at the rated condition. As the NPSHR varies, depending on the head

and flow, it is safer to select the margin at the end of the curve.

If the incoming liquid is at a pressure with insufficient margin above its vapour pressure,

then vapour cavities or bubbles appear along the impeller vanes just behind the inlet edges.

This phenomenon is known as cavitation and has three undesirable effects:

The collapsing cavitation bubbles can erode the vane surface, especially when

pumping water-based liquids.

Noise and vibration are increased, with possible shortened seal and bearing life

The cavity areas will initially partially choke the impeller passages and reduce the

pump performance. In extreme cases, total loss of pump developed head occurs

The three undesirable effects of cavitation described above begin at different values of

NPSHA and generally there will be cavitation erosion before there is a noticeable loss of

pump head. However for a consistent approach, manufacturers and industry standards,

usually define the onset of cavitation as the value of NPSHR when there is a head drop

of 3% compared with the head with cavitation free performance. At this point cavitation is

present and prolonged operation at this point will usually lead to damage. It is usual

therefore to apply a margin by which NPSHA should exceed NPSHR.

7.3.0 Cost

The ultimate deciding factor for a pump in the Oil pipeline Industry is the cost . The cost

is to be minimized.

7.4.0 Purpose

That is the desired function of the pump . The function of the pump is same creating a

head difference so that product can be transported . For example for irrigation a pump

might be used to extract water from an underground well . For this the pump can be

place in the ground immersed in water or if the net suction is sufficient it can be placed

above ground and water can be pumped out .

7.5.0 Efficiency

Selecting a correct pumping plant not only will conserve valuable energy supplies but

also will reduce total annual pumping costs. Inefficient pumping plants can increase

costs dramatically.

The efficiency of a pump is a measure of the degree of its hydraulic and mechanical

perfection. Pump efficiency is the ratio of the output water horsepower to the input shaft

horsepower.

Some of the energy losses that result in lower efficiency are friction in the bearings that

support the pump shaft, friction between the shaft and the packing in the stuffing box,

unavoidable leakage between areas of high pressure and adjacent areas of low

pressure inside the pump case, and the friction caused by the water moving across the

metallic surfaces in the pump. There are also other losses of a more complex nature.

To conserve maximum energy the BEP should be between the rated point and the

normal operating point.

The efficiency of a pump is determined by actual tests. The power required to turn the

pump during the process of maximum flow and minimum head, you will note that the

power is at a minimum for this typical centrifugal pump when there is no water being

discharged from the pump and that the power required will gradually increase as the rate

of flow increases and the head decreases. The maximum efficiency will be about

midway between zero flow and maximum flow.

7.6.0 Range

The range is basically region of operation of that unit .It is the region where the efficiency

is maximum according to our requirements .The lowest mark on the range corresponds

to the NPSHR to avoid cavitation .running the pump outside the recommended operating

range could and most likely will damage the pump by shortening bearing and seal life or

even damage the shaft

7.7.0 Cost

A cost analysis of pumping will consider initial cost of capital investment, annual fixed

cost and operating cost. All three costs are somewhat dependent on each other. The

type of pumping equipment, size of pipelines, size of pumps and type of water supply

affect not only the initial cost but also the fixed cost as well as the operating cost. For

example, piping systems using large pipes may cost more but could allow the use of

smaller horsepower pumps which cost less, require smaller power sources and cost less

to operate than a piping system with small diameter pipe. The lowest priced system is

not always the best buy, especially if the lower price means less efficient pumps. To get

the most efficient pump, an analysis should be made of all pumping requirements.

CHAPTER 8

8.0.0 SPILLING OF PARAMETERS

8.1.0 OBJECTIVES

Why should we split the parameters

Pumps in parallel

Pumps in Series

8.1.0 Why should we split the parameter.

Using circulating pumps in parallel or series configurations can attain many economic

and operational gains as opposed to using one large pump to supply a system’s

pumping requirements.

Employing a combination of in-line pumps rather than base-mounted pumps to

accomplish a pumping requirement eliminates the need for pump mounting pads,

grouting, and shaft alignment. Equipment room floor space can be utilized for something

else. The installed cost of two low-cost stock in-line pumps will be less than the installed

cost of one large base-mounted pump, and can provide standby protection at no extra

cost.

