Hit Projects

TM.P. S.p.A. Termomeccanica Pompe

Hit ProjectsA 100 YEARS OF HISTORY

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TM.P. S.p.A.Termomeccanica Pompe

Since its establishment more than a hundred years ago, Termomeccanica has manufactured and installed all over the world more than a hundred thousand rotating machines.We have gathered this Hit Projects collection, token of our experience, to share some of the important sup-plies we have completed over the last years.The reported projects are recognized as amongst the most prestigious in the world, both in terms of technology and installed power.

The successes we have achieved epit-omize our constant will and capacity to offer customized complex engineered solutions to our customers, based on our partnership approach.I deem that the well deserved pride of our staff can be bestowed to all those who have cooperated to the accom-plishment of the projects and who, like us, believe in Italian technology.

Edoardo Garibotti Managing Director

Italian Technology runs fast

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Projects List

Project Pump Type Application Field Service Power Head Flow Rate (KW) (m) (m3/h)

1 Hidd Power & Desalination Plant API 610-VS1 Power Generation Sea Water 4,050 33 34,370 Bahrain page 4 TMP CPP model vertically suspended, single-stage, mixed flow, pull-out

2 Montalto di Castro Power Plant API 610-BB5 Power Generation Boiler Feed 30,000 3,830 2,350 Italy page 8 TMP MESB model horizontal, double-casing, radially split, multi-stage (barrel pump)

3 Shoiaba III Water Transmission API 610-BB1 Water Transmission Main Line 9,650 552 5,065 Saudi Arabia page 12 TMP D2D model horizontal, axially split, two-stage, first stage double entry

4 DuPage Water Transmission API 610-BB1 Water Transmission Water Pipeline Supply 1,680 20 19,000 Illinois - U.S.A page 16 TMP DD model horizontal, axially split, one-stage, double entry 5 Basso Flumendosa - Mulargia TMP CPPD model Water Transmission Water Pipeline Supply 3,200 220 3,600 Sardegna - Italy page 20 vertically suspended, multi-stage, first stage double suction entry 6 Saurashtra Branch Canal TMP NV model Water Handling Land Reclamation 4,000 16 72,000 India page 24 wet pit, vertical, concrete volute, mixed flow 7 Shuweihat Power & API 610-VS7 Desalination Brine Recirculation 5,100 95 14,300 Desalination Plant TMP CEXD model U.A.E page 28 single-stage, vertically suspended, volute, double casing, double entry impeller 8 Zubair Oil Field Development API610-BB5 Oil & Gas Water Injection 8,700 1,721 1,100 Iraq page 32 TMP MESBD model horizontal, double casing, radially split, multi-stage (barrel pump)

9 Greater Stella Area Development API 610-BB5 Oil & Gas Export Oil 1,500 2,075 170 FPF1 Offshore Platform TMP MESB model Upgrade & Modification horizontal, double North Sea - U.K. page 36 casing, radially split, multi-stage (barrel pump)

10 Dunkerque LNG Terminal API 610-VS1 Oil & Gas Sea Water 1,350 36 8,975 France page 40 TMP CPP model vertically suspended, single-stage, mixed flow, pull-out

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1 Al Hidd Power & Desalination Plant Bahrain

Name of ProjectEnd User

ClientConsultant

Country

Pump Performance DataPump Type

ServiceRated Capacity

Total HeadSpeed

Specific GravityDrive Power

Design Temperature

Al Hidd Power & Desalination PlantMinistry Electricity & Water (MEW)ABB SAE SADELMI S.p.A. Milan - ItalyLahmeyer InternationalBahrain

API 610-VS1 Sea Water34,370 m3/h33 m422 rpm1.028 kg/dm3

4,050 kW35 °C

Sea water pump - final arrangement at TMP’s workshop

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Project Description

Supply of three vertically suspended, single stage, mixed flow, pull-out type pumps complete with auxiliary equipment and piping for the flashing and cooling water systems.

The vertical pumps mainly provide sea water supply to the Desalination Plant and sea water circulation (as cooling medium) through a steam dump con-denser and other auxiliary systems in Hidd Power & Water Production Faci-lity Phase I.

Two pumps are continuously running, whilst the third one is a common spare.

The vertical pump is coupled to 11 KV electric motor, mounted on the pump frame.

Filtered sea water is used for the co-oling of the pump thrust bearing and for the lubrication and cooling of the pumps shaft guide bearings.

Sea water is available from pump discharge and its filtration is performed by two filters, one operating and the other one as full size spare.

Vertical centrifugal pump API 610-VS1

TMP 120 C1PPAS 95 model

Al Hidd desalination plant

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The supplied vertical pumps 120 C1P-PAS 95 are in pull-out execution, i.e all pump internals can be completely removed as a single piece without di-sturbing the discharge pipe.Therefore, once removed, the electric motor and motor stool, it is possible to extract as a single piece:• the top flanged cover with the thrust bearing itself• the pump shaft and packing seal• the shaft protection• the intermediate guide bearing spider• the inner bowl• the pump impeller

without removing:• the suction bell• the external pump bowl (diffuser) • the column pipe• the discharge elbow.

Pump shaft is enclosed into a pro-tection pipe, providing segregation of shaft and relevant guide bearings from the pumped water. The radial bearings are cutless hard rubber, with longitudi-nal grooves for passage of the filtered sea water.The filtered sea water is injected on the pump topside, forced to circulate

into the annular space between shaft and related protection pipe, passed through all the shaft bearings and then discharged in the pump suction zone. The pump is fitted with three guide bearings and the intermediate one is installed in a suitable spider, properly centered and supported on the inter-nal side of the pump column. In cor-respondence of the bearing contact area, the shaft is provided with remo-vable/renewable sleeves. The pump thrust bearing is antifriction (tape roller) type, oil flooded and the bearing lube oil cooling is achieved by sea water circulation through an internal coil.Pump construction materials are as follows: • All the stationary hydraulic components (suction bell, pump bowl, inner bowl, shroud) are in Ni-Resist cast iron BS 3468 Gr.S2W while the impeller is in ASTM A 743 CF3M.• Discharge elbows and columns are in fabricated stainless steel ASTM A 240 Tp.316 L.• The shaft, sleeves, bolts, etc. in contact with the handled sea water are in duplex stainless steel DIN X2 CrNiMo N22.5.31.4462.

