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Pumps

Oil and Gas Refining Technologies

Great forgiveness
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, working
Thus, the pump: - is used to increase the energy of the fluid, and this energy makes the fluid flow through the

pipes or rise to a higher location, meaning that it transfers the fluid from areas of low pressure to areas of high

pressure.

conditions Distinguished in the industry and in various fields and suitable for all Pumps occupy different
locations and pressures according to the design of the pump. Pumps are used in the oil and chemical

industries, refineries, power plants and many other fields and can withstand temperatures according to the

design and use of the pump. Pumps are

classified into several types: -

• Positive displacement pumps -1

Reciprocating pumps -2

Rotary pumps -3 Centrifugal

pumps

-1 Reciprocating pumps: These are pumps of great importance in industry. They are called by this name

because their basic movement is back and forth if they are horizontal and up and down if they are

vertical. The productivity of this pump is in one direction and the pumping process in these pumps

depends on a piston and seals that are located on the piston arm.

These pumps are used for two main purposes: -

• Moving the liquid from one point to another

• Obtaining high pressure (1400 bar)

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Single-acting piston pump

It consists of the following parts, as shown in Figure (1):

-1 Pump structure

-2 Cylinder

-3 piston

-4 Intake valve -5

Push valve

-6 Compression rings

-7 Lubrication ring

-8 gasket retaining ring

-9 Soft fillings

-10 piston arm

-11 Withdrawal direction

12 - Payment Authority
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How does a single-acting piston pump work?

The piston stroke is defined as the distance traveled by the piston between the two ends of the cylinder, during
which the piston makes two strokes, one of which is the intake stroke and the other the push stroke, through one
revolution of the crankshaft.

-1 Suction condition: When the piston moves inside the cylinder from left to right, a vacuum pressure is created.

(Vacuum) As a result, there will be a difference in pressure between the inside and outside of the cylinder, and

accordingly the suction valve will open and the push valve will be closed at that time.

(Discharge valve) The liquid passes into the suction pipe and then into the pump cylinder. The
process of liquid entry continues as long as the piston is moving to the right until it reaches a point
where its capacity becomes zero. This point is called the (dead point) (point Death Up) as in Figure
2.
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-2 Push condition: Given the disappearance of the piston speed and the continuation of the piston arm’s movement through

the rotation of the crankshaft, the piston has reached the bottom dead center and thus the piston begins to move.

From right to left, while the intake valve is closed and the push valve is open, it expels the compressed liquid from the

cylinder, as in Figure (3).

Figure 3 shows the payment status.

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Single-acting double piston pump

The single-piston double-acting piston pump consists of the following parts, as shown in Figure (4):

Next:

-1 Entry hole

-2 intake port

-3 Intake valve

-4 Push valve

-5 Payment slot

-6 Exit port

-7 Gasket fixing ring

-8 Soft fillings

-9 Piston arm

-10 compression rings

-11 Lubrication ring

-12 Cylinder

13 - Piston

Figure 4: Single-acting double-piston pump

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Working principle of double-acting piston pump

This pump performs both the suction and push strokes during one movement of the piston. This type of pump contains

two suction valves and two push valves, where the liquid enters automatically to each side of the pump. When the piston

moves to the right, the suction valve opens on one side and the push valve opens on the other side. This means that

one of the cylinders is in a state of filling while the second cylinder is in a state of emptying. Thus, the process continues

so that there are two closed valves on each side for each process. When the bag moves to the left, the two closed

valves open and the two valves that were open close, thus the pumping process is completed from the left side and the

suction process is completed from the right side. Thus, the process of entering and exiting the liquid continues, as shown

in Figure (5):

Figure 5: The working principle of the double-acting piston pump

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Main parts of double-acting piston pump:

1- Pump body : The pump body is made of cross-sectional iron for low-pressure pumps, and of steel for high-pressure

pumps. It is made of chromium-nickel alloy and brass if the pump is used to pump chemicals, and of brass for

materials with a weak acidic effect. The body is used to include all fixed and moving parts.

