Chad Wunderlich Viking Pump - Calgary Pump …calgarypumpsymposium.ca/uploads/2013PDFs/EPC... · Chad Wunderlich . Viking Pump . Calgary Pump Symposium 2013 . Chad Wunderlich. Viking

Calgary Pump Symposium 2013

Positive Displacement Pumps

Chad Wunderlich Viking Pump


Calgary Pump Symposium 2013 Calgary Pump Symposium 2013

Chad Wunderlich Viking Pump Engineering Manager – Technical Customer Service 13 Years Experience


Agenda

• Define the difference between positive displacement (PD) and kinetic pump technologies.

• Explore the strengths and weaknesses of each • List examples of where PD pump technology is

typically favored and why.



Agenda

• Look at various positive displacement principles.

• Explore how they operate, each one’s strengths and weaknesses, and list applications where each is commonly used.



PUMPS

POSITIVE DISPLACEMENT KINETIC

CENTRIFUGAL REGENERATIVE TURBINE ROTARY RECIPROCATING

Pump “Family Tree”


Pump Sales

010203040506070

%

Centrifugal

Rotary PD

Diaphragm

Reciprocating

Turbine

Other

Centrifugal 67%, Other 33%


Centrifugal Pump Principle


Centrifugal Pump Principle A centrifugal pump

generates a low pressure area in the impeller to draw fluid in. (The same as a PD Pump)

The fluid velocity is increased as it travels outward along the Impeller.

Velocity is converted to pressure in the diffuser or volute. The pump is a pressure source.


Centrifugal Pump Principle

Centrifugal pumps generate head (pressure) and flow results.

http://www.lightmypump.com/viscosity/Viscosity.html


Positive Displacement Pump Principle

Volume of liquid displaced by the ball


Rotary PD Pump Principle A Positive Displacement (PD) pump displaces a known

quantity of liquid with each revolution of the pumping elements. This is done by trapping liquid between the pumping elements and a stationary casing


Rotary PD Pump Principle A PD pump creates

flow. Pressure created is a result of system restrictions such as pipe shear, liquid shear, or work required (hydraulic systems)

PD pumps generate flow and pressure results.


Centrifugal / PD Comparison PUMP

CHARACTERISTICS

PUMP PRINCIPLE

Kinetic (Centrifugal)

Rotary (Positive Displacement)

Viscosities Handled Typically water-thin

30-3,000 SSU (1-750 cSt)

Typically lubricating liquids 30-Millions SSU (1-1M cSt)

Pressure Low

Up to 500 PSI (34 BAR)

High Up to 3,000 PSI (200 BAR)

Speed High

1150-3450 RPM Medium

1750 RPM or less

Capacity High

To 100,000 GPM (20k M³/hr)

Medium To 3,000 GPM (700 M³/hr)

Efficiency Rapidly drops with increasing viscosity / pressure Relatively High

Performance (Flow) Smooth Smooth

Suction Characteristics Not Self Priming Very Good


Centrifugal to PD Comparison


Review – Low NPSH or Suction Lift Applications – High Viscosity Applications – High Pressure Applications – Low Flow, High Head Applications – Flow Rate Control Required (Metering) – Variable Service Conditions (Pressures,

Viscosities, etc.) – Energy Usage Concerns (Efficiency) – Shear Sensitive Liquids

When to Use PD Pumps


Positive Displacement Pump Principles

• There are over 100 different PD principles and variations available. Each with their own unique advantages and disadvantages.

• Due to time I will be discussing only a few of the most common types. Each is commonly used in oil and gas applications.



