Sulzer Presentation

Sulzer ISO 13709 (API 610) Type BB5 Barrel Pumps

Sulzer Pumps

The Heart of Your Process

Long History of Barrel Pumps

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GSG Sales Presentation | slide 2

Barrel Pumps: Diffuser Style

Sulzer Pumps

45 MW SuperCritical Boiler Feed GSG Sales Presentation | slide 3

Types of Horizontal Multistage Pumps Volute Volute - Horizontal Horizontal Split Split

Sulzer Pumps

Diffuser Diffuser - Segmental Segmental Ring

Volute Barrel

BB3 BB5

BB4 – Not used used on H.C. H.C.

Diffuser Barrel Casing BB5

High Speed Diffuser Barrel BB5


Volute vs. Diffuser Casings Radial loads increase at lower flow, and at flow rates beyond best efficiency point.

Sulzer Pumps

Single Volute Casing

The result is an unbalanced radial load on the rotating element. Small, low flow pumps have relatively small radial loads.

FR


Volute vs. Diffuser 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.

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Dual Volute Casing

F R~ 0


MultiStage Dual (MSD) Volute

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

Top Half Casing

Bottom Half Casing GSG Sales Presentation | slide 7

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

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Diffuser Casing

F R= 0


Diffusers

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Diffuser – Discharge Side

Diffuser – Suction Side

Impeller runs in center Return Channels feed next stage

Stage casings GSG Sales Presentation | slide 9

Axial Thrust Development

Sulzer Pumps

Opposed Impeller Design

Fr Total = 0 Fr 1st Pd 1st

X

Fr xst

X

Pd 1st Pd xst

X

X

Pd xst



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

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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. GSG Sales Presentation | slide 10

Axial Thrust Development

Sulzer Pumps

Inline Rotor Stack

Fr Total = Fr 1st+Fr xst Fr xst

Fr 1st Pd 1st

X

FDrum ~ 85% Fr Total

X

Pd 1st Pd xst

X

X

FDrum Pd xst Ps



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

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

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Developed thrust must be compensated by a hydraulic balancing device. Residual thrust is handled by a thrust bearing. GSG Sales Presentation | slide 11

Axial Thrust Compensation Balance Drum

Sulzer Pumps

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

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

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

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Rotor is fixed in the axially position by thrust bearing.

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Higher amount of leakage - less efficient.

Close clearance pressure breakdown

PSuction

Balance Drum

PDischarge

Balance Drum Liner


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

Axial gap will adjust in response to thrust changes

PSuction

Balance Disk

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Balances 100% of the generated thrust.

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No thrust bearing required.

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Rotor floats axially for proper operation.

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Least amount of leakage - higher efficiency.

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Disc lift off device required for frequent starts and stops

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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.

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

PDischarge

Counter Disk

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Inline Impellers vs. Opposed Impellers

Sulzer Pumps

Sulzer GSG: Inline diffuser Barrel Pump

GSG Back-to-Back diffuser Barrel Pump

Sulzer CP: Opposed Impeller Volute Barrel Pump Note: All are ISO 13709 (API 610) type BB5 GSG Sales Presentation | slide 14

Inline vs. Opposed Rotor Stack

Sulzer Pumps

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.



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ISO 13709 (API 610) requires stable rotordynamics with 2 times normal ISO 13709 (API 610) specified wear ring clearances. 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 injection pumps are designed in this manner.


The “K” factor – large barrel pumps

Sulzer Pumps

“K factor” 2000

120 K Factor

1800

Shaft Span, in.

1600 1400 1200 1000

Back to Back GSG, HPCP or CP

• Rotor Wt. in lbs. 100

• Shaft Span, in.

80

• Shaft Dia. in.

60

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

800 40

600 400

20

200 0

0 Inline 3.38

Inline 4.25

B-B 3.38

Some say K factor of
Type / shaft size, inches 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 GSG Sales Presentation | slide 17

Rotor Sag

Sulzer Pumps

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

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



Sulzer Pumps

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 2 large 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


Direct Drive vs. High Speed Flow of a centrifugal pump varies directly with RPM. Head produced by a stage varies as the square of the RPM.

Sulzer Pumps

High Speed, VFD or Gear; fewer stages

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:

Low Speed, Direct Drive; more stages

- lube system & sleeve/pivot shoe bearings - more extensive instrumentation - gear increaser - special mechanical seals


Cartridge vs Non-cartridge designs

Sulzer Pumps

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 GSG Sales Presentation | slide 21

High 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.

Sulzer Pumps

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.


