The document discusses various topics related to pumps used in process industries including: - The main types of pumps used are centrifugal, reciprocating, rotary, and sealless pumps. Centrifugal pumps are most commonly used. - Pump selection depends on the required head-capacity and properties of the fluid handled. Centrifugal pumps are generally preferred. - Detailed calculations must be performed by the process engineer to determine pump parameters like discharge pressure, NPSH available, power requirement, etc. - Characteristic curves provided by vendors are used to select the duty point where the pump will operate most efficiently. - Other topics covered include standards, materials, drivers, sealing, parallel operation, and process data

1. TP-KTI
PUMPS

2. TP-KTI
AGENDA
TYPE OF PUMPS
SELECTION OF PUMPS
CALCULATION BY PROCESS
ENGINEER
PUMP CHARACTERISTIC
CURVE
POWER CALCULATION
AFFINITY LAWS
SEALS
API PLANS
UTILITY REQUIREMENT
PROCESS DATA SHEET
PIPING AND
INSTRUMENTATION
DIAGRAM
CENTRIFUGAL PUMP TYPE
MATERIAL OF
CONSTRUCTION
VENDORS
CHECKLIST
STANDARDS

3. TP-KTI
TYPES OF PUMPS
• PUMPS GENERALLY USED IN PROCESS
INDUSTRIES ARE OF:
CENTRIFUGAL
RECIPROCATING ( PISTON, PLUNGER OR DIAPHGRAM)
ROTARY (GEAR, SCREW, LOBE)
SEALLESS PUMPS ( MAGNETIC-DRIVE, CANNED MOTOR)

4. TP-KTI
TYPE OF PUMPS….
 CENTRIFUGAL PUMP
 A CENTRIFUGAL PUMP, IN ITS SIMPLEST FORM,
CONSISTS OF AN IMPELLER ROTATING WITHIN
A CASING.
 THE PRIMARY ADVANTAGES OF A
CENTRIFUGAL PUMP ARE SIMPLICIY, LOW
MAINTENANCE EXPENSE, QUIET OPERATION,
AND ADAPTABILITY FOR USE WITH A MOTOR
OR A TURBINE DRIVE.

5. TP-KTI
TYPES OF PUMP…..
• POSITIVE DISPLACEMENT PUMP
– IN ALL POSITIVE-DISPLACEMENT PUMPS, A CAVITY
OR CAVITIES ARE ALTERNATEDLY FILLED AND
EMPTIED OF THE PUMPED FLUID BY THE ACTION OF
THE PUMP.
• THERE ARE THREE CLASSES OF RECIPROCATING
PUMPS.
– PISTON: A CYLINDRICAL PISPON BEING CAUSED TO
MOVE BACK AND FORTH IN A CHAMBER

6. TP-KTI
TYPES OF PUMP…..
• PLUNGER PUMPS
– PLUNGER PUMPS HAVE ONE OR MORE
CONSTANT-DIAMETER PLUNGERS
RECIPROCATING THROUGH PACKING GLANDS
AND DISPLACING LIQUID CYLINDERS IN WHICH
THERE IS CONSIDERABLE RADIAL CLEARANCE.
– THEY ARE ALWAYS SINGLE-ACTING, IN THE
SENSE THAT ONLY ONE END OF THE PLUNGER IS
USED IN PUMPING THE LIQUID

7. TP-KTI
TYPES OF PUMP…..
• DIAPHRAGM PUMPS
– THESE PUMPS PERFORM SIMILAR TO PISTON AND
PLUNGER PUMPS, BUT THE RECIPROCATING DRIVING
MEMBER IS A FLEXIBLE DIAPHRAGM FABRICATED OF
METAL, RUBBER, OR PLASTIC. THE CHIEF ADVANTAGE
OF THIS ARRANGEMENT IS THE ELIMINATION OF A LL
PAKING AND SEALS EXPSOED TO THE LIQUID BEING
PUMPED

8. TP-KTI
SELECTION OF PUMP TYPE
 SELECTION OF THE PUMP TYPE CAN BE
MADE ON THE BASIS OF CAPACITY-HEAD
REQUIREMENT OR FLUID PROPERTIES
E.G VISCOSITY, SOLID CONTENT AND
CORROSIVE OR EROSIVE NATURE
 PRELIMINARY SELECTION OF THE TYPE
OF PUMP REQUIRED IS MADE BY THE
PROCESS ENGINEER.

