Process STD 400-1.2 PDF

PROCESS STD 400-1.
2
FOSTER WHEELER MECHANICAL PAGE Content-1
EQUIPMENT REV 10
PROCESS PLANTS DIVISION RECIPROCATING PUMPS DATE July 2002
CONTENTS
Page
.10 GENERAL 1.01-1
.11 Classifications and Definitions 1.01-1

.111 Steam Pumps 1.01-1
.112 A Power Pump 1.01-2
.113 Metering Pumps 1.01-2
.114 Diaphragm Pumps 1.01-3
.12 Revised Pump Process Data Form 1.01-3
.13 Services for Reciprocating Pumps 1.01-3
.14 Unsuitable Services for Reciprocating Pumps 1.01-4
.15 Size Designation 1.01-5
.16 Pump Ratings 1.01-6
.17 Capacities of Duplex Pumps 1.01-6
.18 Basic Speed 1.01-7
.19 Viscosity and Water Temperature Corrections 1.01-8
.20 SUCTION LIFT 2.01-1

.21 Maximum Discharge Pressure and Relief Valve 2.01-1
.22 Steam Consumption 2.01-2
.23 Pressure Surges 2.01-3
.24 Types of Dampers (Surge Absorbers, Accumulators) 2.01-4
.25 Pump Type vs. Need for Dampers 2.01-5
.26 Simplified formulas for Sizing Dampers 2.01-10
.27 Calculation of Line Shock Pressure Due to Valve Closure 2.01-10
.28 Calculation of Damper Volume Required to Reduce Shock 2.01-12
.29 Pump Suction and Discharge Lines Consideration 2.01-13
.30 ACCELERATION HEAD LOSS 3.01-1

.31 Acceleration Head Calculation 3.01-1
.32 Reciprocating Pump Piping Recommendations 3.01-3
.33 Horsepower 3.01-4
.34 Mechanical Efficiency of Steam Pumps 3.01-5
.35 Mechanical Efficiency of Power Pumps 3.01-6
.36 Volumetric Efficiency of Power Pumps 3.01-7
.37 Power Pump Motor Selection Chart 3.01-7
.38 Pump Selection, Horizontal Simplex Steam Pumps 3.01-7
.381 Typical Selection Problem 3.01-8
FOSTER WHEELER ENERGY LIMITED 2002

This is an electronic copy of the Foster Wheeler Process Standards. The information has not been
updated apart from the revision and date of issue. Caution should be exercised in the use of time-
dependent data such as cost information.
PROCESS STD 400-1.2
EQUIPMENT REV 10
.39 Close Clearance Pumps 3.01-9

.391 Close Clearance Simplex Steam Pump Selection 3.01-9
.392 Typical Selection Problem, Close Clearance
Pump Process Conditions 3.01-9
.393 Calculation of Steam (or Water) Rate 3.01-10
4.0 THEORETICAL STEAM RATE 4.01-1
.41 Steam Pump 4.01-1

.411 NPSHR (Net Positive Suction Head Required) 4.01-1
.42 Power Pumps 4.01-4
.421 Typical Performance Curves 4.01-4
.422 NPSHR 4.01-4
TABLES
1 Sizes and Capacities of Horizontal Duplex Pumps Figure-1
2 Simplex Pumps, Recommended Piston Speeds Figure -2
3 Close Clearance Pumps
FIGURES
1 Basic Speeds - Simplex and Duplex Direct Acting Steam Pumps Figure-3
2 Basic Speeds Duplex Piston Pumps Figure-4
3 Basic Speeds _ Triplex & Multiplex Plunger

Pumps
4 GPM vs Piston Speeds For Typical Duplex Figure-5

Direct Acting Steam Pumps
5 Correction Chart for Viscosity and Water

Temperature Figure-6
6 Effect of Feed Viscosity On Piston Speed Figure-7
7 Suction Life Chart for Suplex Trade Pumps Figure-8
8 Pumps Process Data Form Figure-9

9 Power Pumps Req Form Figure-10

PROCESS STD 400-1.2
EQUIPMENT REV 10
10 Reciprocating STM Pump Req Form Figure-11
11 Approximate Steam Consumption Direct acting Steam Pumps Figure-12
12 Acceleration Head Correlations Figure-13
13 Power Pump_Motor Selection Figure-14
14 Simplex Pump Capacity Vs Piston Speed Figure-15
15 Close Clearance Pump, Displacement Ratings
16 Simplex Steam Pumps _ Steam End Size & Pressure Chart Figure-16
17 Close Clearance Simplex Steam Pumps

Steam End Size & Pressure Chart Figure-17
18 NPSHR Correlation For Steam Pumps Figure-18
19 Steam Pump Capacity Vs Height of Valve Desk Figure-19

Above Pump Base
20 Performance Curve Simplex, 2 3/16 Stroke Figure-20
21 Performance Curve-2Stroke Type 5D Duplex Pump Figure-21
22 Performance Curve-3Stroke Type KCF Triplex Pump Figure-22
23 Performance Curve Triplex, 4 Stroke Figure-23
24 Performance Curve-Stroke Type KCFQ Quintuplix Figure-24
25 Performance Curve Quintuplex 8 Stroke Figure-25

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EQUIPMENT REV 10
26 Minimum NPSHR Curves For Power Pumps Figure-26
27 Effect of Pump Speed On NPSHR For Power Pumps Figure-27
28 Minimum NPSHR For Vertical Power Pumps Figure-28
29 Minimum NPSHR For Vertical Power Pumps Figure-29

PROCESS STD 400-1.2
FOSTER WHEELER MECHANICAL PAGE 1.0-1
EQUIPMENT REV 10
.10 GENERAL
Reciprocating pumps are positive displacement pumps whose principal

characteristics are:
1. Their capacity varies directly with speed.
2. Their discharge pressure is only that which is necessary to force the liquid
through the discharge system.
3. Aside from considerations of construction materials, the maximum

pressure obtainable is a function of differential forces developed by the
steam end or if crank driven, by drivers torque.
4. The flow at both suction and discharge is pulsating. This effect can be
reduced by paralleling duplicate units and arranging for overlapping flows.
The addition of proprietary items, generically known as Dampers, will
attenuate or smooth out flows. Dampers are discussed in a subsequent
section.
.11 CLASSIFICATION AND DEFINTIONS
Reciprocating pumps are broadly classified as steam, power and metering.
.111 Steam Pumps
A Steam Pump is a reciprocating pump and a steam engine built

together as a unit. The power to drive the pump is furnished by
the steam engine. Steam pumps fall into nine basic types
according to the mechanical arrangement.
A Single Pump is a reciprocating pump having one liquid piston or

its equivalent single or double acting plunger. Also called
Simplex.
A Duplex Pump is a reciprocating pump having two liquid pistons

or their equivalent single or double acting plungers.
A Horizontal Pump is a reciprocating pump having the axial