Pump Type and Performance Data

Due to the large pump dimensions, a FEM Modal Analysis was carried out to determine its natural frequencies and vibrations modes so as to avoid reso-nance in operating conditions.ANSYS VERSION 5.4 was used for the calculations. The hydraulic design of the pull-out diffuser was carried out based on the characteristics and main dimensions of the pump with non pull-out design.The new diffuser geometry was opti-mized through CFD calculation.Then, a model pump with pull out

diffuser was designed, constructed and tested for the determination of the hydraulic performances. During NPSH tests, stroboscopic flow obser-vation was performed and cavitation bubble distribution reported. As the supply included the test of the full-size pumps, with a maximum capacity of 39,000m³/h, Termomeccanica Pom-pe sized the occasion to upgrade its test center to allow the testing of vertical pumps with flow rates up to 65,000m³/h

Particular Technical Difficulties

Testing of sea water pump at TMP’s in-house test center

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Main boiler feed water pump - API 610 BB5-type - TMP MESB 350.5 model

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2 Montalto di Castro Power Plant Italy


ClientConsultant

Country



Total HeadSpeed


Design Temperature

Montalto di Castro Power PlantENEL PowerENEL PowerENEL PowerItaly

API 610-BB5 Boiler Feed2,350 m3/h3,830 m2,980 rpm0.976 kg/dm3 30,000 kW151 °C

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Project Description

Supply of n. 2 main boiler feed pum-ps (MESB 350.5) and of n. 4 auxiliary boiler feed pumps (MESB 200.6) with their related booster pumps to ENEL, Italian electric power company, for its hypercritical power plant of Montalto di Castro.Each boiler section, including n°1 main pump and n°2 auxiliary pumps, has a production rating of 660 MW. It is important to mention that the main boiler feed pump supplied for this project is actually one of the largest of its type ever manufactured for the European market.

Horizontal centrifugal pump API 610-BB5

TMP MESB 350.5 model

Main boiler feed water pump being tested at TMP’s test center

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The main pumps are driven by a steam turbine. The very high head per stage of these pumps required an accurate investiga-tion of impeller stresses by FEA (Finite Elements Analysis).The barrel casing dimensions were selected and calculated on the basis of the high discharge pressure of the pump.The necessity to adopt small clea-rance between rotating and stationa-ry parts in order to avoid significant hydraulic losses and reach good effi-ciency required the selection of a very rigid shaft. A rotor dynamic analysis was carried out to verify proper pump behavior in new and worn conditions.The radial bearings were specially se-lected in order to be suitable to run at both the high design speed of 5,150

rpm and at the very low speed of ap-proximately 40 rpm corresponding to the pump stand-by condition (turbine barring speed).The pump was tested in Termomec-canica; the test was carried out at re-duced speed due to the impossibility to feed the steam turbine in the TMP test room. A I0,000 kW and 1,500 rpm electric motor and a step-up gearbox were used in order to reach a pump speed of 3,500 rpm.The test was performed at design wa-ter temperature by means of a closed test loop provided with a temperature control system, suitable to maintain a steady temperature value for the entire range of the pump performances.


The supplied pumps are horizontal multistage double casing (barrel) dif-fuser type, designed in accordance with API 610 VIII Edition. Full cartridge pull-out design allows easy removal of complete inner casing without distur-bing pump alignment and piping.The bearing supports are installed on the removable part of the pump and the radial bearings are sleeve-type.The hydraulic axial thrust is balanced by means of a balancing drum system; a tilting pad thrust bearing is provided in order to absorb the residual thrust, especially during transients.The rotor is radially supported by two-sleeve type radial bearings.All the bearings have a lubrication unit

supplied by the driver turbine.

The pump materials are:

• Barrel casing: ASTM A182 CI.3 (alloy chrome-molybdenum steel)

• Internal casting hydraulic parts: ASTM A743 CA6NM (high alloy 12% chrome steel)

• Shaft: ASTM A473 Type 420 (high alloy 12% chrome steel)


Main boiler feed water pump - fully assembled and ready for shipment

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Main line pump - API 610 BB1-type - TMP 500 D2D 80 model

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3 Shoiaba III Water Transmission Saudi Arabia


ClientConsultant

Country



Total HeadSpeed


Design Temperature

Shoiaba III Water TransmissionSaline Water Conversion Corporation Saudi Services for Electro-Mechanics Works Co. Ltd ILF – AustriaSaudi Arabia

API 610-BB1 Main Line5,065 m3/h552 m1,782 rpm0.996 kg/dm3

9,650 kW60 °C

Shoiaba-Mina pipeline system new pumping station - Main line pump (TMP 500 D2D 80 model)

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Project Description

Supply of 32 water transmission pumps for the Shoiaba III Water Transmission Project – Saudi Arabia.The Saline Water Conversion Corpo-ration (SWCC) operates the Phase 1 and 2 Desalination Plants in Shoaiba, which produce potable water for the cities of Jeddah, Makkah and Taif. The Phase 1 Plant has a design capacity of 40 MIGD while Phase 2 is designed for 100 MIGD.Since the cities of Jeddah, Makkah and Taif required additional water to satisfy the increasing demand of the population, SWCC decided to imple-ment a new Desalination Plant, Shoia-ba Phase 3, with a design capacity of 194 MIGD.Phase 3 comprises five pumping sta-tions, three water reservoirs and a 213-mile long pipeline network equipped with 32 pumps transporting water from the Shoaiba desalination plants to the cities of Jeddah, Makkah and Taif.

