Pumps Catalog
Comprehensive catalog of industrial pumps: centrifugal families (single-stage, multi-stage, vertical, slurry, sealless), positive-displacement (gear, screw, lobe, vane, peristaltic, piston, plunger, diaphragm), specialty (canned-motor, submersible, axial, jet, ram, Archimedean), with API/ANSI/ISO standards, mechanical seal piping plans, BEP-to-EOC operating envelopes, and OEM flagship lines. SI units primary; US-customary cross-referenced where the API tradition uses them.
1. Hydraulics Fundamentals — Quick Reference
| Quantity | Symbol | Unit | Definition / Formula |
|---|---|---|---|
| Flow (volumetric) | Q | m³/h, m³/s, gpm | Volume per unit time |
| Head (total dynamic) | H | m, ft | Energy per unit weight; H = (p2 − p1)/ρg + Δz + (v2² − v1²)/2g |
| Specific gravity | SG | — | ρ_fluid / ρ_water |
| Pump power (hydraulic) | P_h | kW | P_h = ρgQH / 1000 = Q·H·SG / 367 (Q in m³/h, H in m, kW) |
| Shaft power | P_s | kW | P_h / η |
| Efficiency at BEP | η_BEP | — | typically 0.55 (small ≤5 kW) → 0.88 (large) |
| Specific speed (metric) | n_s | — | n_s = n √Q / H^(3/4) (n rpm, Q m³/s, H m) |
| Specific speed (US) | N_s | — | N_s = N √Q / H^(3/4) (N rpm, Q gpm, H ft) — multiply n_s by 51.6 |
| NPSH available | NPSHa | m | (p_atm − p_v)/ρg + z_suction − h_friction |
| NPSH required | NPSHr | m | from pump curve; cavitation onset at NPSHa < NPSHr + margin |
| Affinity laws (same impeller) | — | — | Q∝n, H∝n², P∝n³; Q∝D, H∝D², P∝D³ (impeller trim) |
| BEP | — | — | best efficiency point on Q-H curve |
| AOR / POR | — | — | Allowable / Preferred Operating Region per HI 9.6.3 (typically 70–120% / 80–110% of BEP) |
Specific-speed bands shape impeller geometry: n_s < 30 → radial (high head, low flow); 30 < n_s < 80 → Francis/mixed; 80 < n_s < 160 → mixed-flow; n_s > 160 → axial (propeller).
2. Centrifugal — Single-Stage Overhung (OH)
API 610 OH classes — bearing housing supports impeller on one end of shaft, coupling on other.
| OH class | Mounting | Casing | Typical service | Flow Q | Head H | API 610 ref |
|---|---|---|---|---|---|---|
| OH1 | Foot-mounted, flexible coupling | Volute | General chemical, light HC | 5–800 m³/h | 10–150 m | OH1 |
| OH2 | Centerline-mounted (process), foot-supported casing | Volute | Refinery, heavy HC, hot service to 450 °C | 10–2000 m³/h | 15–250 m | OH2 (most common API) |
| OH3 | Vertical inline, separate bearing bracket | Volute | Tight plot space, refinery, condensate | 5–500 m³/h | 10–200 m | OH3 |
| OH4 | Vertical inline, rigid coupling, motor-supported | Volute | Booster, low NPSHa | 5–300 m³/h | 5–60 m | OH4 |
| OH5 | Vertical inline, close-coupled (no coupling, no bearings) | Volute | Light services | 1–80 m³/h | 5–30 m | OH5 |
| OH6 | High-speed integrally geared | Volute or barrel | High-head low-flow, boiler feed booster | 5–500 m³/h | 200–2500 m | OH6 (Sundyne LMV) |
ANSI/ASME B73.1 — chemical-process end-suction equivalent of OH2 with standardized dimensions across mfrs (envelope interchangeability). Sizes A05 → A120 (suction × discharge × impeller dia in inches); e.g., 3×4-10A. Flow 10–1100 m³/h, head to 215 m.
Major OEMs (single-stage OH / ANSI B73.1):
- Sulzer (Switzerland) — AHLSTAR A, CPT (ANSI), OHH/OHC (API OH2)
- Flowserve (USA) — Durco Mark 3 (ANSI), HPX/HPXM (API OH2), Mark 3 ISO (ISO 5199)
- KSB (Germany) — Etanorm (ISO 2858), Megachem (chemical), MegaCPK (API)
- Goulds Pumps / ITT (USA, now Xylem) — 3196 (ANSI flagship), 3796 self-priming, JC submerged, ICP (ISO), 3700 (API OH2)
- ITT Goulds — 3700 (OH2), 3700LF low flow (OH6)
- Ruhrpumpen (Germany) — RON, RPP, SCE (API), CRP-M (ANSI)
- Ebara (Japan) — GS, FS, GSO, EVMS (vertical)
- Pentair (USA) — Aurora 340, Fairbanks-Morse legacy
- Wilo (Germany) — Wilo-CronoNorm NL/NLG (DIN 24255), Wilo-Helix
- Grundfos (Denmark) — NB / NBG / NK / NKG (DIN 24255), CR (multi-stage vertical inline)
- HMD Kontro / Sundyne (USA) — sealless mag drive (API OH2 + ASME B73.3)
- Pacific Pumps (Flowserve legacy), Worthington (Flowserve), United Pumps Australia
ANSI B73.1 frame interchangeability: AA/A05/A10/A20/A30/A40/A50/A60/A70/A80/A105/A110/A120 — bolt-pattern + shaft-end identical across mfrs in same group.