9. TP-KTI
SELECTION OF PUMP TYPE
 AS A GENERAL RULE CENTRIFUGAL PUMPS
SHOULD ALWAYS BE PREFERED WHENEVER
THEY CAN BE USED, SINCE THEY TEND TO BE
CHEAPER AND MORE RELIABLE.
 CENTRIFUGAL PUMPS ARE NOT CONSIDERED FOR
FOLLOWING CASES:
HIGH VISCOSITY (> 400 Cst)
HIGH DIFFERENTIAL HEAD AT LOW FLOW RATE

10. TP-KTI
PUMP SELECTION BASED ON HEAD CAPACITY
REQUIREMENTS
1 15 300 1500
CAPACITY M3/HR
HEAD
M
130
300
800
10
TRIPLEX POSITIVE
DISPLACEMENT
CENTRIFUGAL
MULTISTAGE
CENTRIFULGAL
TWO STAGE
GENERAL PURPOSE
CENTRIFUGAL PUMPS
SINGLE STAGE
CENTTRIFUGAL PUMPS
GENERAL
PURPOSE POSITIVE
DISP PUMPS

11. TP-KTI
CALCULATIONS NEEDS TO BE
PERFORMED BY PROCESS ENGINEER

12. TP-KTI
DISCHARGE PRESSURE CALCULATION
 ALL PRESSURE DROPS IN THE SYSTEM SHOULD BE
CONSIDERED FOR VARIOUS CONDITIONS:
 START UP, SHUT DOWN, FOULED CONDITIONS OF
PIPING/EQUIPMENT.
 PRESSURE DROP THROUGH CONTROL VALVE
 START OF RUN AND END OF RUN ETC.
 STATIC PRESSURE DROP THROUGH PIPING/EQUIPMENT

13. TP-KTI
CONTROL VALVE PRESSURE DROP
 ESTIMATED CONTROL VALVE PRESSURE DROP
5% OF DISCHARGE PRESSURE
0.7 - 1.0 BAR
20% of System dynamic loss

14. TP-KTI
PUMP DEFFERENTIAL HEAD
 THE DIFFERENCE BETWEEN THE DISCHARE
PRESSURE AND SUCTION PRESSURE SO
CALCULATED IS THE DIFFERENTIAL PRESSURE
OR DIFFERENTIAL HEAD WHEN EXPRESSED IN
METERS OF LIQUID.

15. TP-KTI
PUMP SHUT-OFF PRESSURE
 A CENTRIFUGAL PUMP WILL NOT PRODUCE A
HIGHER PRESSURE THAN ITS SHUT-OFF
PRESSURE EVEN IF THE DISCHANGER LINE IS
COMPLETLY BLOCKED
ALL THE EQUIPMENT IN THE SYSTEM E.G
PIPING, VALVES , EXCHANGERS AND VESSELS
SHALL BE DESIGNED FOR THIS SHUT-OFF
PRESSURE
ON THE AVERAGE, SHUT-OFF PRESSURE IS
MAXIMUM SUCTION PRESSURE + 1.2 TIMES THE
DIFFERENTIAL PRESSURE .

16. TP-KTI
SUCTION CONDITION AND NPSH
 IMPROPER SUCTION CONDITIONS ARE THE
LARGEST SOURCE OF PUMP TROUBLES.
 NPSH IS THE NET REMAINING PRESSURE AT THE
SUCTION FLANGE OF THE PUMP AFTER ALL
NEGATIVE FORCES THAT RESTRICT LIQUID FROM
GETTING INTO THE PUMP ARE SUBTRACTED FROM
ALL THE POSITIVE FORCES THAT ASSIST LIQUID IN
GETTING INTO PUMP.

17. TP-KTI
NPSH
 TWO TERMS OF NPSH:
NPSHA: NET POSITIVE SUCTION HEAD
AVAILABLE IN THE SYSTEM EXPRESSED AS
METERS OF LIQUID
NPSHR: NET POSITIVE SUCTION HEAD
REQUIRED BY THE PUMP EXPRESSED AS
METERS OF LIQUID

18. TP-KTI
NPSH AVAILABLE
• NPSHA = TERMINAL PRESSURE IN THE VESSEL
+ HEIGHT OF FLUID ABOVE THE PUMP
SUCTION CENTRE LINE + ATM
PRESSURE
_ VAPOR PRESSURE OF LIQUID
_ FRICTION LOSS IN SUCTION LINE
_ ENTRACE AND EXIT LOSSES
_ LOSS IN SUCTION STRAINER
_ LOSS IN CONTROL VALVE, EXCHANGER
, IF ANY