centerline of the cylinder or cylinders in a horizontal position.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.111 Steam Pumps (Contd)
A Vertical Pump is a reciprocating pump having the axial

centerline of the cylinder or cylinders in a vertical position.
Simple, Steam End - A steam end having a high pressure steam

cylinder (single) or a pair of high pressure steam cylinders
(duplex).
Compound Tandem - A steam end having a high and low pressure

steam cylinder arranged on the same longitudinal or vertical
centerline.
Crank and Flywheel Pump is a reciprocating pump with a

crankshaft on which a flywheel is mounted for storing energy
during the early part of the stroke and imparting this stored energy
to the liquid piston or plunger during the latter part of the stroke,
after the steam is cut off in the steam cylinders. The length of the
stroke is determined by the throw of the main crank.
Compound, Cross (Crank and Flywheel only) - A steam end

having a high and low pressure steam cylinder arranged side by
side with cranks 90F apart.
Trade Pumps, Single or Duplex These are individual

manufacturers standard fitted, horizontal, direct acting, valve plate
type, packed piston steam pumps of 12 inch stroke or less.
.112 A Power Pump is a reciprocating pump driven by power from an

outside source applied to the crankshaft of the pump.
These include, Single, Duplex, Triplex and Multiplex pumps

depending on the number of pistons or their equivalent single or
double acting plungers. In addition, they may be Horizontal or
Vertical in reference to the position of the axial centerline of the
cylinder or cylinders.
.113 Metering Pumps also known as proportioning or controlled volume

pumps are designed for pumping small flows at a constant rate,
which usually can be varied by changing the stroke or speed.
These pumps are of two types; packed plunger or diaphragm.
These are mostly motor driven although other types of drivers e.g.
hydraulic or pneumatic motors, solenoid, etc., can be arranged.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.114 Diaphragm Pumps - In addition to the diaphragm metering pumps,

large diaphragm pumps are available and are useful in pumping
liquids containing gases or vapours, hazardous or toxic liquids as
well as thick pulps, slurries or gritty suspensions. They are slow
speed units of 15-30 strokes per minutes capable of pumping
rates up to about 100 GPM at heads to about 100 psi although
special pumps can operate against discharge pressures up to
3500 psi.
Normally, diaphragm pumps are not used to handle liquids with

viscosities greater than 3500 SSU. They are usually self priming
and can run dry for an extended time period without damage since
the process liquid does not come in contact with the prime moving
parts. Care must be observed that the liquid is compatible with
the composition of the flexible diaphragm. Since the flow is
pulsating, line size is based on peak velocities which averages
between 1.5 - 3.0 times the average velocity. Suction lines should
be as short as possible.
.12 REVISED PUMP PROCESS DATA FORM
Recently, a revised form was developed for specifying process conditions

for all types of pumps. Process Engineers are requested to refer to Design
Bulletin #14 in reporting pump process data to the Project Department for
requisitioning purposes. A reduced copy of the new form is shown on
Figure 8.
.13 SERVICES FOR RECIPROCATING PUMPS
While reciprocating pumps have been generally displaced by centrifugal

pumps, there are certain areas of application where reciprocating pumps,
because of their flexibility of head and capacity with nearly uniform
efficiency over a wide range of conditions are of interest. Their
consideration and use is indicated in the following situations in which there
is acceptance of the fact that flow may have a pulsating character.
1. Capacities varying from below 0.1 GPM to over 2000 GPM against
low or high heads. At low capacities, say up to 20 GPM and at low or
high heads, a centrifugal pump, even provided with a bypass, may
not be the most practical or economic selection.
2. Viscous fluids above the range accommodated by centrifugal pumps.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.13 SERVICES FOR RECIPROCATING PUMPS (contd)
3. Discharge pressures up to about 10,000 psig.
4. Power pumps, which are self priming, are useful in pumping fluids
containing volatile vapors whose presence present problems with a
centrifugal pump.
5. Intermittent service, such as pumpout, where a number of liquids of

widely different viscosities must be handled.
6. Multiple pumping operations involving a wide range of heads and

flowrates. Steam driven reciprocating pumps are especially well
suited for this service since the speed control is by simply throttling
the steam supply.
7. Relatively constant capacity requirements coupled with varying

discharge pressures. This type of service is well suited for crank
driven reciprocating pumps.
8. Steam driven reciprocating pumps are occasionally specified for

standby service for use during an electric power failure. Generally
however, a low cost turbine driven centrifugal pump is a preferred
alternate.
9. Slurry or sludge service. It is important to specify the type, amount

and size range of solids.
10. Exhaust steam from a steam pump may be used for heating
especially if from a non-lubricated steam end pump (Union Pump
Co.) otherwise, the exhaust steam is contaminated with cylinder
lubricant and will foul heat transfer services.
.14 UNSUITABLE SERVICES FOR RECIPROCATING PUMPS
1. Whenever a lower cost pump, e.g., a centrifugal, is capable of

performing the same service.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.14 UNSUITABLE SERVICES FOR RECIPROCATING PUMPS (Contd)
2. Whenever a pulsating flow is objectionable and a uniform flow is a

definite requirement especially if flow and pressure control
instruments are involved. Like any generalization, this statement is
not absolute since pulsations can be damped but only at the expense
of additional equipment. A typical example is in fuel oil service
supplying boilers and heaters. Rotary or centrifugal pumps are
definitely preferred because of their smooth discharge pressures and
flows.
3. Medium capacity, (above about 50 GPM) and discharge pressures

coupled with low to medium viscosity fluids. This service is usually
best served by a centrifugal pump.
4. High capacity and moderate heads with moderate viscosity fluids.

Examples are cooling tower water, loading and charge pumps.
5. High viscosity service, above about 20,000 SSU. A more suitable

pump is a rotary type.
For items 3, 4 and 5 above, refer to Figure 2 of Section 400-1.0 page

4.10, for volume-head limitations of pumps to determine suitability or
unsuitability of pump applications for fluids of reasonable viscosities.
6. Where leakage of pumped fluid is to be avoided because of hazards

such as fire, toxicity or loss of expensive fluid. A possible exception
would be reciprocating diaphragm pumps.
7. Low NPSHA below about 6 feet. Reciprocating steam and power

pumps are limited by the pressure differential necessary for valve
action, i.e. flow through the valve orifice.
.15 SIZE DESIGNATION
The size of a steam driven reciprocating pump is given by a series of three

numbers and these refer respectively to the diameter of the steam
cylinder, the diameter of the liquid cylinder and the stroke length. For
example an 8" x 6" x 12" pump has a steam cylinder of 8" diameter, a
liquid cylinder diameter of 6" and a 12" stroke.
A power pump is sized by two numbers and these refer respectively to

