ImportantAspectsofChemicalMeteringPump

SystemDesign

Walter Schajnoha

Calgary Pump Symposium 2015

2013 1
 PresenterBio

WalterSchajnohahasworkedwithProMinentFluidControlsforover20year
inapplicationanddesignofchemicalinjectionpackagesandwatertreatment
equipment.

Walterhasworkedinavarietyofindustriesreachingfrommunicipaldrinking
watertreatmenttotheoilandgasapplications.

CurrentlyWalterworksfromProMinents Canadianheadofficeasthe
NationalNewBusinessDevelopmentManagerwherehedevelopsinnovative
solutionsfornewapplicationsinchemicalinjection.

Calgary Pump Symposium 2015

2013 2
 Introduction

Step#1 CreatingthePumpDatasheet

Step#2 DevelopingtheP&IDDiagram

Step#3 ClientDocumentSchedule

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2013 3
 TheAPI675Pump

ByDefinition ControlledVolumePositive
DisplacementDiaphragmPump

Strokevolumeadjustment

Developedtoprovideaccurateandrepeatable
dosagesofchemicalstoprocesssystems.

Calgary Pump Symposium 2015

2013 4
 TheAPI675Pump

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2013 5
 TheAPI675Pump

Suction Stroke Discharge Stroke Discharge Stroke

Begins: discharge Suction Stroke
Complete. Fluid Begins: discharge Complete. Fluid in
valve closes, suction valve opens, suction chamber is
valve opens, chamber chamber is full.
valve closes displaced.
fills.

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 TheAPI675Pump
PumpPerformance
SteadyStateAccuracy
Pass Theflowmustnotchangegreaterthan1%
fortwotests5minutesapart.

Linearity
Theflowvaluesmustlieonastraightlinewhen
thestrokeadjusterissetat100%,75%,50%,25%
&10%within3%oftheratedcapacity.

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 TheAPI675Pump
PumpPerformance

Repeatability
Theflowvaluemustreturntotheoriginalvalue
whenthestrokeadjusterreturnedtoafterbeing
settoadifferentvaluewithin3%oftherated
capacity.

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 PROMUS PUMP - TEST DATA DATE: 3/17/2005
Prominent Fluid Controls Stroke Capacity
Setting % GPH
Customer: ProMinent Canada 100 13.94 Steady
Customer Order #: 2005200838 100 14.00 State
Ident Code: 130BSS10001X11H0 75 10.38
Serial Number: 270500960 50 6.82
Strokes Per Min: 138 SPM 25 3.08
Plunger Diameter: 0.8125 Inches 10 0.77
Test Pressure: 600 psi 25 3.00
50 6.76
Steady State Performance: -0.43% 75 10.58
100 14.08

Linearity
1.50%
1.00%
D
E 0.50% All TEST DATA TAKEN W ITH WATER @
V AMBIENT TEMPERATURE
I 0.00%
0 20 40 60 80 100
-0.50%
-1.00%
Setting (%)

Data Points
Curve Fit Pump Performance

16

C 14
A
12
P
A
10
C
I
8
T
Y
6
G 4
P
H 2

0
0 10 20 30 40 50 60 70 80 90 100

Setting (%)
STROKE SETTINGS (%) AT ZERO FLOW : 4.29%

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 TheAPI675Pump
ConsiderationsforPumpSelection

DoestheapplicationwarrantanAPI675Pump?

Alternativescanbepresentedthatadhereto
performancecriteriaofthespecificationata
lowercost.

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2013 10
 TheAPI675Pump
DoyoureallyneedanAPI675Pump?

<150psigoperatingpressurecanbemetwith
mechanicallydrivenunitatamuchlowercost

<50lph flowratescanbemetwithasolenoiddriven
unit

Eachwillprovideadequateperformanceata
fractionofthecost.(50%Savings)

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 TheAPI675Pump

SolenoidDriven
Pressuresupto363psig;Flowsupto50lph
EffectiveFlows constantdosingat1ml/hour

MechanicallyActuated
Pressuresupto150psig
Betterthan100:1turndownwithnolossinperformance

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2013 12
 TheAPI675Pump

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2013 13
 TheAPI675Pump
OperatingData

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 Viscosity

Viscosityhasmanyaffectsonthesystem
Impedesflowonthesuctionside
PumpStarvation
ReductioninAccuracyandpumpperformance
PulsationIncreases
HeadlossonDischarge