19. TP-KTI
NPSH A...
 CALCULATE NPSHA CAREFULLY CONSIDERING ALL
CONDITIONS I.E START-UP, ORIGINAL FILL OF LINES,
WINTER CONDITIONS, EXIT AND ENTRACTE LOSSES.
 PUMP SUCTION CENTRE LINE CAN BE CONSIDERED
ABOVE 600 MM FOR SMALL PUMPS AND 900 MM FOR
LARGE SIZE PUMPS.
 PROVIDE NPSHA AT 0.6 M OVER WORSE CONCEIVED
NPSHR CURVE BY THE MANUFACTURER.
 IN GENERAL, NPSHR OF PUMPS SHOULD BE
CONSIDERED AS 3.0 M.
 NPSHR IS A FUNTION OF FLOW, IT SHOULD ALWAYS BE
DETERMINED AT DESING CAPACITY REGARDLESS OF
THE TOTAL HEAD REQUIRED.

20. TP-KTI
NPSH A..
 WHEN LIQUIDS AT THE BUBBLE POINTS ARE
PUMPED FROM CLOSED VESSELS
 NPSHA = LIQUID LEVEL ABOVE PUMP SUCTION
CENTRE LINE - FRICTIONAL LOSSES IN SUCTION
LINE.
 IN SUCH CASES NPSHA CAN BE INCREASE BY
EVELATING THE VESSELFROM WHICH PUMP IS
DRIVING SUCTION.

21. TP-KTI
NPSH A...
• OTHER WAYS OF INCREASING NPSHA:
DOUBLE ACTING ( PROVIDING TWO PUMP
SUCTION ON OPPOSITE SIDE)
COOLER IN SUCTION LINE
USE BARREL TYPE PUMP
IT IS POSSIBLE TO REDUCE THE NPSHR
REQUIREMENT OF A PUMP TO 50-60% OF
THE ORIGINAL LEVEL BY FITTING AN
INDUCER IN FRONT OF THE IMPELLER.

22. TP-KTI
NPSH - REQUIRED
• SUCTION SPECIFIC SPEED
• nqs = N(Q)0.5 / (NPSHR) 0.75
– nq = suction specific speed
– N = rotative speed in rev/min
– Q = flow m3/sec
• SUCTION SPECIFIC SPEED IS APPROXIMATELY
EQUAL TO 200.
• NPSHR THEN CAN BE BACK CALCULATED
FROM SUCTION SPECIFIC SPEED

23. TP-KTI
SPECIFIC SPEED
• SPECIFIC SPEED
• ns = N(Q)0.5 / (H) 0.75
– nS = specific speed
– N = rotative speed in rev/min
– Q = flow m3/sec
• SPECIFIC SPEED IS A PARAMETER THAT DEFINES THE
SPEED AT WHICH IMPELLERS OF GEOMETRICALLY
SIMILAR DESING HAVE TO BE RUN TO DISCHARGE ONE
GALLON PER MINUTE AGAINST A ONE-FOOT HEAD
• GENERALLY PUMP WITH LOW SPECIFIC SPEEDS HAVE A
LOW CAPACITY AND HIGH SPECIFIC SPEED HAVE HIGH
CAPACITY.

24. TP-KTI
MINIMUM FLOW
• MINIMUM CONTINOUS STABLE FLOW
– THE LOWEST FLOW AT WHICH THE PUMP CAN
OPERATE WITHOUT EXCEEDING THE VIBRATION
LIMITS
• MINIMUM CONTINOUS THERMAL FLOW
– THE LOWEST FLOW AT WHICH THE PUMP CAN
OPERATE WITHOUT ITS OPERATION BEING
IMPAIRED BY THE TEMPERATURE RISE OF THE
PUMPED LIQUID

25. TP-KTI
CHARACTERISTIC CURVES OF
CENTRIFUGAL PUMPS
THE HEAD-CAPACITY CURVE OF THE SYSTEM
IS SUPERIMPOSED ON THE HEAD-CAPACITY
CURVE OF THE PUMP AND THE POINT OF
INTERSECTION OF THE TWO CURVES IS THE
DUTY POINT AT WHICH PUMP WILL OPERATE AT
ITS BEST EFFICIENCY.
PUMP VENDORS WILL SUPPY THE
CHARACTERISTIC CURVE FOR EACH PUMP.