Often a designer will specify two pumps, each one capable of handling the entire load.

In some cases, this may be essential, but on many installations, the cost of providing full

standby capacity is prohibitive.

8.2.0 Pumps in parallel

Energy efficient method of flow control, particularly for systems where static head is a

high proportion of the total, is to install two or more pumps to operate in parallel.

Variation of flow rate is achieved by switching on and off additional pumps to meet

demand. The combined pump curve is obtained by adding the flow rates at a specific

head.

The head/flow rate curves for two and three pumps are shown in Figure

The system curve is usually not affected by the number of pumps that are running. For a

system with a combination of static and friction head loss the operating point of the

pumps on their performance curves moves to a higher head and hence lower flow rate

per pump, as more pumps are started. It is also apparent that the flow rate with two

pumps running is not double that of a single pump. If the system head were only static,

then flow rate would be proportional to the number of pumps operating. It is possible to

run pumps of different sizes in parallel providing their closed valve heads are similar. By

arranging different combinations of pumps running together, a larger number of different

flow rates can be provided into the system.

8.3.0 WORKING

The total system flow divides into two parallel paths. The check valves prevent any flow

short-circuiting, especially if only one pump runs. Since almost all installations of parallel

pumps are with identical pumps, each pump will pump exactly one half of the total flow

rate. Each pump will produce the same pressure head. Each pump will operate at the

same point on its pump curve. In short, when both pumps are running, each pump s

upplies one-half of the total flow rate at the total system head.

If one of the pumps should fail, the other pump should still be able to supply enough flow

to satisfy system demand, except in the worst weather.

8.4.0 Advantages of pump in series

Applying parallel pumps in a system can be a cost-effective solution when capacity

requirements call for an unrealistically large pump and motor. Using parallel pumps can

also reduce current surge during motor startup by staging two or more smaller pumps.

This is a problem which may otherwise require expensive equipment such as electronic

soft starters or part winding type motors. One of the most notable benefits of parallel

pumps is the redundancy built into the system. If one pump were to fail in a two pump

system, the second pump would not only continue to operate, but would also increase its

output

The beauty of parallel pump systems: If one pump were to fail, the second pump would

run out on its curve until it crossed the system curve.

8.5.0 PUMPS IN SERIES

Putting your centrifugal pumps in series, or connected along a single line, will let you add

the head from each together and meet your high head, low flow system requirements.

This is because the fluid pressure increases as the continuous flow passes through each

pump, much like how a multi-stage pump works.

Some things to consider when you connect pumps in series:

Both pumps must have the same width impeller or the difference in capacities (GPM or

Cubic meters/hour.) could cause a cavitation problem if the first pump cannot supply

enough liquid to the second pump.

Both pumps must run at the same speed (same reason).

Be sure the casing of the second pump is strong enough to resist the higher pressure.

Higher strength material, ribbing, or extra bolting may be required.

The stuffing box of the second pump will see the discharge pressure of the first pump.

You may need a high-pressure mechanical seal.

Be sure both pumps are filled with liquid during start-up and operation.

Start the second pump after the first pump is running.

After All the factor have been considered a Pump Data sheet is filled. The pump Data

sheet is used by a purchaser to list its requirements and narrow down a few pumps .

CHAPTER 9 9.0.0 PUMP DATA SHEET : The objective is to study the pump data sheet is to get acquitted

with the various terms used for following pumps such as

9.1.0 Terms and definitions used in pump data sheet

9.1.1 Barrel Pump :- horizontal pump of the double-casing type.

9.1.2 Best Efficiency Point (BEP) :- flow rate at which a pump achieves its highest efficiency..

9.1.3 Critical Speed :- shaft rotational speed at which the rotor-bearing-support system is in a

state of resonance.

9.1.4 Dry Critical Speed :- rotor critical speed calculated assuming that there are no liquid

effects, that the rotor is supported only at its bearings and that the bearings are of infinite

stiffness.

9.1.5 Wet Critical Speed :-rotor critical speed calculated considering the additional support

and damping produced by the action of the pumped liquid within internal running

clearances at the operating conditions and allowing for flexibility and damping within the

bearings.

