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300 Reciprocating Pumps
Abst rac t
This section discusses engineering principles, pump types, application and selection
criteria, and describes two commonly used reciprocating pumps. See Section 1100
for troubleshooting information.
Contents Page
310 Engineering Principles 300-2
320 Pump Types 300-4
321 Single and Double Acting Pumps
330 Application and Selection Criteria 300-7
331 Gas (Steam) Driven Pumps
332 Power Pumps
333 Sizing of Suction Lines
334 Selecting a Reciprocating Pump
CAUTION: Based upon the publication date, this document may not contain the latest
guidance. The user is strongly advised to contact the Technology Manual Sponsor to
determine the appropriate subject matter expert for consultation on applicability to the
users specific case.
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310 Engineering Principles
A reciprocating pump is a positive displacement machine. It traps a fixed volume of
liquid at near-suction conditions, compresses it to discharge pressure, and pushes it
out the discharge nozzle. The basic principle involved is that a plunger or piston will
displace a quantity of liquid equal to its swept volume. In Figure 300-1, plunger A is
lowered into the container, displacing liquid which flows into container B. The
volume of liquid in container B is equal to the product of the cross-sectional area
of plunger A and the depth of immersion. In a reciprocating pump, the action of
plunger A is accomplished by a reciprocating piston, plunger, or diaphragm.
The fluid-handling section of a reciprocating pump is commonly called the liquid
end. The liquid end has a piston or plunger that displaces the fluid being pumped; a
close-fitting cylinder in which the piston travels; and suction and discharge valves
to admit and discharge the pumped fluid. Packing prevents liquid from leaking past
the rod attached to the piston, or, in a plunger pump, past the plunger.
Figure 300-2depicts the suction stroke of a plunger pump. When the plunger moves
away from the head end of the cylinder, the discharge check valve is held closed by
the higher pressure in the discharge pipe compared to the lower pressure in the
liquid cylinder. This lower pressure in the liquid cylinder also causes the suction
valve to be opened by the higher pressure in the suction line. Fluid then flows intothe cylinder until the plunger reaches the end of its travel.
Fig. 300-1 Reciprocating Pump Principles From Pump Handbook, (1976) Edited by Karassik,
Krutzch, Fraser & Messina. Used with permission from McGraw Hill.
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Figure 300-3depicts the discharge stroke of a plunger pump. As the plunger moves
toward the head end, the increasing pressure in the cylinder closes the suction valve.
The pressure in the cylinder continues to rise until it exceeds the pressure in the
discharge line and the discharge valve opens, releasing the volume of fluid
displaced by the plunger.
Unlike the centrifugal pump, which is a kinetic machine, the reciprocating pump
does not require velocity to achieve pressure. This is one of the reciprocating
pumps advantages, particularly for abrasive, slurry, and high-viscosity applica-
tions. High pressures can be obtained at low velocities, and fluid capacity varies
directly with pump speed.
The discharge pressure of a reciprocating pump is only that required to force the
desired volume of liquid through the discharge system. Within the constraints of
pump construction, the maximum pressure developed for gas-driven pumps is
limited only by the differential gas pressure available; for crank-driven pumps, the
driver torque is the only limit.
The flow of liquid from a reciprocating pump pulsates, varying both in flow rate and
pressure. As the piston or plunger moves back and forth in the cylinder, alternately
opening and closing the suction and discharge valves, a cyclic pulsation is set up in
the suction and discharge lines of the pump. Figure 300-4shows the changes in flow
rate as a function of crank angle for duplex, triplex, and quintuplex single-actingpumps. These changes become less severe as the number of stages increases.
Fig. 300-2 Plunger Pump Liquid End During Suction
Stroke From Pump Handbook, (1976) Edited
by Karassik, Krutzch, Fraser & Messina.
Used with permission from McGraw Hill.