3. Centrifugal — Between-Bearing (BB) Multi-Stage and Split-Case
API 610 BB classes — shaft supported by bearings at both ends.
| BB class | Description | Stages | Flow Q | Head H | Service |
|---|---|---|---|---|---|
| BB1 | Axially-split casing, single-stage, between-bearing | 1 | 100–10 000 m³/h | 15–250 m | Cooling water, condensate, fire water, water transfer |
| BB2 | Radially-split casing (compact), single or 2-stage | 1–2 | 50–4000 m³/h | 100–600 m | High-pressure single-stage, pipeline, water injection |
| BB3 | Axially-split, multi-stage | 4–14 | 50–4000 m³/h | 200–2500 m | Boiler feed (utility), water injection, charge pumps |
| BB4 | Single-casing radial-split multi-stage (segmental ring) | 2–14 | 20–1500 m³/h | 150–2000 m | Boiler feed (small/mid), high-pressure water |
| BB5 | Double-casing radial-split, barrel multi-stage | 4–14 | 20–2000 m³/h | 500–5000 m | Boiler feed (supercritical), pipeline (mainline), water injection, CO2 injection |
Single-stage axially-split (BB1) — horizontal split casing, double-suction impeller, end-flanged or top-flanged.
- Flowserve LNN/LNV/HSD, Sulzer SMD/SMN, KSB Omega, Ruhrpumpen HSR, Ebara DS, Xylem A-C 8100
- Bell & Gossett (Xylem) HSC-S — commercial HVAC
- Patterson HSC, Pacific Pumps PAC
Multi-stage axially-split (BB3) — boiler feed in utility, water injection in oilfield.
- Sulzer MSD (most common refinery/utility), MSE
- Flowserve DMX, HDX, WIK
- KSB HGM, CHTD
- Ruhrpumpen HMD, ZM
- Ebara CN, HD
Barrel multi-stage (BB5) — outer pressure casing, inner cartridge cassette; cassette pulls out for service without breaking process piping.
- Sulzer GSG (boiler feed, 4500 m head), HPcp (CO2 injection), MBN
- Flowserve WUC, DMX, WIK
- KSB HGC, CHTC, HDB
- Ebara HGB
4. Centrifugal — Vertical (VS)
API 610 VS classes.
| VS class | Description | Service |
|---|---|---|
| VS1 | Wet-pit, line-shaft, diffuser-style turbine | Sumps, sea water lift, cooling tower |
| VS2 | Wet-pit, line-shaft, volute | Larger flows, condensate |
| VS3 | Wet-pit, line-shaft, mixed-flow / axial-flow | High flow low head — cooling water, flood pumps |
| VS4 | Vertical cantilever, sump | Slurry sumps, drain |
| VS5 | Vertical cantilever, can | Mid-flow |
| VS6 | Vertical can / barrel — double casing, suction can buried below floor | Low NPSHa services — boiler condensate booster, LNG, propane, ammonia |
| VS7 | Vertical can, axially-split barrel | High-head condensate |
Major OEMs (vertical):
- Flowserve — VTP / VPC / VCT / VLT (acquired Pacific, Western Land Roller, IDP)
- Sulzer — VVT (vertical turbine), VPS (sump), SJD (condensate)
- KSB — UPA / UPZ (submersible borehole), Vitachrom (vertical inline)
- Ebara — EVMS / EVMSL / EVMSU stainless multi-stage vertical
- Xylem Goulds — VIT, VIC, JC, NM
- Patterson — vertical turbine pumps (fire service, UL/FM)
- Aurora (Pentair) — vertical inline + fire pumps
- National Pump Company — turbine wells
Vertical turbine — bowl assembly = suction bell + first-stage bowl with impeller + intermediate bowls + discharge bowl + column pipe + line shaft + bearings (rubber/bronze/cutless) + lineshaft enclosing tube (oil-lubed) or open lineshaft (water-lubed) + above-ground discharge head + motor (vertical hollow-shaft VHS, or vertical solid-shaft VSS).
