TECHNICAL DESCRIPTION

WATER INJECTION PUMP

 TECHNICAL DESCRIPTION Date: 26. Jan. -01
Rev.: 30. May.-02

FRAMO WATER INJECTION PUMP Sign.: RB

CONTENT

Introduction................................................................................................................... 3
Overall Design Philosophy .......................................................................................... 3
Conceptual Description ............................................................................................... 3
Basic Hydraulic Design................................................................................................ 4
Mechanical Design ....................................................................................................... 5
Bearing System ............................................................................................................ 5
Mechanical Seals.......................................................................................................... 6
Lube Oil System ........................................................................................................... 6
Service / Maintenance .................................................................................................. 6

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 TECHNICAL DESCRIPTION Date: 26. Jan. -01
Rev.: 30. May.-02

FRAMO WATER INJECTION PUMP Sign.: RB

Introduction
This technical specification gives the overall design philosophy and functional description of the
Framo HP150 and HP200 water injection pump concepts.
Applicable codes, standards and regulations are referenced in the Data Sheets and the Quality
Control and Documentation Plan against the relevant equipment items.
The specification should be read together with the project dedicated Main Specification, Data
Sheets and P&ID´s.

Overall Design Philosophy

The overall design philosophy have been to provide:
• High flexibility regarding adjustments to changing reservoir requirements and maintained
pump performance
By the use of machined high performance impellers it is possible to change design point
within 2 weeks.
• Integrated booster pump, with low NPSH requirements
• Minimum weight and space requirements, both with regards to basic footprint and service
space requirements
• Minimum service down-time. Change of complete impeller set possible within one shift.
• Maintained pump reliability with its inherent mechanical simplicity

Conceptual Description
The Water Injection Pump Unit consists of a booster pump stage and two high speed injection
pump stages. The three pump stages are driven by a common driver, over a spacer coupling and
a gearbox.
st
1 HS stage

Link pipe

Crossover pipe

Electric motor

Discharge nozzle

nd
2 HS stage

Lube oil Cooler

Booster pump stage
Dual lube oil filters

Pre/post lube oil pump

Gearbox
Booster Integrated High Pressure Pump

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 TECHNICAL DESCRIPTION Date: 26. Jan. -01
Rev.: 30. May.-02

FRAMO WATER INJECTION PUMP Sign.: RB

Lube oil pump

Input shaft

The gearbox is built as an integrated

part of the injection pump unit, and the
outgoing shafts include bearings and
mechanical seals for the pumps as well Booster stage
as a direct coupled impellers in each
end.

st
1 stage

nd
2 stage

View of gearbox with upper cover removed

A minimum flow valve directly mounted on the discharge nozzle performs protection of the pump.
Control of the package is maintained, with a minimum number of sensors on the pump and driver
unit, from Central Control System or local control panel.

Basic Hydraulic Design

Booster Pump
The booster pump section of the water
injection pump consists of a double volute
single stage centrifugal pump.
The pump is driven over a step-down of
gearwheels inside the same gearbox as
the high speed pump stages, in order to
give optimum suction performance.
The impeller is of radial design with a high
suction specific speed, i.e. low
NPSHrequired.

High Speed Pump

The high speed section of the water
injection pump consists of two single
stage pump units mounted back to back
on a common shaft.
The high speed impellers are machined
high performance type of radial design,
due to the high head requirements, and
with single suctions as a function of the Section of pumps and gear
construction.
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 TECHNICAL DESCRIPTION Date: 26. Jan. -01
Rev.: 30. May.-02

FRAMO WATER INJECTION PUMP Sign.: RB

A double volute pump casing design is selected. This is done for three basic reasons, which all
point in the same direction:
• Specific speed (NQ) of the pump is within the area, which gives the best performance with a
volute casing.
• Volute casing gives low complexity of the construction and wide operating envelope.
• Volute casing gives easy maintainability.
The double volute casing design is also selected to give good radial balancing of the pump. The
two single stage units mounted back to back also balance the thrust forces in the pumps, by the
design of impeller wear-ring diameters.