Fig. 300-3 Plunger Pump Liquid End During Discharge
Stroke From Pump Handbook, (1976) Edited
by Karassik, Krutzch, Fraser & Messina.
Used with permission from McGraw Hill.
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Fig. 300-5 Typical Single- and Double-acting PumpsCourtesy of The Hydraulic Inst itute
Double-Acting Cylinder Pump
Vertical Single-Acting Plunger Power Pump
Horizontal Single-Acting Plunger Power Pump
Horizontal Double-Acting Piston Power Pump
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Reciprocating pumps are typically classified by:
1. Type of drive
a. Direct-acting, gas-driven
b. Crank-driven (power pumps)
2. Cylinder orientation
a. Horizontal
b. Vertical
3. Liquid end arrangement
a. Plunger (outside packing)
b. Piston (inside piston rings and packing on the piston rod)
c. Diaphragm (plunger or air pushing a flexible diaphragm)
4. Number of pistons or plungers
a. Simplex
b. Duplex
c. Triplex
d. Quintuplex, etc.
Fig. 300-6 Diaphragm Positive Displacement Pump (Shown here as Double Diaphragm posi-
tive Displacement Pump)
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5. Type of action
a. Single-acting (delivers on either forward or backward stroke, not both)
b. Double-acting (delivers on both forward and backward strokes)
Figure 300-7illustrates these classifications. (Metering pumps that use a recipro-cating motion are described in Section 500of this manual.)
321 Single and Double Acting Pumps
Single-acting pumps discharge on either the forward or return stroke of the piston or
plunger; every cycle of the pump displaces only one volume of liquid. In double-
acting pumps, liquid is discharged on both the forward and return stroke of the
piston. Plunger pumps are only single-acting; piston pumps can be either single- or
double-acting. Figure 300-5illustrates this pump action.
Simplex, Duplex, and Multip lex Pumps
The terms simplex, duplex, and multiplex refer to the number of piston-and-rod
assemblies in a pump. Simplex pumps have one piston-and-rod assembly; duplex
pumps have two; multiplex pumps have three or more.
330 Application and Selection Criteria
This section discusses selection of reciprocating pumps. With the accompanying
Pump Applications Guidelines, it will allow an individual to select pumps for most
services.
There is normally little problem in choosing between the two basic types of pumps,
direct-acting gas driven pumps and crank-driven power pumps. Gas driven pumps,
once the workhorse of the industry, are generally limited to utility functions by the
availability of compressed gas such as steam, air, or field gas. Power pumps, which
are motor, turbine, or engine driven, are available in a wide spectrum of capacities
and heads.
Fig. 300-7 Reciprocating Pump Sub-types Permission granted. Chemical Engineering,
September 21, 1981.
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331 Gas (Steam) Driven Pumps
Gas-driven pumps are commonly used for sump pump, transfer, low pressure boiler
feed, or relief drum pump-out. Although their speed and capacity are directly
affected by system pressures, gas driven pumps are of particular value when:
1. Electric power is not readily available or is unreliable.
2. A standby pump is required for use during electric power failures.
3. A wide capacity range, easily achieved by varying pump speed, is required.
4. Steam for pumping is available at little or no cost (when, for example, exhaust
steam from pumps is used to heat the pumped product).
Duplex gas pumps are more generally used than simplex because of their larger
capacity, smoother discharge, and simpler valve mechanism. Duplex pumps are also
made in a greater variety of sizes and types than are simplex pumps, which were
developed largely for vacuum or other low-pressure service.
The simplex is usually slightly more efficient than the duplex and has one less set ofpacking. Simplex pumps are usually preferable in vacuum or other services where
gas or vapor must be handled. Duplex pumps may short-stroke and fail to clear
themselves of vapor. In fact, they may vapor lock and come to a complete stall.
Because the simplex valve mechanism prevents short-stroking, close-clearance
pumps, designed especially to handle gas or vapor, are commonly made only in the
simplex type.
