PUMP RELIABILITY

IMPROVING PUMP RELIABILITY

Maintenance vs. Capital



What does a pump actually cost ? Most plants regard the pump as a commodity... purchased from the lowest bidder with little consideration for:  The operation and maintenance cost of the pump over its life cycle... which could be 20 - 30 years  Costs to be considered:  Spare parts (inventory costs)  Operation downtime (lost production)  Labor to repair (maintenance costs)  Power consumption based on pump efficiency  Environmental, disposal, and recycle costs

TRUE PUMP COSTS



Repair costs can easily exceed the price of a new pump (several times) over its life of 20 30 years Documented Pump failures cost Rs.2.00.000/- or more per incident ( parts and labor) If MTBF was improved from 1 to 2 years for a pump in a tough application  Results in savings of Rs. 1,00,000/- per year over the life of the pump

WHY PUMPS AND SEALS FAIL

MECHANICAL
Affects Bearings, Seals and Shafts -EXTERNAL
1. Operation off the BEP 2. Coupling Misalignment 3. Insufficient NPSH 4. Poor Suction and Discharge Piping Design 5. Pipe Strain / Thermal Expansion 6 Impeller Clearance 7. Foundation and Baseplate

ENVIRONMENTAL
Affects Wet End Components, Bearings and seals
1. High Temperature 2. Poor Lubrication / Oil Contamination 3. Corrosion 4. Erosion 5. Abrasion

-INTERNAL
1. Pump Design and Manufacturing Tolerances 2. Impeller Balance (Mechanical and Hydraulic) 3. Mechanical Seal Design

HOW ARE FAILURES INITIATED?

Installation
   

Piping system & Pipe Strain Alignment Mechanical Seal installation Foundation System: cavitation, dry running, shutoff Product changes: viscosity, S.G., temp. Seal controls: flush, cooling Pump, seal, metallurgy selection

Operational
  

Misapplication


RADIAL LOAD
Operation of a pump away from the BEP results in higher radial loads ... creating vibration and shaft deflection
H E A D B.E.P

FLOW

Radial Forces


By design, uniform pressures exist around the volute at the design capacity (BEP)


Resulting in low radial thrusts and minimal deflection.

Operation at capacities higher or lower than the BEP

Pressure distribution is not uniform resulting in radial thrust on the impeller  Magnitude and direction of radial thrust changes with capacity (and pump specific gravity)


SHAFT DEFLECTION
Most pumps do not operate at BEP:  Due to improper pump selection (oversized)  Changing process requirements (throttling)  Piping changes  Addition of more pipe, elbows and valves  System head variations  Change in suction pressure, discharge head reqd  Buildup in pipes  Filter plugged  Automatic control valve shuts off pump flow  Change in viscosity of fluid  Parallel operation problems (starving one pump

Impeller Radial Force

At Any Flow
F=KxHxSxD xB 2.31

F (lbs.,Kg)

K = THRUST FACTOR H = HEAD (ft, m) S = SPECIFIC GRAVITY D= IMPELLER DIAMETER (in.,cm) B = IMPELLER WIDTH (in., cm)

SPECIFIC SPEED - K vs. CAPACITY

0.5 Ns (SI) 0.4 3500 (71) 0.3 2000
(40)

1500 (27) 0.2 1000 (20) 0.1 500 (10) 0

20

40

60

80

100

120

140

160

PERCENT CAPACITY

PUMP SPECIFIC SPEED

CLASSIFIES IMPELLERS ON THE BASIS OF PERFORMANCE AND PROPORTIONS REGARDLESS OF SIZE OR SPEED  FUNCTION OF IMPELLER PROPORTIONS  SPEED IN RPM AT WHICH AN IMPELLER WOULD OPERATE IF REDUCED PROPORTIONALLY IN SIZE TO DELIVER 1 GPM AND TOTAL HEAD OF 1 FOOT  DESIGNATED BY SYMBOL Ns Ns = RPM(GPM)1/2 H3/4 RPM = SPEED IN REVOLUTIONS / MINUTE GPM = GALLONS /MINUTE AT BEST EFF. POINT H = HEAD IN FEET AT BEST EFF. POINT


PUMP SPECIFIC SPEED (Metric)

