77
USER CASE STUDY ABSTRACT 20 th International Pump Users Symposium TITLE: Reliability Improvement of End Suction Pump in Severe Service through Engineered Component Upgrade ABSTRACT: An end suction pump for amine service at an Ammonia plant was successfully upgraded by improvement of its components. Two 290 kW (390 HP) pumps, turbine/motor driven, rated for 262 m 3 /hr (1,153 gpm) and 271 m (889 ft), operate in severe service conditions due low NPSHA and part-load operation. The equipment exhibited rough operation with high vibration and an elevated repair frequency by recurrent fatigue failure of shaft, severe wear ring rubs, impeller corrosion/erosion, mechanical seal leakage and bearing damages.. After a catastrophic failure, involving pump and electric motor, that caused an emergency plant shutdown, an upgrade for the pumps was engineered. The objective was to overcome design weaknesses and incorporate features to increase reliability. Impeller deficiencies were identified and corrected and its metallurgy improved to endure severe cavitation/recirculation damage. The power end was completely redesigned, incorporating larger shaft and bearing housing stiffness, together with a material upgrade, oversized bearings and lubrication enhancements. As a result, a failure frequency as large as 9 a year has been eliminated since the upgrade and the pump presently accumulates 3 years of continuous operation. An outstanding improvement in reliability was obtained together with considerable savings in investment & maintenance costs. AUTHOR: César A. Morales Casanova Rotating Equipment Specialist PDVSA – Pequiven Morón Petrochemical Complex Edo. Carabobo Venezuela

Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

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A Case Study presented at the 20th International Pump Users Symposium, Houston, TX, USA.March, 2003

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Page 1: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

USER CASE STUDY ABSTRACT 20th International Pump Users Symposium

TITLE: Reliability Improvement of End Suction Pump in Severe Service through Engineered Component Upgrade ABSTRACT: An end suction pump for amine service at an Ammonia plant was successfully upgraded by improvement of its components. Two 290 kW (390 HP) pumps, turbine/motor driven, rated for 262 m3/hr (1,153 gpm) and 271 m (889 ft), operate in severe service conditions due low NPSHA and part-load operation. The equipment exhibited rough operation with high vibration and an elevated repair frequency by recurrent fatigue failure of shaft, severe wear ring rubs, impeller corrosion/erosion, mechanical seal leakage and bearing damages.. After a catastrophic failure, involving pump and electric motor, that caused an emergency plant shutdown, an upgrade for the pumps was engineered. The objective was to overcome design weaknesses and incorporate features to increase reliability. Impeller deficiencies were identified and corrected and its metallurgy improved to endure severe cavitation/recirculation damage. The power end was completely redesigned, incorporating larger shaft and bearing housing stiffness, together with a material upgrade, oversized bearings and lubrication enhancements. As a result, a failure frequency as large as 9 a year has been eliminated since the upgrade and the pump presently accumulates 3 years of continuous operation. An outstanding improvement in reliability was obtained together with considerable savings in investment & maintenance costs. AUTHOR: César A. Morales Casanova Rotating Equipment Specialist PDVSA – Pequiven Morón Petrochemical Complex Edo. Carabobo Venezuela

Page 2: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

20th International Pump Users SymposiumMarch 17-20, 2003. Houston, Texas

César A. Morales CasanovaRotating Equipment SpecialistPDVSA - PequivenEdo. Carabobo - Venezuela

®

RELIABILITY IMPROVEMENTOF END SUCTION PUMP

IN SEVERE SERVICETHROUGH ENGINEERED COMPONENT

UPGRADE

Page 3: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

CONTENTS• Objective• Conditions of service – Amine recovery system• Pump failures

Experience of continued low reliabilityProblem areas – Original designRemedial actions – Historical review 1980 – 1997Catastrophic failure – 1998

• Preliminary analysis – Recurrent pump failures• Problem analysis

Factors associated to low reliabilityCorrelation of causes for low reliability

• Pump upgradeObjectivesAreas of attentionSummary of main improvements

• Upgraded pump testObjectivesResults of performance testingTest conclusions

• Upgrade resultsCost – lead time comparisonCurrent upgrade progress – end 2002Reliability improvement

• Conclusions• Lessons learned• References

Page 4: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

OBJECTIVE

The solution can be used as a reference to yield better mechanical performance of existing equipment in similar services.