-2 Piston: The piston is made of steel and sometimes babbit alloy is used. The piston may be made of a block if its

diameter is small, but if its diameter is larger than (10), it is made of steel. The piston is distinguished by its two ends

being circular to reduce friction or the force obstructing the movement of the liquid. It is made in a cylindrical shape

and leaves a clearance between the piston and the cylinder of (0.1) of the piston diameter. There are spring rings on

it, which are the compression rings and the lubrication ring.

-3 Valves : The benefit of valves is to facilitate the process of drawing and pumping the liquid, and the valve must be

lightweight to avoid hydraulic shocks during the valve closing process.

There is a type of valve that operates automatically, as it opens as a result of the increase in pressure under the

valve under the influence of the spring force. There is another type of valve called ball valves, which consist of a

spherical body (solid ball), a valve seat (Valve Seat) and a valve cover (Cover).

(Valve) The ball is made of steel and sometimes it is hollow. These valves are used for viscous materials and fats.

The factors that determine the best quality of valve are the following:

A- Flow rate of the fluid

b- Liquid entry speed

C- The amount of suction and push pressure

D- Liquid specifications: Clean liquid, viscous liquid

h number of pump cycles

- The amount of payment for the net available positive withdrawal

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-4 Sealing gaskets : used to prevent leakage and seal the connecting rod and the cylinder piston. There is

one type of gasket used in piston pumps, which is soft gaskets. These gaskets are used to prevent liquid

leakage and to prevent air from entering the cylinder. The choice of gasket depends on the type and nature

of the liquid to be pumped by the pump, as well as the amount of pressure and temperature of the liquid.

There are several types of gaskets, some of which are made of asbestos saturated with graphite and are

used when pumping oils, acids and water, and some are made of cloth containing metal wires and are used

when pumping hot materials. These gaskets are placed inside the gasket box and are confined by a
confining ring.

Piston pump malfunctions and how to treat them: -

-1 Scratches occur on the inner wall of the cylinder.

Treatment Causes:

Broken spring rings (lubrication and

Replace spring rings
compression
Protective network check (filter) rings) Impurities in the fluid

-2 High temperature of the supports

Treatment

Fill the tank with oil to the required level. Change the oil Reasons: Low oil level in the tank.
and check the oil filter. Check and repair the Presence of solids or water in the
fault in the cooling system. Check the axle and then oil. Malfunction in the cooling system.
replace it if there is a distortion greater than the specified limit.
Axis distortion

-3 Noises or knocking in the valves

Treatment

Change the riser Causes:

Change the leg MBroken spring, broken leg
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-4 Noises or vibrations inside the pump

Treatment Causes:

Check the air chambers Presence of gaps or gas pockets.

Replace the Consumed supports.

supports Perform a check and replace the axle if the

Axis distortion
distortion is

excessive Replace Spring rings broken Axial

the springs Align the engine and pump axles Tighten fairing is irregular Base nuts are

and secure the base plates well Check the loose Pump speed is higher than required

engine speed and transmission system

-5 Pump thrust is low

Treatment Reasons

Change the for broken spring rings

rings, check the engine and repair the fault in the

Low rotational speed
electric

motor, clean the filter with compressed air and Filter blockage.

repair the fault Check the valves, Faulty or worn out regular gaskets. Faulty valves.

repair or replace the valve,

tighten the mounting connections well, and install the

fluid leaking from inlet valve
control rings.

The control of the installation connection of the suction

Change the location of the pump in relation to the source from which
pipe is not perfect or the control rings are broken, which
the fluid is drawn.
leads to air entering the pump.

Increase the length of the intake tube

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-6 High temperature of the regular filling: -

Treatment

loosen the screws Causes: Bolts are too tight.

Nut tightening is imbalanced
Balancing in the process of tightening nuts
or uneven.
Cooling system check piston There is a malfunction in the cooling system,

rod replacement or there is a bend in the piston rod.

-7 The pump does not pump even though it is running: -

Treatment Causes:

Cleaning the protective mesh, Blockage of the protective network

checking the engine, repairing the fault and correcting the direction of
Low or reversed rotational speed
movement.

Tank monitoring with pump off Low fluid level in tank

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Pumps

Oil and Gas Refining Technologies

Great forgiveness
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Rotary Pumps

It is used in operating many hydraulically powered equipment and mechanical equipment such as cars, aircraft, automatic

presses and various motion equipment.