26. TP-KTI
CHARACTERISTIC CURVES OF
CENTRIFUGAL PUMPS
 FOLLOWING POINTS SHOULD BE CONSIDERED
WHILE FINALLY ACCEPTING THE PUMP:
THE SLOP OF THE HEAD CAPACITY CURVE
SHOULD NOT BE TOO STEEP. SINCE A SMALL
CHANGE IN FLOW WILL CAUSE A LARGE
CHANGE IN DELIVERY PRESSURE
THE SLOPE SHOULD NOT BE TOO FLAT IF
THE PUMP CAPACITY IS TO BE CONTROLLED
BY THROTTLING DISCHARGE ( MANUALLY
OR BY A CONTROL VALVE)

27. TP-KTI
H-Q
Preferred
Operating Region
Allowable Preferred
Operating Region
POWER
EFFICIENCY
NPSHR
Head
(m)
Efficiency
(%)
Power
(kW)
NPSH
(m)
Flow (m3/hr)
PUMP CURVE

28. TP-KTI
POWER CALCULATION
Q (m3/hr) X  (kg/m3) X H (m) X g
SHAFT POWER(kW) = -----------------------------------------------
1000 X 
WHEN PUMP IS OPERATED AT DISCHARGE VALVE
FULL OPEN CONSIDER SHAFT POWER AT END OF
IMPELLER.

29. TP-KTI
CHOICE OF DRIVER
• ELECTRIC MOTOR IS FAR THE MOST COMMON
DRIVE FOR PUMPS IN THE PROCESS INDUSTRY
• OCCASIONALLY, SPECIAL CONSIDERATIONS SUCH
AS RELIABILITY OF POWER, SAFETY
CONSIDERATIONS AND CRITICALITY OF SERVICE
REQUIRE TURBINE DRIVES TO BE USED.
• SOMETIMES, THE PLANT UTILITY BALANCE MAKES
TURBINE DRIVES NECESSARY ON LARGE PUMPS.
• VITAL PUMPS SUCH AS COOLING WATER PUMPS,
ONE PUMPS IS KEPT ON STEAM TURBINE AS
PRECAUSTION AGAINST POWER FAILURE.

30. TP-KTI
CRITERIA FOR MOTOR SELECTION
• API 610 SELECTION CRITERIA SHALL BE FOLLOWED
I.E THE RATIO OF MOTOR NOMINAL POWER AND
PUMP SHAFT POWER AT RATING POINT SHALL NOT
BE LESS THAN:
 1.25 IF THE SHAFT POWER AT RATING POINT IS
< 22KW
1.15 IF THE SHAFT POWE AT RATING POINT IS
FROM 22 TO 55 kW
1.1 IF THE SHAFT POWER AT RATING POINT IS >
55 kW

31. TP-KTI
STANDARD MOTOR RATINGS IN KW
• 0.75
• 1.1
• 1.5
• 2.2
• 3
• 4
• 7.5
• 11
• 15
• 18.5
• 22
• 30
• 37
• 45
• 55
• 75
• 90
• 110

32. TP-KTI
AFFINITY LAWS
• For change in speed with fixed impeller design,
diameter and efficiency, the following
conditions and characteristics change
simultaneously.
– Q2 = Q1( (n2 / n1)
– H2 = H1 (n2 / n1) 2
– (BHP)2 = (BHP)1 (n2/n1) 3
• This relations do not hold exactly if the ratio of
speed change is greater than 1.5 to 2

33. TP-KTI
AFFINITY LAWS...
• FOR CHANGE IN IMPELLER DIAMETER AT
FIXED SPEED AND EFFICIENCY:
– Q2 = Q1 (d2/d1)
– H2 = H1 (d2/d1) 2
– (BHP)2 = (BHP)1 (d2/d1) 3
• CHANGE IN IMPELLER DIAMETER SHOULD
NOT ME MORE THAN 20%

34. TP-KTI
EFFECT OF VISCOSITY
• WHEN VISCOUS LIQUIDS ARE HANDLED IN
CENTRIFUGAL PUMPS, THE BRAKE HP IS
INCREASED, THE HEAD IS REDUCED, AND THE
CAPACITY IS REDUCED AS COMPARED TO THE
PERFORMANCE WITH WATER.
• THE CORRECTIONS MAY BE NEGLIGIBLE FOR
VISCOSITIES IN THE SAME ORDER OF
MAGNITUDE AS WATER, BUT BECOMES
SIGNIFICANT ABOVE 10 CS FOR HEAVY
MATERIALS.