A successful experience of reliability improvement of two process pumps, through the application of a cost-effective, “in-house” engineered component upgrade is presented.

Page 5: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

SITUATION OVERVIEW

PUMP RATINGS:

Q : 262 m3/hr (1,153 GPM)

H : 271 m (889 ft)

N : 3550 RPM

P : 290 kW (390 HP)

MAIN PUMP “A”

Turbine Driven

STAND-BY PUMP “B”

Motor Driven

FCV

PCV

PC-752A/B

C-754 C-752

AMINE RECOVERY SERVICE

Page 6: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

0123456789

10

1995 1996 1997 1998 1999

PC-752B

PC-752A

High VibrationLow CapacityProduct Leakage

ImpellerWear Rings ShaftBearingsMechanical Seal

OPERATION PROBLEMS:

FAILED COMPONENTS:

EXPERIENCE OF CONTINUED LOW RELIABILITY

Page 7: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

PROBLEM AREAS - ORIGINAL DESIGN

Page 8: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

WEAR RINGS

PROBLEM AREAS - ORIGINAL DESIGN

Page 9: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

SEVERE RUBBING AT WEAR RINGS - 1996

PROBLEM AREAS - ORIGINAL DESIGN

Page 10: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

SHAFT

PROBLEM AREAS - ORIGINAL DESIGN

WEAR RINGS

Page 11: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

SHAFT FAILURE AT IMPELLER END - 1992

PROBLEM AREAS - ORIGINAL DESIGN

Page 12: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

IMPELLER

PROBLEM AREAS - ORIGINAL DESIGN

SHAFT

WEAR RINGS

Page 13: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

SEVERE IMPELLER FAILURE - 1992

EROSION W/R RUB

PROBLEM AREAS - ORIGINAL DESIGN

Page 14: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

MECH. SEAL

PROBLEM AREAS - ORIGINAL DESIGN

IMPELLER

SHAFT

WEAR RINGS

Page 15: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

BEARINGS

PROBLEM AREAS - ORIGINAL DESIGN

MECH. SEALIMPELLER

SHAFT

WEAR RINGS

Page 16: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

5313 thrust bearing replaced by 7313Bearings

Trimming of vanes at inletImpeller1997

Impeller trim to pump “B”Impeller1996

Incorporation of 3 partial vanesImpeller1995

Increase in wear ring clearancesWear Rings1994

Impeller capscrew replaced by a nutShaft1992

Local manufacture of impellersImpeller1991

Impeller capscrew replaced to fine thread Shaft1986

Installed pins between shroudsImpeller1980

ACTIONCOMPONENTYEAR

Page 17: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

YEAR COMPONENT DESCRIPTION

1980 Impeller Installed pins between shrouds

Page 18: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

PINS INSTALLED BETWEEN IMPELLER SHROUDS

1980

Page 19: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

YEAR COMPONENT DESCRIPTION

1980 Impeller Installed pins between shrouds

1986 Shaft Impeller capscrew replaced to fine thread

Page 20: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

CAPSCREW M 24 NC TO NF

1986

Page 21: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

YEAR COMPONENT DESCRIPTION

1980 Impeller Installed pins between shrouds

1986 Shaft Impeller capscrew replaced to fine thread

1991 Impeller Local manufacture of impellers

1992 Shaft Impeller capscrew replaced by a nut

Page 22: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW1992

CAPSCRW M 24 NF

IMPELLER NUT M 38 NF

Page 23: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

SHAFT FAILURE AT IMPELLER END - MAY 1999

Pump “B”