The Shoaiba-Jeddah Pipeline system consists of the new Pumping Station with four fixed speed booster (TMP 600DD54 model) and four main line pumps (TMP 400DD40 model) tran-sporting potable water from Shoaiba to the Jeddah Terminal.

The Shoiaba-Quaiza Pipeline system consists of the new Pumping Station with three fixed speed booster (TMP 700 DD 80 model) and three main line pumps (TMP 600DD54 model) tran-sporting potable water from Shoaiba to the Quaiza Reservoir.

The Shoaiba-Mina Pipeline system consists of the new Pumping Station with five fixed speed booster (TMP 600DD56 model) and five main line pumps (TMP 500D2D80 model) tran-sporting potable water from Shoaiba to the city of Makkah with the defined end point in Mina, i.e. the existing 1 million cubic meter reservoir at Mina.The main line pumps have a power of 9,650 kW, a capacity of 5,065 m3/h and a head of 552 m.

The Makkah-Taif Pipeline system con-sists of two new Pumping Stations with four fixed speed main line pumps (TMP PF3 350/450 model), each transporting potable water from the existing Makkah/PS 2 up to Taif.

The complete system transports the water from the coast up to an altitude of 1,700m, creating a pressure of 80bar in the system.

Horizontal centrifugal pump API 610 BB1

TMP 500 D2D 80 model

Pipeline system map

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In consideration of the very high design pressure, a FEM study was carried out to simulate the stress and strain state for casing and cover fastened by stud bolts. In particular, the contact area between lower casing and cover was investigated to ensure proper metal-lic seal. The results of this calculation were then checked and verified during the hydrostatic test by strain gauges installed on the pump.

In order to guarantee a low vibra-tion level, lateral and torsional critical speed analysis were carried out to verify the rotor’s compliance with API 610 VIII Ed.The new supplied pumps have a ca-pacity and hydraulic characteristics compatible with the pumps operating in the existing Plant (Phase 1 & 2).


The supplied two-stage pumps, TMP 500D2D80 model, have two double suction impellers, an horizontal arran-gement and are centre-line mounted. Due to these features, they assure high efficiency and very low NPSH req. values.The double suction impellers allow the axial balancing of the hydraulic thrust. The suction and discharge nozzles are located in the bottom half of the casing in order to remove the rotating assem-bly without disturbing piping and dri-vers and to allow a rapid control and maintenance of the inner parts. The stiff shaft and between bearings de-sign assures rotor stability at high flow and speed.The pumps are fitted with impeller/ca-sing wear rings, shaft sleeves and ba-lanced mechanical seals. The pumps are provided with an automatic venting system to prevent build up of gas in the pump casings.

Radial and thrust bearings are hydro-dinamic type. A lube oil system, mounted near the pump unit, is used to supply the lube oil to the pump and motor. The pump and the electric dri-ve motor are mounted on a separate steel skid.

The materials of major pump items are:

• Casing in cast steel ASTM A216 WCB

• Impeller in cast stainless steel Cr-ASTM A 743Tp. CF3M

• Shaft in stainless steel 13% Cr- ASTM A 473Tp. 420

• Wear rings and sleeves in stainless steel 13% Cr- ASTM A 473 T p. 420


Shoiaba-Jeddah pipeline system pumping stationMain line pump (API 610 BB1-type - TMP 400 DD 40 model)

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Chicago James W. Jardine water purification plant

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4 DuPage Water Transmission - Illinois U.S.A.


ClientConsultant

Country



Total HeadSpeed

Drive PowerWeight

DuPage Water TransmissionDuPage Water Commission - Villa Park - IllinoisS.A. Healy Co. - ChicagoAlvord, Burdick & HowsonU.S.A.

API 610-BB1 Water Pipeline Supply19,000 m3/h20 m352 rpm1,680 kW30,000 kg

Low lift pump - TMP 1000 DD 130 model

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Project Description

Supply of 10 pumps to the DuPa-ge Water Commission for the public aqueduct in Chicago. This water sup-ply system transfers the treated Lake Michigan water to 700.000 residents in 24 DuPage County municipalities.The source of the treated water is Chi-cago’s James W. Jardine Water Purifi-cation Plant, one of the largest filtration plants in the world.

All the pumps for the DuPage pum-ping station were designed and manu-factured by Termomeccanica Pompe. In detail:• n°2 low lift pumps TMP 1000 DD 130 model (horizontal split casing)

• n°4 high lift pumps TMP 750 DD 130 model (horizontal split casing)

• n°4 high lift pumps TMP 750 DDV 130 model (vertical split casing)

Horizontal centrifugal pump API 610 BB1-type

TMP 1000 DD 130 model

Testing of low lift pump (TMP’s test center)

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Although the rated head and, conse-quently, the discharge pressure were not high, stresses and strains of the cast casings had to be carefully cal-culated. A selection of strong cast iron ASTM A48 Cl 40 was therefore used.The metallic seal between pump lower casing and cover casing was a parti-cularly critical item and required an ex-tremely precise machining work of the contact surfaces with strict flatness tolerance and low roughness grade.The casting process of so large a casing presented considerable diffi-culties; investigations and trials were carried out in collaboration with the foundry in order to reach the best compromise between strength and easy castability.The large size and weight of the im-peller imposed a very rugged shaft; rotordynamic lateral analysis was car-ried out to ensure that the natural fre-quencies of the rotor were far over the rotating frequency.The the 1000 DD 130 pump designed and manufactured for this project is actually one of the largest of this type

ever supplied.The double suction impeller assures very low NPSH Required values, with consequent safe running for variable values of the suction head. Moreover, this solution allows to almost totally balance the axial thrust.The axially split casing allows to check the internal parts of the pump and re-move the rotor without piping and mo-tor disassembly.The pump is provided with impeller and casing renewable wear rings. The shaft, supported in-between bearings, is made of high quality construction al-loy steel in order to assure high rotor stability at any flow condition.The pump rotor is supported by two forced lubricated hydrodynamic radial sleeve bearings and one CH Kingsbu-ry type thrust bearing.The lubricating oil unit is integrated in the pump itself; no external oil sy-stem is necessary: a rotating pumping ring installed inside the Non Drive End (NDE) bearing casing provides a suffi-cient oil flow for the lubrication of the Drive End (DE) bearing.