35. TP-KTI
PUMPS RUNNING IN PARALLEL
• IF TWO IDENTICAL PUMPS ARE SIMULTANEOUSLY
WORKING IN PARALLEL, THEY WILL DELIVER THE SUM
OF THE CAPACITIES TO THE SAME TOTAL HEAD.
• EACH PUMP DOES NOT HAVE TO CARRY THE SAME
FLOW, BUT WILL OPERATE ON ITS OWN
CHARACTERISTIC CURVE, AND MUST DELIIVER THE
REQUIRED HEAD.
• CHARACTERISTIC CURVES OF EACH PUMP MUST BE
CONTINOUSLY RISING ( RIGHT TO LEFT), OTHER WISE
WITH DROPPING OR LOOPED CURVES THEY MAY BE
TWO FLOW CONDITIONS FOR ANY ONE HEAD, AND THE
PUMPS WOULD “HUNT” BACK AND FORHT WITH NO
MEANS TO BECOME STABILISED.

36. TP-KTI
PUMP SEALING SYSTEM
• PROCESS DATA SHEETS FOR PUMPS SHOULD
INDICATE THE TYPE OF SEALING TO BE PROVIDED.
•FOLLOWING ARE TYPES OF SEAL
SINGLE MECHNICAL SEAL
DOUBLE MECHANICAL SEAL
PACKING
TANDEM ( WHEN TWO SEALS ARE
ARRANGED FACING IN THE SAME DIRECTION
THEN THE MECHNICAL SEALS ARRANGEMENT
IS CALLED TANDEM SEAL)

37. TP-KTI
PUMP SEALING SYSTEM
GUIDELINES FOR SELECTION OF TYPE OF SEAL
SERVICE TYPE OF SEALING EXTERNAL FLUSHING
Clean HC and non-corrosive
chemicals which do not
solidify at temp upto 300 0
C
& pressure upto 40 kg/cm
2
SINGLE MECHNICAL
SEAL
NOT REQUIRED
Clean Liquids which will
solidy at amb conditions,
temp upto 300 0
C and
pressure upto 40 kg/cm2
SINGLE MECANICAL
SEAL
REQUIRED
Very corrosive, dirty or high
press. Service
DOUBLE MECHANICAL
SEAL
REQUIRED
Slurries PACKED BOX -
Water clean HC, non-
corrosive chemicals at
moderate press
Pumps taking suc. from
sumps where leakage can be
redirected to the sumps
PACKED BOX
PACKED BOX
-
-

38. TP-KTI
SEAL ARRANGEMENT
USE SINGLE SEAL
WITH HARD FACES
AND EXT INJEC
PLAN 32
USE SNGLE SEAL WITH
PUMPING RING AND
SEAL COOLER PLAN 23
USE SINGLE SEAL WITH
THROTTLE BUSHING
PLAN 13
USE SINGLE SEAL WITH AUX
BACKUP AND PRESS
SWITCH PLAN 13
IS LIQUID TOXIC
OR HAZARDOUS
IS THERE GAS AT
SEAL ( IS LIQ SAT)
IS PRESSURE AT
SEAL BELOW
ATMOSPH
DOES LIQUID
CONTS ABRASIVES
IS LIQUID LIABLE
TO CRYSTALLIZE
ON TEMP RISE
IS LIQUID TEMP
HIGHER THAN
MAX ALLOW TEMP
FOR SEAL
IS LIQUID TEMP
> THAN ATMOSP
BOILING TEMP -10K
IS DISCHARGE
PRESSURE AT SEAL
USE DOUBLE
MECHANICAL SEALS
WITH PRESSURIZED
EXTRNL SYSTEM, PLAN 53
USE TANDEM SEAL WITH
NON-PRES EXT
SYSTEM, PLAN 52
USE DOUBLE SEAL
WITH NON-PRESS
EXT SYSTEM PLAN 52
USE TANDEM SEAL
WITH PRESS EXT
SYSTEM, PLAN 52 AND
HARD FACES
IS PRESSURE AT SEAL
HIGHER THAN 10 BARG
DOES LIQUID CONTAIN
ABRASIVES
IS EXTERNAL CLEAN
FLUSH AVAILABLE
IS LIQUID LIABLE TO
CRYSTALLIZE ON
COOLING DOWN
CAN LIQUID BE COOLED
DOWN TO ACCEPTABLE
TEMPERATURE
IS MAJOR LEAKAGE
DURING SEAL
FAILURE ACCEPTABLE
USE SINGLE SEAL WITH
THROTTLE BUSHING
PLAN 11
YES
YES
YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
YES

