reliability improvement of end-suction pump through engineered component upgrade
DESCRIPTION
A Case Study presented at the 20th International Pump Users Symposium, Houston, TX, USA.March, 2003TRANSCRIPT
![Page 1: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/1.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/2.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/3.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/4.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/5.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/6.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/7.jpg)
PUMP FAILURES
PROBLEM AREAS - ORIGINAL DESIGN
![Page 8: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/8.jpg)
PUMP FAILURES
WEAR RINGS
PROBLEM AREAS - ORIGINAL DESIGN
![Page 9: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/9.jpg)
PUMP FAILURES
SEVERE RUBBING AT WEAR RINGS - 1996
PROBLEM AREAS - ORIGINAL DESIGN
![Page 10: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/10.jpg)
PUMP FAILURES
SHAFT
PROBLEM AREAS - ORIGINAL DESIGN
WEAR RINGS
![Page 11: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/11.jpg)
PUMP FAILURES
SHAFT FAILURE AT IMPELLER END - 1992
PROBLEM AREAS - ORIGINAL DESIGN
![Page 12: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/12.jpg)
PUMP FAILURES
IMPELLER
PROBLEM AREAS - ORIGINAL DESIGN
SHAFT
WEAR RINGS
![Page 13: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/13.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/14.jpg)
PUMP FAILURES
MECH. SEAL
PROBLEM AREAS - ORIGINAL DESIGN
IMPELLER
SHAFT
WEAR RINGS
![Page 15: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/15.jpg)
PUMP FAILURES
BEARINGS
PROBLEM AREAS - ORIGINAL DESIGN
MECH. SEALIMPELLER
SHAFT
WEAR RINGS
![Page 16: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/16.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/17.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/18.jpg)
PUMP FAILURES
REMEDIAL ACTIONS – HYSTORICAL REVIEW
PINS INSTALLED BETWEEN IMPELLER SHROUDS
1980
![Page 19: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/19.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/20.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/21.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/22.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/23.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/24.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/25.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/26.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/27.jpg)
PUMP FAILURES
REMEDIAL ACTIONS – HYSTORICAL REVIEW1996
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 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 Head
RATEDPOINT
OPERATINGRANGE
BEP
3550 rpm φ 385 mm
IMPELLER TRIM OF STAND-BY PUMP “B”
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
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
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/28.jpg)
PUMP FAILURES
REMEDIAL ACTIONS – HYSTORICAL REVIEW1996
IMPELLER TRIM OF STAND-BY PUMP “B”
PUMP “B” Imp φ370 mm @ 3550 rpm
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
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/29.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/30.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/31.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/32.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/33.jpg)
PUMP FAILURES
CATASTROPHIC FAILURE – PUMP “B”SEPT 1998
![Page 34: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/34.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/35.jpg)
PROBLEM ANALYSIS
SEPT 1999FACTORS ASSOCIATED TO LOW RELIABILTY
OPERATIONAL• Low NPSHA
![Page 36: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/36.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/37.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/38.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/39.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/40.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/41.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/42.jpg)
PROBLEM ANALYSIS
MAINTENANCE PROBLEMS - 1999FACTORS ASSOCIATED TO LOW RELIABILTY
INOPERATIVE PIPE SUPPORTS
![Page 43: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/43.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/44.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/45.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/46.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/47.jpg)
PUMP UPGRADE
AREAS OF ATTENTION
![Page 48: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/48.jpg)
PUMP UPGRADE
AREAS OF ATTENTION
IMPELLER
![Page 49: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/49.jpg)
PUMP UPGRADE
IMPELLER IMPROVEMENT
VANE CORRECTIONS
BEFORE AFTER
![Page 50: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/50.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/51.jpg)
PUMP UPGRADE
AREAS OF ATTENTION
IMPELLER
WEAR RINGS
![Page 52: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/52.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/53.jpg)
PUMP UPGRADE
AREAS OF ATTENTION
SHAFT
IMPELLER
WEAR RINGS
![Page 54: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/54.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/55.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/56.jpg)
AREAS OF ATTENTION
IMPELLER
WEAR RINGS
BEARING HOUSING
PUMP UPGRADE
SHAFT
![Page 57: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/57.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/58.jpg)
PUMP UPGRADE
BEARING HOUSING IMPROVEMENT
IMPROVED BEARING HOUSING
![Page 59: Reliability Improvement of End-Suction Pump through Engineered Component Upgrade](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/59.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/60.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/61.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/62.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/63.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/64.jpg)
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
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/65.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/66.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/67.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/68.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/69.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/70.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/71.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/72.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/73.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/74.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/75.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/76.jpg)
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](https://reader034.vdocuments.site/reader034/viewer/2022051612/54bd05c24a7959d2058b4576/html5/thumbnails/77.jpg)
THANK YOU !
20th International Pump Users SymposiumMarch 17-20, 2003. Houston, Texas
®