• Casing: Cast Iron ASTM A48 Cl. 40 • Impeller : Bronze ASTM B584 • Shaft: Alloy Steel ASTM A322 Gr.4140

The pump is driven by a variable elec-tric motor connected to a Local Com-mutated Inverter (LCI); due to the very large size of the unit, the pump and relevant motor are separately installed on the concrete base plates in order to guarantee low vibration level.

Pump Materials

Map of Illinois - Lake Michigan, Chicago and DuPage County

Lake Michigan

Michigan

Indiana

Illinois

Wisconsin

Chicago

Waukesha

Milwaukee

Racine

Kenosha

Walworth

McHenry Lake

LakePorter

LaPorte

Starke

Jasper

St. Joseph

Berrien

Cook

DuPage

Kane

DeKalb

Kendall

Grundy

Will

Kankakee

Boone

Newton

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5 Basso Flumendosa - Mulargia Sardegna - Italy

TMP CPPD 800 model during final assembly at TMP workshop


ClientConsultant

Country



Total HeadSpeed


Length

Basso Flumendosa - MulargiaEnte Autonomo del FlumendosaImpregilo S.p.A.Università di PadovaSardegna (Italy)

TMP CPPD model Water Pipeline Supply3,600 m3/h220 m985 rpm1 kg/dm3

3,200 kW33 m

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Project Description

Supply of n°5 centrifugal multistage (four-stage) vertical pumps.The first stage of the pumps is double volute casing design with double entry radial impeller whereas the other stages are diffuser casing and have single entry mixed flow impellers.Each pump is installed inside a vertical well, which connects the support plate of the upper part of the pump with the water inlet tunnel.The vertical pump is coupled to a 6 KV electric motor, mounted on the pump stool and the motor speed is regulated by a variable frequency driver (VFD). Due to the peculiar geological cha-racteristics of the site and the suction water level, the pumps have a length of approximately 30 m between the

support plate and the suction bell.The pumping station has been desi-gned to operate in two distinct con-ditions: a first phase, with a planned operation period of 10 to 15 years, during which the water is to be tran-sferred from the Flumendosa river at the S’Isca Rena intake to the Mular-gia storage basin; a second phase, during which, upon the completion of the Monte Pedrosu dam, the plant will assure the water transfer between the two storage basins.Furthermore the plant will be equipped with a proper by-pass on the delive-ry piping in order to allow the transfer, during critical periods, of 5 million cu-bic meters/ year of water to the Flu-mendosa river bed to benefit the Mu-ravera plain stratum.

Vertical centrifugal pump TMP CPPD 800 model

Flumendosa river - Mulargia dam

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The configuration of the pumping sta-tion intake is very particular since it is composed of a first straight section tunnel followed by a sharp bend that leads into a further straight section from which the pipes that feed the suc-tion wells are derived. For this reason, experimental tests on a 1:6.5 scale plexiglass intake model were carried out to verify the adequacy of the lay-out with respect to the water flow fields approaching the pumps suction flare. Due to the particular constructive solution of the pumps, a FEM analysis of the machine was made in order to determine the stresses produced, ow-ing to own the weight, internal pres-sure, forces produced by the direction change of water flow in the delivery elbow; all of the above in combination with the maximum loads during the start and stop phases of the pump.The shaft line is composed of sev-

eral separate sections which are con-nected by means of rigid intermediate couplings, in two halves, that allow an easy disassembly, even after a long operation period.The shafts are guided by sleeve radial bearings, suitable for dry star, fitted in the pump casings and intermediate supports.The lubrication of all guide bearings is performed by the pumped fluid.The shaft seal is made of packing. The upper part of the delivery elbow sustains the guide and thrust sup-port equipped with two different roll-ing bearings, able not only to support the down hydraulic thrust and the ro-tor weight, but also possible transient conditions which might generate up thrusts.The lubrication of the upper bearing is oil bath type.


The lower hydraulic part of the vertical pumps, TMP CPPD 800 model, is fun-damentally composed of the double suction impeller, the lower suction bell and the double volute casing.The upper suction bell and the two delivery ducts (made of a single pie-ce) are included in the double volute casing itself.The latter allows the balance of the ra-dial thrusts; the water is conveyed by the delivery ducts to the impeller inlet of the subsequent stages through the long pump column. The subsequent stages consist of mixed flow impellers along with the related diffuser.The motor stool and the delivery elbow are two separate components in order to assure a more reliable support of the motor itself.

The power dissipated by the bearings is disposed of by a proper refrigerating coil.