CLASSIFIES IMPELLERS ON THE BASIS OF PERFORMANCE AND PROPORTIONS REGARDLESS OF SIZE OR SPEED  FUNCTION OF IMPELLER PROPORTIONS  SPEED IN RPM AT WHICH AN IMPELLER WOULD OPERATE IF REDUCED PROPORTIONALLY IN SIZE TO DELIVER 1 M3/h AND TOTAL HEAD OF 1 M  DESIGNATED BY SYMBOL Ns Ns = RPM(m3/h )1/2 H3/4 RPM = SPEED IN REVOLUTIONS / MINUTE m3/h = CUBIC METERS / HOUR AT BEP H = HEAD IN METERS AT BEST EFF. POINT


PUMP TYPE VS. SPECIFIC SPEED

HEAD, POWER EFFICIENCY HEAD, POWER EFFICIENCY EFFICIENCY HEAD, POWER EFFICIENCY HEAD

POWER

CAPACITY

CAPACITY

CAPACITY

CENTRIFUGAL

VERTICAL TURBINE

AXIAL FLOW

SPECIFIC SPEED, ns (Single Suction)

10 20 40 60 120 200 300

SI US

500

1,000

2,000

3,000

6,000

10,000

15,000

RADIAL-VANE

FRANCIS-VANE

MIXED FLOW

AXIAL FLOW

RADIAL FORCES ON IMPELLER

BEP RADIAL LOAD

CUTWATER

125%
FLOW

BEP 100%

50%
% CAPACITY of BEP

150% SHUTOFF 0%
Length of Line = Force

THE IMPORTANCE OF ALIGNMENT

Any degree of misalignment between the motor and the pump shaft will cause vibration in the pump. Every revolution of the coupling places a load on the pump shaft and thrust bearing At 2900 RPM, there will be 2900 pulses per minute applied to the shaft and bearing

MISALIGNMENT
Pipe strain Thermal growth Poor foundation / base plate Improper initial alignment. System vibration / cavitation Soft foot on motor

NET POSITIVE SUCTION HEAD (NPSH)



NPSH (Net Positive Suction Head)



Pressure in terms of head above vapour pressure at the inlet / eye of the impeller is known as NPSH (Net Positive Suction Head) Pressure in terms of head above vapour pressure available at the inlet / eye of the impeller is known as NPSHA (Net Positive Suction Head Available)

NPSH available


NPSH


cont.

NPSH required


Pressure in terms of head above vapour pressure required at the inlet / eye of the impeller to avoid cavitation is known as NPSHR (Net Positive Suction Head Required)

NPSH available must always be > NPSH required by a minimum of 3-5 feet (1-1.5m) margin

CAVITATION
 

 

Results if the NPSH available is less than the NPSH required Occurs when the pressure at any point inside the pump drops below the vapor pressure corresponding to the temperature of the liquid The liquid vaporizes and forms cavities of vapor Bubbles are carried along in a stream until a region of higher pressure is reached where they collapse or implode with tremendous shock on the adjacent wall Sudden rush of liquid into the cavity created by the collapsed vapor bubbles causes mechanical destruction (cavitation erosion or pitting)

CAVITATION
  

cont.

Efficiency will be reduced as energy is consumed in the formation of bubbles Water @ 70oF (20oC)will increase in volume about 54,000 times when vaporized Erosion and wear do not occur at the point of lowest pressure where the gas pockets are formed, but farther upstream at the point where the implosion occurs Pressures up to 150,000 psi have been estimated at the implosion (1,000,000 Kpa)

RELATIVE PRESSURES IN THE PUMP SUCTION

E D A B C

ENTRANCE LOSS

FRICTION

TURBULENCE, FRICTION, ENTRANCE LOSS AT VANE TIPS

INCREASING PRESSURE DUE TO IMPELLER

POINT OF LOWEST PRESSURE WHERE VAPORIZATION STARTS

INCREASING PRESSURE

C
POINTS ALONG LIQUID PATH

NET POSITIVE SUCTION HEAD AVAILABLE Hf

PAtmospheric Z

(friction in suction pipe)

NPSH Available = P Atm. - Pvap. pressure - Z - Hf

Correct for specific gravity All terms in feet (meters) absolute

Results of Operating Off BEP

High Temp. Rise Low Flow Cavitation Low Brg . & Seal Life Discharge Recirculation

Head

Reduced Impeller Life Suction Recirculation BEP Cavitation

Low Brg . & Seal Life

Flow

TEMPERATURE RISE
Overheating of the liquid in the casing can cause: Rubbing or seizure from thermal expansion Vaporization of the liquid and excessive vibration Accelerated corrosive attack by certain chemicals Temperature rise per minute at shutoff is: (T oF (oC) / min.= HP (KW)so x K Gal (m3) x S.G. x S.H. HPso = HP (KW) @ shutoff from curve Gal. (m3) = Liquid in casing S.G. = Specific gravity of fluid S.H. = Specific heat of fluid Ex.: Pump takes100HP (75KW) @s.o. , 6.8 gal casing (.03m3) water (at 16 deg C) would reach boiling in 2 min. A recirculation line is a possible solution to the low flow or shut off operation problems....