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2013 15
 Viscosity

Gravitational Force

Bouyancy Force

Drag Force

Spring Tension Force

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 Viscosity

PumpStarvation
Pumpsuctionstrokedoesnotallowforthe
completefillingofthehead

Solution,oversizepumpandrunatalowerspeed
toprovidethetimetofill,(6080spm)

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2013 17
 Viscosity

Lossofaccuracyandpumpperformance
Suctionanddischargevalvesneedadditionaltime
toclose

Solution Addspringstothevalvestoforce
closed(small1.5psispringtoclosevalveagainst
viscosity)

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2013 18
 Viscosity

OtherSolutions
UseLargerValvesonpumpheadifpossible
reduceslossesintoheadandlowersfilltime.
Usevalvelesstechnology,DRRotatingPiston
Pump

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 Viscosity

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 Viscosity

ConsidernonAPI675pumps

Mechanicallyactuatedpumps betterflow
rangewithhigherviscosities.

SolenoidDriven,betteronlowerflows<3,000
cPs.

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 Temperature

Temperaturecancreateissues
Changesofviscosityprofileofchemical
Changesofvapourpressure
PumpMaterialsandhydraulicoilselectionfor
extremecases(45Clowend120Contopend)

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 Temperature

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 Temperature

Lowtemperaturescancausemanychemicals
tofreeze.

Heatingmustbeprovided.

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2013 24
 Temperature

Pipingconfigurationsonmeteringsystemsare
complicated.

Enclosuresareabetteroptionthatheattrace
andinsulation leakagedestroysmaterial.

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 Temperature

Enclosuresshouldbedesignedtohouse
equipmentonlyandnotforhuman
occupancy.

Accesstoequipmentfromoutsideofthe
enclosurewhenpossiblewillminimizecosts

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 EnclosureOptions

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 EnclosureOptions

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 EnclosureOptions

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 EnclosureOptions

PumpSystemandTankin
commonenclosure

Containmentincluded,
completelyintegrated,reduced
commissioningtime

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 EnclosureOptions

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 SolidsContent

SolidsintheFluid
Issueswithsettlinginline
Pluggingpumphead
PluggingPumpValves
Abrasiononpumpheadandvalves
DiaphragmRupture

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 SolidsContent

SolidsintheFluid
Solution
WyeStraineronsuctionsideifthesolidsarenot
neededinthesystem.
Thiscanbesetupandchecked/cleanedeasilyandwill
preventsolidsfromgettingintopump
Solidsizedependsonvalvesizetypically50100um.

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 SolidsContent

Solutions
Issueswithsettlinginline
Sizelinessothatvelocityishighenoughtoscour
productandpreventsettling
23m/sflowrate
Flushlinesonaregularbasistoremovesolids
Blowairthroughlines actstoscourandreentrain
solidsintosolution.

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 SolidsContent

SolidsintheFluid
Pluggingpumphead/valves
Solidswillaccumulateinheadandcausemechanical
failureofthediaphragmorforcetheheadoffofthe
pump.
Flushingsolidsonaregularbasis
Useselfcleaningcheckvalves rotatingvalves.

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 SolidsContent

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 NPSHa andSuctionPressure

NPSHa h fluid hatm h f hvapour ha max

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 NPSHa andSuctionPressure
Challengingconditions
LargeTanks highsuctionhead
HighPotentialSuctionLift Drawingfromtopoftank
LongSuctionLines(>10feet)
UndersizedSuctionLineDiameters

PotentialCavitation,Overfeeding,Starvation
Conditions

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 AccelerationHeadLoss

L LengthofLineinmeters
V Average VelocityinLineinm/s
n Speed ofpump,Cycles/Minute

LVnC C ConstantDependent onpumptype

ha max Simplex0.628,Duplex0.2,Triplex0.066,
Quadruplex 0.115,Quintuplex 0.04
Kg K FluidCompressibility Constant
1.5formostnoncompressibleliquids
2.5forcompressibleliquids
g Gravitational Constant9.81m/s2

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 AccelerationHeadLoss
Solutions ReducetheNumerator
Oversizepump,andrunthepumpslower.

Multiplexthepump,morethanonepumphead
reducestheAHLbykeepingthefluidmoving.