*Rotary pumps are characterized by:

-1 It does not have non-return valves.

-2 Also, the mechanical movement that is transferred to the liquid is produced by the rotation of a part inside the pump body in comparison.
Piston pump. with

-3 The clearance between the rotating and fixed parts must be as low as possible in order to reduce leakage to the return,
which is defined as the seepage of liquid from the discharge line to the suction line.

-4 Small in size.

-5 Easy to maintain.

-6 It also contains a sealed mechanical stuffing box and can be used

Fillings made of polytetrafluoroethylene.

-7 It is also generally used for pumping pure viscous liquids.

Centrifugal pumps
It is a hydraulic equipment used to increase the energy of the fluid, i.e. converting the kinetic energy gained in the

impeller into pressure energy. It has a continuous flow and different pressures, medium and high. The absence of

pistons and their accessories gives it simplicity in design, in addition to high productivity, speed of operation and

shutdown, and ease of adjusting the amount of fluid required to be pumped. Among its uses is that it is used in oil

production units in refineries, in the fields of transporting heavy materials, for irrigation and irrigation purposes, in the

fields of firefighting, and it is used in many other fields

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Working principle of centrifugal pumps

When the propeller rotates, the mechanical energy entering it from the engine is converted into electrical energy.

Hydraulic, the kinetic energy and pressure energy of the liquid increase as it passes through the ducts of the fan

and until it exits to the spiral body or (diffuser), the pressure rises again while the kinetic energy gradually decreases

until it reaches the pump outlet. From this, we see that the pressure increase between the pump inlet and outlet

occurred in two stages, one through the fan and the other (spiral body) or (diffuser), while the speed decreased after

increasing in the fan to the same value at the pump inlet. Parts of the centrifugal pump

The centrifugal pump consists of several parts, as shown in Figure (1), as follows:

-1 Pump structure

Or open vertically The pump body is either open horizontally or open vertically and in most designs it is open

horizontally for easy access to the internal parts for maintenance and inspection. As for the pump pumps, when the

upper part is lifted, the multi-stage parts remain, they are divided into two halves towards the axis of rotation in the

lower part. The function of the body is summarized in collecting the liquid from the impeller and converting kinetic

energy into pressure energy during flow in the spiral chamber. It also protects the internal parts of the pump. The

pump can be double-framed or ring-framed.

The pump -2 axis

The pump shaft is the one that carries all the rotating parts of the pump and its diameter is determined by a number

of factors including the speed axis, length and horsepower. The diameter of the shaft is variable, as it is wide in the

middle and the areas where there are bearings and support areas where it bears more stress - and thinner (less

diameter) at the end for ease of connecting it to the engine. The benefit of the shaft is that it transfers the rotational

torque from the engine to the impeller (the good news) of the fan and is made of different metals including hardened

steel and steel iron. Usually, liners called (sleeve shaft) are used, which are metal pieces usually made of stainless

steel and are placed between the shaft and the gasket. They protect the shaft from liquids that cause corrosion in

the gaskets, as the area to which the fan impeller is connected is more susceptible to corrosion than others.
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-3 The Good News

The impeller is made of bronze or stainless steel, depending on the type of fluid to be pumped, in order to withstand the high

stresses resulting from friction between the fluid molecules. It is designed for rapid rotation in order to be able to give the fluid

high kinetic energy. It is classified into several types, including closed, open, and semi-closed, and sometimes into one or two

inlets depending on the method of fluid entry. Sometimes it is classified according to the direction of fluid flow into radial, axial,

or double.

(Mixed) And sometimes classified according to the angle of the blades, acute, right or obtuse. Open blades are characterized by the fact

that the liquid leaks from them (around them) from all directions, and therefore it is difficult to control the flow rate. It is noted that the

blades of the blade are narrow at the base and then increase in expansion at the exit, in order to reduce the speed and increase the

pressure, as the speed is high at the beginning and the pressure is low, then the speed decreases with the increase in the cross-section

. and with the increase in pressure.

-4 Publisher

The diffuser is a fixed blade surrounding the impeller. Its function is to direct the fluid and increase energy, as kinetic energy

is converted into pressure energy by increasing the cross-section from the inlet to the outlet, where the speed decreases and the

.pressure increases.

