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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.
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
Critical Factors in Pump Sizing Cont.
Critical Factors in Pump Sizing Cont
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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
Critical Factors in Pump Sizing Cont.
Critical Factors in Pump Sizing Cont
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Fluid Type And Composition – Pump component material selection
– Effect on expendable products
Temperature – Effect on Vapor Pressure, Pump
– Components/Expendables
Critical Factors in Pump Sizing Cont.
Critical Factors in Pump Sizing Cont
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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.
Critical Factors in Pump Sizing Cont.
Critical Factors in Pump Sizing Cont
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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
Critical Factors in Pump Sizing Cont.
Critical Factors in Pump Sizing Cont.
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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.
Critical Factors in Pump Sizing Cont.
Critical Factors in Pump Sizing Cont.
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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
Critical Factors in Pump Sizing Cont.
Critical Factors in Pump Sizing Cont.
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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.
.
Critical Factors in Pump Sizing Cont.
Critical Factors in Pump Sizing Cont.
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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
Critical Factors in Pump Sizing Cont.
Production Solutions
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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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Typical Curve Centrifugal Pump
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
3. Effects of Viscosity
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3. Effects of Viscosity
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
Typical Curve Centrifugal Pump
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Typical Curve Centrifugal Pump
5. Performance At Constant Speed
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5. Performance At Constant Speed
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.
6. Performance At Constant Speed
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6. Performance At Constant Speed
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