Page 24: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

YEAR COMPONENT DESCRIPTION

1980 Impeller Installed pins between shrouds

1986 Shaft Impeller capscrew replaced to fine thread

1991 Impeller Local manufacture of impellers

1992 Shaft Impeller capscrew replaced by a nut

1994 Wear Rings Increase in wear rings running clearance

1995 Impeller Incorporation of 3 partial vanes

Page 25: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW1995

IMPELLER PATTERN WITH 3 PARTIAL VANES ADDED

EROSION CONTINUED

Page 26: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

YEAR COMPONENT DESCRIPTION

1980 Impeller Installed pins between shrouds

1986 Shaft Impeller capscrew replaced to fine thread

1991 Impeller Local manufacture of impellers

1992 Shaft Impeller capscrew replaced by a nut

1994 Wear Rings Increase in wear rings running clearance

1995 Impeller Incorporation of 3 partial vanes

1996 Impeller Impeller trim to pump “B”

Page 27: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW1996

200

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320

340

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H [m

]

640

700

760

820

880

940

1000

1060

1120

0 200 400 600 800 1000 1200 1400 Q [GPM]

H [f

t]

Publ Head

RATEDPOINT

OPERATINGRANGE

BEP

3550 rpm φ 385 mm

200

220

240

260

280

300

320

340

0 50 100 150 200 250 300 350Q [m3/hr]

H [m

]

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700

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H [f

t]

Publ Head

RATEDPOINT

OPERATINGRANGE

BEP

3550 rpm φ 385 mm

IMPELLER TRIM OF STAND-BY PUMP “B”

200

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340

0 50 100 150 200 250 300 350Q [m3/hr]

H [m

]

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0 200 400 600 800 1000 1200 1400 Q [GPM]

H [f

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Publ HeadCorr Head

RATEDPOINT

OPERATINGRANGE

BEP

3550 rpm φ 385 mm

200

220

240

260

280

300

320

340

0 50 100 150 200 250 300 350Q [m3/hr]

H [m

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H [f

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Publ HeadCorr Head

RATEDPOINT

OPERATINGRANGE

BEP

3550 rpm φ 385 mm

PUMP “A” Imp φ385 mm @ 3200 rpm

PUMP “B” Imp φ348 mm @ 3550 rpm

PROCESS FLOW NOT REACHED

30%

Page 28: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW1996

IMPELLER TRIM OF STAND-BY PUMP “B”

PUMP “B” Imp φ370 mm @ 3550 rpm

200

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0 50 100 150 200 250 300 350Q [m3/hr]

H [m

]

640

700

760

820

880

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1000

1060

1120

0 200 400 600 800 1000 1200 1400 Q [GPM]

H [f

t]

Publ HeadCorr Head

RATEDPOINT

OPERATINGRANGE

BEP

3550 rpm φ 385 mm

200

220

240

260

280

300

320

340

0 50 100 150 200 250 300 350Q [m3/hr]

H [m

]

640

700

760

820

880

940

1000

1060

1120

0 200 400 600 800 1000 1200 1400 Q [GPM]

H [f

t]

