OIL & GAS ACTIVITIES Sheet 1

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How to size a pump ?

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1. THEORY ABSTRACT............................................................................................................. 3
1.1. MINIMUM SUCTION PRESSURE............................................................................................ 3
1.2. MAXIMUM DISCHARGE PRESSURE.......................................................................................3
1.3. PUMP DIFFERENTIAL HEAD................................................................................................ 4
1.4. AVAILABLE NPSHA............................................................................................................ 4
1.5. DESIGN PRESSURE............................................................................................................ 5
1.5.1. Suction line design pressure...................................................................................5
1.5.2. Discharge circuit design pressure: pump shut off pressure.....................................5
1.6. INSTALLED MOTOR POWER................................................................................................. 6

2. PROBLEM DESCRIPTION..................................................................................................... 8

3. Calculation procedure............................................................................................................. 9

Appendices:

A Process flow diagram

B Typical lines sizing criteria and list of the main usual line diameters
C Isometrics for suction an discharge lines
D Equivalent length for valves and fittings
E Hysys output
F PIDs
G Pump process datasheet
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1. THEORY ABSTRACT

1.1. MINIMUM SUCTION PRESSURE

The minimum suction pressure at normal capacity available at the centerline of the
pump suction flange is determined with the characteristics of the suction section
piping.

Psm Pst 0.0981 * * hsm ( P ) fs

Where:
Psm = Minimum suction pressure at the centerline of the pump suction flange (bara)

Pst = Minimum operating gas pressure above the liquid level in suction vessel (bara)

= Liquid density at pumping liquid temperature (kg/l)

hsm = Liquid suction static head, between the low liquid level in the suction vessel and
the centerline of the pump suction flange (m).

(P)fs = Total pressure loss in suction piping due to friction in straight line length and
resistance of piping components (bends, valves, etc) at normal flowrate (bar).

1.2. MAXIMUM DISCHARGE PRESSURE

The maximum discharge pressure at normal capacity available at the centerline of

the pump discharge flange is determined with the characteristics of the discharge
section piping.

PdM Pdt 0.0981* * hdm ( P) fd

Where:
PdM = Maximum discharge pressure at the centerline of the pump discharge flange
(bara)

Pdt = Maximum operating gas pressure above liquid level in discharge vessel (bara)

= Liquid density at pumping liquid temperature (kg/l)

hdm = Liquid discharge static head, between the higher point reached by the liquid in
the discharge line or in the discharge vessel at operating conditions and the
centerline of the pump discharge flange (m)
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(P)fd = Total pressure drop in discharge section (bar). It results from the sum of the
following pressure losses:
Pressure loss in discharge piping due to friction in straight line length and
resistance of piping components (bends, valves) at normal capacity (bar)
Pressure loss through process equipment in the discharge circuit such as
heat exchangers, filters, heaters, reactors, restricted orifice for flow
measurement.
Pressure loss through control valve which is variable according to the
process control requirement.

For control valve pressure drop at normal flowrate will be the maximum of the
following values:

10% Pd if Pd < 15 barg

Pcontrol valve = 0.2 * Pf +
1.5 bar if Pd 15 barg

Pcontrol valve = 0.7 bar

With: Pf : total pressure in the discharge circuit

Pd : operating pressure in the discharge equipment.

1.3. PUMP DIFFERENTIAL HEAD

Pump head is the differential pressure at which the pump is expected to operate. It is
defined as follows

( PdM Psm ) * 10 5
Pump head
9.81 *
where
Pump head is in meter of liquid (m)
P = PdM Psm is the differential head of the pump in bar
= Fluid density (kg/m3)

1.4. AVAILABLE NPSHA

The Available Net Positive Suction Head (NPSHA) is defined as the difference
between the suction head of the piping system and the vapor pressure of the liquid at
the suction of the pump.
To be more conservative, use the lowest liquid level reachable by the liquid in the
vessel (LSLL) for the calculations.
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1.5. DESIGN PRESSURE

The mechanical design pressure of a line/equipment is a value given by Process

department and used by piping/equipment departments (together with the design
temperature) to calculate the equipment or the line thickness which will be suitable
for the whole operating conditions range.

1.5.1. Suction line design pressure

The suction line design pressure will be calculated as follows:

Pdesign suction = PDsuction vessel + 0.0981**hSM

With:
Pdesign suction = Design pressure of the suction line (barg)

PDsuction vessel = Design pressure of the suction vessel above the liquid level (barg)

= Liquid density at pumping liquid temperature (kg/l)

HSM = Maximum liquid suction static head, between the high liquid level in the suction
vessel and the centerline of the pump suction flange (m).