The pump materials are: • Cast static parts (suction bells, volute casing, diffusers, first stage delivery branches): nodular cast iron ASTM A 536 65.45.12

• Fabricated static parts: carbon steel ASTM A 283 Gr. D

• Rotating parts: stainless steel 13% impellers ASTM A 743 CA6NN; wear rings & shaft sleeves ASTM A 473 Tp. 420

• Shafts: carbon steel ASTM A 322 Gr.4140


Short version of the CPPD 800 pump to allow testing at TMP’s test center

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Advertising published in the Italian press on the occasion of the inauguration of the Sardar Sarovar pumping station

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6 Saurashtra Branch Canal India


ClientConsultant

Country



Total HeadSpeed


Saurashtra Branch Canal Pumping SchemeSardar Sarovar Narmada Nigam Ltd.Kirloskar Brothers Ltd.N.T.P.C.India

TMP NV3000 model Water Handling72,000 m3/h16 m200 rpm1 kg/dm3

4,000 kW

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Project Description

Design, supply and erection of the five pumping stations for the Saurashtra Branch Canal, which is a major branch of the main Canal of the Sardar Saro-var Project on the Narmada River in the north of India.The order was awarded to Kirloskar Brothers Ltd. together with Termo-meccanica Pompe.The Sardar Sarovar Project, the world’s largest pumping system, has changed the morphology of the Gujarat State

from a desert to an irrigated agricultu-ral area covering 1,800,000 hectares, benefiting 132 major towns as well as a large number of villages.A total number of 26 concrete volu-te pumps have been installed in the pumping stations.The initial total installed capacity for irri-gation and drinking water is 1,476,000 m3/h, however, an additional 39 iden-tical pumps might be installed in a fur-ther stage to complete the project.


The five pumping stations of the Sau-rashtra Branch Canal have a similar arrangement. The figures above show the general arrangement of one of the pumping station as well as the cross-sectional drawing of a typical concrete volute pump. The impeller is semi-open, mixed-flow type, overhung and supported by a pair of radial bearings.The lower bearing is lubricated by the

pumped liquid while the upper one is installed in the oil bath of the bearing housing.The axial thrust is borne by the bea-ring of the reduction gear box, which is located between the pump and the electrical motor.The shaft seal is packing type and pro-visions have been included to avoid flo-oding of the pumping station during re-moval of the packing for maintenance.

Concrete volute pumpTMP NV3000 model

Pumping station arrangement Pump & motor assembly

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The discharge volute and the suction duct are made of concrete and are in-corporated into the civil works. Some embedded metallic parts are provided to support the impeller liner and the pump cover and to reinforce and pro-tect the volute tongue area. The con-crete pouring method and several ca-sting steps have been defined through close cooperation between the pump designer and the civil engineers. The hydraulic performances of the pump, including the suction channel and the discharge siphon, have been validated by tests carried out by CFD analysis and also by reduced dimen-sion model pump. Very extensive measurements were performed in order to verify the be-haviour of the impeller under cavita-tion conditions; visual examination of the flow fields on the impeller blades were recorded through stroboscopic examinations.The increase of the bub-ble length on the suction side of the impeller blade, as a result of lowering the available NPSH, was shown at two different flow rates. Particular attention was paid to the geometry of the di-scharge siphon in order to achieve mi-nimum losses during normal operation and to assure proper priming during pump start-up.


Sardar Sarovar dam

NV concrete volute pump - sectional drawing

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7 Shuweihat Power & Desalination Plant U.A.E.


ClientConsultant

Country



Total HeadSpeed

Drive PowerDesign Temperature

Weight

Shuweihat Power & Desalination PlantShuweihat CMS International Power CompanyFISIA ITALIMPIANTI S.p.A.PB Power Ltd.U.A.E.

API 610-VS7 Brine Recirculation 14,300 m3/h95 m495 rpm5,100 kW45 °C66,000 kg

Brine Recirculation pump being tested at TMP’s test center

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Project Description

Supply of n° 39 pumps to Fisia ltalim-pianti for the Shuweihat Complex S1 Combined Cycle Power & Desalination Plant. Such plant is the largest distil-ler in the world with a capacity of 16.6 Mgd.The evaporators are multi-stage flash (MSF) type, with brine recirculation and cross tube, using an improved chemical as antiscale treatment for seawater make-up.

Termomeccanica Pompe manufactu-red the Plant’s main process pumps; in detail:• 12 brine recirculating pumps TMP 1300 CEXD 180 model• 12 brine blow down pumps TMP 75 C1EX 68 model• 12 distillate pumps TMP 58 C1EX 53 model• 3 potable water export pumps TMP 1000 DD 130 model

The brine recirculation pumps (2 x 50% each distiller, operating in pa-rallel) inject the brine, mixed with fresh sea water make-up into the last reco-very stage tube bundle, and recirculate it through all recovery stage bundles.

Vertical centrifugal pump API 610-VS7

TMP 1300 CEXD 180 model

Shuweihat desalination plant

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The 1300 CEXD 180 brine recircu-lation pumps are of an exceptionally large size. Moreover, the materials in contact with the handled fluid, brine from sea water with high salinity grade, have to be very accurately selected for high corrosion resistance.These two factors have presented specific problems for the design acti-vity. The very large dimensions of the pressure retaining parts, such as ca-sing, connection casing, columns and elbow, are heavily stressed due to the high value of the total head.A strong and corrosion resistant au-stenitic cast iron was thus selected; the casing wall shape and thickness were also accurately investigated and a specific FEM analysis was carried out.The suction barrel wall, of a 3,650 mm

diameter, was calculated for external pressure condition (vacuum inside); the highly strong carbon steel structu-re was internally cladded with 2.5 mm of CuNi 90-10 in order to guarantee the corrosion resistance to the brine fluid in contact with it.The 5,100 kW electric motor is loca-ted on a motor frame: its dimensions (3,650mm width x 4,500mm height) and its 45,500kg weight have required a special supporting frame configura-tion allowing static strength and dyna-mic stability.The pump was tested at full operating conditions in a TMP test room. The depth of the test basin and the high capability of the crane hook allowed to test the entire pump unit, complete of job motor, for a total height of 15 m above the ground level.