CASING GROWTH DUE TO HIGH TEMPERATURE

ROTATION

10 inches 250 mm

COEFFICIENT OF THERMAL EXPANSION FOR 316 S/S IS 9.7X10-6 IN/IN/F OR 17.5 X10-6 MM/MM/C CALCULATION IS T x 9.7 X10-6 X LENGTH IN INCHES T x 17.5X10-6 X LENGTH IN MILLIMETERS EXPANSION MILLIMETERS 0.245 MM 0.490 MM 0.735 MM 0.900 MM 1.230 MM 1.470 MM

T F 100 F 200 F 300 F 400 F 500 F 600 F

T C 55 C 110 C 165 C 220 C 275 C 330 C

INCHES 0.0097 IN 0.0190 IN 0.0291 IN 0.0388 IN 0.0485 IN 0.0582 IN

IMPELLER CLEARANCE
Critical for open impellers Normal setting .015 (.38mm) off front cover High temperature requires more clearance - Potential rubbing problem causes vibration and high bearing loads - Set impeller .002 (.05mm) addl clearance for every 500 F (280C) over ambient temp. Important for maximum efficiency

IMPELLER BALANCE
MECHANICAL - Weight offset from center of impeller - Balance by metal removal from vane HYDRAULIC - Vane in eye offset from impeller C/L - Variation in vane thickness - Results in uneven flow paths thru impeller - Investment cast impeller eliminates problem - Careful machining setup can help

TYPICAL ANSI (or DIN) PROCESS PUMP

Small dia. shaft with excessive overhang
Stuffing box designed for packing Shaft sleeve Light to medium duty bearings Rubber lip seals protecting the bearings Snap ring retains thrust bearing in housing Shaft adjustment requires dial indicator Double row thrust bearing Cast jacket on bearing frame for cooling Small oil reservoir

ANSI (ISO/DIN) STANDARD PUMPS

Industry standards for dimensions based on requirements for packed pumps Shaft overhang a function of no. of packing rings and space for gland and repack accessibility Clearance between shaft and box bore based on packing cross-section If most pumps today use mechanical seals why do we continue to use inferior designs made for packing ??

BEARING OIL SEALS



Rubber Lip Seals Provided To Protect Bearings in standard ANSI pumps  Have life of less than four months  Groove shaft in first 30 days of operation  External contamination causes bearing failure

LIP SEAL LIFE



AUTOMOBILE


100,000 Miles @ 40 Miles /hr. = 2500 hrs. of operation

PUMP
24 hrs./day x 365 days / year = 8760 hours  60% of lip seals fail in under 2000 hours  Lip seals may be fine for automobiles, but not for pumps


THRUST BEARING SNAP RING

    

Thrust bearings in standard ANSI pumps are held in place with a snap ring Snap ring material harder than bearing housing Wear in bearing housing results in potential bearing movement Difficult to remove and install If installed backwards - potential loose bearing

SIMULTANEOUS DYNAMIC LOADS ON PUMP SHAFT

Radial Thrust due to Impeller and Misalignment Coupling Impeller Radial Thrust Impeller Axial Thrust Hydraulically Induced Forces due to Recirculation & Cavitation

Seal Axial Load from Misalignment and Impeller Motor

Radial Thrust due to Impeller and Misalignment

Hydraulic Imbalance

SHAFT DYNAMICS
Radial movement of the shaft occurs in 3 forms:  Deflection - under constant radial load in one direction  Whip - Cone shaped motion caused by unbalance  Runout - Shaft bent or eccentricity between shaft sleeve and shaft It is possible to have all 3 events occurring simultaneously  ANSI B73.1 and API 610  Limit radial deflection and runout of the shaft to 0.002 T.I.R. at the stuffing box face(0.05mm)  Solid shafts are critical for pump reliability  Eliminate sleeve runout  Improved stiffness


SHAFT DEFLECTION
Shaft deflects because of unbalanced radial loads on the impeller Shaft revolves on own centerline even when deflected load is constant in direction and magnitude Shaft stays bent as long as operating conditions remain the same