Reciprocating gas pumps range in size from a small 3 2.75 3-ft. pump, rated to
handle 23 gpm water, up to a 25 12 24-ft. pump capable of handling 1150 gpm
with a maximum liquid-end working pressure of 750 psi. Simplex pumps are ordi-
narily not made for capacities over about 500 gpm.
Selection of gas driven pumps requires attention to pump speed as it relates to the
required capacity in any given service. Figure 300-8shows the maximum recom-
mended piston speeds and corresponding revolutions per minute for direct-acting
gas pumps in various services. This figure represents the manufacturers recommen-
dation for maximum speed in these services. These speeds are acceptable for
standby or infrequently operated pumps, but should be reduced for pumps in contin-
uous service. For best operation, continuous duty pumps should be sized to run from
50 percent to 75 percent of the maximum speed shown on Figure 300-8.
See Figure 300-9for additional application guidelines.
Sizing of Steam Cylinders
When possible, steam-cylinder diameters should be selected based on the required
work. Oversizing steam cylinders permits overspeeding the pumps with greatly
increased wear and high maintenance costs. Steam consumption is increased and
there is the possibility of overpressure. If a steam cylinder of the proper size is
selected, overspeeding will be minimized and it will not be necessary to place a
relief valve on the pump discharge.
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300-9
Fig. 300-8 Maximum Recommended Speed and Capacity of Direct-Acting Gas Pumps
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On the other hand, steam cylinders should not be too small. An adequate allowance
should be made for tight packing, leaking valves, and other bad service conditions.
Such an adequate allowance will result if steam inlet pressure is taken as the
minimum pressure actually available at the inlet to the pump after making properallowance for piping and valve losses, and the mechanical efficiencies given below
are applied.
In general, the tendency is to make the liquid piston too small and the steam piston
too big with the result that the pump has no difficulty in meeting the required pres-
sure, but has to be overspeeded to meet its capacity. If the liquid piston is gener-
ously large, there is no incentive for the operator to overspeed the pump; and, if the
steam cylinder is not too large, it may be impossible to overspeed it.
A formula for estimating the required diameter of the steam-end cylinder is as
follows:
(Eq. 300-1)
Fig. 300-9 Reciprocating Pump Application Guidelines
Pu mp Des cr ipt io n Di rect A ct in g Po wer Pl un ger Po wer Pi sto n
Self Priming Y Y Y
Can Run Dry-Short Time Y Y Y
Will Emulsify N N N
Field Alignment Reqd N Y Y
Good for Some Entrained Gas Y Y Y
Good for Abrasives Y N Y
Parallel or Series Recommended P P P
Brgs Lub. (Oil, Grease, Stock) S O O
Coupling Rigid or Flexible N/A F F
Legend:
Y = yes, N = no
P = parallel
O = oil
S = stock
F = flexible
N/A = not applicable
Note: Pumps are commercially available outside the parameters shown. These pumps should be
avoided or, if they are used, special care should be taken to maintain reliability.
Ds2 DL
2
E----------
Pd Ps
Pi Pe-----------------=
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where:
Ds = Steam piston diameter, inches
DL = Liquid piston diameter, inches
Ps = Pump suction pressure, psig
Pd = Pump discharge pressure, psig
Pi = Steam inlet pressure, psig
Pe = Steam exhaust pressure, psig
E = Mechanical efficiency
Reduce above efficiencies by 1/10 if viscosity exceeds 4000 SSU or differential
pressure exceeds 300 psi.
Steam Consumption
The steam consumption of a steam-driven reciprocating pump may vary consider-
ably from one pump to another even though they are all identical in design and
under similar service conditions. The steam consumption will be affected by the
mechanical condition of the pump, the accuracy of the valve timing, the tightness of
the packing, etc. Figure 300-10illustrates how to determine the approximate steam
rate of direct-acting duplex-steam pumps in pounds per hydraulic horsepower hour.The steam rate of simplex pumps can be obtained by taking about 93% of that
obtained for a duplex pump. Figure 300-11illustrates the formula with applicable
notes corresponding to Figure 300-10.