Publ HeadCorr Head

RATEDPOINT

OPERATINGRANGE

BEP

3550 rpm φ 385 mm

CAVITATION

PUMP “B” Imp φ370 mm @ 3550 rpm

Page 29: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

YEAR COMPONENT DESCRIPTION

1980 Impeller Installed pins between shrouds

1986 Shaft Impeller capscrew replaced to fine thread

1991 Impeller Local manufacture of impellers

1992 Shaft Impeller capscrew replaced by a nut

1994 Wear Rings Increase in wear rings running clearance

1995 Impeller Incorporation of 3 partial vanes

1996 Impeller Impeller trim to pump “B”

1997 Impeller Trimming of vanes at inlet

Page 30: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW1997

VANE TRIM AT IMPELLER INLET TO REDUCE NPSHR

IMPROPERLY EFFECTED

Page 31: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW

YEAR COMPONENT DESCRIPTION

1980 Impeller Installed pins between shrouds

1986 Shaft Impeller capscrew replaced to fine thread

1991 Impeller Local manufacture of impellers

1992 Shaft Impeller capscrew replaced by a nut

1994 Wear Rings Increase in wear rings running clearance

1995 Impeller Incorporation of 3 partial vanes

1996 Impeller Impeller trim to pump “B”

1997 Impeller Trimming of vanes at inlet

Bearings 5313 thrust bearing replaced by 7313 BG

Page 32: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

REMEDIAL ACTIONS – HYSTORICAL REVIEW1997

THRUST BEARING UPGRADE FROM 3313 TO 7313 BG

Page 33: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP FAILURES

CATASTROPHIC FAILURE – PUMP “B”SEPT 1998

Page 34: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

SEPT 1999

Unsuccessful efforts to improve reliability.

Solutions mainly focused in the consequences rather than the causes for the problems.

Improper procedures contribute to failures.

Complex problem with multiple correlated causes and failure modes.

Global solution required.

RECURRENT PUMP FAILURES

PRELIMINARY ANALYSIS

Page 35: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

SEPT 1999FACTORS ASSOCIATED TO LOW RELIABILTY

OPERATIONAL• Low NPSHA

Page 36: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

SUCTION CONDITIONS - 1999FACTORS ASSOCIATED TO LOW RELIABILTY

FCV

PCV

PC-752A/B

C-754 C-752

PLUGGING OF PLATE COOLER

INOP. FILTER

TEMP INCREASE & REDUCTION OF SUCTION

PRESSURE MEA RECOVERY SYSTEM

Page 37: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

SUCTION CONDITIONS - 1999FACTORS ASSOCIATED TO LOW RELIABILTY

4.00 ?[m]

[m]

[m3/hr]

[kg/cm2 g]

[kg/cm2 a]

[ºC]

NONE

4.00 ?

2.45 – 5.90

200 – 220

0.25 – 0.60

99

30% MEA

MEASURED

INSUFFICIENT38%NPSH MARGIN

6.50NPSH R

4.909.00NPSH A

200 – 220228 – 262Flow

0.500.60Suct. Press.

1.050.78VP

1.0150.965SG

95 – 9992Temp

30% MEA20% MEAFluid

REVISED 1997DESIGN

Page 38: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

SUCTION CONDITIONS - 1999FACTORS ASSOCIATED TO LOW RELIABILTY

13.1 ?[ft]

[ft]

[GPM]

[psia]

[psia]

[F]

NONE

13.1 ?

8.0 – 19.3

880 – 970

3.5 – 8.5

210

30% MEA

MEASURED

INSUFFICIENT38%NPSH MARGIN

21.3NPSH R

16.029.5NPSH A

880 – 9701000 – 1153Flow

7.18.5Suct. Press.

14.911.1VP

1.0150.965SG

203 – 210198Temp

30% MEA20% MEAFluid

REVISED 1997DESIGN

Page 39: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

SEPT 1999FACTORS ASSOCIATED TO LOW RELIABILTY

OPERATIONAL• Low NPSHA• Part load operation

Page 40: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

PART LOAD OPERATION - 1999FACTORS ASSOCIATED TO LOW RELIABILTY

EVIDENCES OF RECIRCULATION AT DISCHARGE

EROSION & SHROUD

SEPARATION

Page 41: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

SEPT 1999FACTORS ASSOCIATED TO LOW RELIABILTY

OPERATIONAL• Low NPSHA• Part load operation• Process disturbances

(flow/pressure surges)

MAINTENANCE• Inoperative pipe supports

- Transmission of pipe forces- Excessive deflection

MAY MAY CONTINUECONTINUE

Page 42: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

MAINTENANCE PROBLEMS - 1999FACTORS ASSOCIATED TO LOW RELIABILTY

INOPERATIVE PIPE SUPPORTS

Page 43: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

SEPT 1999FACTORS ASSOCIATED TO LOW RELIABILTY

OPERATIONAL• Low NPSHA• Part load operation• Process disturbances

(flow/pressure surges)