the diameter of the liquid cylinder and the stroke length.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.16 PUMP RATINGS
Reciprocating pumps are rated using cold water. For fluids of different
physical characteristics it may be necessary to apply correction factors.
For example, a reciprocating pump is derated for use with high viscosity
fluids, as is shown in Figure 5 and Table 1. Figure 5 also shows the
deration for water at different temperatures.
A reciprocating pump will pump at its rated capacity only as long as the
feed flows freely and with no change of phase into the pump cylinder. The
flowrate of liquid into a reciprocating pump varies from zero at the
beginning of a stroke, reaches a maximum and then decreases to zero
again in one power stroke. As fluid viscosity is increased a situation is
reached when the viscous liquid can not flow fast enough to fill the swept
cylinder volume and it becomes necessary to decrease the pump speed to
allow additional time for flow.
In pumping flashing liquids sufficient suction pressure must be provided to

prevent vaporization or else capacity will be reduced. If excessive
vaporization occurs, the pump may become gas-bound. NPSH
calculations for reciprocating pumps account for this acceleration effect by
including a term called Acceleration Head. The above factors are
discussed more fully in following sections.
.17 CAPACITIES OF DUPLEX PUMPS
Capacities of typical, horizontal Duplex steam pumps are presented in

Table 1, Page 26 in terms of cold water capacities as well as in derated
values for liquids having an SSU viscosity range from cold water up to
10,000 SSU and also for hot boiler feed water. The values are a vendors
maximum recommended flows and are for pumps in excellent condition. If
the pumps are to be used in continuous service, clients may specify lower
maximum capacities, though this could result in additional costs. Larger
capacity pumps are available and if details are required, refer to the
Mechanical Equipment Group.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.18 BASIC SPEED
This term, expressed in units of feet per minute, refers to the average
piston speed and is used primarily as a guide or measuring point for
normal pump operations based on cold water or liquids not in excess of
250 SSU viscosity. The Hydraulics Institute has published curves
correlating piston speed in Ft./minute vs. stroke length in inches for
conventional types of steam and power pumps, and these correlations
have been accepted by industry. Pumps having special features, such as
extra large valve surfaces or other design innovations, are suitable for
speeds higher than those indicated by the basic speed correlations which
relate only to conventional designs.
Figure 1 shows the basic speed curve for conventional Simplex and
Duplex direct acting steam pumps; Figure 2 for Duplex Piston Pumps
(Power Pumps) and Figure 3 for Triplex and Multiplex Plunger Pumps.
These curves show that long stroke pumps may be run at higher piston
speeds than those of short stroke length. Consequently, long stroke
pumps can be expected to have higher capacities than short stroke length
pumps even though both may have identical liquid cylinder diameters.
Over a short period of time, pumps are occasionally run at greater than
recommended speeds, (up to about 125% of vendors values) at the risk,
however, of possible damage and personal injury.
Some clients have developed their own speed limitations and these may
be different than the basic speeds shown by the Hydraulic Institute.
Another parameter indicating the reasonable minimum speed has been

added to Figure 1 and provides a graphical representation of the wide
range of pumping rates which is obtainable with this type pump.
Figure 4 was developed to assist in pump selection and show the variation
in capacity (GPM) for a number of different Duplex direct action steam
pumps as a function of piston speed.
.19 VISCOSITY AND WATER TEMPERATURE CORRRECTIONS
To obtain the viscosity deration factor for viscous feeds for steam and
power pumps refer to the graph shown on Figure 5. This graph,
developed by the Hydraulic Institute also covers the deration of pumps for
water at elevated temperatures.

PROCESS STD 400-1.2
EQUIPMENT REV 10
However, since most hot water or Boiler Feed Water pumps now specified
are not reciprocating pumps, this particular ordinate of the graph is of
limited use.
Figure 6 is also descriptive of the deration accorded to fluids of varying

viscosities.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.20 SUCTION LIFT
The suction lift obtainable with a reciprocating pump at various altitudes is

affected by the type of pump as well as the design of suction valves,
pistons and suction passages. The limits shown in Figure 7 are applicable
to common trade pumps, similar to a 6" x 4" x 6" valve plate design, duplex
pumps.
.21 MAXIMUM DISCHARGE PRESSURE AND RELIEF VALVE
The necessity for installing a relief valve on the pump discharge side of a
direct connected steam pump depends on whether the maximum
discharge pressure which can be developed using the maximum possible
steam differential pressure available plus the maximum suction pressure of
the liquid is greater than either the design pressure of the pump itself or
the design pressure of the piping and equipment downstream of the pump.
This pressure is also called the Stall with Stall Steam and is included on
the FWC steam pump requisition form to determine if a relief valve is
required. A number of other terms are included on this form and are
defined as follows:
Normal Steam represents the conditions, which FWC uses for utility
consumption.
Worst Steam represents the minimum inlet and maximum exhaust

at which the pump must deliver rated flow and
pressure.
Stall Steam is the maximum steam inlet and minimum steam

exhaust pressures. For this condition, the steam
piston will produce its maximum force, with the
result that the liquid piston also produces its
maximum force and consequently the maximum
differential pressure to the liquid.
Stalling Pressure is specified by the vendor since it is a function of the

pumps proportion and Stall Steam differential
pressure. It can be calculated from the following
equation:
2
(Stm. Cyl. Diam.)
Max.!P Fluid = 2
x Stall Steam !P
(Liq. Cyl. Diam.)

PROCESS STD 400-1.2
EQUIPMENT REV 10
.21 MAXIMUM DISCHARGE PRESSURE AND RELIEF VALVE (Contd)
In requisition form, Figure 10, the vendor indicated that his pump would
develop a liquid differential pressure of 152 psi under Stall Pressure
conditions. Since the liquid feed has a maximum suction pressure of 30
psig, the Stall with Stall Steam pressure is 152 + 30 = 182 psig.
If required for pump or downstream equipment protection, the relief valve

should be located in the discharge line as near the pump discharge as
possible and ahead of any block or check valve that may be located in the
discharge line.
.22 STEAM CONSUMPTION
The steam consumption chart, Figure 11 affords a means of quickly

obtaining an approximate figure for the steam rate of direct acting steam
pumps.
For duplex pumps, divide the water horsepower by 2, before applying it to

the curves. These curves were made up on the basis of hydraulic
horsepower per cylinder, and if the above procedure is not followed,
inaccurate results will be obtained.
PROCEDURE: Starting with the hydraulic horsepower per cylinder:
a) Move vertically to the curve for steam cylinder size.
(Diam. x stroke)
b) Move horizontally to the curve for 50 feet per minute piston speed.
This is the basic curve from which the other curves were plotted.
c) Move vertically to the actual piston speed at which the pump will run.
If actual speed is not known, estimate using basic speed curves.
d) Move horizontally to the steam rate scale, and read same in pounds
of steam per hydraulic horsepower hour.
e) Multiply above result by total hydraulic horsepower to obtain steam