9.1.6 Suction Pressure max :- highest suction pressure to which the pump is subjected

during operation

9.1.7 NPSH ,Net Pressure suction Head :-total absolute suction pressure determined at the

suction nozzle and referred to the datum elevation, minus the vapour pressure of the

liquid

9.1.8 NPSHA , Net Pressure Suction Head Available :- NPSH determined by the purchaser

for the pumping system with the liquid at the rated flow and normal pumping temperature.

9.1.9 Rated flow :The pump inlet flow, which will be measured, and guaranteed, when the

pump is tested. Rated flow is associated with rated differential head for rotodynamic

pumps, and rated outlet pressure for positive displacement pumps.

9.1.10 Suction Pressure: Operation of the pump creates suction (a lower pressure) at the

suction side so that fluid can enter the pump through the inlet. Pump operation also

causes higher pressure at the discharge side by forcing the fluid out at the outlet.

9.1.11 Rated Suction pressure :Rated suction pressure would be the suction pressure needed

when the pump is discharging its rated flow.

9.1.12 Discharge Pressure: Discharge pressure describes the pressure of a liquid as it leaves

a pump.

9.1.13 Differential Pressure. it is the amount of head that is added to the system .Differential

pressure is the pressure increase provided by the pump between the pump inlet and

outlet. It is measured as the difference between the pressure at the pump’s discharge

flange and the suction flange.

9.1.14 NPSHA :The absolute pressure at the suction port of the pump.NPSHA MUST be

greater than NPSHR for the pump system to operate without cavitating.

NPSHA = HA ± HZ - HF + HV – HVP

HA=The absolute pressure on the surface of the liquid in the supply tank

HZ=The vertical distance between the surface of the liquid in the supply tank and the

centerline of the pump

HF=Friction losses in the suction piping

HV=Velocity head at the pump suction port

HP=Absolute vapor pressure of the liquid at the pumping temperature .

9.1.15 Area classification : method of analysing and classifying the environment where

explosive gas atmospheres may occur so as to facilitate the proper selection and

installation of equipment to be used safely in that environment

9.1.16 Class : The Class defines the general nature (or properties) of the hazardous material

in the surrounding atmosphere which may or may not be in sufficient quantities

a) Class I—Locations in which flammable gases or vapors may or may not be in

sufficient quantities to produce explosive or ignitable mixtures

b) Class II—Locations in which combustible dusts (either in suspension,

intermittently, or periodically) may or may not be in sufficient quantities to

produce explosive or ignitable mixtures.

c) Class III—Locations in which ignitable fibers may or may not be in sufficient

quantities to produce explosive or ignitable mixtures.

9.1.17 Division—The Division defines the probability of the hazardous material being able to

produce an explosive or ignitable mixture based upon its presence.

a. Division 1 indicates that the hazardous material has a high probability of producing

an explosive or ignitable mixture due to it being present continuously, intermittently, or

periodically or from the equipment itself under normal operating conditions.

b. Division 2 indicates that the hazardous material has a low probability of producing an

explosive or ignitable mixture and is present only during abnormal conditions for a short

period of time

9.1.18 Group—The Group defines the type of hazardous material in the surrounding

atmosphere. Groups A, B, C, and D are for gases (Class I only) while groups E, F, and

G are for dusts and flying’s (Class II or III).

a) Group A—Atmospheres containing acetylene.

b) Group B—Atmospheres containing a flammable gas, flammable liquid-produced

vapor, or combustible liquid-produced vapor whose MESG is less than 0.45 mm

or MIC ratio is less than 0.40.

c) Group C—Atmospheres containing a flammable gas, flammable liquid-produced

vapor, or combustible liquid-produced vapor whose MESG is greater than 0.45

mm but less than 0.75 mm or MIC ratio is greater than 0.40 but less than 0.80.

Typical gases include ethyl either, ethylene, acetaldehyde, and cyclopropane.