5. Centrifugal — Specialty by Impeller / Service
| Type | Impeller | Q range | H range | Notes / OEMs |
|---|---|---|---|---|
| End-suction industrial | Closed | 5–2000 m³/h | 10–200 m | Goulds 3196, KSB Etanorm, Flowserve Mark 3 |
| Inline circulator | Closed semi-open | 1–500 m³/h | 5–80 m | Grundfos UPS/Magna, Wilo Stratos, Bell & Gossett |
| Self-priming | Closed with recirc | 5–500 m³/h | 10–60 m | Gorman-Rupp T/U/V series, Godwin (Xylem), Pioneer |
| Slurry — heavy-duty | Open / impeller with elastomer or hard-iron lining | 10–10 000 m³/h | 10–80 m per stage | Weir Warman AH/HR/L, GIW LCC/MDX, Metso/Outotec MD/MM, KSB GIW LSA |
| Slurry — froth | Open with airfoil-style vanes | 50–3000 m³/h | 10–40 m | Warman AHF, GIW Froth-X |
| Slurry — dredging | Open, large free passage | 500–50 000 m³/h | 30–100 m | Weir GEHO, GIW TBC, IHC Merwede MTI |
| FGD (flue-gas desulfurization) | Open + corrosion-resistant alloy (CD4MCuN, A-49) | 500–20 000 m³/h | 20–60 m | Sulzer LHD, Flowserve LFM, Weir Warman MCR |
| Paper stock | Vortex / open / semi-open | 200–10 000 m³/h | 15–80 m | Sulzer Ahlstar A, AT, Andritz ACP |
| Sewage / non-clog | Single-channel, vortex, multi-channel, chopper | 5–10 000 m³/h | 5–60 m | Xylem Flygt N (adaptive sweeper), KSB Sewatec, Wilo Rexa, Gorman-Rupp T-series, ITT Vaughan chopper |
| Magnetic drive (sealless) | Closed | 1–500 m³/h | 5–150 m | HMD Kontro GSP, Sundyne ANSIMAG, Iwaki MX, Klaus Union SLM, Flowserve HPX-M, Goulds 3296 |
| Canned motor (sealless) | Closed | 1–500 m³/h | 5–250 m | Hermetic Pumpen / Lederle, Teikoku, Nikkiso, Hayward Tyler |
| Regenerative turbine | Peripheral with radial buckets | 0.5–60 m³/h | 30–250 m | Roth, MTH, DEKO, Burks (Crane) |
| High-speed partial-emission | Pitot / partial-emission | 1–500 m³/h | 100–2500 m | Sundyne LMV/LMC/BMP, Roto-Jet (Weir), Sulzer MBN |
Slurry duty classifications (Hydraulic Institute / HI 12.1):
- Class 1 mild — sand/water, low concentration
- Class 2 medium — phosphate slurry, fly ash
- Class 3 heavy — hard-rock concentrates, copper/iron ore tailings, coarse gravel
- Class 4 severe — bottom-ash, FGD limestone, scale
Materials: white iron (ASTM A532 Class III Type A — Ni-Hard, 28% Cr), high-chrome (A532 IIIA), rubber-lined steel (natural rubber soft for fine; hard chloroprene for medium), polyurethane.
6. Positive Displacement — Rotary
| Type | Mechanism | Q range | p_max | μ range | Slip vs p | Self-prime? | OEMs |
|---|---|---|---|---|---|---|---|
| External gear | Two meshing spur/helical gears | 0.05–500 m³/h | 25 bar (industrial) / 350 bar (hydraulics) | 1–10⁶ cP | linear | yes | Viking (IDEX), Bosch Rexroth, Parker Commercial, Tuthill, Eaton Vickers, Marzocchi, Casappa |
| Internal gear (gerotor/crescent) | Inner rotor inside outer gear, crescent separator | 0.1–250 m³/h | 25 bar (ind) / 250 bar (hyd) | 1–10⁶ cP | linear | yes | Viking, Tuthill, Pyles, Maag, Truninger, IMO (Colfax) |
| Lobe (rotary lobe) | Two non-contacting lobes synchronised by external gears | 0.5–1000 m³/h | 15 bar | 1–10⁶ cP | linear, low | yes (filled) | Alfa Laval (SRU/SX), SPX FLOW (Waukesha Cherry-Burrell U, 200/300 series), Boerger (BLUEline), Vogelsang VX, Jung-Process, Wangen RC |
| Vane (sliding) | Sliding vanes in slotted rotor | 0.5–600 m³/h | 17 bar | 1–10⁵ cP | low | yes | Blackmer (Dover), Corken (IDEX), CDS-John Blue, Tuthill, Howden Roots |
| Vane (flexible impeller) | Elastomeric vanes | 0.05–30 m³/h | 4 bar | 1–10⁵ cP | low | yes | Jabsco (Xylem), Johnson Pump (SPX), March, ITT Marlow |
| Progressive cavity / PC / Moineau | Helical rotor in elastomer stator | 0.05–1000 m³/h | 48 bar per stage; up to 240 bar w/ multi-stage | 1–10⁶ cP (incl. shear-sensitive, abrasive) | low, viscosity-independent | yes | NETZSCH NEMO, Seepex BN/BT/BW, PCM Moineau, ALLWEILER AEB, Mono (NOV), Continental |
| Twin screw | Two intermeshing screws synced by timing gears | 1–3000 m³/h | 100 bar | 1–10⁶ cP (multiphase) | low | yes | Leistritz L2/L3/L4, Bornemann (ITT) MW/MX, Colfax IMO, Flowserve LSJ-S, KRAL screw |