rate in pounds per hour.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.22 STEAM CONSUMPTION (Contd)
For steam cylinders with diameters as shown, but with longer stroke,
deduct 1% from the steam rate for each 20% additional stroke. Thus, a 12
x 24 steam end will have a steam consumption about 5% less than for a
12 x 12 steam end. For 5 x 5 and 4 x 4 steam ends, the 6 x 6 curve
will give approximate figures. For cylinders of intermediate diameters,
interpolate between the curves.
To correct for superheated steam, deduct 1% for each 10 degrees of

superheat.
To correct for back pressure, multiply the steam rate by a correction factor
equal to:
P + BP
, where
P
P = net steam pressure to drive pump (inlet-exhaust pressure)
BP = back pressure
.23 PRESSURE SURGES
Pressure surges or water hammer sufficient to cause equipment and

piping damage may be the result of one of the more common following
situations:
1. Pulsating flow patterns established by reciprocating pumps.
2. Fast closing valves located in the discharge line.
3. Power failure in a pumping operation discharging into an uphill line

resulting in a back-flow surge, etc.
To minimize the possibility of damage, a number of proprietary items

called dampers have been developed. As proprietary items they are to
be sized and guaranteed by the vendor not FWC.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.24 TYPES OF DAMPERS (SURGE ABSORBERS, ACCUMULATORS)
Several different types are available. One consists of an enlarged chamber

containing a flexible diaphragm, which separates the pumped liquid from a
gas filled section. The damping effect is obtained by compression of the
gas resulting from the inflow of additional liquid. One or more of these
units may be mounted on the pipe line to hold the pressure rise within
reasonable limits. The standard diaphragm is suitable for continuous
operation at temperatures from 25F to +190F, although special
diaphragms can extend this range. In another variation, the diaphragm is
replaced by an elastomeric bag or bladder, which is inflated to a pressure
of about 60% of the line pressure. As line pressure is increased due to
pulsation or shock loading, liquid flows into the metal container decreasing
the volume of the bladder and thereby cushions and alleviates build up of
excessive pressures. An inert gas, such as nitrogen (not air), should be
used when the line liquid is combustible. This type is stocked in sizes from
1.5 cubic inches to 10 gallons capacity for pressures to 3000 and 6000 psi
In some cases where the pumped fluid is not compatible with diaphragm
materials, another type of pulsation damper is indicated. This consists of a
closed tank floating on the line and in which a gas phase is maintained
with no diaphragm separating the phases. Usually a gauge glass is added
to indicate the need for injecting additional gas to replace that lost by
solubility effects. This type will require attention to assure the presence of
sufficient gas to maintain its effectiveness since the gas blanket will be
eventually lost by dissolution in the liquid. Refinements include high and
low level alarms.
To avoid gas solution problems, a piston type accumulator has been

developed in which a floating piston separates the gas from the liquid. The
piston type is available in sizes from 5 cubic inches to 50 gallons capacity,
with working pressures up to 10,000 psi.
Another type called a pressure alleviator utilizes a spring loaded piston to

absorb the energy of the pressure surge.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.25 PUMP TYPE VS NEED FOR DAMPERS
The following list is in order of their declining need for dampers.

Steam Pumps Power Pumps
Simplex Double Acting Simplex - Single Acting
Duplex - Double Acting Simplex - Double Acting
Duplex - Single Acting
Duplex - Double Acting
Triplex - Single and Double Acting
Quadruplex - Single and Double Acting
Quintuplex - Single and Double Acting
The following sketches illustrate the variation in the flow velocity diagrams
for some piston pumps.

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.26 SIMPLIFIED FORMULAS FOR SIZING DAMPERS for pump speeds up

to 100 RPM.
Pump Type Damper Volume, USGPM
Simplex, single-acting 5 xDisch.Rate

V" (GPM)
RPM
Simplex, double-acting 2.5 xDisch.Rate

V" (GPM)
RPM
Duplex, double-acting 1.3 xDisch.Rate

V" (GPM)
RPM
Triplex, single & double- 0.45 xDisch.Rate

acting V" (GPM)
RPM
Note: For pump speeds above 100 RPM multiply the above volumes by
PumpRPM
to get required damper volume.
100
.27 CALCULATION OF LINE PRESSURE DUE TO VALVE CLOSURE
The magnitude of line shock can be calculated by the following formula
W
P= x V P (V - v)
144g

PROCESS STD 400-1.2
EQUIPMENT REV 10
.27 CALCULATION OF LINE PRESSURE DUE TO VALVE CLOSURE

(Contd)
where P = increase in pressure due to shock, psi

Vp = velocity of pressure wave propagation in pipe
(approx. 4000 ft/sec in small pipes)
W = Sp Gr of liquid flowing, lbs/cu. ft.
V = velocity of liquid in pipe before valve closure, ft/sec.
v = velocity of liquid in pipe at an interval equivalent to
the time that a pressure wave will travel up the pipe
and back after the valve starts closing, ft/sec
g = Acceleration of gravity 32 ft/sec2
Example
A 3" line, 1000 ft. long is carrying water at a pressure of 250 psig and at a
velocity of 10 ft/sec. is suddenly shut off by a valve closing in 0.3 seconds.
Assuming that the velocity of the pressure wave in the pipe is

approximately 4000 ft/sec., it would take 0.5 seconds for the wave to travel
up the pipe and back. This is slower than the time required for the valve to
close and consequently v, (the velocity through the valve after the
pressure wave has made one complete cycle) is equal to zero.
Substituting in the equation
62.5
P= x 4000 (10 - 0)
144 x 32.2
P = 540 psi
Adding the above value to the original pressure the,
Total Surge pressure = 540 + 250 = 790 psig
In general, water hammer will occur when the total surge pressure
exceeds twice the static pressure. Therefore, in this example, water
hammer will occur.
.28 CALCULATION OF DAMPER VOLUME REQUIRED TO REDUCE

PROCESS STD 400-1.2
EQUIPMENT REV 10
SHOCK
Dampers to absorb the shock of fast closing valves are mounted just up-
stream of the valve. To calculate the minimum surge volume, the following
equation may be used.
0.004 R P2 (L - T)
A=
P2 - P1
Where A = surge volume required in U.S. gallons
R = pipe flow rate in gals/min.
T = normal closing time of valve in sec. (if the valve
closure is instantaneous, T = zero)
L = length of pipe in feet
P1 = flow pressure at valve = pipe inlet pressure minus
line pressure drop to valve
P2 = the upper pressure limit which the surge should be
limited to in absorbing the decelerating flow on valve
closure. This should be set at 1.5 times the static
pressure in the line when the valve is closed and the
liquid is at rest.
Example
Using the same conditions in the previous example, the volume flow in a 3"
sch. 40 line, 1000 feet long flowing 10'/sec. is 230 GPM. Friction drop in a
1000 ft. line is equal to 4.5 psi/100 ft or 45 psi for 1000 ft. The pressure at
the valve when the liquid is flowing is 250-45 = 205 psig. The factor P2 is
equal to 1 x 250 = 375 psig.
Substituting
0.004 x 230 X 375 (0.005 X 1000 - 0.3)