A simple direct-acting steam pump cannot take any advantage of expansion of the
steam. Therefore, the steam rate is not materially reduced if steam pressures higher
than about 150 psi are used. Thermodynamically, it is better to take advantage of
expansion above this pressure in other equipment. Exhaust back pressure always
increases the steam rate materially.
Inlet steam pressure is not mentioned in the formula or the graph. The formula
assumes that enough initial steam pressure is available to do the required amount ofwork. This will be true if the steam cylinder is of the proper size. Steam pumps are
almost invariably operated with a hand or automatic valve, throttling the inlet steam
to provide the required pressure, and limit or regulate the speed.
Stroke Inches Approx. Eff.
Up to 6 .60
8 to 12 .70
Above 12 .75
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Fig. 300-11 Steam Rate of Direct-Acting Duplex Steam Pumps (1 of 2)
The following formula is very simple to use and will give a good approximation of the steam consumption of a simple
duplex steam pump in fair mechanical condition. Experience shows that under the most favorable circumstances,
some pumps do better, but that many with leaky valves or otherwise in poor condition do worse.
(Eq. 300-2)
where:
S = Total steam consumed, pounds per hour.
Q = Gallons per minute of liquid pumped.
P = Difference between suction and discharge pressure, in pounds per square inch.
es = Steam efficiency See table below.
Pb = Back pressure on exhaust pounds per square inch gage.
P = Friction m.e.p. referred to steam cylinder in lbs. per sq. in. See table below.
ev = Volumetric efficiency; usually over .95, and usually taken as 1.0 for rough figures; may be as low
as .5 for pumps in bad condition.
r = cylinder ratio, or ratio of area of the steam cylinder to the liquid cylinder.
Approx imate Steam Ef ficiency and Fr ic tion M.E.P.of Dup lex Steam Pumps
Stroke of pump 3" 4" 5" 6" 8" 10" 12" 15" 18" 24"
Steam eff., es .35 .375 .39 .40 .425 .45 .475 .50 .525 .55
Friction m.e.p., P
outside packed pumps
31.8 28.8 25.8 23.4 20.4 17.4 15.6 14.4 13.2 11.4
Ditto, inside packed pumps 30 27 24 21 18 15 13.5 12 10.5 9
Notes: Simplex steam pumpswill ordinarily have a steam efficiency from 7% to 10% higher than given for duplex pumps, largely
because they are built with smaller clearance and do not short-stroke when properly adjusted. The friction m.e.p. can be
markedly reduced by the use of high-class metallic packing.
Superheat .100of superheat will reduce steam consumption to 87%; 200will reduce it to 78% of that shown.
SQ
57.5esev
---------------------- P r Pb
P 18.5+ + + =
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332 Power Pumps
Crank driven power pumps are typically used in high pressure, low-to-moderateflowrate services on pipelines and in producing field applications such as water-
flood, mud pumps, and gathering systems.
Power pumps are divided into two common types; single-acting plunger and double-
or single-acting piston. Piston pumps are limited to approximately 1500 psig, but
plunger pumps typically go to 6000 psig and have been designed for discharges as
high as 30,000 psig.
Discussion
The formula given is sound theoretically, and the proper values of esand P will give true results. It is based
on the following assumptions:
1. Specific volume of steam in cylinder is
(Eq. 300-3)
cu. ft per lb., which holds well between 25# and 125# (gage).
where: Psis the available pressure in the steam line.
2. Gage pressure of steam in cylinder at end of stroke equals
(Eq. 300-4)
3. Steam efficiency is ratio of displacement of steam cylinder to steam actually used. The low efficiency invariablyfound is mainly due to the clearance volumewhich traps steam from the steam pipe to the exhaust pipe without
doing any work, and secondarily, to cylinder condensation. Valve leakage also plays a part. Although taken as a
constant, this efficiency is apt to vary considerably with conditions.