39. TP-KTI
API PLANS

40. TP-KTI
API PLAN DEFINATION AND
OBJECTIVE
DIAGRAM
PLAN 11 TO LUBRICATE THE PRIMARY
PRODUCT SEAL AND DISSIPATE
HEAT GENERAED BY THIS SEAL.
INLET POINT IS AT THE DISCHARGE
OF PUMP (HIGHER PRESSURE) AND
IS PIPED TO SEAL FLANGE. USED
FOR CLEAN FLUID. STUFFING BOX
PRESSURE IS BETWEEN SUC AND
DISCH.
PLAN 13 TO LUBRICATE THE PRIMARY
PRODUCT SEAL AND DISSIPATE
HEAT GENERAED BY THIS SEAL.
INLET POINT IS AT SEAL AND IS
PIPED TO PUMP SUCTION OR SOME
LOW PRESSURE POINT
USED WHEN SEAL CHAMBER IS AT
OR NEAR DISCHARGE PRESSURE.
USED FOR CLEANED FLUIDS.
PUMP
DIS
DRIVER
SHAFT
SUC
sewe
r
SUC
DIS

41. TP-KTI
API PLAN DEFINATION AND
OBJECTIVE
DIAGRAM
PLAN 21 TO LUBRICATE THE PRIMARY
PRODUCT SEAL AND DISSIPATE
HEAT GENERAED BY THIS SEAL.
INLET POINT IS AT THE DISCHARGE
OF PUMP (HIGHER PRESSURE) AND
IS PIPED THROUGH H.E TO SEAL
FLANGE. GOAL IS TO REDUCE SEAL
FLUSH TEMP BY 37-65 0
C BEFORE IT
ENTERS SEAL CHAMBER
PLAN 23 TO REDUCED THE TEMPERATURE
OF PUMPED PRODUCT LUBRICATE
AND DISSIPATE HEAT GENERAED
BY THIS SEAL.
PRODUCT IS CIRCULATED TO AND
FROM THE PRIMARY SEAL FLANGE
THRO A H.E.
H.E
H.E
VENT LINE
SEWER

42. TP-KTI
API PLAN DEFINATION AND
OBJECTIVE
DIAGRAM
PLAN 31 TO CLEAN THE PROCESS LIQUID
GOING TO THE SEAL CHAMBER.
INLET POINT IS AT THE DISCHARGE
OF PUMP (HIGHER PRESSURE) AND
IS PIPED THROUGH CYCLONE
SEPERATOR TO SEAL FLANGE.
PLAN 32 THIS PLAN IS USUALLY FOUND
WHEN PROCESS CONDITIONS ARE
VERY DIRTY AND A CLEAN FLUID IS
NEEDED FOR PROPER SEAL
PERFORMANCE.
EXTERNAL SOURCE AT HIGHER
PRESSURE THEN THE STUFFING BOX
PRESSURE AND PIPED TO PRIMARY
SEAL FLANGE.
PI

43. TP-KTI
API PLAN DEFINITION AND
OBJECTIVE
DIAGRAM
PLAN 52 A SECONDARY SEAL API PIPING
PLAN DESIGNED TO VENT PRODUCT
THAT HAS LEAKED ACROSS THE
PRIMARY SEAL AND IS TRAPPED IN
THE SECONDARY SEAL CHAMBER
TO THE FLARE HEADER OR LOW
PRESSURE POINT FOR DISPOSAL.
TO CONTROL PRODUCT LEAKAGE
TO ATM FOR COMPLIANCE WITH
EPA/SAFETY REGULATIONS
SEC
SEAL
TO FLARE
HEADER
PI

44. TP-KTI
API PLAN DEFINITION AND
OBJECTIVE
DIAGRAM
PLAN 53 A SECONDARY SEAL API PIPING
PLAN OPERATE AT A HIGH
PRESSURE THAN THAT OF PRIMARY
SEAL CHAMBER TO PROVIDE A
BARRIER BETWEEN THE PRODUCT
IN THE PUMP AND THE ATM.
PLAN 54A A CLEAN EXTERNAL FLUID
SUPPLIED TO THE SECONDARY
SEAL OF DUAL SEAL
CONFIGURATION THAT ENTERS
AND EXIT THE SECONDARY SEAL
GLAND AND IS EITHER PIPED TO A
CLOSE SEWER, OR A LOW
PRESSURE COLLECTION POINT.
SEC
SEAL
PRESSURE
SOURCE
PI
PI
External
supply