Upsizesuctionlinediameter/shortensuctionline

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 NPSHa andSuctionPressure
Solutions
Keepmeteringpumpascloseaspossibletothetank
andprovidefloodedsuction.
SizeSuctionlineatleastthediameterofthepump
inlet.Oversizetoreducevelocity.
ProvideAccumulatorTankonthesuctionlineto
preventcavitationoroverfeeding.

Keepinmind,fluidpropertieswillexasperatethe
potentialissues

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 ExampleCalculation
Pump Type MfS 180/90 Rated Capacity [l/h] 1840 Factor C : Factor K :
Stroke [cm] 4 Pipe Length [m] 10 Simplex 0.628 2.5 for compressible
Bore [cm] 9 Factor 'K' 1.4 Duplex 0.2 1.4 for non-compressible
No. of Heads 1 Factor 'C' 0.628 Triplex 0.066
Efficiency 0.855 Theoretic Capacity [l/h] 2152.807782 Quadruplex 0.115
Speed [min-1] 141 Effective Capacity [l/h] 1840.650653 Quintuplex 0.04

DN [mm] vrtd [m/s] vmaxQ [m/s] ha(rtd) [m] ha(max) [m] ha(rtd) [ft] ha(max) [ft]
52.5 2" 0.236 0.276 15.223 17.810 49.943 58.433
62.7 2 1/2" 0.166 0.166 10.673 10.676 35.015 35.028
73.7 3" 0.120 0.120 7.725 7.727 25.343 25.352
97.2 4" 0.069 0.069 4.441 4.443 14.570 14.575

Note: DN is the inner diameter of the tube. If required, just type other values there.

Pump Type MfS 180/52-52-52 Rated Capacity [l/h] 1840 Factor C : Factor K :
Stroke [cm] 4 Pipe Length [m] 10 Simplex 0.628 2.5 for compressible
Bore [cm] 5.2 Factor 'K' 1.4 Duplex 0.2 1.4 for non-compressible
No. of Heads 3 Factor 'C' 0.066 Triplex 0.066
Efficiency 0.855 Theoretic Capacity [l/h] 2155.997127 Quadruplex 0.115
Speed [min-1] 141 Effective Capacity [l/h] 1843.377543 Quintuplex 0.04

DN [mm] vrtd [m/s] vmaxQ [m/s] ha(rtd) [m] ha(max) [m] ha(rtd) [ft] ha(max) [ft]
52.5 2" 0.236 0.277 1.600 1.875 5.249 6.150
62.7 2 1/2" 0.166 0.166 1.122 1.124 3.680 3.687
73.7 3" 0.120 0.120 0.812 0.813 2.663 2.668
97.2 4" 0.069 0.069 0.467 0.468 1.531 1.534

Note: DN is the inner diameter of the tube. If required, just type other values there.

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 ExampleCalculation
Pump Type MfS 180/90 Rated Capacity [l/h] 1840 Factor C : Factor K :
Stroke [cm] 4 Pipe Length [m] 10 Simplex 0.628 2.5 for compressible
Bore [cm] 9 Factor 'K' 1.4 Duplex 0.2 1.4 for non-compressible
No. of Heads 1 Factor 'C' 0.628 Triplex 0.066
Efficiency 0.855 Theoretic Capacity [l/h] 2152.807782 Quadruplex 0.115
Speed [min-1] 141 Effective Capacity [l/h] 1840.650653 Quintuplex 0.04

DN [mm] vrtd [m/s] vmaxQ [m/s] ha(rtd) [m] ha(max) [m] ha(rtd) [ft] ha(max) [ft]
52.5 2" 0.236 0.276 15.223 17.810 49.943 58.433
62.7 2 1/2" 0.166 0.166 10.673 10.676 35.015 35.028
73.7 3" 0.120 0.120 7.725 7.727 25.343 25.352
97.2 4" 0.069 0.069 4.441 4.443 14.570 14.575

Note: DN is the inner diameter of the tube. If required, just type other values there.

Pump Type MfS 180/120 Rated Capacity [l/h] 1840 Factor C : Factor K :
Stroke [cm] 4 Pipe Length [m] 10 Simplex 0.628 2.5 for compressible
Bore [cm] 12 Factor 'K' 1.4 Duplex 0.2 1.4 for non-compressible
No. of Heads 1 Factor 'C' 0.628 Triplex 0.066
Efficiency 0.855 Theoretic Capacity [l/h] 2171.468842 Quadruplex 0.115
Speed [min-1] 80 Effective Capacity [l/h] 1856.60586 Quintuplex 0.04

DN [mm] vrtd [m/s] vmaxQ [m/s] ha(rtd) [m] ha(max) [m] ha(rtd) [ft] ha(max) [ft]
52.5 2" 0.236 0.279 8.637 10.193 28.336 33.441
62.7 2 1/2" 0.166 0.167 6.055 6.110 19.867 20.046
73.7 3" 0.120 0.121 4.383 4.422 14.379 14.509
97.2 4" 0.069 0.070 2.520 2.542 8.267 8.341

Note: DN is the inner diameter of the tube. If required, just type other values there.