MAINTENANCE• Inoperative pipe supports

- Transmission of pipe forces- Excessive deflection

• Improper procedures

MAY MAY CONTINUECONTINUE

EASILY EASILY CORRECTEDCORRECTED

Page 44: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

SEPT 1999FACTORS ASSOCIATED TO LOW RELIABILTY

MANUFACTURING DEFICIENCIES• Shaft (own shop)• Impeller (local mfr)

DESIGN WEAKNESSES • Dated 1969• Hydraulics• Component Stiffness• Choice of Materials

PUMPUPGRADE

PUMPPUMPUPGRADEUPGRADE

Page 45: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PROBLEM ANALYSIS

CORRELATION OF CAUSES FOR LOW RELIABILITY

• IMPELLER

• WEAR RINGS

• SHAFT

• BEARINGS

• MECH. SEAL

EXPECTED FAILURE

DESIGN

• Improper part. vane position• Insufficient shaft fillet radii

MANUFACTURE

• Inoperative pipe supports• Improper wear ring materials

• Improper vane trim at inlet

• Plugged Filters / Coolers• Too low NPSHA

• Part load operation

• Process disturbances

NOTICEABLE EFFECTSCONSEQUENCESIMMEDIATE

EFFECTSMAIN CAUSES

• Deficiencies in hydraulics• Insufficient stiffness

• Inadequate shaft end design

• Choice of materials

• VIBRATION INCREASE

• NOISE

• LOSS OF CAPACITY

• SEAL LEAKAGEMAINTENANCE

• IMPELLER EROSION

• IMBALANCE

• LARGE LOADS

• LARGE STRESSES

• LARGE DEFLECTIONS

• SEVERE RUBS

• LOSS OF RUNNING CLEARANCES

• SHAFT FATIGUE

• LOSS OF FUNCTION

• CAVITATION

• INTERNAL RECIRCULATION

• TURBULENCE

• VIBRATION

• INCREASE OF NPSHR

• PIPE FORCES

• STRESS RISERS

• INSUFFICIENT MAT PROPERTIES

• MAT OF SIMILAR GALLING TENDENCY

OPERATION

Page 46: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

IMPLEMENTATION OF SOLUTIONS

Identify & solve design weaknesses.Correct component manufacturing deficiencies.Incorporate modifications for improved reliability.Withstand tough operating conditions with low NPSHA.Manufacture of new parts, pump refurbishment, stand testing & performance adjustment to requirements by a qualified supplier.

OBJECTIVES:

Page 47: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

AREAS OF ATTENTION

Page 48: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

AREAS OF ATTENTION

IMPELLER

Page 49: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

IMPELLER IMPROVEMENT

VANE CORRECTIONS

BEFORE AFTER

Page 50: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

IMPELLER IMPROVEMENT

VANE LEADING EDGE / MATERIAL IMPROVEMENT

BEFORE

AFTER

18Cr-16Mn

NEW

AISI 304

ORIGINAL

MANUFACTURING MATERIAL:

Page 51: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

AREAS OF ATTENTION

IMPELLER

WEAR RINGS

Page 52: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

WEAR RINGS IMPROVEMENT

MANUFACTURING MATERIALS:

ALT 2ALT 1

18Cr-16Mn

AISI 304 + Cr. Plating

AISI 304

18Cr-16Mn

NEW

AISI 304AISI 304CASING

AISI 304AISI 304 Stellitted

IMPELLER

IN USE (1999)DESIGN

WEAR RINGS MATERIALS

Page 53: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

AREAS OF ATTENTION

SHAFT

IMPELLER

WEAR RINGS

Page 54: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

SHAFT IMPROVEMENT

API 610 Ed.