PD Pumps to be Covered

• Rotary – Gear

• Internal Gear • External Gear

– Vane – Timed Lobe

• Reciprocating – Hydraulically Actuated Diaphragm – AOD (Air Operated Diaphragm)



Internal Gear Pumps


Internal Gear Pump Operating Principle


Internal Gear Pump Operating Principle


Internal Gear Pump Design

Relief Valve

Relief Valve • Provides over-pressure

protection • All positive displacement

pumps need to have some form of over-pressure protection


Internal Gear Pump Advantages

• ADVANTAGES • DISADVANTAGES

• Only one stuffing box • Ideal for high-viscosity liquids • Operates well in either direction • Can be made to operate with one

direction of flow with either rotation

• Low NPSH required • Single adjustable end clearance • Flexible design offers application

customization

• Usually requires moderate speeds • Medium pressure limitations • One bearing runs in the product

pumped • Overhung load on shaft bearing


Internal Gear Pump Performance Range

FLOW RANGE 0.5 TO 1600 GPM

VISCOSITY RANGE

0.1 cPs - 1,000,000 cPs

MAXIMUM DIFFERENTIAL PRESSURE 400 PSI (2800 kPa)

TEMPERATURE RANGE -100°F to 800°F (-80°C to 425°C)


Example Applications

Asphalt refining, transfer, blending, and delivery



Pipeline sampling



• Well Stimulation (hot oil trucks)

• Shale Fracturing (frac trucks)

• Gathering (wellhead to local storage)

• Transfer (local storage to terminal, barge or refinery)



Lube oil blending, loading/unloading


External Gear Pumps


External Gear Pump Operating Principle


External Gear Pump Operating Principle


Gear Cuts

Spur Gears Helical Gears Herringbone Gears

• Lowest Cost • No thrust

• Moderate Cost • Lower noise • Lower NPSH • Thrust in opposite

directions

• Highest Cost • Lower noise • Lower NPSH • No thrust


Double Pumps


External Gear Pump Advantages

ADVANTAGES DISADVANTAGES

• High speed • High pressure capability • No overhung bearing loads • Design accommodates wide

variety of materials • Sections can be stacked for

multiple inlets and outlets • Bi-Directional

• Four bushings in liquid area • No solids allowed • Fixed end clearances


External Gear Pump Performance Range

FLOW RANGE 0.001 TO 1500 GPM

VISCOSITY RANGE

0.1 cPs - 1,000,000 cPs

MAXIMUM DIFFERENTIAL PRESSURE 3000 PSI (20,000 kPa)




Fuel oil & Lube oil filtering, dewatering, and dispensing



Injection of additives into pipeline. (i.e. dyes, mercaptum, etc.)



Acid or caustic transfer (composite pump)



Duplex fuel oil skids for backup power gen sets or burner systems



Rust preventative or lube oil delivery to multiple points with a single pump


Vane Pumps


Vane Pump Operating Principle


Vane Pump Operating Principle


How the Vanes Work

1. Push rods initiate the vane extension when the opposing vane is pushed into its slot.

2. Centrifugal force, slings the vanes to the outside.


How the Vanes Work

1. Push rods initiate the vane extension when the opposing vane is pushed into its slot.

2. Centrifugal force, slings the vanes to the outside.

3. Grooves in each vane’s leading edge allow liquid to feed in under pressure to push behind the vane.


Self Compensating for Wear


Vane Pump Advantages


• Sliding contact of vanes make this pump good for thin liquids

• Can run dry for short periods • Pump normally has one seal

chamber

•Can have two seal chambers •Not suitable for high

pressures •Not suitable for high viscosity •Not good with abrasives •Failure mode is catastrophic

when vanes fail


Vane Pump Performance Range

FLOW RANGE 5 to 2000 GPM

VISCOSITY RANGE 0.1 cPs – 25,000 cPs

MAXIMUM DIFFERENTIAL PRESSURE

150 PSI (1000 kPa)




Propane, Butane, Liquid CO2, and other liquefied gases.



Water


Lobe Pumps


Lobe Pump Operating Principle


Lobe Profiles

Bi-Wing (or Scimitar) Tri-Lobe Multi-Lobe Multi-Lobe

(SIP)

Twin-Wing Rotor Single-Wing Rotor


Lobe Pump Advantages


• Pass medium solids • No metal-to-metal contact • Superior CIP/SIP

capabilities • Long term dry run (with

lubrication to seals)

• Requires timing gears • Requires two seals • Reduced lift with thin

liquids


Lobe Pump Performance Range

FLOW RANGE 5 to 800 GPM

VISCOSITY RANGE

0.1 cPs – 1,000,000 cPs

MAXIMUM DIFFERENTIAL PRESSURE 400 PSI (2800 kPa)