The 1300 CEXD 180 is a vertical pump, equipped with n°1 radial type double suction impeller (with a 1,700 mm outlet diameter). This size is ac-tually the largest supplied for this type of pump and service.The hydraulic part of the pump inclu-des the casting components (suction bell, casing, impeller, discharge con-nection branches) connected to the rising column. On the ground level, the motor frame is arranged, including the discharge elbow of a 1,300 mm dia-meter. The 2,000 mm diameter suc-tion nozzle is located on the suction barrel in vacuum condition.The double suction impeller solution guarantees low NPSH values that al-low to limit the length of the barrel and to assure the necessary safety mar-gin between Available and Required NPSH. The double suction impeller is moreover fully balanced; no hydraulic thrust is produced on the rotor so the upper thrust bearing is loaded by the rotor weight only. The thrust bearing is located on the motor frame; the elec-tric motor has a proper thrust bearing.In the upper bearing casing, oil bath lu-bricated combined sleeve radial/titling pad axial thrust bearings are provided.

The very low axial load in comparison with the maximum allowable load of the bearing assures a very long life of the pads. Casing and impeller wear rings are provided in order to preser-ve the integrity of these components during possible transient contacts between stationary and rotating parts. The pump shaft is connected to the motor shaft by a gear coupling with spacer; the spacer removal allows the thrust bearing maintenance without motor removal.

The pump materials are:• Casing: NiResist Cast Iron Din1694 GGGNiCrNb 20.2 • lmpeller:S.Steel-ASTMA 743 CF3M • Shaft: Duplex S.S. Steel - UNS S31803 • Riser Columns: Stainless Steel Plate ASTM A 240Type 316L• Discharge Elbow: Stainless Steel Plate ASTM A 240Type 316L• Suction Barrel: Carbon Steel - Internally cladded with CuNi 90-1 0 - 2.5 mm th.


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Main water injection pump being tested at TMP’s test center

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8 Zubair Oil Field Development Iraq


ClientCountry



Total HeadSpeed


Design Temperature

Zubair Oil Field DevelopmentMinistry of Oil - South Oil CompanyEni Iraq b.v.Iraq

API 610-BB5 Water injection 1,100 m3/h1,721 m5,350 rpm1.064 (max 1.13) kg/dm3

8,700 kW27-40 °C

TMP test center - main water injection pump (back left) connected to booster pump (front right)

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Project Description

Supply of 12 API 610 pumping units, which include the operation & monito-ring of the stations injecting water into the wells to extract crude oil.Each pumping unit is composed of a main water injection pump (MWIP), API 610 BB5-type, with a capacity of 1,100 m³/h and a head of 1,721 m at a speed of 5,350 rpm connected to a booster pump, API 610 BB1-type, with the same capacity of 1,100 m³/h and a head of 106 m at a speed of 1,485 rpm, which, in its turn, is dri-ven by a motor with a capacity of 500 kW, a voltage of 6,000 V at a speed of 1,485 rpm. The MWIP is driven by an electric motor with a capacity of 8,700 kW, a voltage of 3,300V and a speed of 1,495 rpm. A gearbox is positioned between the pump and motor in order to increase the speed from 1,495 rpm (motor shaft) to 5,625 rpm (maximum pump shaft speed).The motors that drive the main water injection pumps are equipped with variable frequency drives (VFDs) in or-der to optimize production and related consumption depending on the various requirements of the plant over time.The pumping unit composed of MWIP, gearbox and electric motor is lubrica-ted by a lube oil system with a capacity of 5,000 l and a flow of 300 l/min.Each MWIP is equipped with a 10MW power transformer which decreases the voltage from 32kV to 4x1.8kV and goes to a VFD connected to the mo-tor. Considering the importance of the equipment and of the uninterrupted operation of the plant, each pumping unit is also equipped with a LER (Lo-cal Electric Room) ensuring the control of the most relevant parameters such as temperatures, pressures and vi-bration levels. Such parameters allow to assess the correct operation of the pumping units, even by remote control, minimizing any chance of faults thus extending maintenance intervals.As the electric powers in question are high (10 MW), the heat level reached requires the use of important cooling systems. For this reason, each pum-ping unit is equipped with an oil heat exchanger for the cooling of lube oil system as well as with a water chiller for the cooling of the VFD.

Horizontal centrifugal pumpAPI 610 BB5-type

TMP MESBD 300.4 type

Main water injection pump - machining of the barrel

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The main water injection pump, TMP MESBD 300.4 model, is a full cartridge pull-out pump, with double entry first stage impeller, designed according to the API 610 Standard latest edition.The cartridge includes rotor with in-line impellers, diffusers, intermediate casings, cover heads, mechanical seals and bearing housings. The car-tridge can be easily withdrawn without disconnecting the pipe flanges and wi-thout moving the driver.The barrel casing is cast with inclined suction nozzle and on top discharge nozzle.

Due to the pump service and the pum-ped water characteristics, super du-plex materials have been used.In particular, the following materials have been selected for the main com-ponents:• barrel: ASTM A890 Gr. 5A• impellers: ASTM A890 Gr. 5A• diffusers: ASTM A890 Gr. 5A• casings: ASTM A890 Gr. 5A• shaft: ASTM A182 Gr. 55

Pump type and materials

The equipment are to be installed at three different sites, Zubair Mishrif, Hammar Mishrif and Rafidiya, areas with severe environmental conditions. This has entailed the application of stringent design regulations ensuring that the pumping units are suitably re-liable over time.Furthermore, given the particular com-plexity of the supply, the customer requested the workshop string test of the pumping unit, with all its auxiliary components in the final on-site confi-guration.Termomeccanica Pompe is actually one of the only companies in the world with the know-how and facilities to support such a complex test set-up.In fact, the string test of the pumping units in question required 1,000 m² of the total 2,500 m² of the overall testing facilities. Moreover, even though it was not included in the contract terms, TMP purchased and installed in its test center a 10MW power transfor-mer transforming 6 kV with 4x1.8 kV outputs, similar to the one to be in-stalled on site in order to replicate as well as possible the plant’s operating conditions.