| Three-screw | Driving + 2 idler screws | 0.5–500 m³/h | 200 bar | 1–10⁵ cP | low | yes | IMO (Colfax), Settima/Continental ContinuumX, Leistritz, KRAL, Allweiler |
| Single screw (Archimedean-style rotor) | Helical rotor in elastomer stator (PC subset) | — | — | — | — | — | — |
| Peristaltic / hose | Roller/shoe compresses hose | 0.001–80 m³/h | 16 bar | 1–10⁶ cP (slurries, abrasive, shear-sensitive) | none (positive lock-out) | yes (dry suction) | Watson-Marlow Bredel (Spirax-Sarco), Verderflex (Verder), Flowrox, ProMinent Dulco, Ragazzini, Albin (Atlas Copco) |
| Circumferential piston | Pistons rotate around centerline | 0.5–250 m³/h | 30 bar | 1–10⁶ cP | low | yes | SPX FLOW Waukesha Universal 1/2/3/TS |
| Sinusoidal | Sinusoidal rotor + scrapers | 0.1–80 m³/h | 15 bar | 1–10⁵ cP | low | yes | Watson-Marlow MasoSine (Certa) |
7. Positive Displacement — Reciprocating
| Type | Drive | Q range | p_max | μ range | OEMs |
|---|---|---|---|---|---|
| Piston (power) | Crankshaft → crosshead → piston rod, packed stuffing box | 0.5–1000 m³/h | 700 bar typical, to 1400 bar | 1–10⁴ cP | Gardner Denver, NOV (National Oilwell Varco), Weatherford, Halliburton, SPM/Weir, Kerr |
| Plunger (power) | Crankshaft → crosshead → plunger, packed stuffing box | 0.05–500 m³/h | 2000 bar typical, to 4000 bar (water jet 6000+) | 1–10⁴ cP | Hammelmann, Jetstream, Cat Pumps, Pratissoli (Interpump), Hawk, Comet, KAMAT, Hauhinco |
| Plunger (controlled-volume metering) | Crankshaft + variable stroke + check valves | 0.0001–10 m³/h | 700 bar | 1–10⁵ cP | Milton Roy / LMI (IDEX), ProMinent Sigma, Lewa Ecoflow, SERA, Bran+Luebbe (SPX) |
| Diaphragm (single, mechanically actuated) | Crankshaft + linkage | 0.001–10 m³/h | 25 bar | 1–10⁶ cP | ProMinent gamma/X, Walchem, Iwaki, Grundfos DDA |
| Diaphragm (hydraulically actuated) | Plunger pressurizes hydraulic oil behind PTFE diaphragm | 0.05–250 m³/h | 1000 bar | 1–10⁶ cP | Lewa triplex, Milton Roy mROY/PRIMEROYAL, Wanner Hydra-Cell, McFarland, Bran+Luebbe |
| AODD (air-operated double-diaphragm) | Compressed air alternating between two chambers | 0.05–250 m³/h | 8.6 bar (= 1× supply) | 1–10⁵ cP | Wilden (Dover), ARO (Ingersoll Rand), Sandpiper (Warren Rupp), Yamada, All-Flo, Versa-Matic, Graco Husky, Verder VA |
| Pulsation-damped (membrane / air chamber) | — | — | — | — | Pulsation dampener + pressure-relief pulsation control to <3% pulse |
| Bellows (welded metal) | Plunger compresses welded metal bellows | 0.001–5 m³/h | 50 bar | 1–10⁵ cP | Sera, Lewa, Bran+Luebbe |
API 674 + API 675 + API 676 — covers reciprocating PD (674), controlled-volume metering (675), and rotary PD (676) for refinery / petrochemical service.
8. Specialty Pumps
| Type | Principle | Service / OEMs |
|---|---|---|
| Submersible borehole | Multistage centrifugal driven by submersible motor (wet-stator / canned) | Grundfos SP, KSB UPA, Franklin Electric, Pentair Sta-Rite, Goulds GS |
| Submersible sewage | Single-stage non-clog driven by submersible motor (oil-cooled) | Xylem Flygt, KSB Amarex, Wilo Rexa, Tsurumi, Ebara DML |
| Submersible mine dewater | Multi-stage centrifugal in stainless | Grundfos SP, KSB Movitec U, Tsurumi LH |
| Axial flow (propeller) | Propeller-style impeller in tube | Bedford, Patterson, Hidrostal, ITT Goulds AF (flood control) |
| Mixed flow | Combination radial + axial vanes | Most vertical turbines for cooling water and lift |
| Jet / ejector (venturi) | Motive fluid through nozzle creates suction | Schutte & Koerting, Croll-Reynolds, Graham (steam ejector); domestic shallow-well |
| Steam ejector (vacuum) | Steam through nozzle | Graham, Croll-Reynolds, Körting; 5 mbar absolute and below |
| Hydraulic ram | Water-hammer pulse | Schlumpf Aqua-Ram, Folk Ram |
| Archimedean screw | Inclined rotating screw | Spaans Babcock, Landustrie, Ritz-Atro; sewage influent + low-head irrigation |
| Air-lift | Compressed air injected into riser pipe | Aquaculture, deep-well dewater |
| Centrifugal blower / regenerative blower | — see Compressors & Blowers catalog (separate) | — |
| Cryogenic | Multistage centrifugal with vacuum-insulated jacket | Ebara, Nikkiso ACD, Cryostar, Air Liquide-Cryolor — LNG, LIN, LOX, LAr, LHe |