-5 protective ring for the eye of the Annunciation

It is a metal ring that protects the gospel from corrosion and friction. It is made of bronze or stainless steel.

-6 Stuffing box

The stuffing box prevents leakage from the pumps. If the pumps operate at negative lift, i.e. the suction tank is located below

the pump, the pressure inside the pump is less than atmospheric pressure. Therefore, the stuffing box prevents air from leaking

from outside to inside. If the pressure inside the pump is higher than atmospheric pressure, the stuffing box prevents fluid from

leaking from inside the pump to outside. In most pumps, the stuffing box is cylindrical and filled with stuffings surrounding the

shaft or the shaft liner. If it is decided to use a lubricated box, a ring is used.
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-7 Supports and bearings

All types of bearings can be used in centrifugal pumps where two bearings are used.

External in case of single stage double suction pump one at each end of the housing

Use oil or cherries for lubrication and fixing the bearing. Y There are types of bearings that are resistant to friction

and are held in place by clamps or fixed to the structure during design. Because of the heat generated by the bearing

or the heat generated by the circulation of the fluid, sometimes other cooling methods are used than radiation to the air

in order to reduce the temperature of the bearing to the required limit. If the bearing uses a forced system, cooling is

usually done by circulating oil through a heat exchanger (water-oil).

** Secondary accessories and pump protection system

-1 The filter

-2- All types of scales

-3 Entry and exit ports

-4 Valves of all kinds

5 - Balancing piston

Figure (1): Parts of a centrifugal pump

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**Comparison between piston pump and centrifugal pump

piston pump Centrifugal pump -1 It is

simple to install due to its small number of parts -1 It is difficult to install due to its large number of parts -2 The total

weight of the pump is greater to give the same thrust -2 The total weight of the pump is less to give the same thrust.

-3 Suitable for small amounts of discharge. -3 Suitable for large amounts of discharge and pressures.

-4- High pressures Low

require a large area and a strong foundation -5- -4 It requires a small space and a simple foundation. -5

Quick corrosion -6- It is less corrosive.

Higher maintenance costs -6 Maintenance cost is lower.

-7 Water holds less dirt -7 It can carry water laden with dirt.

-8 It cannot rotate at high speeds. -8 It can rotate at high speeds.

-9 Its flow is -9 Its flow is continuous

intermittent -10 It needs an air chamber -10 You do not need an air chamber.

-11 It requires precision in operation. -11 It is simple to operate.

-12 No preparation required -12 Need to prepare

-13 High efficiency -13 Its efficiency is low

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Centrifugal pump emergency failures

-1 The pump is not capable of pumping.

Reasons

A- Pump rotation is reversed.

b- The intake tube is empty.

C- Presence of air or gas pockets in the intake tube

D- The pressure in the suction tube is not sufficient.

E - Air leak in the intake pipe

-2 The pumping amount is low.

Reasons

A- The presence of air or gas pockets in the pump.

B- The pressure in the suction pipe is less than the design limit.

C- The viscosity of the material is more than the design limit.

D- Low pump speed (in case of steam engine or diesel engine)

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-3 Pops inside the pump.

Reasons

A- High speed

B- Presence of air or gas bubbles in the suction tube

C - The pressure in the suction pipe is insufficient.

There is a break in the feathers of the gospel.

.h There is a break in the anti-corrosion rings.

-4 The temperature of the cushions is high.

Reasons

A - The amount of oil is small

B- The oil quality is not good.

C- The presence of impurities or water droplets in the oil

D- The pump and motor are not in line.

E- Rotation axis distortion.

- Lack of axial balance

Z- The supports are worn out.

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-5 Abnormal vibration

Reasons

A - The obstruction of the gospel

b- The pump base is not fixed

The pump and motor are not in line. C-

D- The presence of air or gas bubbles in the suction tube.

- Filter clogged and intake tube empty

Z- The good news is unbalanced, lack of axial balance

-The supports are worn out.

6- Increase in engine horsepower required

Reasons

A - The density of the material is higher than normal.

B- Presence of air or gas bubbles in the suction tube

C- High rotational speed

D- The pump and motor are not in line.

There is an engine malfunction.