Sundyne High Speed Pump ( OH6)

Sundyne Pumps

Kerry Kramlich Compressor Engineering Manager July 2014

Sundyne Pumps

Sundyne - CONFIDENTIAL

How It All Started... • In the late 1950’s Boeing approached Sundstrand Aerospace with a unique pump application • Water Injection Pump for Boeing 707 to increase thrust during take off • Required to run dry during flight • 100 GPM/23 M3/hr, 1100 Ft/330 M

Sundyne - CONFIDENTIAL

The First Sundstrand High - Speed Pump • German engineer U.M. Barske had an “unconventional” pump • Suited for low specific speed • Straight radial blades

• Concentric bowl around the impeller • Single point emission: termed “Diffuser Pump”

Sundyne - CONFIDENTIAL

Boeing 707 Water Injection Pump made by Sundstrand Aerospace

Sundyne - CONFIDENTIAL

From Aerospace to Industrial

• First Sundyne pump sold in 1963 • First Sundyne compressor sold in 1965

LMV-2 Sundyne - CONFIDENTIAL

Where do we fall in? Pumps Positive Displacement

Centrifugal

Reciprocating

Axial

Screw

Mixed Flow

Sliding Vane Rotary Lobe

Sundyne - CONFIDENTIAL

Sundyne Gearboxes

Gearbox Code: 1

Gearbox Code: 2

Gearbox Code: 3

Gearbox Code: 4

Nominal Power: 200 hp

Nominal Power: 50 hp

Nominal Power: 250 / 400 hp

Nominal Power: 400 hp

Notes:

Notes:

Notes:

Notes: a.k.a. the Phoenix Gearbox

LMV-3XX Sundyne - CONFIDENTIAL

Sundyne Pump Cases

Case Code: 1

Case Code: 2

Case Code: 3

Case Code: 6

Case Code: 8

Size: 3”x 2”

Size: 3”x 2”

Size: 6”x 4”

Size: 3”x 2”

Size: 4”x 3”

Flange Rating: 600,900#

Flange Rating: 600#

Typ. Flange Rating: 600#

Flange Rating: 300,600,900, 1500#

Typ. Flange Rating: 600#

Notes: Separable Diffuser

Notes: Typically used in the LMV-322

Notes: Used for High – Flow Pumps

Notes: High Pressure

Notes: Used with BMP

LMV-XXX Sundyne - CONFIDENTIAL

Modular Design - Gearboxes

Sundyne - CONFIDENTIAL

Modular Design - Hydraulics

Sundyne - CONFIDENTIAL

Sundyne Features & Benefits

Feature

Benefit

Large Impeller Clearances

Robust – tolerant to process upsets

0.035”

Ease of maintenance (no shims required) Able to pump soft slurries

Can be protected by suction screen Modular Design

Custom hydraulics sizing for every pump sold Ability to re-rate hydraulics Sundyne - CONFIDENTIAL

0.035”

Head vs. Pressure

• Head (H) is the amount of energy in the fluid measured in units of height • Pressure (P) is force / unit area • H = P x 2.31/S.G. • Pump and compressor performance are defined in units of HEAD, not PRESSURE

Sundyne - CONFIDENTIAL

Head vs. Pressure

Diesel Fuel

Water

Sulfuric Acid

1000 ft

Sundyne - CONFIDENTIAL

This is an example of ‘Head’

Head vs. Pressure Diesel Fuel

Water

SG = 0.8

350 psi

Sulfuric Acid

SG = 1.0

430 psi Sundyne - CONFIDENTIAL

SG = 1.8

780 psi

1000 ft

Low Flow - High Head

Reciprocating Pumps

Multistage Barrel Pumps Typical Single Stage Overhung Pump

Sundyne Pumps

Sundyne - CONFIDENTIAL

Sundyne Pump Hydraulic Envelopes

Sundyne - CONFIDENTIAL

Low Flow - High Head

Sundyne - CONFIDENTIAL

Source: Karassik, Igor J.; Messina, Joseph P.; Cooper, Paul; Heald, Charles C. (2001). Pump Handbook (3rd Edition).. McGraw-Hill.

Pump Specific Speed

Dimensionless used to select the impeller geometry for maximum efficiency

• Ns Between 200 and 1000 = BARSKE • Ns Between 1000 and 5000 = Conventional Impeller • Ns Between 5000 and 15000 = Axial Flow Pump (Inducer)

Sundyne - CONFIDENTIAL

Conventional vs. Barske  Example: > Head: 1000 ft > Flow: 100 GPM

Barske Hydraulics •14,000 rpm • Impeller Diameter: 3.5” • Height of impeller exit 0.49”

Conventional Hydraulics • 3,600 rpm •Impeller Diameter: 17.5” • Height of impeller exit 0.117”

At 17.5”, the Francis Wheel is 5 times the diameter of the Barske Wheel – think of the material costs!