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2013 43
 NPSHa andSuctionPressure
Solutions
Keepmeteringpumpascloseaspossibletothetank
andprovidefloodedsuction.
SizeSuctionlineatleastthediameterofthepump
inlet.Oversizetoreducevelocity.
ProvideAccumulatorTankonthesuctionlineto
preventcavitationoroverfeeding.

Keepinmind,fluidpropertieswillexasperatethe
potentialissues

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2013 44
 AccelerationHeadLoss

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 VapourPressure

VapourPressure
ImpactsNPSHa oftheoverallfluid
WithimplicationofAcceleratedHeadLosscan
leadtocavitationinthesuctionline
HighTemperatures,SimpleHydrocarbons,
Combinationsaretipstothepotentialissue

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 VapourPressure

Solutions
UpsizeSuctionline,lowerslosses
Multiplexhead lowersAHL
Lowerthespeedofthepump (oversize)
Coolingofmaterialifpossible
Pressurizematerialinsupplytankifpossible
FloodSuction(elevatesupplyoverpumphead)

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 RangeofFlows

Processconditionsmayrequireextreme
turndownconditions.

Turndownofahydraulicallyactuatedpumpis
ultimatelybasedonacertainminimumstroke
speed.

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 RangeofFlows

MotorVFDandStrokeLengthAdjustment
Speedshouldnotdropbelow1418spm ona
hydraulicallyactuatedpump
StrokeLengthshouldnotdropbelow10%tostaywithin
API675rangeofaccuracy

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 RangeofFlows

LowStrokeLength
Percentageoffluid/strokeonfillanddischargeis
reducedagainstthepercentageoferror
Pumpaccuracyisreducedoverall
Suctioncapabilityisreducedwiththereductionof
stroketravel

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 RangeofFlows

Lowspeed
CheckValvesdonothavethefluidmomentumto
properlyopenandclose pumpperformanceis
reduced
Hydraulicsbecomeairlockedandthedeaeration
valveonthepumpheadceasestofunctioncausinga
reductioninperformance

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 RangeofFlows
StrokeLength
Positives Negatives
Canpresent alowercost Slowtotrack 1second/%
solutioninhazardousareas strokelength
wheremotorcontrolsarenot
innonhazardousarea
Continueadjustment puts
stressonpump
Cannotchangewhenpumpis
notworking
LowerStrokelengths(<10%)
willloosepumpaccuracy
Manualcontrol noteasydone
atpump

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 RangeofFlows

MotorSpeed
Positives Negatives
Fast Responsetoprocess Pumping speedshouldnot
changes dropbelow14spm turn
downisnotalways10:1
Lower wearonpump Can becostlytoimplement
mechanism localmotorcontrolsin
hazardousarea
Costis lowerwhencontrols
areinnonhazardousarea
Pumpstill hasmanualstroke
lengthforlocalfinetuning

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 RangeofFlows

GeneralBestPractice
Primaryadjustmenthandledwithspeed
adjustment
SecondaryadjustmentwithStrokeLengthifturn
downcannotbeachievedsolelywithspeedalone

UltimateTurnDown=SpeedTDXStrokeTD

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 RangeofFlows

Solution
Selectionofdifferentpumptechnology,betterrangeof
flowwithsolenoiddrivenormechanicallyactuated
pumps
Nostalling,constantspeed,betterstrokecontrol
Floodsuctionconditions relievesomeoftheissueson
suctionside enhanceflowintopumponshortsuction
lowspeed

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 ShopTesting/Certificates

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 TheAPI675Pump
Testingofthepumps;

APIPerformanceTesting notanexpensivetest.

NPSHr costly,notrecommendedformost
applicationsunlessthehydraulicsofthesystem
provelowNPSHa,estimationsaretypically
accurate.