Mechanical Design
The water injection pump and step-up gearbox is built as an integrated unit with combined
bearings for gearbox output shafts and pump shafts. The impellers are directly fitted on the output
shafts, with a light interference fit and two symmetrical keyways.
The design allows individual balanced impellers to be fitted on the shaft on site without
rebalancing of the complete rotating assembly. This further contributes to the serviceability and
performance flexibility of the unit. The short overhang of the impeller shaft combined with the
generously sized bearings, gives a very stiff and rugged rotating element with speed far below
first critical speed.
At running condition the distance to the 1st critical speed is even greater due to the dampening
effect of the water between the wear-rings.
The gearbox is designed for indefinite life in accordance with the practice of the compressor
industry that for years have been operating at high speeds with a minimum of gearbox problems.
The gear standard used is ISO 1328 quality Class 5. The maximum peripheral speed of the gear
is approx. 90 m/sec. This is in comfortable distance from the recommended max. 127 m/sec.
given for indefinite life with the actual load, lubricated conditions, application factor and materials.
To eliminate fixing and sealing difficulties under the high differential pressure and high rotational
speeds of the pump, integral impeller wear rings are formed by overlaying the wear ring area with
Stellite. The casing wear-rings also have a Stellite overlay, ensuring excellent concentricity and
wear properties.

Bearing System
The bearing system of the pump and gearbox output shaft as shown by the conceptual drawing is
combined both for thrust and radial bearings.
The bearings are selected based on our bearing computer calculation program developed by
Advanced Bearing Technology Ltd. Both for the radial- and thrust bearing compensated tilting
pad bearings are selected for worst case load parameters.
The large diameter radial bearings ensure optimum load bearing capacities and vibration levels
within recognized standards.

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 TECHNICAL DESCRIPTION Date: 26. Jan. -01
Rev.: 30. May.-02

FRAMO WATER INJECTION PUMP Sign.: RB

The conceptual solution with the two single impellers back to back, allows hydraulic balancing of
the impellers to cater for varieties in thrust due to wear and running in off- duty conditions. The
thrust bearings have, however, been designed with good margins even for worst case conditions.

Mechanical Seals
The water injection pump utilize double mechanical seals with an integrated barrier fluid system.
The barrier fluid protects the gear box from any leakage from the process fluid.
The mechanical seals are working against a differential pressure of 10-15 bar and are
overpressurized by a closed loop barrier system. This means that a controlled leakage from the
barrier fluid always will be present, giving optimum operation conditions for the seals. In addition
to give enhanced protection of the gear-box, the barrier fluid system also monitiors the condition
of the seals, that is, high leakage from the seals will be detected giving alarm and trip levels. The
barrier fluid is usually a water-glycol mixture.
The seal materials selected are carbon on the flexible static seal and silicon carbide on the
dynamic seal half. Between the mechanical seal and the gear box, a chamber drained to
atmospheric pressure ensures that no water or barrier fluid should enter the gear box even if one
of the seals should fail and also to drain the small amount of barrier fluid leakage. This chamber is
also sealed by a labyrinth seal against the gear box side.

Lube Oil System

In accordance with philosophy of a compact water injection pump, the lube system is combined
for the pump and gear units, and integrated into the gearbox.
The integrated design eliminates the use of lube oil return pipe work from the pump bearings, and
also simplifies the total lube oil feed pipe work and valving.
A benefit of this integration is that the overall skid can be made considerably smaller, which
further adds to the reduction in weight of the pump unit.
The lube oil system can also be used for combined lubrication of the pump and driver unit.
To give optimum lubrication conditions, the lube oil is continuously cooled and filtered.

Service / Maintenance
From the illustration on next page it can be seen that the access to the rotating wear and tear
parts of the pump is very easy and that the pump thereby offers features of simple maintenance
procedures, minimum of service space and lay down areas.

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 TECHNICAL DESCRIPTION Date: 26. Jan. -01
Rev.: 30. May.-02

FRAMO WATER INJECTION PUMP Sign.: RB

Mechanical seal
Pumping ring
Wear ring
Impeller
Impeller nut

Suction cover

nd
Explode view of the 2 stage wear and tear parts

It should also be noted that the weights involved for dismantling of the rotating parts are small
compared to a conventional pump, e.g.:

Cartridge of barrel pump: approx. 3500 kg

One impeller of high speed pump: approx. 10 - 20 kg.

This, together with the quick in-situ impeller exchange feature of the pump, opens for an all new
maintenance- and pump availability philosophy.
It has been demonstrated that the exchange of one impeller and mechanical seal can be carried
out in less than two hours from pump shutdown until the pump is back on line.

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