• Sanitary • Food • Personal Care • Pharmaceutical

• Industrial • Chemical • Pulp and Paper

• Municipal • Sludge • Slurry



Wax in shale oil refinery


Hydraulically Actuated Diaphragm Pumps


Diaphragm Pump Operating Principle


Diaphragm Pump Advantages


• No shaft seal required • High pressure capability • Excellent metering capability • Variable flow (either

mechanically or speed) • High temperature capacity

•Pulsing flow •Internal hydraulic system to

maintain •Potential for contamination

when diaphragm fails •High cost, especially for large

flows


Diaphragm Pump Performance Range

FLOW RANGE 0.001 to 70 GPM



6000 PSI (40,000 kPa)




Polymer metering


Air Operated Diaphragm Pumps


AOD Pump Operating Principle


AOD Pump Operating Principle


Is an AOD a PD pump or not?


AOD Pump Advantages


• No shaft seal required • Portable • Handles solids and abrasives • Can run dry • Easy to run • Explosion proof • Inexpensive

•Pulsing flow •Inconsistent flow due to

system changes •May be expensive to operate •Diaphragm failure causes

immediate leakage •Limited diaphragm life due to

constant flexing •Discharge pressure limited by

air pressure


Diaphragm Pump Performance Range

FLOW RANGE 0.5 to 300 GPM



125 PSI (850 kPa)




Waste water / sludge


Comparison of Technologies

Principle High Flows Low Flows High Pressure High Temperature

Internal Gear 1600 GPM 0.5 GPM 400 PSI 800°F

External Gear 1500 GPM 0.001 GPM 3000 PSI 500°F

Vane 2000 GPM 5 GPM 150 PSI 225°F

Lobe 800 GPM 5 GPM 400 PSI 400°F

3 Screw 3400 GPM 1 GPM 4500 PSI 500°F

2 Screw 5000 GPM 20 GPM 1500 PSI 650°F

Progressive Cavity 2400 GPM 1 GPM 1500 PSI 350°F

Hydraulic Diaphragm 70 GPM 0.001 GPM 6000 PSI 800°F

Air Diaphragm (AOD) 300 GPM 0.5 GPM 125 PSI 212°F



Principle High Viscosity Low Lubricity Dry Run Multiphase

Internal Gear Excellent Good Short No

External Gear Excellent Good Short No

Vane Fair Excellent Short No

Lobe Excellent Excellent Yes Yes

3 Screw Good Poor Short No

2 Screw Good Excellent Yes Yes

Progressive Cavity Excellent Good No Yes

Hydraulic Diaphragm Fair Excellent Yes Yes

Air Diaphragm (AOD) Fair Excellent Yes Yes



Principle Abrasive Liquids Liquids w/ Solids Shear Sensative

Internal Gear Yes No Yes

External Gear No No No

Vane No No No

Lobe Yes Yes Yes

3 Screw No No No

2 Screw Yes Yes Yes

Progressive Cavity Yes Yes Yes

Hydraulic Diaphragm Yes Yes Yes

Air Diaphragm (AOD) Yes Yes Yes



Principle Smooth Output Sealless Option Sanitary Option

Internal Gear Steady Output Yes Yes

External Gear Steady Output Yes NSF Options

Vane Steady Output Yes NSF Options

Lobe Slight Pulsing No Yes

3 Screw Steady Output Yes No

2 Screw Steady Output No Yes

Progressive Cavity Steady Output No Yes

Hydraulic Diaphragm Pulsed Output Inherently Sealless Yes

Air Diaphragm (AOD) Pulsed Output Inherently Sealless Yes


Other Considerations For Selection

• Frequency of maintenance and ease of repair • Spare part consistency/availability • Mechanical Efficiency • Total cost of ownership


Thank You

• UNDERSTAND LIQUID CHARACTERISTICS

• UNDERSTAND THE PUMPING SYSTEM

• UNDERSTAND THE PUMP PRINCIPLE

Documents

Chad Wunderlich Viking Pump - Calgary Pump …calgarypumpsymposium.ca/uploads/2013PDFs/EPC... · Chad Wunderlich . Viking Pump . Calgary Pump Symposium 2013 . Chad Wunderlich. Viking