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Sulzer PumpsSulzer ISO 13709 (API 610) Type BB5 Barrel Pumps

The Heart of Your Process

GSG Sales Presentation<Copyright © Sulzer Pumps> | slide 2

Sulzer PumpsLong History of Barrel Pumps


Sulzer PumpsBarrel Pumps: Diffuser Style

45 MW SuperCriticalBoiler Feed


Sulzer PumpsTypes of Horizontal Multistage Pumps

Volute - Horizontal Split

BB3

Diffuser Barrel CasingBB5

Volute Barrel

BB5

Diffuser - Segmental Ring

BB4 – Not used on H.C.

High Speed Diffuser Barrel

BB5


Sulzer Pumps

Single Volute Casing

Volute vs. Diffuser Casings

FR

Radial loads increase at lower flow, and at flow rates beyond best efficiency point.

The result is an unbalanced radial load on the rotating element.

Small, low flow pumps have relatively small radial loads.


Sulzer Pumps

Dual Volute Casing

Volute vs. Diffuser

FR~ 0

A dual volute casing has an additional passageway 180º from the main throat area which will almost balance the generated radial force.

Horizontally split, dual Volute Multistage Pumps have 1 throat are in the top half, 1 in the bottom half - to balance radial forces.


Sulzer PumpsMultiStage Dual (MSD) Volute

Volute throat in top half of casing.

Bottom Half Casing

Top Half Casing

Volute throat in bottom half is on opposite side for radial force balance.


Sulzer PumpsVolute vs. Diffuser

Diffuser Casing

FR= 0

A diffuser has multiple discharge passageways with equal area distributed throughout the circumference -resulting in radial load balance.


Sulzer PumpsDiffusers

Diffuser – Discharge Side

Impeller runs in center

Stage casings

Diffuser – Suction Side

Return Channels feed next stage


Sulzer Pumps

Opposed Impeller Design

X X

Fr xst

Pd xst Pd xstPd 1stPd 1st

Fr 1st

X X

Unbalanced pressure distribution on impellers results in a thrust in the direction of suction.

Fr Total = 0

Opposed impeller design offsets the unbalanced pressure distribution (thrust) effectively balancing axial thrust. When there are odd number of stages, thrust is handled by adjusting the diameter of the throttle bushing with residual handled by a thrust bearing.

Axial Thrust Development


Sulzer Pumps

Inline Rotor Stack

FDrum ~ 85% Fr TotalFr Total = Fr 1st+Fr xst

Stacked impeller design results in adding thrust in the direction of suction.

Fr 1st

X X X X

Fr xst

Unbalanced pressure distribution on impellers results in thrust in the direction of suction.

Ps

FDrum

Developed thrust must be compensated by a hydraulic balancing device. Residual thrust is handled by a thrust bearing.

Pd xst

Pd 1stPd 1st Pd xst

Axial Thrust Development


Sulzer Pumps

Balances 85 - 90% of generated thrust. Residual thrust handled by a thrust bearing.

With inline rotor stack, this is most reliable design for transient conditions (start up and run down, temperature changes, daily starts and stops).

Easy and safe axial rotor setting due to radial gap as compared to axial gap (explained on next slide).

Rotor is fixed in the axially position by thrust bearing.

Higher amount of leakage - less efficient.

Axial Thrust CompensationBalance Drum

PSuction PDischarge

Close clearance pressure breakdown

Balance Drum Balance Drum Liner


Sulzer Pumps

Balances 100% of the generated thrust.

No thrust bearing required.

Rotor floats axially for proper operation.

Least amount of leakage - higher efficiency.

Disc lift off device required for frequent starts and stops

ISO 13709 (API 610) Para. 5.7.1 requires radial running clearance be used for axial thrust balance. That precludes the use of this device.