[in]

[in]

86%– 20%14%39%–Improvement

18.4433024.734.3L3 / D42.440

11.50

MFR 3 8th APPLIED

2.625

11.25

2.953

11.18

MFR 2 8th

2.9372.480D

12.2510.91L

SAME MFR 7th

DESIGN (1969)

SHAFT FLEXIBILITY COMPARISON

L

D

Page 55: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

SHAFT IMPROVEMENT

SHAFT END / MATERIAL IMPROVEMENT

AISI 420

NEW

AISI 304

ORIGINAL

MANUFACTURING MATERIAL:

R 1/4”R 5/32”

INCREASED TO M48x2 FROM M38x2

R 1/32”

KEYWAY CORNER RADIUS

Page 56: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

AREAS OF ATTENTION

IMPELLER

WEAR RINGS

BEARING HOUSING

PUMP UPGRADE

SHAFT

Page 57: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

BEARING HOUSING IMPROVEMENT

A216 WCB

NEW

CAST IRON

ORIGINAL1” NEW

5/8” ORIGINAL

Page 58: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

BEARING HOUSING IMPROVEMENT

IMPROVED BEARING HOUSING

Page 59: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

AREAS OF ATTENTION

BEARINGS & LUBRICATION

PUMP UPGRADE

IMPELLER

WEAR RINGS

BEARING HOUSING

SHAFT

Page 60: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

BEARINGS & LUBRICATION IMPROVEMENT6216 M

HSG BORE TOL: +0,06 / +0,04 mm

FINISH GROUND

7314 BECBMHSG BORE TOL:

+0,045 / +0,025 mm

Page 61: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

AREAS OF ATTENTION

PUMP UPGRADE

STUFF. BOX COOLING

BEARINGS & LUBRICATION

IMPELLER

WEAR RINGS

BEARING HOUSING

SHAFT

Page 62: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

PUMP UPGRADE

SUMMARY OF MAIN IMPROVEMENTS

AFTERBEFORE

18 Cr-16 Mn / AISI 304

AISI 304 + Cr / 18Cr-16 Mn

ROUNDED & THINNED IN PTRN• VANE LEADING EDGES (ALL)

DISC PACK / NON-LUBR.GEAR/LUBRICATEDCOUPLING

YESNO• STUFF. BOX COOLINGMECH. SEAL

ENHANCED / CIRCULATINGLUBRICATION

6216 M / 7314 BGM6215 / 7313 BG• RADIAL / THRUSTBEARINGS

CAST STEEL A216 WCBCAST IRON• MATERIAL

25 mm (1.0”)16 mm (5/8”)• THICKNESS AT TRANSITION PIECEBEARING HSG

AISI 420AISI 304• MATERIAL

1/4” AT END / 1/32” AT KW

M48 + FILLET RADIUS 5/32”

18.4

2

1

18 Cr – 16 Mn

TRIMMED IN PATTERN

EXTENDED & CORRECTED

3/32” AT END / SHARP KW• RADII AT SHOULDERS / CORNERS

M38 + FILL. RAD. 3/32”• END THREAD SIZE / FILLET RADIUS

34.3• L3/D4

SHAFT

AISI 304 / AISI 304• IMPELLER / CASINGWEAR RINGS

AISI 304• MATERIAL

IMPROPER TRIM• MAIN VANES AT INLET

MISPOSITIONED• PARTIAL VANES

IMPELLER

Page 63: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADED PUMP TEST

STAND-TESTING OF UPGRADED PUMP

Determine actual performance for modified impeller.

Quantify actual NPSHR.

Reduce effects of adverse operating conditions:

OBJECTIVES:

• Trim impeller of pump “B” to reduce part load operation.

• Rework impeller, if required, to help prevent cavitation.

Guarantee trouble-free operation at the plant.