The complete site replication also re-quired to feed the main injection pump with its booster pump, fed in its turn by a vertical auxiliary pump of the test center. Such auxiliary pump sucks wa-ter from the test center basins (with a depth of up to 10m and a total volume of 3,000 m³).

How the string test is performed:Various valves and electromagne-tic flow meters as well as pressure transmitters are positioned in the pi-ping connecting the pumps (test cen-ter auxiliary pump, booster pump and MWIP). Through the regulation of the above-mentioned valves (opening or closing) and the MWIP speed, flow is modified and it is possible to observe the operation of the system under va-rious conditions which are defined by a specific procedure. Once the system is stabilized at each specific flow, all main parameters are measured and recorded: flow, heads, powers, tem-peratures and vibrations.


Test center string test configuration

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Export oil pipeline pump (BB5-type)

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9 Greater Stella Area Development FPF1 Offshore Platform Upgrade & Modification North Sea – U.K.

Name of Project

End UserClient

Country

Main Pump Performance DataPump Type


Total HeadSpeed


Design Temperature

Greater Stella Area DevelopmentFPF1 Offshore Platform Upgrade & ModificationIthaca EnergyPetrofac U.K.North Sea - U.K.

API 610-BB5 Export Oil170 m3/h2,075 m3,280 rpm0.804 kg/dm3

1,500 kW60 °C

FPF1 on dry dock barge

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Project Description

Design and supply of all the16 centrifu-gal pumps for the refurbishment of the FPF1 platform assigned to the offsho-re processing and export of hydrocar-bons extracted from the Greater Stella Area located in the UK’s Central North Sea continental shelf.

The supply is composed of:

• 2 export oil pumps with their booster pumpsThe export oil pumps are API 610 BB5-type, TMP MESB 150.11 model, with a power of 1,500kW, a head of 2,075 m and a capacity of 170m³/h while the booster pumps are API 610 OH2-type, TMP 100 AP 50 model, with a power of 132kW, a head of 122m and a capacity of 185m³/h. (see next page for further details)

• 3 cooling circulation pumps For the cooling medium circulation service, the contract included the sup-ply of 3 vertical “in-line” pumps, with a flow rate of 1,050 m³/h at a 56.5 m head and driven by a 230 KW elec-tric motor. The specific requirements of the project, particularly the need to reduce the overall dimensions of the machinery without affecting its techni-cal performances, led to a tailor-made solution with the supply of Termomec-canica DDBV-type pumps.

• 9 utility pumps

Vertical suspended pumpsTermomeccanica Pompe’s supply in-cluded 2 vertically suspended pum-ps: one VS2-type pump, working as glycol transfer pump (Termomeccani-ca CPP50.1 model) and one VS4-type pump, working as drain sump pump

(Termomeccanica 25CPPL16 model).Once again, the peculiarities of the project prevailed over design stan-dardization. The lack of space on the platform deck did not allow the development of design according to API610 standard as originally planned. In fact, the entire upper part of the pump surmounting the baseplate had to be completely re-designed so as to reduce height and allow installation as well as maintenance of the pumps in the small space available on the deck.

Utility pumpsThe remaining utility services of the platform are covered by 7 overhung OH2-type pumps: two off-gas com-pressor suction drain pumps (TMP 25AP32 model), three heating medium circulation pumps (TMP 80AP20 mo-del) and two methanol make-up pum-ps (TMP 25AP32 model).

As it is usual for offshore projects, cer-tification has represented an essential component of the scope of work of the supply. In addition to the CE mar-king and ATEX certification, project specifications have further required the involvement of the Lloyd’s Register as Inspection & Verification body for ma-rine classification, of Bureau Veritas as third party inspector and of T.U.V. for the P.E.D. related activities.

It is also important to note that with this supply Termomeccanica Pompe had to face many design and manage-ment challenges due to the numerous special requests, going well beyond the usual complexity that mark offsho-re projects, which emanated from both client and end-user.

Horizontal centrifugal pumpAPI 610 BB5-type

TMP MESB150.11 model

Export pipeline booster pump (OH2- type)

Cooling medium circulating pump (TMP DDBV model)

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Base Plate - General Arrangement – Bottom View Base Plate FEM model

It is important to remember that this project stems from the refurbishment of an existing platform, with already defined spaces and a pre-existing hull, platform which moreover is to operate in rough sea conditions. The combina-tion of these additional project-specific factors have entailed a further increase of the supply’s design complexity. In fact, design not only had to be adap-ted to the particularly limited spaces available but also had to take into ac-count the tight constraints of vessel motion specification on structural ele-ments and accessories; design further had to take into consideration interfa-ce loads higher than usual for this type of application. All the above requirements have called for the necessity to dedicate conside-rable resources to engineering activi-

ties, substantially higher than for other comparable projects, whether related to the “ad hoc” design of the basepla-te and other skid structural elements of the main oil export pump or to the methodical use of FEM analysis for both design and verification of various components of the supply.The engineering of auxiliary and elec-trical components such as inverters, electric motors and lube oil systems was also subject to the limitations im-posed by the afore-mentioned requi-rements.

A HAZOP review was conducted at design completion in order to verify that all measures necessary to gua-rantee the safe operation of the plant had been taken into account during the design phase.

The export of oil in the FPF1 platform is carried out by two BB5-type pum-ps, TMP MESB 150.11 model, i.e. an 11-stage barrel pump made of ASTM A743 CA6NM material.Each pump is coupled with a 1,5 MW electric motor working under inverter. The use of the inverter was necessary to guarantee the pump working range under the various conditions expected during the development of the oil field, i.e. for a flow rate of 170 m³/h with the head ranging from 1,350 m to 2,073 m, obtained by increasing speed from 2,720 rpm up to 3,280 rpm.The use of the inverter also proved ne-cessary to increase the pumping pres-sure so as to remove wax obstructions that could be generated during pum-ping stop at typical North Sea tempe-ratures, with the possibility to reach up to 2,584 m at 3564 rpm with a flow rate reduced to 120 m³/h.