Barrel Head Closure Methods

Sulzer Pumps

Studs & Nuts – Most common – requires stretching or torquing  Supernuts – more expensive, no stretching; hand tool torquing or  Sulzer’s Patented Twist Lock On lower temperature services, to speed overhaul, some customers prefer Sulzer’s patented Twist Lock barrel end cover design – no studs/nuts and no torquing required. 

Head Installed

Head partially rotated

Head Rotated & Locked


Sulzer Pumps

GSG: SMALLER SIZES 

50 Hz, 2 pole motor speed

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Gray or white are inline rotor

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


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GSG: LARGER SIZES 


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Sulzer Pumps

GSG: SMALLER SIZES 


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Sulzer Pumps

GSG: LARGER SIZES 


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Hydraulics

Sulzer Pumps

A double suction impeller reduces the NPSHr by about 30%

Double suction first stage available on larger sizes


Impellers and Diffusers

Sulzer Pumps

Hydraulic layout  Multiple hydraulic impeller & diffuser sets per pump size Mixing of impeller / diffuser hydraulics in single pump is possible  Double suction first stage is available in larger size pumps 

Dynamic balanced impellers & rotor > 3 stages  Radial load is balanced 


Mixing of Impeller Hydraulics with Interstage Bleed Off Pumped Medium Density Temperature kinem. Viscosity Head (design) Capacity (design) Total efficiency Pump Power

: : : : : : : :

Boiler Feed Water 909.2 kg/m³ 318 °F 0.19 mm²/s 4,600 ft 900 gpm 75.8 % 1,350 HP

0 0 0 6

Sulzer Pumps

Speed : 3570 rpm Stage Number : 8 nq : 20.0 Impeller Set : B/B/B Basis 4335.11.11/2 & 4335.11.11/2 & 4335.11.11/2 Extraction head : 1,268 ft Extraction capacity : 250 gpm

MD 100-300 / 8

Note the all “B”

Tender : /1 impeller hydraulics Characteristic : TS/1 Impeller diameter : 11.1 inch Impeller dia. (max) : 11.8 inch : 19 ft NPSHR

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

0 0 0 5

0 0 0 4

] t f 0 [ 0 0 H 3 0 0 0 2

RATED Max. ∅

By mixing impeller hydraulics efficiency and power can be optimized 2 Max.

0 0 0 1

∅

RATED

0 0 gpm

200 gpm

400 gpm

600 gpm

800 gpm

1000 gpm

1200 gpm

1400 gpm

1600 gpm

1800 gpm

2000 gpm


Mixing of Impeller Hydraulics with Interstage Bleed Off Pumped Medium Density Temperature kinem. Viscosity Head (design) Capacity (design) Total efficiency Pump Power

: : : : : : : :

Boiler Feed Water 909.2 kg/m³ 318 °F 0.19 mm²/s 4,600 ft 900 gpm 78.7 % 1,301 HP

0 0 0 6

Sulzer Pumps

Speed : 3570 rpm Stage Number : 9 nq : 20.0 Impeller Set : B/B/S Basis 4335.11.11/2 & 4335.11.11/2 & 4335.11.21/1 Extraction head : 1,268 ft Extraction capacity : 250 gpm

MD 100-300 / 9

Now the “B” hydraulics have Tender : /1 with “S” after been replaced Characteristic : TS/1 thediameter interstage bleed Impeller : 10.9 inch off. Impeller dia. (max) : 11.0 inch : 19 ft NPSHR

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

0 0 0 5

0 0 0 4

] t f 0 [ 0 0 3 H 0 0 0 2

RATED Max. ∅

By mixing impeller hydraulics efficiency and power can be optimized 2 Max. ∅

0 0 0 1

RATED

0 0 gpm

200 gpm

400 gpm

600 gpm

800 gpm

1000 gpm

1200 gpm

1400 gpm

1600 gpm

1800 gpm


Bearing Type Selection

Sulzer Pumps

) m 5000 p r 0 0 4000 6 3 ( P 3000 H P E 2000 B @1000 r e w o 0 P

% 0 2

Pivot Shoe Thrust & Sleeve Radial – Lube System required

Anti-Friction Thrust & Sleeve Radial – Ring Oil Lube

Anti-Friction Thrust & Radial – Ring Oil Lubrication

% 0 3

% 0 4

% 0 5

% % % % % 0 0 0 0 0 0 1 2 3 9 1 1 1 1 Pump Flow - % of BEP

% 0 6

% 0 7

% 0 8

Exact bearing system will depend upon application


Anti-Friction with Ring Oil Lubrication

Sulzer Pumps

Radial Bearing

Thrust Bearing

Cooling Fan

Oil Rings

Oil Reservoir

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 177 o C (350 F). °


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

Sulzer Pumps

Radial Bearings

Cooling Fan Oil Rings Oil Reservoir

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. °


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

Sulzer Pumps

Sleeve Radial Bearings

Shaft Driven Oil Pump

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. GSG Sales Presentation | slide 35

Journal and Thrust Bearing Arrangement

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Sleeve Bearings


Tilting Pad Thrust Bearing Arrangement

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Thrust Bearing Lubrication 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.