A=
375 - 205
= 10.2 gals.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.29 PUMP SUCTION AND DISCHARGE LINES CONSIDERATION
The flow of liquid in and out of any reciprocating pump varies in a cyclic
manner due to the speed variations of the piston or plunger. The greater
the number of these, the smaller will be the variation. As an extreme
example, the flow variation of a simplex single acting pump (see sketch on
Page 2.0 - 6) is 320% of the average but is only 3.6% for a single acting
septuplex (seven plungers) provided with equally spaced cranks. The
actual flow change in gallons per minute is dependent on the size of the
machine. Large machines with large diameter plungers create large flow
changes while the opposite situation prevails for small diameter plungers.
The cyclic frequency of the flow change is a function of the number of
plungers and the speed. A triplex (3 plungers) pump for instance,
generates 6 flow pulses (3 large and 3 small) per revolution. At a speed of
400 RPM, there are 1200 large pulses per minute or 20 per second.
Pipe line vibration is caused by this cyclic flow through the elbows. When
the flow increases the elbows move outward and when the flow diminishes
the elbow returns. If the flow is changing 1200 times per minute, all the
elbows in the line will try to change position at this rate. As discussed
previously, dampers can be very useful devices for quieting pipe line
vibration and hydraulic noises since these cushion the surge flow and
thereby reduces elbow movement and pressure pulsations.

PROCESS STD 400-1.2
FOSTER WHEELER MECHANICAL PAGE3.01- 1
EQUIPMENT REV 10
30 ACCELERATION HEAD LOSS
Another factor that must be considered in planning a reciprocating pump

installation is acceleration head loss in the suction line. Though not a loss in the
true sense of the word, it is just as harmful to pump operation as friction loss and
can be explained by the following. If the liquid in a line is changing velocity due to
plunger velocity change, acceleration must be present. To accelerate a column of
liquid, a differential pressure must exist between the two ends of the column. Large
velocity changes require high acceleration, therefore, large pressure differences.
Also, the longer the supply line, the larger the pressure differences must be to get
the mass of liquid moving. This pressure difference is obtained because the
plunger tends to leave a void in the cylinder as it moves on its suction stroke. If the
suction supply pressure is not high enough, the pressure in the cylinder may fall
below the vapor pressure of the liquid and flashing or cavitation may occur. The
cylinder would then be partly filled with vapor instead of liquid. As the plunger
begins the discharge stroke, it compresses the gas and then strikes the liquid while
moving at a relatively high speed. The impact sets up very undesirable shock
waves which can be damaging to both lines and equipment.
This sequence of events is modified by the installation of a damper. A damper

functions by reason of having a zone of compressed gas acting on a relatively
small volume of liquid which is stored until it is needed on a suction stroke. The
effect is to establish an almost constant flow in the suction line because almost all
of the surge and acceleration takes place in the suction manifold of the pump.
.31 ACCELERATION HEAD CALCULATION
Under certain situations, the acceleration head can be greater than the
head required by pump valving systems and fluid friction losses. The
following empirical formula is used for this calculation.
LVRC
ha =
Kg
Where Ha = acceleration head, feet

L = actual line length, feet (not equiv. length)
V = mean velocity in line, feet per second
R = pump speed, RPM
C = 0.2 for Simplex Double-acting
= 0.2 for Duplex Single-acting
= 0.115 for Duplex Double-acting
PROCESS STD 400-1.2
EQUIPMENT REV 10
= 0.066 for Triplex Single or Double-acting

= 0.040 for Quintuplex Single or Double-acting
= 0.028 for Septuplex Single or Double-acting
K = 2.5 for relatively compressible liquids (ethane, hot
oil)
= 1.4 for water, amine, glycol
g = Gravitational constant = 32.2 ft/sec/sec
.31 ACCELERATION HEAD CALCULATION (Contd)
Example: Determine the Acceleration head for a system consisting of a 2"

x 5" triplex pump operating at 360 RPM and pumping 73 GPM of water
with a suction line made up of 4 ft. of 4" SCHD.40 and 20 ft. of 6"
SCHD.40 pipe.
73 GPM
Av. Vel. in 4" line = = 1.84 Ft/sec
60 sec/min x 7.48 gal/cu.ft. x .0884 sq. ft.
73
Av. Vel. in 6" line = = 0.811 Ft/sec
60 x 7.48 x 0.2006
4 x 1.84 x 360 x 0.066

ha in 4" pipe = = 3.88 Ft.
1.4 x 32.2
20 x 0.811 x 360 x 0.066

ha in 6" pipe = = 8.55 Ft.
1.4 x 32.2
Total Acceleration Head = 3.88 + 8.55 = 12.43 Ft.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.31 ACCELERATION HEAD CALCULATION (Contd)
An examination of the above formula indicates that the acceleration head

of a system can be decreased by:
1. Decreasing the length of the suction line.
2. Increasing the diameter of the suction line.
3. Using slower speed pumps. (This could be expensive and

impractical)
4. Using multiplex type pumps with more cylinders.
Figure 12 has been prepared to expedite the calculation or estimation of

acceleration head values.
.32 RECIPROCATING PUMP PIPING RECOMMENDATIONS
Suction Piping should:
1. Be as short and direct as possible and anchored near but

independent of the pump and perfectly aligned with the pump flanges
to avoid strains on the pump casing.
2. Be one or two pipe sizes larger than pump suction connection.
3. Have a velocity less than, 2 ft/Sec for speeds up to 250 RPM 1

ft/sec for speeds up to 330 RPM, 1 ft/sec for speeds above 330
RPM.
4. Contain a minimum number of turns. Necessary turns should be

accomplished with long-radius elbows.
5. Be designed to preclude the collection of vapor in the piping. (No

high points unless vented) (Use eccentric reducer at pump cylinder
with flat side up.)
6. Be designed so that acceleration head, friction loss, and pump NPSH

required (added together) do not exceed the NPSH available from
the system.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.32 RECIPROCATING PUMP PIPING RECOMMENDATIONS (Contd)
7. Include a suction bottle or suitable pulsation damper if it is found that

the acceleration head is excessive. Care must be taken in the
application of dampers to suction systems since many dampers are
not suitable for low pressure application. (The extra suction
connection on the fluid cylinder, standard on some pumps, is an
excellent point to connect a suction bottle or surge chamber. Also
see sketch, in Page 2.0-9 for preferred location.)
8. A foot valve should be installed if the pump is to operate under a high

suction lift.
Discharge Piping should:
1. Be as short and direct as possible.
2. Be one to two pipe sizes larger than pump discharge connection.
3. Have a velocity not exceeding twice the suction velocity.
4. Contain a minimum number of turns, utilizing long-radius elbows

where possible.
5. Include a suitable pulsation damper or provisions for adding a

damper at a later date. The extra discharge connection on the fluid
cylinder, standard on some pumps, is an excellent point to connect a
bladder-type damper on constant-pressure applications.
6. Include a stop valve if liquid can backflow into the pump during repair
periods.
.33 HORSEPOWER
Horsepower calculations for reciprocating pumps are based on net

differential heads usually expressed in pounds per square inch and liquid
flows in terms of GPM.
GPM x !P (psi)
Hydraulic Horsepower* (HHP) =
1715
alternate forms of the same equation are:

PROCESS STD 400-1.2
EQUIPMENT REV 10
.33 HORSEPOWER (Contd)
GPM x !Head(ft) x Spec. Gravity

HHP =
3960
GPM x !Head(ft) x Spec. Gravity x 8.33

HHP =
33000 Ft. Lbs. per Minute
* HHP is also referred to in the literature as liquid HP, fluid HP, water
HP or theoretical HP.
In order to determine the actual power input to the pump, hydraulic,

volumetric and mechanical losses must be included. For simplification
purposes, the hydraulic and volumetric losses may be considered to total
about 10% while the mechanical loss is a variable depending on the type
of pump. The actual or Brake Horsepower is then,
GPM x !P (psi)
BHP =
1715 x 0.90 x Mech. Eff.
.34 MECHANICAL EFFICIENCY OF STEAM PUMPS
The following table lists conservative mechanical efficiencies used in sizing

steam piston cylinders.
Stroke in Inches 3 4 5 6 7 10 12 18 24
Mech. Piston Pump 50 55 60 65 65 70 70 73 75
Eff.
Plunger Pump 47 52 57 61 61 66 66 69 71

PROCESS STD 400-1.2
EQUIPMENT REV 10
.35 MECHANICAL EFFICIENCY OF POWER PUMPS
The following table lists conservative mechanical efficiencies at discharge

pressures between 75-100% of maximum rated discharge pressure and
are useful for process design calculations in lieu of specific vendors data.
Stroke Length, Inches 2 3 4 5 6
Mech. Eff. % 83 85 85 87 87
The mechanical efficiency of power pumps decreases when actual
discharge pressures are substantially less than maximum rated pressure
for a given plunger diameter. This increases BHP requirements. See
table below.
Stroke % Max. Rated Pressure

Length
70 60 50 40 30 25 20 15 10
2 82 80.5 79 76.5 72 69 65 58 49
3 & 4 84 82 80 78 74 70 66 59 50
5 & 6 86 84 81 79 75 71 67 60 52

PROCESS STD 400-1.2
EQUIPMENT REV 10
.36 VOLUMETRIC EFFICIENCY OF POWER PUMPS
The volumetric efficiency of power pumps may be assumed to be 95%.
.37 PUMP MOTOR SELECTION CHART
Refer to Figure 13 for an estimate of the motor horsepower requirements

of power pumps.
.38 PUMP SELECTION HORIZONTAL SIMPLEX STEAM PUMPS
To select this type of pump, it is first necessary to select the proper liquid
end and then determine what steam end is required to obtain the desired
liquid pressure with the steam available.
First determine the maximum recommended piston speed for each stroke
pump from Table 2. Then using Figure 14, determine the smallest liquid
piston diameter which will give you a piston speed equal to or less than the
maximum recommended. This diameter and corresponding stroke is the
liquid end size.
Next, determine the steam end size from the curves on Figure 15. The
upper curve is for 8 and 12 inch stroke pumps. The lower curve for 18 and
24 inch stroke pumps. Enter the proper curve at the correct net liquid
pressure. Read horizontally to the line corresponding to the liquid piston
diameter. Then move vertically downward to the line corresponding to the
steam end size which will require less steam pressure than is available.
This is the correct steam end size.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.381 Typical Selection Problem, Simplex Steam Pump Process

Conditions
Liquid pumped Oil
Pumping temperature 200oF
Viscosity 2500 SSU
Capacity 110 gpm
Discharge pressure 450 psig
Suction pressure 0 psig
Net liquid pressure 450 psi
Steam inlet pressure 190 psig
Steam exhaust pressure 15 psig
Net steam pressure 175 psi
Selection
1. For 2500 SSU the maximum recommended piston speed is 53 fpm

for 8-inch stroke and 62 fpm for 12-inch stroke per Table 2.
2. Entering curve Figure 14 at 110 gpm and moving vertically note that
no 8-inch stroke pump listed can operate within the recommended
speeds.
3. However, a 7-inch diameter piston will run at a piston speed of 56

fpm which is less than the 62 fpm maximum for a 12-inch stroke.
Therefore, the correct liquid end size is 7 x 12.
4. On Figure 16 read horizontally along the line corresponding to 450

psi net working pressure to the curve for the 7-inch diameter liquid
piston. Then read vertically downward to 175 psi net steam
pressure. Note that the smallest steam end requiring less than 180
psi steam will be the 14 x 12.
5. The correct size pump is a 14 x 7 x 12.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.39 CLOSE CLEARANCE PUMPS
This type is used for high volatility fluids such as propane and butanes.
The liquid end of the pump is designed with close clearances, without
restricting passageways and usually with direct upward flow to eliminate
any pockets within the pump where gas can collect. It is usually a simplex
type where short stroking cannot occur and even under gassing
conditions, full displacement will occur. These pumps may operate
unevenly especially at high suction pressures due to the unbalanced
piston forces on the liquid side due to the presence of the piston rod. In
revamp designs, secure the advice of the Mechanical Equipment Group or
pump vendor for maximum suction pressure limits.
.391 Close Clearance Simplex Steam Pump Selection
1. Refer to Table 3 for size of liquid end for the nearest capacity
in excess of the process requirement.
2. If piston speed is desired, refer to Figure 15.
3. Refer to appropriate parameter of Figure 17 and obtain the

smallest steam end suitable for the differential steam
pressure.
.392 Typical Selection Problem, Close Clearance Pump Process

Conditions
Liquid pumped Butane

Pumping temperature 145oF
Capacity 50 gpm
Discharge pressure 250 psig
Suction pressure 100 psig
Net liquid pressure 150 psi
Net steam pressure 160 psi
Exhaust steam pressure 30 psia
1. From Table 3, the 6 x 12 liquid end gives the nearest
capacity in excess of 50 gpm.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.392 Typical Selection Problem, Close Clearance Pumo Process

Conditions (Contd)
2. From appropriate curve on Figure 17 move horizontally on

line for 150 psi net liquid pressure to curve for 6 inch
diameter liquid piston. Then move vertically downward to
line corresponding to 160 psi net steam pressure. The
smallest steam end that requires less than 160 psi net steam
is the 8 x 12.
3. Correct size pump is an 8 x 6 x 12.
.393 Calculation of Steam (or Water) Rate
The Hydraulic Horsepower for the above pump is,
50 x 150
HHP = = 4.38 say 4.4
1715
From Figure 15, the piston speed for a 6" x 12" liquid end at 50
GPM capacity is 35 FPM. From Figure 11, for an 8" x 12" steam
end pump of 4.4 HHP, the steam (or water) rate is estimated as
112 pounds per HHP.
Total Steam Rate = 4.4 x 112 = 493 #/hr