45. TP-KTI
API PLAN DEFINATION AND
OBJECTIVE
DIAGRAM
AN 61 A SECONDARY SEAL API PIPING
PLAN DESIGNED TO VENT PRODUCT
THAT HAS LEAKED ACROSS THE
PRIMARY SEAL AND IS TRAPPED IN
THE SEACONDARY SEAL CHAMBER
TO THE FLARE HEADER OR LOW
POINT FOR DISPOSAL
PLAN 62
AN ATM API PIPING PLAN
DESIGNED TO QUECH THE ATM
SIDE OF A MECH SEAL THRO THE
QUENCH PORT ON THE PRIMARY
SEAL FLANGE. THE COMMON
QUECH SOURCES ARE STEAM,
NITROGEN OR WATER..
PI
PI
N2 OR
STEAM
FLARE
HEADER
R

46. TP-KTI
API PLAN VENDOR
• KIRLOSKAR EBARA
• SULZER
• INGRESOLL RAND
• KSB

47. TP-KTI
MECHANICAL SEAL VENDORS
• DURAMETALLIC INDIA
LIMITED
• RATHI
• SEALOL HINDUSTAN LTD

48. TP-KTI
PROCESS DATA SHEET FOR PUMPS

49. TP-KTI
UTILITY REQUIREMENTS
• COOLING WATER
– COOLING BEARING, PEDESTAL, GLAND
PACKING ETC.
– GENERALLY, THE WATER AFTER COOLING
IS ROUTED TO DRAIN
– REQUIREMENT
• UP TO 120 DEC C 0.5 M3/HR
• UPTO 250 DEG C 1.5 M3/HR
• ABOVE 250 DEG C 2.0 M3/HR

50. TP-KTI
UTILITY REQUIREMENT...
• STEAM FOR QUENCHING AND JACKETING
– PUMPS HANDLING HIGH POUR PT
PRODUCTS LIKE BITUMEN, LSHS, DMT ,
PHTHALIC ANHYDRIED ARE OFTEN STEAM
JACKETED. SPECIFY STEAM CONDITIONS
AVAILABLE IN THE DATA SHEET.
– THE APPROXIMATE REQUIREMENTS OF
STEAM FOR EACH SUCH PUMPS MAY BE 200
KG/HR

51. TP-KTI
MATERIAL OF CONSTRUCTION
• IN THE PETROLEUM AND PETROCHEMICAL
INDUSTRIES, THE SELECTION OF PUMP
MATERIALS OF CONSTRUCTION IS USUALLY
DICTATED BY CONSIDERATION OF
CORROSION, EROSION, PERSONAL SAFETY
AND LIQUID CONTAMINATION
• TABLE G-1 AND H-1 GIVEN IN API 610 8TH EDN
CAN SERVE AS A USEFUL GUIDE TO THE
PROCESS ENGINEER FOR SELECTION OF
MARTERIAL OF CONSTRUCTION OF PUMPS.

52. TP-KTI
CHECK LIST FOR PUMP VENDOR
INFORMATION / DRAWINGS
• COMPARE AGAINST PROCESS DATA SHEET
– FLOW : MAX, NOR, MIN
– PRESSURE: SUCTION AND DISCHARGE,
DIFFERENTIAL HEAD
– VAPOR PRESSURE
– VISCOSITY
– CORROSIVE ELEMENTS
– MOC: IMPELLER / CASING
– MECHANICAL SEAL

53. TP-KTI
CHECK LIST ….
• IS PUMP TO CODE API 610 ( 6TH EDI OR 8TH
EDI)
• IS NPSHA (PDS) - NPSHR (VDS) = 0.6 M MIN
• INDUCER HAVE USED TO REDUCE NPSHR.
CHECK THE ACCEPTANCE OF INDUCER?
• CHECK MINM CONTINOUS FLOW QUOTED BY
VENDOR.
– IF THIS IS HIGHER THAN PUMP MIN FLOW THAT
PUMP MUST BE PROVIDED WITH MIN FLOW BYPASS.
THE FLOW IS USEFUL FOR CHECKING THE MIN FLOW
BYPASS LINE SIZE. FIND OUT FROM CURVE, THE
HEAD DEVELOPED AT MIN FLOW, THIS WILL GIVE
INFORMATION FOR ORIFICE SIZING

54. TP-KTI
CHECK LIST ….
• IMPELLER SHOULD NOT BE THE MAX SIZE FOR
CASING. THERE SHOULD BE ATLEAST 10%
SCOPE TO INCREASE HEAD BY CHANGING
IMPELLER OF HIGHER DIA
• NOTE DOWN MOTOR KW AND UPDATE LOAD
LIST
• CHECK API SEAL FLUSH PLAN- WHAT IS
FLUSHING FLUID, WATER OR STEAM, SIZE OF
TAPPINGS. SHOW IN ON UDD/P&ID. ANY
ADDITIONAL VALVE? CHECK THE SCOPE OF
SUPPLY?