D) Group D—Atmospheres containing a flammable gas, flammable liquid-produced

vapor, or combustible liquid-produced vapor whose MESE is greater than 0.75

mm or MIC ration is greater than 0.80. Typical gases include acetone, ammonia,

benzene, butane, ethanol, gasoline, methane, natural gas, naphtha, and propane.

e) Group E—Atmospheres containing combustible metal dusts such as aluminum,

magnesium, and their commercial alloys.

f) Group F—Atmospheres containing combustible carbonaceous dusts with 8% or

more trapped volatiles such as carbon black, coal, or coke dust.

g) Group G—Atmospheres containing combustible dusts not included in Group E or

Group F. Typical dusts include flour, starch, grain, wood, plastic, and chemical .

9.1.19 Location of pump : Location of pumps are based on the application .

Typical applications include

Water disposal

Secondary recovery

Glycol dewatering

Amine sweetening

Chemical injection

Crude transfer

Fire protection

Pipeline Transfer

Produced water disposal

Secondary recovery (water flood)

Chemical injection Glycol dehydration

Well servicing

Blow out preventer

Liquefied natural gas

Lean oil circulation

Closed drain pump-out

Knockout drum pump-out

Driver Type : can be and induction motor or a steam turbine or other type of

power sources

9.2.0 Full Load : Full Load is the expected performance of the motor at the rated or

nameplate hp. Maximum Load is often also referred to as service factor amps or max

amps

9.3.0 Locked Motor AMPS : Locked Rotor Current" also called LRA which stands for Locked

Rotor Amps, is commonly found on electric motor nameplates. Locked Rotor essentially

means the motor is not turning. The current or amps in this case have to do with the

amount of electrical energy required to start the motor. At the instant the motor is switched

on, it is not turning, and draws the maximum current. As the motor starts to turn, the

current goes down. This required energy is much greater than the Full Load Amps or

Running Amps, which is the current drawn when the motor is running at normal speed

under full load. The current required to start the motor will depend on the type of motor as

well as the specified design voltage required for the motor, typically the higher the voltage,

the lower the required amperage or current.

9.4.0 Radial Bearing : Radial bearings accommodate loads that are predominantly

perpendicular to the shaft. The bearings are typically classified by the type of rolling

element and shape of the raceways.

9.5.0 Classfication of Flammable Liquid : a flash point below 100 degrees Fahrenheit (38

degrees Celsius). Less-flammable liquids (with a flashpoint between 100 degrees and

200 degrees Fahrenheit) are defined as combustible liquids.

9.6.0 Flash Point : Flash point is the lowest temperature at which a liquid can form an

ignitable mixture in air near the surface of the liquid. The lower the flash point, the easier

it is to ignite the material.

9.7.0 Chloride conc : The concentration of these salts in the crude oil depends on the oil

field from which the crude is extracted, but it is usually present within the range of 3 to

300 pounds per barrel. In heavy crude oils this value tends to be higher.

9.8.0 H2S conc : Crude oils usually contain sulfides that can cause corrosion at high

temperatures. This is called sulfidation. It is a well-known corrosion in different units in oil

refineries. The amount of total sulfur in a crude oil depends on the type of oil field and it

varies from 0.05 percent to 14 percent. Of course, sulfur values as low as 0.2 percent

are enough to create sulfidation corrosion in plain steels and low alloy steels. These

kinds of steels are usually proposed to be used in several parts of refinery units.

9.9.0 Pump Performance Curve : The pump characteristic is normally described graphically

by the manufacturer as a pump performance curve. The pump curve describes the

relation between flow rate and head for the actual pump.

9.10.0 Impeller Diameter : The calculations are based on the affinity laws which in turn are

derived from a dimensionless analysis of three important parameters that describe pump

performance . If the speed (revolutions per minute) of the impeller remains the same

then the larger the impeller diameter the higher the generated head. Note that as you

increase the diameter of the impeller the tip speed at the outer edge of the impeller

increases commensurately. However, the total energy imparted to the liquid as the

diameter increases goes up by the square of the diameter increase. This can be

understood by the fact that the liquid's energy is a function of its velocity and the velocity

accelerates as the liquid passes through the impeller. A wider diameter impeller

accelerates the liquid to a final exit velocity greater than the proportional increase in the

diameter.

9.11.0 Maximum allowable Pressure : MAWP being the maximum pressure based on the

design codes that the weakest component of a Pressure vessel can handle. Commonly

standard wall thickness components are used in fabricating pressurized equipment, and

hence are able to withstand pressures above their design pressure.

