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Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps:Pumps:
Failure Modes Failure Modes and and Ways Ways toto
Investigate the Investigate the CauseCause
Dr. Juergen Dr. Juergen WeinerthWeinerthFriatecFriatec -- Rheinhuette GmbH & Co. KGRheinhuette GmbH & Co. KG
RheingaustrasseRheingaustrasse 96 96 –– 989865203 Wiesbaden, Germany65203 Wiesbaden, Germany
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
FRIATEC-Rheinhütte GmbH & Co.KGRheingaustraße 96-98D-65203 WiesbadenGermany
Founded in 1857 as an iron foundry
Tel.: +49 - (0) 611 - 604 - 0Fax: +49 - (0) 611 - 604 - 328
Webpage: www.rheinhuette.deEmail: info@rheinhuette.de
24h Service: +49 - (0) 172 -7 25 98 51Email service: service@rheinhuette.de
Employees: 280Turnover: EURO 42 Mio.
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Standardized chemical pumps
Magnetic drivepumps
Chemical pumps in heavy duty design
Circulation pumps Vertical chemical pumps
Liquid ring vacuum pump
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Quote Quote from from HansHans--Jürgen BittermannJürgen Bittermannofof Process TechnologiesProcess Technologies: :
Wrong operation and wrong selectioncauses 90 to 95 per cent of pump failures!
Problems can only be avoided if it is understood what caused them!
17.12.2007
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Broken shaft at the coupling end of a vertical pump
Damaged submerged bearings of a vertical pump
Cracked mechanical seal of a axial flow propeller pump
Abnormal increased spare part consumption
Some more pictures...
Case ExamplesCase Examples
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Wrong Operation
Broken Shaft at the Coupling End of a Vertical Pump
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Vertical Pumpfor Hot SulphuricAcid
QPump = 600m³/hH = 30m
99,5% H2SO4T = 220°C
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Complete Metallurgical Analysis of the Shaft
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Wrong Process Operation
Damaged submerged bearings of a vertical pump
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Vertical Pumpfor Ammonium NitrateSolution
QPump = 55m³/hH = 39mT = 157°CNPSHA = 3,5mNPSHR = 3,0m
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Incorrect Operating Data
Cracked Mechanical Seal ofan Axial Flow Propeller Pump
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Axial Flow Propeller Pump QPump = 6000m³/hDN 700 for 9% Phosphoric H = 7mAcid T = 130°CMaterial Alloy 825 (2.4858) P = 13 bar
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Information from the customer:
-Propeller did not turn anymore-Leackage at the mechanical seal
After site inspection:
-Cracked seal ring on atmospheric side-Pump has to be operated at 170°C!
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Abnormal High Spare Part Consumption
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Fertilizer Plant in Norway
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Various horizontal heavy duty chemicalpumps
Nitric andPhosphoric Acid
T up to 135°C
Pumps have been running over 10 years, since 2 years increasedspare part consumption
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Step 1: List of the 5 Items with the highest spare part consumtion(according to the customer)
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Step 2: Preparation of a specific questionnaire sheet
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Information such as:
•Serial-Number•Installed Impeller Diameter•Information Regarding the Fluid•Current Operating Conditions•Pipe Layout
Step 3: Collect information on the plant site
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Analysis:
•Original Data Sheet•Compare the ProvidedInformation•Analysis of the Duty Point
Step 4: Analysis of the information
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Step 5: Current and differential pressure measurements
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Step 6: Analysis of the result and plant visit
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Some more Pictures...
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
Pumps: Failure Modes and Ways to Investigate the Cause
AIChE Clearwater Convention 2009; Dr. Jürgen Weinerth
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