Potential for contact causes this design to be considered less forgiving than balancing drum

Axial Thrust Compensation balance disk - Not allowed by ISO 13709 (API 610)

PSuction PDischarge

Balance DiskCounter Disk

Axial gap will adjust in response to thrust changes


Sulzer PumpsInline Impellers vs. Opposed Impellers

Note: All are ISO 13709 (API 610) type BB5

Sulzer GSG:

Inline diffuser Barrel Pump

Sulzer CP:

Opposed Impeller Volute Barrel Pump

GSG Back-to-Back diffuser Barrel Pump


Sulzer PumpsInline vs. Opposed Rotor Stack

Direct drive, inline diffuser barrel pumps are the least expensive barrel pumps to build.

High Speed inline pumps require tilting pad thrust bearings and lube system, high speed seals, VFD or gear speed increaser, etc. which add to the cost.


Sulzer Pumps

ISO 13709 (API 610) requires stable rotordynamics with 2 times normal ISO 13709 (API 610) specified wear ring clearances.

Inline vs. Opposed Rotor Stack

Back to back diffuser stack is often used on smaller pumps or high energy pumps with many stages where rotordynamics require a midspan bearing. The Sulzer Thunderhorse 650 Bar, 13MW injectionpumps are designed in this manner.


Sulzer PumpsThe “K” factor – large barrel pumps

0

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Inline 3.38 Inline 4.25 B-B 3.380

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120K FactorShaft Span, in.

“K factor”

• Rotor Wt. in lbs.

• Shaft Span, in.

• Shaft Dia. in.

K=(W*L^3/D^4)^0.5

Lower “K” factor is generally better. It can be achieved either with fewer stages & large high speed shaft on inline rotor, or back-to-back rotor and direct drive

Back to Back GSG, HPCP or CP

Type / shaft size, inches

Some say K factor of </= 1200 is good; “Semi-stiff shaft” is another term they use


Sulzer Pumps

For small pumps with many stages, the rotor will rest on center bushing. When the pump starts, Lomakin effect lifts rotor for non-contact running.

Non-galling material selection is important. Sulzer uses a stellite coated, or nitrided throttle bushing and center bushing on opposed impeller pumps.

Rotor Sag


Sulzer PumpsInline vs. Opposed Rotor Stack

Back to Back (Opposed impeller) diffuser or volute design is also used in remote locations where customers prefer not to have a lube system to maintain. Opposed impellers balance axial thrust and may allow use of an antifriction thrust bearing.

Back to Back (Opposed impeller) volute multistage barrel pumps are used in abrasive services where 2large throat diameters are preferred in lieu of many smaller diffuser throats. The inner volute casing is larger in diameter than diffusers so volute style barrel pumps often cost more than diffuser style


Sulzer PumpsDirect Drive vs. High SpeedFlow of a centrifugal pump varies directly with RPM. Head produced by a stage varies as the square of the RPM.

In other words, to make the same head, operating a smaller pump 42% faster would make the same head with half the number of stages.

However, some customers prefer direct drive 2 pole pumps for reliability and reduced items to maintain. Direct drive pumps often do not require these costly accessories:

- lube system & sleeve/pivot shoe bearings

- more extensive instrumentation

- gear increaser

- special mechanical seals

High Speed, VFD or Gear; fewer stages

Low Speed, Direct Drive; more stages


Sulzer PumpsCartridge vs Non-cartridge designs

A “Cartridge” design barrel pump allows the inboard bearing housing and seal chamber to be withdrawn from the barrel with the bundle.

On small pump sizes this is impractical because the IB bearing housing is larger than the barrel opening on the IB end.

On smaller pumps, a “Non-Cartridge”design barrel pump requires the inboard bearing housing and seal chamber to be removed before withdrawal of the bundle from the outboard end. That adds a little time to disassembly/reassembly but parts are relatively small and can often be handled by hand


Sulzer PumpsHigh Temperature – Thermal Expansion

To accommodate axial growth due to high temperature operation the suction end of the barrel is equipped with a pin which fixes the Drive End of the pump.

The discharge end is equipped with a key slot which will allows the barrel to expand in the direction of the NDE end. The barrel to pedestal bolts are torqued to a specific value to accommodate the axial growth.