9.12.0 Design Pressure : The most severe condition of coincident internal or external pressure

and temperature (minimum or maximum) expected during service”.

9.13.0 OTHER TERMS AND DEFINITIONS USED IN PUMP DATA SHEET

OPERATING CONDITIONS

SITE DATA

DRIVER TYPE

MOTOR DRIVER

LIQUID

MATERIAL

PERFORMANCE

UTILITY

CONSTRUCTION

SURFACE PREPARATION AND PAINT

HEATING AND COOLING

BEARINGS AND LUBRICATION

9.13.1 OPERATING CONDITIONS

PARAMETER GIVEN BY REQUIREMENTS

Flow, Rated Purchaser Rated flow is associated with rated differential head for roto-dynamic pumps, and rated outlet pressure for positive displacement pumps.

Suction pressure max. Purchaser Some factor like pump's suction flange which limits suction pressure to the given maximum value.

Suction Pressure rated Purchaser It depends on rated flow . Discharge Pressure Discharge pressure depends on the

pressure available on the suction side of the pump

Differential Pressure Determined by evaluating all pressure (or head) losses from the liquid level in the receiver through all piping and

components of the system and back to the receiver.

NPSHA Purchaser It depends on five factors 1)The absolute pressure on the surface of the liquid in the supply tank. 2)The vertical distance between the surface of the liquid in the supply tank and the centerline of the pump 3)Friction losses in the suction piping 4)Velocity head at the pump suction port 5)Absolute vapor pressure of the liquid at the pumping temperature

Service: continuous/intermittent/ parallel operations required

Purchaser The type of service depends on the requirement of the product , the cost of operation that is incurred , the eeficiency.

9.13.2 SITE DATA

PARAMETER GIVEN

Location: Purchaser Based on the application of pump and the location of the plant.

Altitude Purchaser Based on location of plant. Barometer Purchaser Based on location of plant Range of ambient temperature

Purchaser Based on location of plant

Relative Humidity Purchaser Based on location of plant Usual Conditions 1)Dust 2)Fumes

Purchaser Based on location of plant

ELECTRICAL CLASSIFICATION AREA

Class Purchaser It depends on the general nature of the explosive material . It might be 1)gas or vapour 2)Dusts 4)Fiber

Group Purchaser Depends on the type of hazardous material in the surrounding atmosphere. Groups A, B, C, and D are for gases (Class I only) while groups E, F, and G are for dusts and flyings (Class II or III).

Division Purchaser Depends on the probability of the hazardous material being able to produce an explosive or ignitable mixture based upon its presence.

9.13.3 DRIVER TYPE

PARAMETER GIVEN BY REQUIREMENT

Driver type Purchaser The types of drives that can be used are turbines , induction motor , engines etc.

9.13.4 MOTOR DRIVER

PARAMETER GIVEN BY REQUIREMENT

Power Manufacturer The power at which the motor driver operates and provides the required impeller speed , head , flow rate.

Frame Manufacturer The Frame type of the motor driver . VOLTS/PHASE/HERTZ Manufacturer The specifications of electricity supply

required by the motor. Minimum Starting Voltage Manufacturer The voltage below which the motor will

not start. Insulation Manufacturer The insulation of motor from the liquid

being used. Temperature rise manufacturer The rise in temperature in the motor due

the working of the motor driver , the friction when coupled.

Full Load AMPS Manufacturer expected performance of the motor at the rated or nameplate hp.

LOCKED rotor AMPS Manufacturer depend on the type of motor as well as the specified design voltage required for the motor

Starting Method Manufacturer The motor driver is and electrical device it is important to mention the starting method . Is it battery operated or another electrical supply is attached

Radial Bearing Type Manufacturer The type of bearings used to reduce the friction . These are lubricated .

9.13.5 LIQUID

PARAMETER GIVEN BY REQUIREMENT

Liquid type ; Hazardous/Flammable

Purchaser a flash point below 100 degrees Fahrenheit (38 degrees Celsius). Less-flammable liquids (with a flashpoint between 100 degrees and 200 degrees Fahrenheit) are defined as combustible liquids.