Shaft Whip
Shaft changes 180o from its centerline every revolution Usually caused by unbalanced impeller Heavy side of impeller on same side of shaft Whip and deflection can occur at same time Moved to one side by the amount the shaft deflects

OPTIMUM PUMP DESIGN

 OBJECT:

Create a better environment and greater stability for the dynamic pump components (seals and bearings) .to withstand the damaging forces inflicted upon them

SHAFT STIFFNESS
500 Lbs. (225Kg)

500 Lbs. (225Kg)

Derivation of Stiffness Ratio

= Deflection of shaft P = Load I = Moment of Inertia E = Modulus of Elasticity L = Length of Overhang P = PL3 3EI = PL3 3E P D4 64 I= 4 D4 64 = L3 D4
L

cancel all common factors

Stiffness Ratio Examples

D

D
1.50" 1.62" 1.75" 1.87"

L
8" 8" 8" 8"
3 4 3

L /D = 8 /(1.50) = 512/5.06 = 101 L3/D4 = 8 3/(1.62)4 = 512/6.89 = 74 L /D = 8 /(1.75) = 512/9.38 = 55 L /D = 8 /(1.87) = 512/12.23 = 42
3 4 3 4 3 4 3 4

Stiffness Ratio Examples

D

L D 1.87"
1.87"

L 8"
6"

L /D = 8 /(1.87) = 512/12.23 = 42 L /D = 6 /(1.87) = 216/12.23 = 17

3 4 3 4

Stiffness Ratio Examples

D

L
L /D = 200 3
3 4 3 4 3

38mm 200mm 40mm 200mm 45mm 200mm 48mm 200mm

/ 38

= 8000000/2085136 = 3.84

3/ 40 4 = 8000000/2560000 = 3.13 L /D = 200

L /D = 200 L /D = 200
3 4

/ 45
4

= 8000000/4100625 = 1.95 = 8000000/5308416 = 1.51

L/D<2.0 is Adequate

/ 48

Stiffness Ratio Examples

D

D
48mm

L
200mm
3

L
4 4 = 200 3 / 48 L /D

= 8000000/5308416 = 1.51 = 3375000/5308416 = .64

48mm 150mm

3 / 484 L /D = 150
4

L/D < 2.4 Considered Adequate

MAXIMUM STIFFNESS RATIO



L3 / D4 RATIO Less than 60 (Inch) Less than 2.4 (Metric)

EFFECTIVE PUMP OPERATIONAL ZONES

PUMP CURVE BEP ZONE L3/D4

INCH

HEAD

A B C D 80 40 20 10 0 10 15 20 25

A B C D A B C D

> 80 60 > 80 26 > 60 < 26 > 3.2 2.4 to 3.2 1.0 to 2.4 < 1.0

METRIC

PERCENT OF BEP

FLO W

ALIGNMENT
EVERY TIME A PUMP IS TORN DOWN, THE MOTOR SHAFT AND PUMP SHAFT MUST BE REALIGNED  UNPROFESSIONAL OPTION TO RE-ALIGN USE A STRAIGHT EDGE  PROFESSIONAL OPTION IS TO USE DIAL INDICATORSTO MINIMIZE TOTAL RUNOUT  MODERN METHOD IS LASER ALIGNMENT WHICH IS VERY ACCURATE


Drawbacks of Present Alignment Methods



   

All provide precision initial alignment  Degree of accuracy varies  Cost of system, training, and time involved in their use is dramatic Time consuming (possibly 2 workers, 4-8 hrs.) Difficult to compensate for high temperature applications Requires worker skill, dexterity, and training to achieve accurate results After pump startup, cannot insure continued alignment due to temperature, pipe strain, cavitation, water hammer, and vibration

SEAL CHAMBERS
LARGE BORE

OLD STYLE

Designed specifically for seals 20 Times greater fluid volume Provides superior cooling,cleaning, and lubrication for the seal Solids centrifuged away from seal Eliminate seal rub problems

Designed for packing Small radial clearances -Seal contacting bore Limited fluid capacity -Poor heat removal Easy to clog with solids

ELIMINATING SHAFT SLEEVES

REDUCES SEAL SIZE
  

 

Sleeves are necessary for packed pumps, but with todays new seals they serve no purpose Add no stiffness to shaft Run out tolerance between shaft and sleeve compounds motion of seal faces in addition to deflection and shaft run out already present Deflection must be a maximum of .002 at the seal faces, yet faces are lapped within 2 helium light bands Deflection or motion at seal faces is 1000 times greater than the face flatness