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 TheAPI675Pump
Testingofthepumps;

MTR/PMIonthecontactmaterials typically
additionalpaperwork,mostpumpcompaniesare
checkingmaterialspriortofabricationanyhow,
notworththeinvestmentinthetest.

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 TheAPI675Pump
Testingofthepumps;

NoiseTesting lowHPpumps,relativelynonoise
produced,>10kWconsideronasingletestor
CertificateofConformancethatthepumpwill
operatebelowcertainnoiselevel.

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 TheAPI675Pump

ImportantItems AreaClassificationandVoltage

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 Part#2 EffectiveP&ID

Engineersmustputtimeintothe
developmentoftheP&ID thisisconsidered
theBibleintermsofscope

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 Part#2 EffectiveP&ID

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 Part#2 EffectiveP&ID

LineSizeandPipingSpecification

ProperIsolationandVentvalve

InclusionofAccessories

TagNotations

SetPressures

ControlofPumps

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 Part#2 EffectiveP&ID

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 Part#2 EffectiveP&ID

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 PulsationDampeners

Somequicktellswhenyoumayneeda
dampeneronthedischarge

Longdischarge>100feet
Highviscosity(>250cPs)
HighSpecificGravity(>1.5SG)
Tuninginstrumentationondischarge(FlowMeter)

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 PulsationDampeners

Somequicktellswhenyoumayneeda
dampeneronthesuction
Highviscosity
HighSpecificGravity(>1.5SG)
HighTemperature
HighProductVapourPressure
LongSuctionLine>10feet
TallTanks>5mcreatinghighsuctionforce
LowNPSHa eliminatesaccelerationheadloss

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 Accessories?

BackPressure
Variablebackpressurecanaffectthepumpaccuracyin
extremecases(+/ 2530%change)
Canaffectthetuningofthepulsationdampenerasthe
PDneedsaconstantpressure(PDonsystem)
Cancreatesiphoningwheresuctionpressureexceeds
dischargepressure(SP>DP)
Pumpsrequireatleast15psigofpressuredifference
betweensuctionanddischargetoworkproperly

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 DischargeConditions
BackPressure

Solutionistoadda
pressureregulatingvalveor
backpressurevalve

Canbeacostlyaccessory
thatisnotalwaysrequired

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 PipingSpecification/ChemicalCompatibility

TwoClassificationsofChemicals

Commodities NaOH,NaOCl,H2SO4,HCl

Specialties FLW165,CE1165,Cortrol,
Demulsifiers,Polymers

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 ChemicalCompatibility
Understandingchemicalcompatibilityandthe
physicalparametersofspecialityproductsis
paramounttoeffectivedesign.

Significantdelaysarecausedbynothaving
thisinformation.

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 ChemicalCompatibility
MSDSSheetsdonotprovidethisinformation.

Informationmustcomefromchemicalvendor

Compatibilityofpipingandsealmaterials

Limitationsoftemperatureonsealmaterials

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 ChemicalCompatibility
Costimplications

When316SSisnotcompatiblearenonmetallic
optionsacceptable?

Plasticscanaccommodatelowerpressuresand
meetASME31.3codesatsignificantcostsavings.

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 ClientDocumentSchedules

DocumentationandTesting
Documentationaccountsforasignificant
percentageofcostsonsomeprojects.
Costisproportionaltotime

#Systemsx#Tagsx#Docs/Tagx#Hours/Doc

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 ClientDocumentSchedules

ImportantProjectInformation
ProjectITPPlan
ProjectDocumentSchedule
ProjectDeliverySchedule
NameplateandTagList
DataBookandIOMManual

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 ClientDocumentSchedules

ImportantDesignInformation
GeneralArrangementDrawing
ProcessandInstrumentationDiagram
BillofMaterialsDrawing
FabricationDrawing
Pump/Instrument/MotorDatasheet
PumpCurves,ReliefValveCalculations

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 ClientDocumentSchedules

ImportantEngineeringCalcs
PipingCalculations ifapplicable
LiftingLugCalculations ifapplicable
ABSAPaperwork

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 ClientDocumentSchedules

ImportantTestingInformation
Finalinspectiontestreport
WeldandNDEProcedures Ifapplicable
PaintProcedure ifapplicable
WeldNDEMap
InstrumentTestReports
CRNInformationoncomponents
MTRoncomponents ifapplicable

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 Summary

Aneffectivebidpackageincludes
CompletePumpDatasheet
AccurateP&ID
AccurateSupplierDocumentList

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