| Magnetic-bearing canned hermetic | Magnetic levitation, oil-free | MAN HOFIM, Siemens STC-ECO, Mitsubishi ICC — pipeline CO2, hydrogen, ethylene |
| Metering peristaltic micro | Roller compresses small-bore tubing | Watson-Marlow 120 / 323 / 530, Cole-Parmer Masterflex, Ismatec |
| Syringe (lab / medical) | Linear stepper drives syringe plunger | Harvard Apparatus, Chemyx, KD Scientific, New Era |
| Gear-driven micropump (MEMS) | Piezo / electrostatic actuation | Bartels mp6, TTP Ventus, ThinXXS, Dolomite Mitos |
9. API 610 — Refinery + Petrochem Centrifugal Pumps
API 610 12th Edition (2021) / ISO 13709:2009 is the dominant spec for hydrocarbon process service > 1.5 MPa or > 150 °C. Defines:
| Section | Topic |
|---|---|
| Section 5 | Materials of construction — Class S-1 (carbon steel) through A-8 (Ni-base) |
| Section 6 | Casing thickness, pressure-temperature ratings, ANSI flange ratings #150 / #300 / #600 / #900 / #1500 / #2500 |
| Section 7 | Shafts, deflection < 50 µm at seal faces, L₃/D₄ rigidity index |
| Section 8 | Bearings — anti-friction L10h ≥ 25 000 h continuous + 16 000 h with seal/coupling design loads; hydrodynamic option |
| Section 9 | Lubrication — pure oil mist, sump oil with constant-level oiler, oil mist + circulation; oil-water separation |
| Section 10 | Auxiliary piping — API 682 seal piping plans; cooling water; flush |
| Section 11 | Vibration limits — 3 mm/s RMS unfiltered overall at design point per ISO 10816 / API 670 |
| Section 12 | Allowable nozzle forces and moments — Table 5 (about 2× ANSI B73.1 OH allowable) |
| Section 13 | Testing — hydrostatic 1.5× MAWP, performance per HI/API |
API material classes:
| Class | Casing | Internals | Service |
|---|---|---|---|
| S-1 / S-3 / S-4 | Carbon steel | 12 Cr, 13 Cr | Cool HC, water, lube oil |
| S-5 / S-6 / S-8 | Carbon steel | 13 Cr / 304 SS | Hot HC, condensate |
| C-6 / C-7 / C-8 | 12 Cr / 304 / 316 | matching | Corrosive |
| A-7 / A-8 | 316 / Alloy 20 / Duplex | matching | Acid, brine |
| D-1 / D-2 | Duplex 2205 / Super-duplex 2507 | matching | Sea water, chloride |
| I-1 / I-2 | Alloy 20 / Hastelloy C-276 | matching | Sulfuric, HCl |
10. ANSI / ASME B73 — Chemical Process Centrifugal
| Standard | Title | Equivalent to |
|---|---|---|
| ASME B73.1 | Horizontal end-suction centrifugal for chemical process | API 610 OH1 (lighter) |
| ASME B73.2 | Vertical inline centrifugal for chemical process | API 610 OH3/OH5 |
| ASME B73.3 | Sealless horizontal end-suction (mag-drive + canned) | API 685 (sealless heavy duty) |
ISO 5199 (heavy-duty) and ISO 2858 (lighter / dimensional only) are European-tradition counterparts; many EU OEMs build ISO 2858 envelope + ISO 5199 mechanical rigor.
11. Hydraulic Institute (HI) Standards
| HI Number | Topic |
|---|---|
| HI 1.x | Centrifugal types & nomenclature |
| HI 1.3 | Centrifugal design + application |
| HI 1.6 | Centrifugal pump tests |
| HI 9.6.1 | NPSH margin |
| HI 9.6.2 | Allowable nozzle loads |
| HI 9.6.3 | Allowable operating region (POR/AOR) |
| HI 9.6.4 | Vibration measurements |
| HI 9.6.5 | Condition monitoring |
| HI 9.6.7 | Effects of liquid viscosity on rotodynamic pumps |
| HI 14.x | Rotary PD |
| HI 7.x | Reciprocating power pumps |
| HI 11.6 | Submersible pump tests |
| HI 12.x | Slurry pumps |
| HI 40.6 | Methods for rotodynamic pump efficiency testing (now harmonized with ISO 9906) |
ISO 9906:2012 — rotodynamic pumps acceptance tests — grade 1B/1E (precision), grade 2B/2E (general industry), grade 3B (commercial).
12. Sealing — Packing and Mechanical Seals
12.1 Compression Packing
| Material | Service |
|---|---|
| PTFE-impregnated synthetic fiber (Garlock 1303-FEP, Chesterton 1622) | General water, mild chemical |
| Graphite filament (Chesterton 1400R, Garlock 5000) | Hot water, steam, hydrocarbons to 480 °C |
| Aramid (Kevlar) + PTFE | Abrasive |
| PTFE + graphite | Universal mid-temp |
| Carbon fiber + graphite | High-temp valve stems |
OEMs: Garlock (Enpro), Chesterton, John Crane (Smiths Group), SEPCO, Klinger, Latty.