BEARING OIL SEALS

Three basic types:  Lip seal
Inexpensive, simple to install, very effective when new  Elastomeric construction  Contact shaft and contributes to friction drag and temp. rise in bearing area  After 2000-3000 hours, no longer provide effective barrier against contamination  Will groove shaft


BEARING OIL SEALS



Labyrinth seals
Required by API 610  Non-contacting and non-wearing  Unlimited life  Effective for most types of contaminants  Do not keep heavy moisture or corrosive vapors from entering the bearing frame (especially in static state)


BEARING OIL SEALS



Face seals and magnetic seals

Protect bearings from possible immersion  Good for moisture laden environment  Expansion chamber should be used to accommodate changes in internal pressure and vapor volume  completely enclosed system (can be submerged)  Generate heat  Limited life


BEARING LIFE


   

Bearing life calculations assume proper lubrication and an environment that protects the bearing from contamination The basic dynamic load rating C is the bearing load that will give a rating life of 1 million revolutions L10 Basic Rating Life is life that 90% of group of brgs. will exceed ( millions of revs or hrs. operation) Rating Life varies inversely as the cube of the applied load Reduction of impeller dia. from maximum improves life calculation by the inverse ratio of the impeller diameters to the 6th power

BEARING LIFE cont.

90% of all bearings will fail prematurely and not reach their rated L10 life - Calculated life by design over 20 years - Actual life maybe 3 years Failures: -Fatigue due to excessive loads (20-50% of failure) -Lube failure - excessive temperatures & contaminants -Poor installation

BEARING LUBRICATION FAILURE

OXIDATION Chemical reaction between oxygen & oil New compounds produced which deteriorate the life of oil and bearings Reaction rate increases with the presence of water and increases exponentially with temperature CONTAMINATION Water breaks down lube directly reducing brg. life - .003% water in oil reduces life of oil 50% Oil life decreases by 50% for every 20oF (11oC) rise in temp. above 140oF (60oC)

SYNTHETIC Lower OILS in viscosity with temp. change change

-One synthetic can take place of several oils Provides good lube at high temps. 300oF (160oC) -Does not oxidize (breakdown) At low temps.- good fluidity boosts efficiency and reduces component wear during cold weather Achieves full lubrication quickly Offers longer life - less consumption Lasts 1.5-2 times longer than conventional oils Maintains lube properties with water contamination better than mineral oils

ANGULAR CONTACT BEARINGS



  

Used as thrust bearing in pairs (also carry radial load)  Mounted back to back (letters to letters)  Provides maximum stiffness to shaft Avoid ball skidding under light loads  Small preload eliminates potential  Line to line design clearances  Shaft fit provides preload Eliminates shaft end play Greater thrust capacity Required by API 610 Specification

BEARING PRELOAD
  

Pump radial bearings have positive internal clearance Thrust bearings can be either positive or negative clearance. Preload occurs when there is a negative clearance in the bearing  Desirable to increase running accuracy  Enhances stiffness  Reduces running noise  Provides a longer service life under proper applications

BEARING CLEARANCES / PRELOAD

LIFE

Preload

Clearance

Goal: improved pump and Mechanical seal reliability

Eliminate or reduce mechanical and environmental influences that cause pump and seal problems. Specify proper pump design criteria to minimize the impact of mechanical and environmental influences. Specify proper mechanical seal and environmental controls to maximize seal life

Optimum pump design summary

           

Low L3D4 ratio as possible Solid shaft ( no sleeves) Large bore seal chamber Large oil capacity bearing housing Angular contact thrust bearings Retainer cover to hold thrust bearing (no snap rings) Fin tube cooling for bearing housing Labyrinth seals Positive / precision shaft adjustment method Investment cast impellers Magnetic drain plugs in oil sump Centerline support for hot applications

Requirements for proper emission control and maximum seal life

         

Shaft runout at impeller within .001 T.I.R. (.03mm) Coupling alignment within .005 T.I.R. on rim & face (.13mm) Operation of the pump at or close to best efficiency point (definition dependent upon pump size, speed, and LD ratio) NPSH available to be at least 5 feet (1.5m) greater than NPSH required Proper foundation and baseplate arrangement Absolute minimum pipe strain on suction and discharge flanges All impellers dynamically balanced to ISO G 6.3 spec. Face of seal chamber square to shaft within .002 T.I.R. (.05mm) Seal chamber register concentric to shaft within .003 T.I.R. (.08mm) Shaft end play less than .0005 (.015mm)