Sulzer PumpsBarrel Head Closure Methods

Studs & Nuts – Most common – requires stretching or torquingSupernuts – more expensive, no stretching; hand tool torquingorSulzer’s Patented Twist LockOn lower temperature services, to speed overhaul, some customers preferSulzer’s patented Twist Lock barrel end cover design – no studs/nuts and notorquing required.

Head Installed Head partially rotated

Head Rotated & Locked


Sulzer Pumps

GSG: SMALLER SIZES 50 Hz, 2 pole motor speed

Gray or white are inline rotor

Light blue are only available in back-to-back rotor


Sulzer Pumps

GSG: LARGER SIZES 50 Hz, 2 pole motor speed




Sulzer Pumps

GSG: SMALLER SIZES 60 Hz, 2 pole motor speed




Sulzer Pumps

GSG: LARGER SIZES 60 Hz, 2 pole motor speed




Sulzer PumpsHydraulics

Double suction first stage available on larger sizes

A double suction impeller reduces the NPSHr by about 30%


Sulzer Pumps

Hydraulic layoutMultiple hydraulic impeller & diffuser sets per pump sizeMixing of impeller / diffuser hydraulics in single pump is possibleDouble suction first stage is available in larger size pumpsDynamic balanced impellers & rotor > 3 stagesRadial load is balanced

Impellers and Diffusers


Sulzer Pumps

Pumped Medium : Boiler Feed Water Speed : 3570 rpm MD 100-300 / 8 Density : 909.2 kg/m³ Stage Number : 8 Temperature : 318 °F nq : 20.0 kinem. Viscosity : 0.19 mm²/s Impeller Set : B / B / B Tender : /1Head (design) : 4,600 ft Basis 4335.11.11/2 & 4335.11.11/2 Characteristic : TS/1Capacity (design) : 900 gpm & 4335.11.11/2 Impeller diameter : 11.1 inchTotal efficiency : 75.8 % Extraction head : 1,268 ft Impeller dia. (max) : 11.8 inchPump Power : 1,350 HP Extraction capacity : 250 gpm NPSHR : 19 ft

2

RATED

RATED

Max. ∅

Max. ∅

010

0020

0030

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0050

0060

00

0 gpm 200 gpm 400 gpm 600 gpm 800 gpm 1000 gpm 1200 gpm 1400 gpm 1600 gpm 1800 gpm 2000 gpm

H [

ft ]

Mixing of Impeller Hydraulics with Interstage Bleed Off

By mixing impeller hydraulics efficiency and power can be optimized

Note the all “B”impeller hydraulics

Note efficiency = 75.8% and power is 1,350 hp


Sulzer Pumps

Pumped Medium : Boiler Feed Water Speed : 3570 rpm MD 100-300 / 9 Density : 909.2 kg/m³ Stage Number : 9 Temperature : 318 °F nq : 20.0 kinem. Viscosity : 0.19 mm²/s Impeller Set : B / B / S Tender : /1Head (design) : 4,600 ft Basis 4335.11.11/2 & 4335.11.11/2 Characteristic : TS/1Capacity (design) : 900 gpm & 4335.11.21/1 Impeller diameter : 10.9 inchTotal efficiency : 78.7 % Extraction head : 1,268 ft Impeller dia. (max) : 11.0 inchPump Power : 1,301 HP Extraction capacity : 250 gpm NPSHR : 19 ft

0

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RATED

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Max. ∅

Max. ∅

010

0020

0030

0040

0050

0060

00

0 gpm 200 gpm 400 gpm 600 gpm 800 gpm 1000 gpm 1200 gpm 1400 gpm 1600 gpm 1800 gpm

H [

ft ] By mixing impeller

hydraulics efficiency and power can be optimized

Efficiency now = 78.7% and power is 1,301 hp (49 hp reduction)

Now the “B” hydraulics have been replaced with “S” after the interstage bleed off.