12.2 Mechanical Seals — Configurations
| Configuration | Sketch | Use case |
|---|---|---|
| Single — pusher (springs push primary ring) | Single rotating face on stationary | General HC, water |
| Single — non-pusher (metal bellows) | Welded-metal bellows; no dynamic O-ring | High-temp HC, FGD, light hydrocarbons that crystallize |
| Tandem (dual unpressurized) | Two seals in series; buffer fluid between at process pressure | LPG, light HC, partial backup |
| Double (dual pressurized) | Two seals; barrier fluid at >process pressure between | Hazardous, toxic, near-vapor-pressure |
| Gas-lubricated (dry gas seal) | Spiral / T-groove face lifts off on gas film | Compressors; emerging on light HC pumps |
| Cartridge | Pre-assembled gland + sleeve + seal — drop-in | All modern industrial pumps (saves install errors) |
12.3 API 682 — Shaft Sealing Systems for Centrifugal and Rotary Pumps
API 682 4th Ed (2014). Categorizes seals by:
| Category | Service |
|---|---|
| Category 1 | ASME B73 chemical service; lighter duty |
| Category 2 | API 610 heavy-duty refinery service |
| Category 3 | Above + qualification testing per API 682 Annex F |
Arrangements:
- Arrangement 1 — single seal
- Arrangement 2 — two seals, intermediate (containment) at near-atmospheric, dry-running or wet buffer
- Arrangement 3 — two seals with pressurized barrier fluid > process pressure (no process leakage to atmosphere)
Seal types:
- Type A — pusher (multi-spring or single-spring, O-ring secondary)
- Type B — metal bellows, non-pusher
- Type C — metal bellows, high-temp (typically > 175 °C)
12.4 API 682 Piping Plans (Common)
| Plan | Description | Use |
|---|---|---|
| Plan 01 | Internal recirc (case → seal chamber) | Clean cool fluid only |
| Plan 02 | Dead-end with cooling jacket | Hot oil; no recirc |
| Plan 11 | External recirc from discharge to seal chamber via orifice | Default for single seals (clean fluid) |
| Plan 12 | Discharge to seal via Y-strainer + orifice | Mild solids |
| Plan 13 | Recirc from seal chamber back to suction | Vertical pumps; vent vapors |
| Plan 14 | Combined Plan 11 + Plan 13 | Vertical hot-service |
| Plan 21 | Discharge → cooler → seal chamber | Hot fluid, cooled to seal |
| Plan 22 | Plan 21 + strainer | Mild solids in hot fluid |
| Plan 23 | Closed-loop recirc via pumping ring → cooler → seal | Hot water, boiler feed (preferred over 21 — energy efficient) |
| Plan 31 | Cyclone separator on Plan 11 | Heavy solids in suspension |
| Plan 32 | Clean external flush injected into seal chamber | Slurry, dirty service |
| Plan 41 | Plan 31 + cooler | Hot dirty |
| Plan 51 | Quench reservoir, dead-end | Crystallizing fluids, freeze protection |
| Plan 52 | Unpressurized buffer reservoir between two seals (Arrangement 2) | LPG, light HC |
| Plan 53A | Pressurized barrier reservoir, gas-pressurized bladder (N2) | Toxic / hazardous, moderate pressure |
| Plan 53B | Pressurized barrier reservoir, pre-charged accumulator | Higher pressure |
| Plan 53C | Pressurized barrier reservoir, piston accumulator driven by pump discharge | Pressure tracks process |
| Plan 54 | Pressurized barrier from external clean source | Highest hazard |
| Plan 62 | External quench (steam, water, N2) to atmospheric side | Coking products, sub-zero |
| Plan 65A / 65B | Leakage detection drain pot + level switch | Lifecycle monitoring |
| Plan 66A / 66B | Throttle bushing + pressure/level alarm | Toxic backup |
| Plan 71 | Dry buffer gas, dead-end | Dry-gas tandem (Arrangement 2) |
| Plan 72 | Dry buffer gas, vented | Vapor recovery |
| Plan 74 | Pressurized barrier gas (Arrangement 3 dry) | Toxic light HC, ammonia |
| Plan 75 | Liquid leakage detection from containment seal | Plan 72 + recovery |
| Plan 76 | Vapor leakage to flare/vent | Plan 72 alternative |
12.5 Mechanical Seal OEMs
| OEM | Country | Notable lines |
|---|---|---|
| John Crane (Smiths Group) | UK/USA | Type 1648, T-series (T+, T-MAX), 5860/5840 dry gas (compressor), 28 cartridge |
| EagleBurgmann (Freudenberg / EKK joint) | DE/JP | MR, M7N, HJ977, DTM cartridge, DGS dry gas |
| Flowserve (Pacific-Wietz, Durametallic) | USA | ISC2, BX, GX, PSS cartridge |
| AESSEAL | UK | CDSA, CURC, CSE |
| Chesterton | USA | 155, 280, 442 (high-pressure pulper), DualPac, MagnaSafe |
| SEPCO | USA | SE Series, SEPCO 460 |
| Vulcan (UK) | UK | Vulcan 8B, A8 |
| Latty | France | LattyBag, T804 |
| Roten / KSB Roten | DE | KSB-supplied OEM |
| Smiths Sealol (legacy) | USA | Now JC |
12.6 Seal Face Materials
| Face material | Hardness HV | Properties |
|---|---|---|
| Carbon-graphite (resin, antimony, Babbitt impregnated) | 100–250 HV | Lubricous, soft mating face |
| Silicon carbide (sintered SSiC, reaction-bonded RBSiC, graphite-loaded SiC) | 2500 HV | Hard, excellent abrasion resistance, slight thermal-shock risk (SSiC) |
| Tungsten carbide (Co-bonded WC, Ni-bonded for low-chloride) | 1600 HV | Hard, tough, mating to carbon or SiC |
| Aluminium oxide (alumina, ceramic) | 1800 HV | Cheap, used in domestic and small pumps |
| Stellite (Co-Cr-W hardfacing) | 700 HV | Hardfaced seal seats |
13. Drivers, Couplings, Baseplates
- Standard drivers: NEMA / IEC induction motor (IE3 / IE4 / IE5 efficiency); steam turbine; gas turbine; diesel; hydraulic
- Variable frequency drive (VFD) — broadens operating envelope, reduces throttling losses; ABB, Siemens, Schneider, Rockwell, Yaskawa
- Coupling types — spacer disc-pack (Rexnord/Falk Thomas, John Crane Metastream), gear (Lovejoy, Renold), elastomeric (Rexnord Omega, Falk Steelflex grid), magnetic (Magnetic Technologies)
- Baseplate — fabricated steel, polymer-concrete (Itt Goulds PermaBase, Sulzer Polyplate), grouted with non-shrink grout per API 686
- Alignment — laser shaft alignment (Pruftechnik Rotalign, Easy-Laser XT) target <0.05 mm/100 mm
14. Cavitation, NPSH, Suction-Specific Speed
| Symbol | Definition |
|---|---|
| NPSHr | Required NPSH at 3% head drop on flat-curve test (HI / API definition); also “NPSH₃” |
| NPSHa | Available NPSH from system |
| NPSH margin | NPSHa − NPSHr; per HI 9.6.1 typically 1.1–2× NPSHr depending on energy density and impeller eye |
| S (suction specific speed, US) | S = N √Q / (NPSHr)^(3/4) |
| S (metric) | s = n √Q / (NPSHr)^(3/4) |
S > 11 000 (US) or s > 213 (metric) indicates large-eye low-NPSH impeller — narrower stable operating window, risk of suction recirc at part-load.