Sundyne - CONFIDENTIAL

For Example

Sundyne - CONFIDENTIAL

Source: Karassik, Igor J.; Messina, Joseph P.; Cooper, Paul; Heald, Charles C. (2001). Pump Handbook (3rd Edition).. McGraw-Hill.

Specific Speed vs. Efficiency

Sundyne - CONFIDENTIAL

Source:Stepanoff, Alexey J. (1957). Centrifugal and Axial Flow Pumps (2nd Edition). John Wiley & Sons, Inc.

Benefit of Low Ns Design Process conditions: 100 gpm @ 600 ft. head _ 22.71 m3/hr @ 182.9 meters Typical Francis impeller performance Typical Barske, open radial blade impeller

NS 393 599

Pump Speed 3560 7200

Efficiency

BHP / kW

36% *52%

42 / 31 *29 / 21.6

* Result of optimized NS; increased hydraulic efficiency, lower BHP / kW

Sundyne - CONFIDENTIAL

Pressure-Velocity Machine • A centrifugal pump is a PRESSURE-VELOCITY MACHINE • A pump changes a system pressure by changing the velocity of the fluid

1 Po  p   2  gZ 2 Po  total _ pressure v  velocity

  density Z  heigth

Sundyne - CONFIDENTIAL

Pressure-Velocity Machine

Velocity

Pressure

Sundyne - CONFIDENTIAL

Centrifugal Pump Curve

Sundyne - CONFIDENTIAL

Source:Stepanoff, Alexey J. (1957). Centrifugal and Axial Flow Pumps (2nd Edition). John Wiley & Sons, Inc.

Shock Losses Design Flow

Separation

Reducing Flow Sundyne - CONFIDENTIAL

Recirculation

Nomenclature Of Sundyne Pumps

Mechanical Seal(s) Diffuser Cover

Impeller Inducer Sundyne - CONFIDENTIAL

Diffuser

Z- Series 24 Blade Impeller

Sundyne - CONFIDENTIAL

Concentric Bowl Series

Single Point Emission Diffuser

8-Blade Impeller

Concentric Annulus

Bottom View Sundyne - CONFIDENTIAL

Engineering BEP 1

Speed 2

4

Impeller Diameter

3

Inducer Series 5 Sundyne - CONFIDENTIAL

Inlet Diameter

Blade Height and Throat Diameter

Inducers

Sundyne - CONFIDENTIAL

General CFD Uses

Sundyne - CONFIDENTIAL

Sundyne OH pumps in API 610

LMV 8XX w/ Bearing Box

LMV 8XX LMV 3XX

Sundyne - CONFIDENTIAL

GEN5 GEARBOX FEATURES 1. API-610 L10 life compliant anti-friction bearings 2. Idler shaft supported by spherical roller bearings 3. Helical upper gear mesh 4. Bolt-in uni-directional lube pump (hydrodynamic bearing selection limited) 5. No aux lube pump necessary under 450-psig suction pressure 6. New output seal 7. New desiccant breather 8. Standard splined impeller connection WET-END REQUIREMENTS NONE  Standard 31X/33X parts

HYDRAULIC

Concentric Bowl

Z-Series

Dual Throat

INPUT

50-HZ

60-HZ

50-HZ

60-HZ

> 13K

< 13K

MAX HP

182

182

200

230

245

275

Sundyne - CONFIDENTIAL

IDLER SHAFT SPHERICAL BEARINGS Meets API-610 Life Requirements • 25,000-HRS life at rated HP • 16,000-HRS life at max HP

Oil galley-ways pressure feed bearing outside diameter annulus; bearing internal roller elements receive pressurized and equal distribution of oil Sundyne - CONFIDENTIAL

IDLER SHAFT

Hydrodynamic bearings replaced with spherical bearings Sundyne - CONFIDENTIAL

BOLT-IN LUBE PUMP

NEW PROTOTYPE PUMP • Pump bolts to bearing plate • Internal reversing (bi-directional pumping) capability • Use limited by hydrodynamic bearing selection

Sundyne - CONFIDENTIAL

31X UPGRADE KIT Upgrade kit designed to increase the reliability and robustness of the 31X gearbox FEATURES 1) New output seal 2) New desiccant breather 3) Modified bearing plate to accept lube pump rotation modification 4) Lube pump plate 5) API compliant input shaft and idler shaft bearings

OUTPUT SEAL

BREATHER

BREARING PLATE

LUBE PUMP PLATE

BEARINGS

25-007

• • •

Available as field retrofit-able kit Available as option for exchange units Offered on new 31X units as standard equipment (in discussion TBD)

Sundyne - CONFIDENTIAL

PU01AB05 LUBE PUMP PLATE • Eliminates bearing plate rotation pin • Drive plate provides larger contact area to minimize stress

Sundyne - CONFIDENTIAL