Page 64: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

200

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H [f

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Publ HeadTest Head

ORIGINAL RATEDPOINT

BEP

REVISED RATEDPOINT

BEP

OPERATINGRANGE

3550 rpm φ 385 mm

200

220

240

260

280

300

320

340

0 50 100 150 200 250 300 350Q [m3/hr]

H [m

]

640

700

760

820

880

940

1000

1060

1120

0 200 400 600 800 1000 1200 1400 Q [GPM]

H [f

t]

Publ HeadTest Head

ORIGINAL RATEDPOINT

BEP

REVISED RATEDPOINT

BEP

OPERATINGRANGE

3550 rpm φ 385 mm

UPGRADED PUMP TEST

RESULTS OF PERFORMANCE TESTING

HEAD VS FLOW – FULL SIZE IMPELLER

Page 65: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADED PUMP TEST

RESULTS OF PERFORMANCE TESTING

PWR & EFF VS FLOW – FULL SIZE IMPELLER

0

100

200

300

400

500

0 50 100 150 200 250 300 350Q [m3/hr]

Pow

er [H

P]

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200 1400 Q [GPM]

η (%

)

Publ Pwr Test Pwr Publ Eff Test Eff

AVAILABLE MOTOR POWER

OPERATINGRANGE

0

100

200

300

400

500

0 50 100 150 200 250 300 350Q [m3/hr]

Pow

er [H

P]

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200 1400 Q [GPM]

η (%

)

Publ Pwr Test Pwr Publ Eff Test Eff

AVAILABLE MOTOR POWER

OPERATINGRANGE

Page 66: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADED PUMP TEST

RESULTS OF PERFORMANCE TESTING

HEAD VS FLOW – TRIMMED IMPELLER

200

220

240

260

280

300

320

340

0 50 100 150 200 250 300 350Q [m3/hr]

H [m

]

640

700

760

820

880

940

1000

1060

1120

0 200 400 600 800 1000 1200 1400 Q [GPM]

H [f

t]

Publ HeadTest Head

ORIGINAL RATEDPOINT

BEP

REVISED RATEDPOINT

OPERATINGRANGE

3550 rpm φ 385 mm

3550 rpm φ 350 mm

200

220

240

260

280

300

320

340

0 50 100 150 200 250 300 350Q [m3/hr]

H [m

]

640

700

760

820

880

940

1000

1060

1120

0 200 400 600 800 1000 1200 1400 Q [GPM]

H [f

t]

Publ HeadTest Head

ORIGINAL RATEDPOINT

BEP

REVISED RATEDPOINT

OPERATINGRANGE

3550 rpm φ 385 mm

3550 rpm φ 350 mm

Page 67: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADED PUMP TEST

RESULTS OF PERFORMANCE TESTING

NPSHR @ 220 m3/h (970 GPM) – TRIMMED IMPELLER

230

235

240

245

250

255

260

2 3 4 5 6 7 8 9 10NPSH [m]

H [m

]

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

6,5 11,5 16,5 21,5 26,5 31,5 NPSH [ft]

Suct

ion

pres

s @

ope

r. co

nd.

[kgf

/cm

² g]Test NPSH

Suct Press

3% DROP

60% MARGIN

MIN REQ'D = 0,50 kgf/cm² g

NPSHR 3% = 3,4 m (11 ft)

3550 rpm φ 350 mm

( 7,1 psig )

230

235

240

245

250

255

260

2 3 4 5 6 7 8 9 10NPSH [m]

H [m

]

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

6,5 11,5 16,5 21,5 26,5 31,5 NPSH [ft]

Suct

ion

pres

s @

ope

r. co

nd.

[kgf

/cm

² g]Test NPSH

Suct Press

3% DROP

60% MARGIN

MIN REQ'D = 0,50 kgf/cm² g

NPSHR 3% = 3,4 m (11 ft)

3550 rpm φ 350 mm

( 7,1 psig )

Page 68: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADED PUMP TEST

TEST CONCLUSIONS

Performance of modified impeller was determinedHead: Larger due to partial vanesBEP: Coincident at 300 m3/hr (1320 GPM)Efficiency: Coincident with originalNPSHR: 15% lower than expected

Adjustments for revised conditions of service:

Pump “A”: Full-size impeller @ 3150 rpmPump “B”: 91% dia impeller @ 3550 rpm

Min suct. press.: 0.5 kgf/cm² g (7.1 psig)Required NPSH Margin: 60%

Page 69: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADED PUMP “A”