Net Positive Suction Energy (NPSE) = NPSH × g — energy-form metric per modern HI 9.6.1.
15. Curve Anatomy and Operating Envelope
Reading a centrifugal Q-H curve:
- BEP — minimum slope; highest η
- Shutoff head (Q=0) — typically 110–125% BEP head for radial impellers
- Runout (max flow) — efficiency falls off; cavitation risk rises (NPSHr increases sharply)
- POR — Preferred Operating Region: 70–120% BEP per HI 9.6.3
- AOR — Allowable Operating Region: 30–120% (low-energy) to ~70–115% (high-energy)
- MCSF (Minimum Continuous Stable Flow) — below this, recirculation + radial thrust damage rates rise
Modern smart-pump packages (Sulzer Sense, Flowserve RedRaven, Grundfos Predictive Maintenance, KSB Guard) combine vibration + bearing temperature + power on-curve estimation to flag off-BEP operation.
16. Vibration Acceptance — API 610 / ISO 10816 / HI 9.6.4
| Pump class | Allowed at design point | Allowed at AOR |
|---|---|---|
| API 610 horizontal Y < 300 kW | 3.0 mm/s RMS unfiltered | 4.5 mm/s |
| API 610 horizontal ≥ 300 kW | 4.5 mm/s | 6.0 mm/s |
| API 610 vertical | 5.0 mm/s | 7.0 mm/s |
| HI 9.6.4 commercial / ANSI | 4.5–6.5 mm/s depending on size | — |
API 670 — machinery protection systems (proximity probes, accel sensors, alarm/trip thresholds).
17. Energy and Efficiency
- EU MEI (Minimum Efficiency Index) Regulation EC 547/2012 — applied to water pumps ≥ 1 kW; MEI ≥ 0.40 effective Jan 2015
- US DOE — pump energy-conservation standard (CCEP — Commercial and Consumer Equipment Programs); PEI_CL / PEI_VL (Pump Energy Index Constant / Variable Load)
- ISO/ASME 14414 — pump system energy assessment
- IE3/IE4/IE5 motor efficiency (IEC 60034-30-1)
- Variable speed: affinity laws give cubic power savings for friction-dominant systems
18. Major OEM Summary
| OEM | HQ | Strengths | Flagship lines |
|---|---|---|---|
| Sulzer | Switzerland | API, water, paper, mining, slurry | OHH, MSD, GSG, HPDM, AHLSTAR, MD/MM (slurry) |
| Flowserve | USA | API, sealless, vertical, mining, FGD | Mark 3, Durco, HPX, WUC, LNN, LFM |
| KSB | Germany | API, water, mining, building services, nuclear | Etanorm, MegaCPK, RUV, HG/HGC, Amarex, GIW |
| Xylem | USA (Sweden via Flygt) | Submersible, water/wastewater, HVAC | Flygt N, Goulds 3196/3700, Bell & Gossett, Lowara, Wedeco UV |
| Grundfos | Denmark | Circulators, building, water, dosing, EVMS | CR, CRN, Magna, NB/NK, SP, DDA |
| Wilo | Germany | Building services, HVAC, water | Stratos, CronoNorm, Rexa, Helix |
| Goulds Pumps (ITT) | USA | ANSI process, vertical, slurry | 3196 (ANSI ref), 3700, JC, NM |
| Ebara | Japan | API + general industry + vertical | GS, EVMS, HGM, EVMU |
| ITT Industrial Process | USA | API + Goulds + Bornemann + Vogel | 3700, Bornemann MW, Vogel |
| Ruhrpumpen | Germany / Mexico | API, fire pumps, defense | RON, RPP, ZM, HMD, SCE |
| Pentair / Aurora / Sta-Rite / Fairbanks | USA | Fire pumps, building services, pool | Aurora 340/480, Fairbanks-Morse, Fairbanks Nijhuis |
| Weir Group | UK | Slurry, mining, fracking, valves | Warman, GEHO PD, SPM, Lewis pumps |
| GIW Industries (KSB) | USA | Severe-duty slurry | LCC-M, MDX, LSA, TBC |
| Metso Outotec / Mogensen | Finland | Mining slurry, FGD | MD, MM, MR |
| Andritz | Austria | Paper stock, pulp, hydro | ACP, ACR, EnP, hydro pump-turbines |
| Pleuger / Hayward Tyler | DE/UK | Submersible motors, nuclear, oil-and-gas | Subsea pumps, RCP nuclear |
| Sundyne | USA | High-speed integrally-geared centrifugal + sealless | LMV-322/801/802, BMP, ANSIMAG (mag-drive) |
| HMD Kontro (Sundyne) | UK | Mag-drive sealless | GSP, GSPX |
| Iwaki | Japan | Mag-drive + AODD chem | MX, MD, EHE diaphragm |
| Klaus Union | Germany | Mag-drive + canned-motor | SLM, SLMC, SLP |
| Nikkiso | Japan | Canned-motor (LNG, refinery, ammonia) | Non-Seal HN |