Journal and Thrust Bearing Arrangement

Sulzer Pumps

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


Forced Feed Lube Oil Systems

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Seal Chambers & Jackets

Sulzer Pumps

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.


Seal Flush Plans

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TI

FO

FI

Q/D

A variety of seal flush plans are available


Instrumentation - options NDE X-Y Shaft vibration

Balance Leakoff flow

NDE Bearing temperature

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

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DE Shaft vibration

DE Bearing temperature

Barrel Temperature, Bottom & Top (for hot standby) GSG Sales Presentation | slide 42

Vibration Instrumentation

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Firm contact from shaft to bearing frame

Velomitors

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. GSG Sales Presentation | slide 43

Vibration Instrumentation

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Film contact from shaft to bearing frame

Probes and Proximitors

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. GSG Sales Presentation | slide 44

API Material Classes

Sulzer Pumps

Material classes and abbreviations Part

S-1

S-5

S-6

C-6

CS/Cast Iron

CS/CS

CS/12% Chrome

12% Chrome/ 12% Chrome

Pressure Casing

Carbon Steel

Carbon Steel

Carbon Steel

12% Chrome

Inner Case

Cast Iron

Carbon Steel

12% Chrome

12% Chrome

Impeller

Cast Iron

Carbon Steel

12% Chrome

12% Chrome

Case Wear Rings

Cast Iron

12% Chrome Hardened

12% Chrome Hardened

12% Chrome Hardened

Impeller Wear Rings

Cast Iron

12% Chrome Hardened

12% Chrome Hardened

12% Chrome Hardened

Shaft

Carbon Steel

AISI 4140

AISI 4140

12% Chrome

Throat Bushings

Cast Iron

12% Chrome Hardened

12% Chrome Hardened

12% Chrome Hardened

Interstage Sleeves

Cast Iron

12% Chrome Hardened

12% Chrome Hardened

12% Chrome Hardened

Interstage Bushings

Cast Iron

12% Chrome Hardened

12% Chrome Hardened

12% Chrome Hardened

Case and Gland Studs

AISI 4140

AISI 4140

AISI 4140

AISI 4140


API Material Classes

Sulzer Pumps

Material classes – cont’d. A-8

D-1

D-2

316SS/316SS

Duplex SS

Super Duplex

Part

Pressure Casing

316L SS

Duplex

S.D.

Inner Case

316L SS

Duplex

S.D.

Impeller

316L SS

Duplex

S.D.

Case Wear Rings

Duplex SS

Duplex

S.D.

Impeller Wear Rings

316l SS HF

Duplex

S.D.

Shaft

Duplex SS

Duplex

S.D.

Throat Bushings

316L SS HF

Duplex

S.D.

Interstage Sleeves

316L SS

Duplex

S.D.

Interstage Bushings

316L SS HF

Duplex

S.D.

Case and Gland Studs

AISI 4140

AISI 4140

AISI 4140 GSG Sales Presentation | slide 46

Pre-Warming

Sulzer Pumps

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


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 < 260 oC (500oF). Above that temperature, the barrel drains can be used to uniformly warm the pump, or maintain hot standby. Barrel RTD’s can provide indication of uniform temperatures.


GSG Cross Section and Features Radial split identical stage casings, diffusers and impellers

Sulzer Pumps

Interstage bleed connections available

Low NPSH 1st stage impeller. Double suction available.

Thrust bearing - antifriction or double acting tilting pad. Radial bearing - sleeve or anti-friction.

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

Bearings protected by Labyrinth type oil seals

Hydraulic balance device is Drum type

Stacked rotor design with staggered keyways to provide positive torque to impellers

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


Pictures

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GSG Boiler Feed pump with speed increasing gearbox, lube system, suction strainer and automatic recirculation control valve GSG Sales Presentation | slide 50

Pictures

Sulzer Pumps

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.


Sulzer Presentation

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