1.5.2. Discharge circuit design pressure: pump shut off pressure

For a centrifugal pump, the maximum differential pressure the pump is able to
develop corresponds to the flowrate value equal to zero (blocked outlet case). It is
called the shut off pressure. This pressure is used as mechanical design pressure for
the discharge line and equipment.
This pressure is calculated by cumulating the following events:
Suction vessel is operated at its design pressure
High liquid level in the suction vessel
Blocked outlet: pump delivers its maximum head (tentatively 1.2*Differential
Head Pressure at normal flow)

* g * H M AX
PDD PD Suction 1.2 * PN
10 5
Where:
PDD = Shut off pressure (barg)
P DSuction = Design pressure of the suction vessel (barg)
HMAX = Maximum operating level in the suction vessel (m)
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PN = Differential pressure at normal conditions (bar)

= Maximum fluid density (kg/m3)

1.6. INSTALLED MOTOR POWER

The hydraulic power is the theoretical pump work assuming 100% efficiency:

Q * ( * g * Pump head )
Hydraulic power
36 *10 5
where
Hydraulic power is in kW
Pump head: Pump differential head (m)

The brake pumping power (or brake horsepower BHP) takes into account the pump
efficiency:

Hydraulic power
Brake pumping power
pump efficiency
where
Brake pumping power in kW
= Pump efficiency.

To select the motor, an overdesign has to be assumed as follows:

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Brake pumping power (Wp) Installed motor

(kW)
< 18.5 > 125% Wp
22 to 55 > 115% Wp
> 55 > 110% Wp

Then, a standard nominal power has to be selected within the here-below list,
immediately above the calculated value:

Nominal motor power (kW)

0.75
1.1
1.5
1.85
2.2
3
3.7
4
5.5
7.5
9
11
15
18.5
22
30
37
45
55
75
90
110
132
160
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2. PROBLEM DESCRIPTION

The aim of this exercice is to perform the process sizing of a pump collecting liquid at
the bottom of an atmospheric separation drum 81 DS 363 and transferring it at a gas
boot 81 DS 362 for final degassing before export. (See appendix A and F for process
schemes).

The sizing activity includes the determination of all the process parameters listed in
the hereafter procedure (see chapter 3).
To allow these calculations, the following data are given:
Some theory basis in chapter 1
A list of input data in the here below table
Process flow diagram (Appendix A)
Typical lines sizing criteria and list of the main usual diameters (Appendix B)
Isometrics for suction and discharge lines (Appendix C)
Equivalent length for valves and piping fittings (Appendix D)
An hysys output (see appendix E) showing the pumping stream with normal
flowrate and with fluid properties
Process and instrument diagram (Appendix F)

Required input data for pump calculations

Pumping stream

Feed normal flowrate 372 m3/h

Feed properties Refer to appendix B
Requested capacity overdesign 10% overdesign on normal flowrate

Suction drum description (81 DS 363)

Operating temperature 45C

Drum operating pressure 0.2 barg
Drum design pressure 3.5 barg
Drum levels
LSHH 2250
LAH 1900
LAL 950
LSLL 550

Equipment and item pressure drop

Orifice plate 0.2 bar

Exchanger 0.5 bar

Discharge drum description (81 DS 362)

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Maximal operating pressure 0.1 barg

3. CALCULATION PROCEDURE

1. Define the line diameters of suction and discharge lines.

2. Calculate the minimum suction pressure based on pump normal flowrate

3. Calculate the total friction losses through the discharge circuit for the pump
normal flowrate

4. Determine the requested pressure drop through the control valve

5. Calculate the maximum discharge pressure based on pump normal flowrate

6. Calculate the pump differential head

7. Determine the available NPSH

8. Determine the design pressure of the suction line

9. Estimate the pump shut off pressure

10. Estimate the motor installed power

11. Fill the pump process data sheet

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Appendix A Process flow diagram

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Appendix B Typical lines sizing criteria and list of the main usual line
diameters

Liquid line type P bar/km max Maximum velocity (m/s)

Pumps suction
Liquid at bubble point 0.9 1.2
Non boiling liquid 3.5 1.5
Pumps discharge
Discharge P < 50 barg 4.5 4.5
Discharge P > 50 barg 9.0 4.5

DN Inside diameter considering the

Inches standard schedule (Sch 40)
(mm) (mm)
2 52.5
(50)
3 77.9
(80)
4 102.3
(100)
6 154.1
(150)
8 202.7
(200)
10 254.5
(250)
12 304.8
(300)
14 336.6
(350)
16 387.4
(400)
18 438.2
(450)
20 489.0
(500)
24 590.6
(600)
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Appendix C Isometrics for suction an discharge lines (3 sheets)

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Appendix D Equivalent length for valves and fittings

Type of valve/fitting Le (m)

Valves Ball valve Reduced bore 45 D
(fully open) Check valve Swing type 135 D
Tee Flow straight through 20 D
Fittings Flow through side outlet 65 D
Elbow 90 20 D
45 16 D
Strainer Pump suction strainer 250 D
Miscellaneous Nozzle Product outlet nozzle 32 D
Product inlet nozzle 64 D

With D = nominal pipe diameter (DN 50, 100, 150) in meter.

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Appendix E Hysys output (2 sheets)

Stream 331: before cooler at 45.1C

Stream 339: at cooler outler at 35.4C
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Appendix F PIDs (3 sheets)

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Appendix G Pump process data sheet