| Hermetic-Pumpen / Lederle | Germany | Canned-motor (LPG, refrigerant, refinery) | CN, CNK, CAM |
| Teikoku USA | USA/Japan | Canned-motor (refinery, chemical) | F, J, K, X-Type |
| Lewa (Atlas Copco) | Germany | High-pressure metering diaphragm | Ecoflow, triplex |
| Milton Roy / LMI / Sundyne | USA | Dosing + metering | mROY, PRIMEROYAL, gamma, Sigma |
| ProMinent | Germany | Dosing + chlorination | gamma/X, Sigma X, Hydro |
| NETZSCH | Germany | Progressive cavity + rotary lobe | NEMO, TORNADO T2, NOTOS |
| Seepex | Germany | Progressive cavity | BN, BT, BW, MAX |
| PCM | France | Progressive cavity, food, oil | Moineau, EcoMoineau |
| Mono (NOV) | UK / USA | Progressive cavity | Compact-C, EZstrip |
| Alfa Laval | Sweden | Hygienic centrifugal + lobe | LKH, SRU, SX |
| SPX FLOW (Waukesha Cherry-Burrell) | USA | Hygienic + Universal | U1/U2/U3/UTS, W series, 200/300 lobe |
| Watson-Marlow (Spirax-Sarco) | UK | Peristaltic + sinusoidal | Bredel APEX/AX, 530/630, MasoSine Certa |
| Verder (Verderflex) | NL | Peristaltic | Dura, Vantage, iDura |
| Wilden / ARO / Sandpiper / Yamada | USA / JP | AODD | Pro-Flo (Wilden), EXP (ARO), S05/S07/S15 (Sandpiper) |
| Hammelmann | Germany | Plunger high-pressure | HDP series 800–4000 bar |
| KAMAT | Germany | Plunger high-pressure water | K series, 1500+ bar |
| Cat Pumps | USA | Triplex plunger | 3/5/7/15 frame |
| Pratissoli (Interpump) | Italy | Plunger | LL, K, KE, KX |
| Gardner Denver (Ingersoll Rand) | USA | Power piston + reciprocating | T-class, Joy, Robuschi |
| Leistritz | Germany | Twin-screw multiphase | L4MG, L5NG (subsea) |
| Bornemann (ITT) | Germany | Twin-screw multiphase, food | MW, MX |
| KRAL | Austria | Three-screw + twin-screw | C, K, L, B series |
| IMO (Colfax / Enerpac) | USA/SE | Three-screw lubrication | ACE, ACG, IMO 3D |
| Cryostar | France | Cryogenic centrifugal | SC, MC, CM-S series LNG / industrial gases |
| Nikkiso ACD | USA | Cryogenic centrifugal + reciprocating | LP, MP, HP-CE LNG carriers + import terminals |
| Ebara Cryodynamics | USA/Japan | Cryogenic submerged | EC-3, LNG marine + onshore |
| Air Liquide-Cryolor | France | Industrial gas cryo | LIN/LOX/LAr submerged + centrifugal |
19. Common Pitfalls
- Specifying single-stage when multi-stage is needed: high impeller speed/diameter to achieve head → low η and poor reliability
- Operating far off-BEP: radial thrust, recirculation, premature seal + bearing failure; HI 9.6.3 AOR limits exist for a reason
- Inadequate NPSH margin in hot service: vapor pressure rises rapidly with temperature; rule-of-thumb 1× NPSHr margin insufficient when liquid is near boiling
- High-suction-specific-speed impellers (S > 11 000) selected for marginal NPSHa: narrow stable operating window; suction recirc at part-load damages eye
- Mechanical seal flush plan chosen without thinking through process: Plan 11 in slurry → seal lasts weeks; Plan 32 with clean external flush essential
- Sealless mag-drive run dry: bearings cooled by process fluid; loss-of-flow → coupling decoupling and torque slip is normal protection, but bearings still see thermal shock
- Self-priming pump without vent path: prime is lost; loss-of-prime detection (pressure switch + dry-run protection) essential
- VFD on flat-curve / centrifugal selected for static-head dominated system: affinity laws give linear flow but quadratic head — power savings limited by static-head fraction
- Diaphragm metering pump sizing only at design flow: turn-down (typically 10:1) and back-pressure variability often determine actual sizing
- Vertical turbine column length over-specified: shaft critical-speed problems; column joints + lineshaft bearings + sleeves more critical than head
- Slurry pump impeller and liner not matched to particle distribution: fine slurry on coarse-slurry impeller wears unevenly