PROCESS STD 400-1.2
EQUIPMENT REV 10
.40 THEORETICAL STEAM RATE
The theoretical steam rate can be calculated using a Mollier steam chart and
considering the expansion of steam to be isentropic. Based on the pump
conditions and calculations of paragraphs 3.92 and 3.93, proceed as follows:
Enthalpy at (160 + 30) psia = 1198 BTU/#
Enthalpy at 30 psia (constant entropy) = 1053 BTU/#
!Enthalpy = 145 BTU/#
4.4 x 2545
Theoretical Steam Rate = = 77.3 # /hr.
145
In Paragraph .393, the total steam rate was calculated as 493 #/hr. Based on
these results the thermal efficiency is = 77.3 x 100/493 = 15.7%.
.41 STEAM PUMP
.411 NPSHR (Net Positive Suction Head Required)
The net positive suction head required by a steam pump has been
defined as that head above the vapor pressure of the liquid being
handled, necessary to lift the suction valves and fill the pump to
the discharge deck. The NPSHR is determined by the pump
vendor and can be varied according to the vendors selection of
the type and number of inlet valves, the force necessary to
overcome the weight and spring tension of the suction valves and
fluid flow friction through the suction opening and through the
valves. NPSHR is invariably expressed in psi, not in feet of liquid
as in a centrifugal pump. This may be converted to feet of liquid
head by multiplying by 2.31 and dividing by the specific gravity of
the fluid at flowing conditions.
When vendor information on NPSHR is not available, an estimate

may be made using the following procedure which was developed
by Worthington Corp.
Step 1 Calculate Q, the maximum flow per suction valve from

the appropriate following equations.

PROCESS STD 400-1.2
EQUIPMENT REV 10
.411 NPSHR (Net Positive Suction Head Required) (Contd)
GPM SP.GR
For Duplex Pumps, Q=
n
GPM SP.GR
For Simplex Pumps, Q=
0.75 n
Where GPM = actual capacity pumped
SP. GR = specific gravity at pumping temperature
N = number of suction valves per section
NOTE: Worthingtons present line of cap and valve plate pumps
have one suction valve per section. For pot valve pumps
refer to vendors literature or if not available use table
below.
Pump No. Of Suction
Pump Size Range
Type Valves/Section
Horizontal (6x3x8) to (14x7x12) 1
Simplex
(8x6x18) to (12x6x18) 2
(10x8 x18) to (20x12x24) 4
Horizontal (6x4x6) to (14x7x12) 1
Duplex
(10x6x18) to (14x7x18) 2
(12x8 x18) to (22x12x24) 4
Step 2 Refer to proper set of curves of Figure 18 (bronze disc

valve, 11-13 chrome disc valve etc.) and locate Q.
Move vertically to intercept the curve of the valve size
for the pump selected. Follow horizontally to the left to
determine the NPSHR in psi. Wing valves are
recommended for discharge pressure above 450 psig.
The table below indicates the valve size for different
Simplex and Duplex Steam Pumps.

PROCESS STD 400-1.2
EQUIPMENT REV 10
Simplex Pumps
(Valve Size) (Valve Size)

Pump Size Pump Size
(Diam. In.) (Diam. In.)
6x3x8 2 13/16 (8x6x18) to (12x6x18) 4 1/16
(6x4x12) to 3 5/16 (8x7x18) to (14x7x18) 4 5/8

(10x4x12)
(6x5x12) to 4 1/16 (10x8 x18) to (18x8 4 1/16

(12x5x12) x18)
(8x6x12) to 4 5/8 (12x10x18) to 4 5/8

(12x6x12) (20x10x24)
(8x7x12) to 5 3/8 (14x12x24) to 5 3/8

(14x7x12) (20x12x24)
Duplex Pumps
(Valve Size) (Valve Size)
Pump Size Pump Size
(Diam. In.) (Diam. In.)
3x2x3 1 6x5 3/4x6 4
4 x2 3/4x4 2 9x5 x10 4
4 x 3 3/4x4 2.7/8 10x6x10 4 5/8
5x3x5 2 7/8 10x7x10 4 5/8
6x4x6 3 3/8 8x7x12 5 3/8
7x5x6 3 5/8 10x7x12 5 3/8
5x4 3/4x5 3 5/8 8x8x12 5 3/8

PROCESS STD 400-1.2
EQUIPMENT REV 10
Step 3 Convert NPSHR from psi (above the discharge valve

deck) to feet and add the height from the pump base to
the valve deck since in this case the NPSHR datum
line is the pump base. Refer to Figure 19 for an
estimate of the deck height above pump base.
.42 POWER PUMPS
.421 Typical Performance Curves
Refer to Figures 20-25 for typical performance curves of simplex,

duplex, triplex and quintuplex power pumps. These curves relate
pump speed and capacity with parameters of plunger diameters.
In addition, some of these provide brake horsepower information
calculated for maximum pressure differentials shown. This series
of curves is helpful in estimating pump sizes when specific vendor
information is not available.
.422 NPSHR
NPSH required for power pumps may be estimated from Figure

26. Note that NPSHR is provided in terms of PSI and represents
approximate minimum values. As speed is increased, NPSHR
also increases. Figure 27 has been included to show the
significantly greater NPSHR as speed varies between Normal and
Maximum. Tests conducted by a major vendor indicates that
NPSHR becomes greater as pressure differentials are increased.
This is related to the necessity of using stronger valve springs to
assure valve closure especially at high RPM. These tests also
affirmed that as plunger diameter is increased, NPSHR also
increases.