The export oil pumps are coupled with OH2-type pumps (Termomeccanica 100AP50 model) working as booster. Both the main and booster pumps are provided with double pressurized me-chanical seals with API PLAN 53/b.

Furthermore, the customer, Petrofac Engineering, required both the main and booster pumps to be installed on three-point baseplates and to have a special blast load resistance design.


Pump Type and Performance Data Main oil export pumps & booster pumps

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Sea water pump - API610 VS1-type - TMP 75C1PP63 model

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10 Dunkerque LNG Terminal France


ClientCountry

Performance DataRated Capacity

Total HeadSpeed


Design Temperature

Dunkerque LNG TerminalDunkerque LNGUTE TS LNG DUNKERQUE – Italy & Spain France

8,975 m3/h36 m595 rpm1.03 kg/dm3

1,350 kW34 °C

Dunkerque LNG aerial view

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Project Description

An LNG receiving terminal is the arrival point for LNG tankers in a gas utiliza-tion region. It is where a ship’s liquefied natural gas cargo is unloaded and sto-red in its liquid state, then re-gasified and fed to the natural gas pipeline sy-stem as required by market demand.

The Dunkerque Liquified Natural Gas regasification plant has three 190,000 m³ storage tanks and is designed to produce 13 BCMA (Billion Cubic Me-ters per Annum) of natural gas, equa-ling a supply of 1,9 million m³(n)/h (cu-bic meters per hour). It is equipped with a jetty, unloading arms and pipes, storage tanks, sy-stems for regasification and gas emis-sion, a BOG (boil-off gas) recovery sy-stem, a flare stack, a seawater pump system for vaporization, auxiliary sy-stems and a series of buildings (offi-ces, control buildings, safety facilities, etc.) specifically designed for the ope-rations.

Termomeccanica Pompe has supplied for the Dunkerque LNG regasification plant n.5 sea water pump systems,

which include the pumps with their re-levant instrumentation, electric motors and air release valves as well as the following 9 firefighting units:• 1 main pump and its electric motor• 2 diesel pumps complete with diesel engines, tanks, control switchgears and angle gears• 2 jetty pumps and their electric motors• 3 jockey pumps (2 main+1 spare), electric motors and common baseplates• 1 test pump, electric motor and common baseplate

Sea water pumps (SWPs) represent a particularly high added value supply for an LNG terminal in relations to the re-gasification phase. Indeed, Open Rack Vaporisers (ORV) are commonly used to heat and vaporize the LNG using the seawater that is pumped from vertically suspended pumps in-stalled in a sea water intake. As such, the SWPs play a critical role in this ap-plication, both in terms of reliability and energy consumption.

Vertical centrifugal pumpAPI 610 VS1-type

TMP 75C1PP63 model

Sea water pump - API610 VS1-type - TMP 75C1PP63 model

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Test pump - API610 OH2-type TMP 100AP40 model

Diesel pump - API 610 VS2-type TMP 400CPPD60 model

The sea water pumps supplied by Termomeccanica Pompe are vertically suspended with mixed flow impeller. All cast and fabricated steel compo-nents have been manufactured using duplex steel, except the motor stools that have been manufactured with the following materials:• Wet parts: duplex steel• Non wet parts: carbon steel

The same pump type and materials were selected for the firefighting ver-tical pumps, i.e. the main, diesel and jetty pumps while the test and jockey pumps are horizontal, overhung type and their main components are made of carbon steel.

Pump type and materials

Given that the settlement of the definiti-ve geometry of a pump intake is on the critical path of an LNG project sche-dule and that, consequently, the sea water pumps are the first equipment to be commissioned, Termomeccani-ca Pompe has cooperated with both the end user and EPC contractor for the design of the pump intake of the project. TMP’s Research & Development De-partment actually verified that the pump intake met the criteria the De-partment had defined through its own experience and that it also complied with the recommendations establi-shed by the Hydraulic Institute Stan-dards through two different steps:• a Computational Fluid Dynamic analysis which allows to implement the modifications necessary to eliminate disturbances and vortices in the ap-proach flow patterns and within each pump sump; this study implied to con-sider all possible operating conditions; • physical tests on the intake model of reduced dimensions which allow to observe any type of vortex (free-surfa-ce, sub-surface) with the help of dye

or artificial debris and to verify whether the HI acceptance criteria are satisfied; finally, swirl angles in the pump suction were measured by proper swirl meter and compared with the maximum allo-wable value.

In order to guarantee a high level of quality, an accurate pump inspection test plan was strictly followed, inclu-ding several preliminary tests on each main components such as hydraulic tests on the pressure components and a balancing test on the impeller which were performed at TMP’s workshop. Very special attention was dedicated to the painting cycle of carbon steel parts because of very aggressive am-bient conditions.In accordance with the API 610 stan-dards, a performance test of each pump and related electric motor was finally carried out at the company’s in-house test center in order to verify the contractual parameters such as flow, head, power consumption, minimum submergence level, vibrations, tempe-rature and noise level.


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Trinidad and TobagoThailandTunisiaTurkeyU.A.E.U.K.

UruguayU.S.A.

VenezuelaYemen

Wordwide presence

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TM.P. S.p.A. Termomeccanica Pompe

TM.P. S.p.A. - Termomeccanica PompeVia del molo, 3 - 19126 La Spezia - ItalyTel. +39 0187 5521 / Fax. +39 0187 552506e-mail: [email protected] T

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