This formula shows the steam consumed, but does not showwhether the pump can actually perform the work
or not, either as regards capacity or pressure. The maximum pressure that the pump can put up is
theoretically
(Eq. 300-5)
However, at least a 25% additional margin of safety is desirable; the working pressure should be no more than
75% of that found above. The proper working capacity of a duplex pump in gallons per minute is
approximately
(Eq. 300-6)
where:
D = Diameter of liquid end, inches.
L = Length of stroke, inches.
Fig. 300-11 Steam Rate of Direct-Acting Duplex Steam Pumps (2 of 2)
460
Ps
18.5+----------------------
Ps
1
r---P P P
b+ +=
P r Ps
Pb
P =
Q10D
2L
L 10+-----------------=
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334 Selecting a Reciprocating Pump
The following steps may be used to select a reciprocating pump. For additional
guidance, see Section 2100.
1. Determine process duty.
2. Calculate liquid properties, if necessary.
3. Determine pipe pressure losses.
4. Calculate the suction head (same as for centrifugal pump).
5. Calculate the discharge head (same as for centrifugal pump).
6. Calculate the total head (same as for centrifugal pump).
7. Convert total head to pressure rise.
8. Calculate the NPSHA.
The expression for calculating the NPSHA for a reciprocating pump is similar
to that for a centrifugal pump except that acceleration head is included. Accel-
eration head is the force required to accelerate the fluid in the suction line. The
NPSHA for a reciprocating pump may be obtained as follows:
(Eq. 300-7)
Fig. 300-12 Suction Line Liquid Acceleration Head (ft) for Double-Acting Duplex Power Pumps
Average Suc tion Line
Velocity (fps)
Suction Line Acceleration Head for Suction Line Length (ft)
25 50 75 100
0.5 1.7 3.3 5.0 6.5
1.0 3.3 6.0 59.8 13.02.0 6.5 13.0 19.5 26.0
Notes: Refer to Section 130for a detailed discussion of acceleration head.
(1) For triplex pumps, use 57% of the values shown.
(2) For single-acting duplex and simplex pumps, use 174% of the values shown.
(3) Multiply values given above by the actual RPM divided by 60.
(4) Length of line is actual feet, not equivalent length. For pumps with suction stabilizers, length of line equals
10 pipe diameters.
(5) Acceleration head is added to the NPSH required by the pump.
(6) The NPSH requirement for a reciprocating pump, covering pressure loss from the inlet flange to the cylinder, is
primarily determined by the liquid velocity through the suction valve, the weight of the valve, spring loading on the
valve, and the liquid viscosity.(7) 12-ft NPSH allowance for a reciprocating gas pump is desirable.
(8) 8-ft to 10-ft NPSH is sufficient with some slower speed pumps.
(9) Special close clearance simplex pumps are available when some vaporization on the suction side may be expected.
(10)For hydrocarbons, use 75% of the values shown.
NPSHA hp hs hf hvpa hacc+=
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where:
hp = absolute pressure at suction source, e.g., a vessel (ft)
hs = static suction head (ft)
hf = friction head loss in suction piping including entrance losses (ft)
hvpa = vapor pressure of the fluid at pumping temperature (ft)
hacc = Acceleration head (ft)
(See Section 130for calculating acceleration head.)
9. Calculate brake horsepower.
(Eq. 300-8)
where:
GPM = Flow Rate in U.S. gallons per minute
psi = total differential pressure (pounds per square inch)
eff = pump efficiency (non-dimensional)
Note Use the following equation to convert head in feet to psi:
(Eq. 300-9)
where:
ht = Total head (ft)
SG = Specific gravity of liquid
10. Select particular pump.
Using the pump manufacturers literature and catalogs, select the pump for the
conditions obtained in the calculation. If possible, avoid selecting the largest
piston or plunger size for the pump case. Also avoid pumps which would have
to operate continuously at maximum allowable speed.
