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Overview of the refinery pump
Centrifugal pumps are the most commonly used in refineries, accounting for approximately 80% of all pump applications. Other types such as reciprocating pumps, metering pumps, screw pumps, sealless pumps (including shielded and magnetic pumps), diaphragm pumps, and pipe pumps also play important roles depending on specific process requirements. In recent years, with the continuous advancement in sealless pump technology and growing environmental awareness, the use of sealless pumps has been increasing in refinery units. The size and operating conditions of pumps vary significantly across different refining processes, and due to the continuous nature of refinery operations, pump reliability is a critical factor. As a result, many centrifugal pumps in refineries are designed as cantilever or end-supported types.
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(1) Cantilever Pumps:
OH1 is a single-stage horizontal foot-mounted cantilever pump suitable for normal temperature (below 150°C) and low operating parameters. OH2 is a single-stage horizontal centerline supported cantilever pump, ideal for high-temperature applications where the pump can be cooled using bearings. However, modern trends show a move away from using cooling water, especially when the medium temperature is below 200°C. For temperatures above 200°C, manufacturers consider cooling water to meet API 610 bearing life and oil bath temperature standards. Cooling jackets are often no longer used, as it helps reduce water consumption, lower costs, and avoid issues like scaling and condensation in lubricating oil. Additionally, thermal expansion of piping, installation errors, and support displacement can affect the alignment between the pump and driver, impacting mechanical seals and bearing life.
Vertical pipeline pumps offer advantages such as smaller load on the pipe, twice the force and torque capacity compared to horizontal pumps, compact footprint, easy installation, and lower base costs. Although OH5 pumps require removing the pump to replace the seal (unlike API 610 which allows seal replacement without removing the motor or nozzles), they are still preferred for low-power applications (flow less than 400 m³/h, temperature under 200°C, head under 200m). For even lower power (under 55kW) and lower temperature, OH3 or OH2 pumps may be more suitable. OH6 is designed for small flow and high head applications.
(2) Two-Stage or Double-Suction Pumps:
Pumps with power exceeding 375 kW typically do not use a cantilever structure but instead adopt a two-end supported design, such as BB1 or BB2. BB2 is widely used in oil refining plants, while BB3 is used for long-distance pipelines. BB4, though cost-effective, has lower reliability in high-temperature and high-pressure environments, leading to a trend of replacing it with BB5. BB5 is now widely used in high-temperature and high-pressure applications.
(3) Vertical Suspended Pumps:
Vertical suspended pumps are also used in refineries, mainly in special installations or where NPSH requirements are not strict. However, their maintenance is inconvenient, so they are only used in specific cases.
(4) Mechanical Seals:
Most centrifugal pumps in refineries use mechanical seals, while packing seals are rarely used. Standards like SH3156 and API 682 guide seal selection. Despite the cost-effectiveness and reliability of single seals, double seals are becoming more common due to stricter environmental regulations. Dry gas seals have also seen rapid development in recent years.