Mixing of Impeller Hydraulics with Interstage Bleed Off


Sulzer Pumps

0

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40%

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60%

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80%

90%

100%

110%

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Pump Flow - % of BEP

Pow

er @

BEP

- H

P (3

600

rpm

)Bearing Type Selection

Anti-Friction Thrust & Sleeve Radial – Ring Oil Lube

Pivot Shoe Thrust & Sleeve Radial – Lube System required

Anti-Friction Thrust & Radial –Ring Oil Lubrication

Exact bearing system will depend upon application


Sulzer PumpsAnti-Friction with Ring Oil Lubrication

Ring Oil Lubrication – Oil rings rotate with shaft, dip down into an oil reservoir and “throw” oil onto bearings. Grooves or channels are located in the bearing housing to distribute oil throughout the bearing(s). Shaft mounted cooling fans provide cooling up to a liquid temperature of 177o C (350° F).

Oil RingsOil Reservoir

Thrust Bearing Radial Bearing

Cooling Fan


Sulzer Pumps

Anti-Friction Thrust & Sleeve Radial Bearingswith Ring Oil Lubrication (GSG Back-to-Back only)

Ring Oil Lubrication – Oil rings rotate with shaft, dip down into an oil reservoir and “throw”oil onto bearings. Grooves or channels are located in the bearing housing to distribute oil throughout the bearing(s). Shaft mounted cooling fans provide cooling up to a liquid temperature of 177o C (350° F). Optional water cooled finned tubing is available.

Oil RingsOil Reservoir

Thrust BearingRadial Bearings

Cooling Fan


Sulzer Pumps

Double Acting Tilting Pad Thrust & Sleeve Radial Bearings with Force Feed Oil Lubrication

Forced Feed Lubrication – Bearing lubrication is provided by an external lube oil system. Depending on specification requirements lube oil systems can be very basic or very elaborate. Standard lube system could cost < 20,000 Euro/USD. ISO 13709 (API 610) Lube system is typically 40,000 Euro/USD. ISO 10438 (API 614) could be 3 to 4 times that cost. If customers specify lube systems, they often specify bearing RTD’s and vibration measurement instrumentation which adds further cost.

Double Acting, Tilting Pad Thrust Bearing Sleeve Radial Bearings

Shaft Driven Oil Pump


Sulzer PumpsJournal and Thrust Bearing Arrangement

Sleeve Bearings


Sulzer Pumps

Thrust Bearing Lubrication

Tilting Pad Thrust Bearing Arrangement

An “oil wedge” builds up between each stationary thrust pad and the rotating collar, and no metal-to-metal contact occurs during normal operation.

The babbit lining of the pads is designed to be tolerant of any minute particles of grit that may get through.


Sulzer Pumps

Double Acting “Pivot Shoe” or “Tilting Pad” Thrust Bearing

Journal and Thrust Bearing Arrangement


Sulzer PumpsForced Feed Lube Oil Systems


Sulzer PumpsSeal Chambers & Jackets

Seal Chambers are designed to ISO 13709 (API 610) Table 6 dimensions and features.

ISO 21049 (API 682) single, double or tandem seals are available

Seal Chamber cooling or heating jackets are available on this model pump.


Sulzer Pumps

Q/DFIFO

TI

Seal Flush Plans

A variety of seal flush plans are available


Sulzer Pumps

NDE Bearing temperature

DE Bearing temperature

NDE X-Y Shaft vibration DE Shaft vibrationBalance Leakoff flow

Instrumentation - options

Barrel Temperature, Bottom & Top (for hot standby)

In lieu of more expensive X-Y probes & proximitors, normally bearing bracket velocity is adequate for direct drive pumps


Sulzer Pumps

With anti-friction bearings the shaft is firmly connected to the bearing frame via the bearings.

Any vibration of the rotating element will be transferred from the shaft to the bearings to the bearing housings and there will not be any relative movement of the shaft to the bearing housings.

Vibration is measured by the relative RMS velocity or acceleration of the bearing frame - by either velomitors or accelerometers.

Firm contact from shaft to bearing frame

Velomitors

Vibration Instrumentation


Sulzer Pumps

With sleeve bearings, the shaft “floats” on a film of oil and is free to move within the clearance of the sleeve bearings.

This allows the rotating element to vibrate within the sleeve bearings while the actual bearing frame may not vibrate at all.