11. Consult pump Vendor.
Discuss pump selection with the Vendor for further recommendations and as a
check of the selection procedure.
12. Prepare pump data sheet and specification. See specification for reciprocating
pumps and API Specification 674.
BHP GPM psi 1715 eff =
psi ht SG 2.31=
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Pump Description Positive displacement-reciprocating-piston-duplex-direct acting-
gas driven (steam, air or process gas)
Typical Service Relief drum pumpout. Low pressure boiler feed. Water. Sludge.
Sump pump. Transfer.
Typical Pressure/Capacity Range 0700 psig/0500gpm
Max Allowable Temperature 350F
Typical Speed Range 30 to 60 RPM (with piston speeds usually between 50 and
100 FPM)
Construction Features Normal duplex, double acting, simplex available. Normally C. I.
steam and liquid ends with steel or bronze rods & trim
Typical Control Method Speed control by throttling drive gas (steam, air, process gas),
usually manual
Advantages Self priming. Will operate at very low speeds. High efficiency.Minimizes liquid emulsification. Handles viscous stocks. No elec-
trical power is required. Suitable for unattended remote installations
Disadvantages Pump speed is affected by system pressure. Subject to vapor lock
with low NPSH available. Will stall with too-high system back
pressure. Pulsating flow can affect sensitive instrumentation
downstream
Specification API 674. See also PMP-PC-1081 in this manual.
Data Sheet API 674, Appendix A. See also PMP-PC-1081 in this manual.
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Fig. 300-13 Duplex, Direct-acting, Gas-driven, Piston Reciprocating Pump
Part
No. Name of Part
Part
No. Name of part
Part
No. Name of Part
1 Steam Cylinder 10 Valve Rod 19 Valve Cover
2 Steam Cylinder Head 11 Valve Rod Lever 20 Valve Stem
3 Steam Piston 12 Liquid End Piston Rod 21 Valve Spring
4 Steam Piston Rings 13 Gland 22 Valve
5 Steam End Piston Rod 14 Gland Bushing 23 Valve Seat
6 Condensate Drain 15 Stuffing Box
7 Steam Chest 16 Liquid Piston
8 Slide Valve 17 Liquid Piston Rings9 Valve Rod Adjustment Nut 18 Cylinder Liner
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Pump Description Positive displacement-reciprocating-plunger (power pump)
Typical Service High pressure/low flow. Gathering systems/pipeline. Waterflood.
Drawing rig. Mud pumps. Well workover.
Typical Pressure/Capacity Range 5006000 psi/10600 gpm
Max Allowable Temperature 400F
Typical Speed Range 0450 RPM
Construction Features Vertical configurations available up to 200 HP. Available in duplex
through nonuplex, although triplex is most common. Crank driven
with motor, turbined with gearbox, or engine drivers. Steel liquid
end. Cast iron and steel power end. Self-contained lubrication
system.
Typical Control Method Variable speed or flow bypass
Advantages Higher pressures available than with piston pumps (up to 30,000 psi).
Self-priming. Constant delivery at high efficiency over wide pres-
sure range. Minimum fluid emulsification. Handles viscous stocks.
Can run dry for a limited time.
Disadvantages and Limitations Pulsing flow. Low capacity. High first cost and maintenance cost.
Low tolerance for abrasives. Subject to vapor lock at low suction
pressure with high vapor pressure stock.
Specification API 674. See also PMP-PC-1081 in this manual.
Data Sheet API 674, Appendix A. See also PMP-PC-1081 in this manual.
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Fig. 300-14 Reciprocating Plunger Power Pump Copyright 1995 Ingersol l Dresser Pumps. Worthington is a
trademark of Ingersoll Dresser Pump Company
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