PROCESS STD 400-1.2
FOSTER WHEELER MECHANICAL PAGE Figure-1
EQUIPMENT REV 10
TABLE 1
SIZES AND CAPACITIES OF HORIZONTAL DUPLEX STEAM PUMPS
3) MAX. RECOMMENDED CAPACITY BOILER

SIZE
CAPACITY (GPM) FEED
STROKE,
DIAM. IN. COLD SSU VISCOSITY-VISCOUS LIQUIDS (HOT HP
INCH.
STM. LIQ. WATER, H20)
250 500 1000 5000 10000
CYL. CYL GPM GPM
3 2 3 12 12 11 10 8 4 7 90
3 2 3/4 3 23 23 22 20 8 4 - -
4 1/2 2 3/4 4 29 29 28 26 19 9 17 220
5 1/4 3 1/2 5 53 53 50 47 34 17 32 420
4 1/2 3 3/4 4 54 54 52 48 36 18 -- --
6 4 6 78 78 75 69 51 25 47 610
7 1/2 4 6 78 78 75 69 51 25 47 610
9 4 6 78 78 75 69 51 25 47 610
7 1/2 4 6 78 78 75 69 51 25 47 610
5 1/4 4 3/4 5 98 98 92 87 63 31 -- --
7 1/2 5 6 123 123 117 110 80 40 73 960
7 1/2 4 1/2 10 124 124 119 111 81 40 74 975
9 5 10 153 153 147 137 100 50 91 1190
9 5 1/4 10 169 169 162 151 110 55 101 1320
6 5 3/4 6 162 162 154 143 105 52 -- --
7 1/2 5 3/4 6 162 162 154 143 105 52 -- --
9 5 3/4 6 162 162 154 143 105 52 -- --
7 1/2 6 10 220 220 212 197 144 72 -- --
9 6 10 220 220 212 197 144 72 -- --
10 6 10 220 220 212 197 144 72 132 1720
10 6 12 235 235 224 209 153 76 140 1830
10 7 10 300 300 288 268 196 98 180 --
12 7 12 320 320 304 284 208 104 190 2500
14 7 12 320 320 304 284 208 104 190 2500
8 7 1/2 12 367 367 348 326 238 119 -- --
10 7 1/2 12 367 367 348 326 238 119 -- --
8 8 1/2 12 471 471 447 418 306 153 -- --
10 8 1/2 12 471 471 447 418 306 153 -- --
Notes
1. The actual displacement in U.S. Gals, for a single stroke of a single acting pump is =
.0034 LD2 where L = stroke length in inches and D = liquid cyl. diameter in inches.
2. Higher capacity duplex pumps than those listed (3000 GPM) are available but are
not listed due to low demand.

PROCESS STD 400-1.2
EQUIPMENT REV 10
3. The normal capacity is about 75% of maximum recommended capacity.

TABLE 2
SIMPLEX PUMPS, RECOMMENDED PISTON SPEEDS - Feet Per Minute
White
Heavy Products **
Products*
Stroke, Up to 450F
Inch
o Above
Up to 90 F Liquids
450F
under 250 250 to 500 500 to 1000 1000 to 2500 2500 to 5000
SSU visc. SSU visc. SSU viscosity SSU visc. SSU visc.
8 27 68 65 61 53 45 27
12 40 80 77 71 62 52 40
18 60 95 91 85 73 62 60
24 80 105 100 94 81 68 80
* White Products **Heavy Products Gas Oil

Gasoline Crudes Heavy Distillates
Naphtha Topped Crudes Recycle Stock
Benzine Fuel Oil Tar
Butane Lubestock Bottoms
Propane Power Oil Residuum
TABLE 3
CLOSE CLEARANCE PUMPS, MAX. RECOMMENDED CAPACITIES
Liquid End Sizes Normal Piston Speed in FPM *Displacement GPM
Diam. Stroke
3 x 8 32 11.7
4 x 12 42 27.4
5 x 12 42 42.8
6 x 12 42 61.5
7 x 12 42 84.0
7 x 18 54 108.0
8 1/2 x 18 54 160.0
10 x 18 54 220.0
# In accordance with standard practice, loss due to piston rod not accounted for in these ratings.

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PROCESS STD 400-1.

.10 GENERAL 1.01-1

.11 Classifications and Definitions 1.01-1

.20 SUCTION LIFT 2.01-1

.30 ACCELERATION HEAD LOSS 3.01-1

FOSTER WHEELER ENERGY LIMITED 2002

.39 Close Clearance Pumps 3.01-9

4.0 THEORETICAL STEAM RATE 4.01-1

.41 Steam Pump 4.01-1

1 Sizes and Capacities of Horizontal Duplex Pumps Figure-1

2 Simplex Pumps, Recommended Piston Speeds Figure -2

3 Close Clearance Pumps

2 Basic Speeds Duplex Piston Pumps Figure-4

3 Basic Speeds _ Triplex & Multiplex Plunger

4 GPM vs Piston Speeds For Typical Duplex Figure-5

5 Correction Chart for Viscosity and Water

6 Effect of Feed Viscosity On Piston Speed Figure-7

7 Suction Life Chart for Suplex Trade Pumps Figure-8

8 Pumps Process Data Form Figure-9

FOSTER WHEELER ENERGY LIMITED 2002

10 Reciprocating STM Pump Req Form Figure-11

11 Approximate Steam Consumption Direct acting Steam Pumps Figure-12

12 Acceleration Head Correlations Figure-13

13 Power Pump_Motor Selection Figure-14

14 Simplex Pump Capacity Vs Piston Speed Figure-15

15 Close Clearance Pump, Displacement Ratings

17 Close Clearance Simplex Steam Pumps

18 NPSHR Correlation For Steam Pumps Figure-18

19 Steam Pump Capacity Vs Height of Valve Desk Figure-19

20 Performance Curve Simplex, 2 3/16 Stroke Figure-20

21 Performance Curve-2Stroke Type 5D Duplex Pump Figure-21

22 Performance Curve-3Stroke Type KCF Triplex Pump Figure-22

23 Performance Curve Triplex, 4 Stroke Figure-23

24 Performance Curve-Stroke Type KCFQ Quintuplix Figure-24

25 Performance Curve Quintuplex 8 Stroke Figure-25

FOSTER WHEELER ENERGY LIMITED 2002

26 Minimum NPSHR Curves For Power Pumps Figure-26

27 Effect of Pump Speed On NPSHR For Power Pumps Figure-27

28 Minimum NPSHR For Vertical Power Pumps Figure-28

29 Minimum NPSHR For Vertical Power Pumps Figure-29

FOSTER WHEELER ENERGY LIMITED 2002

Reciprocating pumps are positive displacement pumps whose principal

1. Their capacity varies directly with speed.

3. Aside from considerations of construction materials, the maximum

.11 CLASSIFICATION AND DEFINTIONS

Reciprocating pumps are broadly classified as steam, power and metering.

.111 Steam Pumps

A Steam Pump is a reciprocating pump and a steam engine built

A Single Pump is a reciprocating pump having one liquid piston or

A Duplex Pump is a reciprocating pump having two liquid pistons

A Horizontal Pump is a reciprocating pump having the axial

FOSTER WHEELER ENERGY LIMITED 2002

.111 Steam Pumps (Contd)

A Vertical Pump is a reciprocating pump having the axial

Simple, Steam End - A steam end having a high pressure steam

Compound Tandem - A steam end having a high and low pressure

Crank and Flywheel Pump is a reciprocating pump with a

Compound, Cross (Crank and Flywheel only) - A steam end

Trade Pumps, Single or Duplex These are individual

.112 A Power Pump is a reciprocating pump driven by power from an

These include, Single, Duplex, Triplex and Multiplex pumps

.113 Metering Pumps also known as proportioning or controlled volume

FOSTER WHEELER ENERGY LIMITED 2002