Pumping Temp. Purchaser The temperature at which the liquid is to be pumped.

Vapour Pressure Purchaser Vapor pressure or equilibrium vapour pressure is defined as the pressure exerted by a vapor in thermodynamic equilibrium with its condensed phases (solid or liquid) at a given temperature in a closed system. It is The property of the liquid .

Relative Density Purchaser Relative density, or specific gravity, is the ratio of the density (mass of a unit volume) of a substance to the density of a given reference material.It is the property of the liquid used

Viscosity Purchaser The viscosity of a fluid is a measure of its resistance to gradual deformation by shear stress or tensile stress. For liquids, it corresponds to the informal concept of "thickness"

Specific Heat Purchaser The specific heat is the amount of heat per unit mass required to raise the temperature by one degree Celsius. It is the property of the liquid.

Chloride Concentration Purchaser The concentration of these salts in the crude oil depends on the oil field from which the crude is extracted,

H2S concentration purchaser Total sulfur in a crude oil depends on the type of oil field and the conc with H2.

9.13.6 MATERIALS

PARAMETER GIVEN BY REQUIREMENT

ANNEX H CLASS Purchaser Materials and material specifications for pump parts

reduced hardness material required

Purchaser Annexure H

Barrel case Purchaser Annexure H Impeller Purchaser Annexure H Impeller Wear Rings Purchaser Annexure H Shaft Purchaser Annexure H Diffusers Annexure H

9.13.7 PERFORMANCE

PARAMETER GIVEN BY REQUIREMENT

Proposal Curve No. Purchaser A pump can be selected by combining the System Curve and the Pump Curve

Impeller dia (Rated/max./min)

Purchaser The calculations are based on the affinity laws which in turn are derived from a dimensionless analysis of three important parameters that describe pump performance . three things are Head , Flow and speed of impeller

Impeller type Purchaser Closed , open or semi open. Efficiency Purchaser Required efficiency that is

calculated using the pump curves and system curves

Rated Power Purchaser Power that is supplied for the impeller to produce the required efficiency

Min. continuous Flow (Thermal/Stable)

Purchaser The minimum rate of flow required to avoid problems like Cavitation

Preferred Operation Region Purchaser Range of operation where the efficiency obtained is maximum and cavitation is avoided

Max. head @rated impeller Purchaser Maximum head generated if

the impeller runs at the given parameters

9.13.8 UTILITY

PARAMETER GIVEN BY REQUIREMENT

Electricity Purchaser Electricity requirement of the driver used .

Steam Purchaser The maximum /allowable pressure of the steam used in the turbine (if a turbine is used)

Cooling water Purchaser Maximum and allowable temperature and pressure of the cooling water used in the turbine . a better cooling system provides a better efficiency of the turbine

9.13.9 CONSTRUCTION

PARAMETER

Rotation Purchaser Viewed from coupling end Pump Type Purchaser Which type of pump required . Max. Allowable working pressure

Purchaser The should be able to withstand design pressure.

Hydrotest Pressure Purchaser Pressure above the design pressure . Pipes are deformed

Nozzle Connection 1)Size Purchaser The size of the nozzle is dependent on the

head that is to be provided. 2)Flange Rating Purchaser A flange is a connection between the main

pipeline and the pump thus the pressure in the pipeline decides the flange rating. flange rating decides the flange size , the flange bolt size.

Coupling Manufacturer It includes Model , Rating , Spacer length , Type of coupling , coupling guard .

9.13.10 SURFACE PREPARATION AND PAINT

Parameter Given By Requirement

Pump Surface Preparation Purchaser Rp standard Primer Purchaser Rp standard finish coat purchaser Rp standard

9.13.11 HEATING AND COOLING Parameter Given By Requirement

Cooling water piping plan Purchaser Cooling water required for pumping volatile liquids which become flammable at room temperature

C.W.Piping Material Purchaser The material is important as it indicates the efficiency of rate of cooling.

9.13.12 BEARINGS AND LUBRICATION

Parameter Given Requirement

Oil Heater Requirement Purchaser If the liquid transported is at a particular temperature then the lubricant used should be at the same temperature so as to reduce the loss of energy .