PUMP IN SERVICE – MAY 2000

MAIN PUMP INSTALLED SEPT 1999

Page 70: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADED PUMP “A”

PUMP IN SERVICE – MARCH 2002

MAIN PUMP INSTALLED SEPT 1999

Page 71: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADE RESULTS

COST – LEAD TIME COMPARISON

11 MONTH FINISHED

11 MONTH ON SITE

$ 5,0 K$ 5,0 K

$ 17,0 K$ 12,0 K

$ 39 K

$ 3,0 K$ 90,0 K

$ 5,0 K$10,0 K

$ 108 K

COST & LEAD TIMEPROS - CONS

• ENGINEERING• BRG HSG PATTERN• MAIN PARTS• MFG, ASSY & TEST

TOTAL:

No field work required Less cost

PUMPUPGRADE

• ENGINEERING• 1 PUMP & DRIVER• 2 YR SPARE PARTS• FOUND. & PIPING

TOTAL:

Field work required Larger cost

PUMP REPLACEMENT

Page 72: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADE RESULTS

CURRENT UPGRADE PROGRESS – END 2002

MAIN PUMP “A”Fully upgraded

STAND-BY PUMP “B”Partially upgraded

• Impeller & wear rings• Shaft end design & material

Impeller size increased from 91% to 96% (370 mm)• Flow requirement not reached• Measured suct. press.: ≈ 0.25 kgf/cm² g (3.6 psig)• Full cavitation, NPSH margin < 0

Page 73: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

UPGRADE RESULTS

RELIABILITY IMPROVEMENT – END 2002

0123456789

10

1995 1996 1997 1998 1999 2000 2001 2002

PC-752B

PC-752A UPGRADE "A"

0123456789

10

1995 1996 1997 1998 1999 2000 2001 2002

PC-752B

PC-752A UPGRADE "A"

FAILURE HISTORY BEFORE AND AFTER THE UPGRADE

MAIN PUMP “A”

Fully upgradedNo failures

STAND-BY PUMP “B”

Partially upgradedFailures at brgs & seal only

Projected savings over 10 years: US$ 900 K

Page 74: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

CONCLUSIONS

Pump upgrade objectives were successfully achieved.Upgrade of existing pump was the best choice for a cost-effective solution.In-house engineering allowed a custom design with some features exceeding current mfr. specs.Impeller revised configuration is not an optimum solution, but provided a remarkable service life improvement.Detected design deficiencies played an important role on low reliability, but not on catastrophic failures.

Page 75: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

LESSONS LEARNED

In general, improvement of existing equipment represents lower investment and lead time.Check your equipment for upgrade opportunities, specially if they exhibit low reliability.

Page 76: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

REFERENCES

RELIABILITY IMPROVEMENT OF END SUCTION PUMP IN SEVERE SERVICE THRU ENGINEERED COMPONENT UPGRADE

Mc. Caul, Colin. An Advanced Cavitation Resistant Austenitic Steel for Pumps. Corrosion 96, The NACE International Annual Conference and Exposition. Paper Nº 415, 1996.

Bloch, Heinz P. Improving Machinery Reliability. 2nd Edition. 1988. Gulf Publishing Company

Bloch, Heinz P. Pump Reliability Improvement Program. Pump Failure Reduction Programs. PRIME Seminar notes

J.F. Gülich. Selection criteria for suction impellers of centrifugal pumps. Part 1: The suction specific speed – a criterion for flow recirculation and pump reliability ?, Sulzer Pumps Ltd, PO Box, CH-8400 Winterthur, Switzerland.

Summers-Smith, J.D. A Tribology Casebook. P.83. Mechanical Engineering Publications London and Bury St. Edmunds, 1997.

Pfleiderer, Carl. Bombas Centrífugas y Turbocompresores. Editorial Labor, 1960.

Page 77: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade

THANK YOU !

20th International Pump Users SymposiumMarch 17-20, 2003. Houston, Texas

®