Vibration is the relative movement of the shaft within the bearing frame. Probes are mounted with very close proximity to the shaft (Bently Nevada type systems) to detect displacement movement.

Probes and Proximitors

Film contact from shaft to bearing frame

Vibration Instrumentation


Sulzer Pumps

AISI 4140AISI 4140AISI 4140AISI 4140Case and Gland Studs

12% Chrome Hardened

12% Chrome Hardened

12% Chrome HardenedCast IronInterstage Bushings

12% Chrome Hardened

12% Chrome Hardened

12% Chrome HardenedCast IronInterstage Sleeves

12% Chrome Hardened

12% Chrome Hardened

12% Chrome HardenedCast IronThroat Bushings

12% ChromeAISI 4140AISI 4140Carbon SteelShaft

12% Chrome Hardened

12% Chrome Hardened

12% Chrome HardenedCast IronImpeller Wear Rings

12% Chrome Hardened

12% Chrome Hardened

12% Chrome HardenedCast IronCase Wear Rings

12% Chrome12% ChromeCarbon SteelCast IronImpeller

12% Chrome12% ChromeCarbon SteelCast IronInner Case

12% ChromeCarbon SteelCarbon SteelCarbon SteelPressure Casing

12% Chrome/ 12% ChromeCS/12% ChromeCS/CSCS/Cast Iron

C-6S-6S-5S-1

Material classes and abbreviations

Part

API Material Classes


Sulzer Pumps

AISI 4140AISI 4140AISI 4140Case and Gland Studs

S.D.Duplex316L SS HFInterstage Bushings

S.D.Duplex316L SSInterstage Sleeves

S.D.Duplex316L SS HFThroat Bushings

S.D.DuplexDuplex SSShaft

S.D.Duplex316l SS HFImpeller Wear Rings

S.D.DuplexDuplex SSCase Wear Rings

S.D.Duplex316L SSImpeller

S.D.Duplex316L SSInner Case

S.D.Duplex316L SSPressure Casing

Super DuplexDuplex SS316SS/316SS

D-2D-1A-8

Material classes – cont’d.

Part

API Material Classes


Sulzer Pumps

Pre-warming of this style pump is required. Maximum ramp-up temperature is 10º C (20ºF) per minute and 110ºC (200 ºF) instantaneous thermal shock

On Horizontally split multistage pumps, the casing is not uniformly thick. It has very heavy cross sections that take time to reach operating temperature.

The rotor & lower half casing gets hot and expands quickly.

Pre-Warming


Sulzer Pumps

The Sulzer GSG Pumps are designed with uniform thicknesses and clearances on the inner case components to minimize distortion. Warmup is not required on many applications < 260oC (500oF).

Above that temperature, the barrel drains can be used to uniformly warm the pump, or maintain hot standby.

Pre-Warming

Barrel RTD’s can provide indication of uniform temperatures.


Sulzer Pumps

Thrust bearing - anti-friction or double acting tilting pad.

Radial bearing - sleeve or anti-friction.

Radial split identical stage casings, diffusers and impellers

Interstage bleed connections available

Low NPSH 1st stage impeller. Double suction available.

Radial Split barrel casing with confined gasket. Either casting or forging available.Stacked rotor design with

staggered keyways to provide positive torque to impellers

Hydraulic balance device is Drum type

GSG Cross Section and Features

Bearings protected by Labyrinth type oil seals

Studs & Nuts, Super-nuts or Twist Lock barrel closure on Back-to-Back only


Sulzer PumpsPictures

GSG Boiler Feed pump with speed increasing gearbox, lube system,suction strainer and automatic recirculation control valve



GSG portion of hydrotreater train (GSG pump, clutch, MSD-T power recovery turbine) with full instrumentation and insulation.

Sleeve bearing RTD, Active Thrust RTD, Inactive thrust RTD, X-Y vibration probes, Key phasor.



10 stage GSG on 0.4 Sp.Gr. cold Ethylene

VFD driven at > 4,000 RPM with fan cooled antifriction bearings

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