55. TP-KTI
CHECK LIST….
• MECHANICAL SEAL: IS IT SINGLE OR DOUBLE?
IF DOUBLE WHAT IS THE SEAL FLUID? IT
SHOULD BE COMPATIBLE WITH PROCESS
FLUID. INFORM TO MECHANICAL
• CHECK RPM BY PUMP VENDOR, IT SHOULD
MATCH WITH MOTOR VENDOR , IF BOTH ARE
SUPPLIED BY DIFFERENT VENDOR
• IS PUMP CURVE AT OPERATING POINT
DROPPING OR FLAT. A DROPPING CURVE IS
PREFFERED

56. TP-KTI
CHECK LIST….
• FIND HEAD DEVELOPED AT ZERO FLOW FOR
CALCULATION OF SHUT OFF PRESSURE
– SHUT OFF PRESSURE = HEAT AT ZERO
FLOW CONVT TO KG/CM2 + MAX SUCH
PRES
– MAX SUC PRESS = UPSTREAM VESSEL
SAFETY VALVE SET PRESSURE + STATIC
HEAD FROM HLL TO CL OF PUMP (KG/CM2)
• IF PUMP DEVELOPS HIGH PRESSURE AND
DISCHARGE NOZZLE RATING IS 300#, THEN
SUCTION SHOULD ALSO BE 300#

57. TP-KTI
CHECK LIST….
• FIND SUCTION AND DISCHARGE NOZZLE SIZE
OF PUMP IN ORDER TO SHOW REDUCERS AS
NECESSARY IN P&ID
• CHECK VENT AND DRAIN SIZE ON PUMP
CASING FOR PRESENTATION IN P&ID
• IF POSITIVE DISPLACEMENT PUMP, IS SAFETY
VALVE IN VENDOR SCOPE? IS IT PROVIDED?
WHAT IS THE SET PRESSURE? IS EXTERNAL
SAFELY VALVE TO BE PROVIDED APART FROM
INTERNAL SAFETY VALVE IN PUMP VENDOR’S
SCOPE. WHAT IS ITS SET PRESSURE

58. TP-KTI
PRESENTATION OF CENTRIFUGAL PUMP
ON P&ID

59. TP-KTI
PRESENTATION OF RECIPROCATING
PUMP ON P&ID

60. TP-KTI
CENTRIFUGAL PUMP TYPES
OH 1
FOOT
MOUNTED
OH 2
CENTRELINE
MOUNTED
HORIZONTAL
OH3
IN-LINE
BEARING
FRAME
VERTICAL
FLEXIBLY
COUPLED
OH 4
IN-LINE
VERTICAL
RIGIDLY
COUPLED
OH5
VERTICAL
IN-LINE
OH 6
HIGH
SPEED
INTEGRAL
GEAR
CLOSE
COUPLED
OVERHUNG
Type title here
BB1
AXIALLY
SPLIT
BB2
RADIALLY
SPLIT
1 & 2 STAGE
BB 1
AXIALLY
SPLIT
BB 4
SINGLE
CASING
BB 5
DOUBLE
CASING
RADIALLY
SPLIT
MULTISTAGE
BETWEEN
BEARINGS
VS 1 /
VS2 /
VS3
DIFFUSER /
VOLUTE /
AXIAL FLOW
DISCHARGE
THRU
COLUMN
VS4 /
VS 5
LINE SHAFT /
CANTILEVER
SEPARATE
DISCHARGE
(SUMP)
SINGLE
CASING
VS 6/
VS 7
DIFFUSER /
VOLUTE
DOUBLE
CASING
VERTICALLY
SUSPENDED
CENTRIFUGAL
TYPES

61. TP-KTI
PUMP VENDOR
• KIRLOSKAR EBARA
• INGRESOLL RAND
• KSB
• KISHORE
• SULZUR
• ROTO
• BEACON WEIR
• JOYTI PUMPS

62. TP-KTI
STANDARDS
• API STANDARD 610 ( EIGHT EDITION)
CENTRIFUGAL PUMPS FOR PETROLEUM HEAVY
DUTY CHEMICAL AND GAS INDUSTRY SERVICES
• API STANDARD 675 ( SECOND EDITION )
POSITIVE DISPLACEMENT PUMPS - CONTROLLED
VOLUME