DESIGN AND OPERATION OF PUMPS FOR HOT STANDBY SERVIC! by Charles C, Heald Chief Engineer/Produet Engineering Manager Ingersoll-Rand Company Engineered Purmp Division Phillipshurg, New Tersey and Da G. Penry Manager, Engineering, Ingersoll-Rand Company, Limited Gateshead, England Charles C. Heald is Chief Engineer and Product Engineering Manager for Process and Industrial Pumps, Engi- neored Pump Division, Ingersoll-Rand Company, Phillipsburg, New Jersey. He 4s responsible for design, development, product engineering and contrects Mr. Heald received « B.S. degree in Mechanical Engineering from the Univer. sity of Maine in 1960. Since that time, he hhas held various positions with Ingersoll Rand, including Development Engineer, Senior Hydraulic De- sign Engineer, Manoger of Pump Design and Chief Engineer. He is a member of ASME and the API Centrifugal Pump Man- anfacturers Subcommittee, and has recently serced on the API (610 7th Edition Task Force. He has authored several articles and technical publications on centrifugal pumps. David G. Penrys Product Manager for Process and Industrial Pumps, Ingersoll Rand Company Limited, Gateshead, «England, UK. In this function, he main tains close contact with Ingersoll-Rand Pump Group headquarters in the United States in the design and application of puraps for the European served area rior to joining Ingersoll-Rand in 973, Mr. Penry wasa Seetion Engineer for AEI Company, Limited, where he was directly concerned with rotating equipment, particularly CO2 circula- tors, for gas-cooled nuclear reactors. He subsequently spent three years atecturer in thermodynamics and fluid mechanics Defore joining C.A. Parsons Company, Limited, as « Group En gineer in the Compressor Department, where he was Fesponst- Bie forthe design of «helium cteuator for the gas-coaled mu Mr. Fenry graduated witha B.Se. degree in Mechanical Eng neering in 1853 and seas elected to membership inthe Institute of Mechanical Engineers in 1965. While at C. A. Parsons Company, Limited, he presented a paper at an I. Mech, E. Conference en- titled "Cireilator Design for High lemperature Reactors,” ABSTRACT Pump thermal distortion problems routinely arise in refinery applications where hot fluids mast be handled. This is partieu- lavly the ease when warming up standby pumps. The single stage, double suetion configuration which is best suited for sich services, is analyzed in terms of the mechanical interferences that arise from thermal distortion. This js done withthe aid of finite element modelling, whieh eot only led to the solution of the interference problems via design improvements, but also led to recommendations for application and operation of pumps tunder hot-fluid cosditions APPL{CABILITY OF SINGLE STAGE DOUBLE SUCTION PUMPS In a variety of eefinery pumplog services, high flowrate and developed head requirements dictate the type of pump re aired. In addition, these services can also have high pumping temperatures (above 400°F/200°C) and liquid spelie graves below 0.70. ‘ap design alternatives for these applications include the following I} + single stage, double suction, vertically spit + singe stage, overhung, vertically split + culistage vertically spit (bare) + two stage vetialy or horizontally spt (single case Advantages of thesinglestage, double uetion, vertically split design (Figore I} over the other alternatives listed makes ithe fbvious selection +A double suction design equites Tes suction pressure than a single suction design (typically at least 30 percent less) atthe Same speed. This aso meas that sinaler, higher speed putnp car be selected, which may also cost less and be more ecient than a siege scbion exit 4 single stage unitcan more easly be arranged with radial (circular) tain easing joint with a confined, controlled compres- sion gasket to,more positively contain hazardous Gammmable, toxic) fighids than a multistage unt * A double suction symmetrical design can be constructed with a heavy shaft extending through the impeller eves (inlets) kun supported with beariggsat both ends ofthe shaft (an API 10 requirement for double suetion Impellets). This redvces Shaft deflection at mechanical seal faces and weassvgs al ve-no PROCEEDINGS OF THE FIFTH INTERNATIONAL PUMP USERS SYMPOSIUM Figure I. Typical single Stage, Double Suction, Vertically Split Process Pump Design sults ina stable rotor design that operates well below first lateral critical speed levels. + The nominal axial balance ofthe single stage double suetion design minimizes thrust bearing loads when suction pressures fare high. Overhung pump desigis must accommodate suetion [pressure thrust because ofthe single stuffing bovseal chamber ‘design. Multistage pumps are usually arranged to balance the pressure on each seal chamber, but this s usually accomplished In conjunction with close fiting throttling devices, such that axial balance can change (significautls} with normal pump wear + Suction and discharge nozales can usualy be arranged for either top or side locations, depending on which is more conve nient for the specific application, Usually top suction and dis- charge arrangements are preferred for hot services with over. hhead piping to improve piping arrangements and provide more resistance to nozzle forces and moments created by thermal srowth. + A double suction impeller can have # lower inlet tip speed than a single suction impeller. Since refinery Muids may contain suspended solids, this means impellers with lower tip speed will tend to suffer less abrasive erosio ‘Thereare, ofcourse, some disadvantages tothe single stage dow De suction desiga as well ‘A two bearing design requires two mechanical seals whereas a singlestage overhung design requires on this means that for low flows, and where suetion p adequate for NPSH requirements, the overhung design may be preferred + Thehigherenersy-per-stage ina single stage doublesuction ‘pump may dictate higher minimuin Noss than a multistage unt. Also, for higher head applications, the specific speed of a multi- stage pump may be more nearly optimum, and result in higher operating eficieney. Units of two or more stages, however, are move susceptible to interual alignment problems when high ‘operating temperatures impose severe thermal forces and tem perature gradients throughout the pamp, * Double suction pumps-whether single stage or the frst stage of multistage pumps-require symmetrical low tothe s tion nozzle. If piping leading to the pump creates unequal flow to-each impeller eye (inlet), an axial unbalance ean oceur, lead- ing to high thrust bearing loads. This also results in unequal flows within the impeller, which may cause one side of the im- peller to cavitate. Unequal flows can als result in rotor oscila- tons, which eause nasteady bearing and seal loads —and prema ture fedares, Suction piping arrangements are less critical on single suction pumps. This presentation will outline experiences with large single stage double suction sefinery pumps applied ta severe hot bot touts service. It will discuss the application and operational problems encountered and how they ae being adesed and ‘The pumps described inthis application are single stage, dou bie suction, vertically split with 220 in discharge, 16 in suction and 31 in noming! anpeller diameter. The pumps are rated for 5,000 US gpm, 2954, operating at 1780 rpm, The service is main fractionator bottoms, 640°F (338°C) with a specific gravity of 0.552 at pumping temperature. The pump was designed for 720, psi working pressure at the pumping temperature, Material of ‘construction i carbon steel (ASMT-A2I6 WCC). The pump is equipped with sleeve radial bearings and ball thrust bearings (Duplex, back-to-back) with ol ring lubrication and purge mist The pump was built in accordance with API-610, 5th Fdition ‘The mechanical seals were specified tobe of single, balanced ear tridge design, with esternal evo oi sh, ‘This pump represents ane ofthe lagest single stage machines applied to this type of service anywhere in the world, Not only 's the pumping temperature high, but the ambient temperate (Middle East is also very high INSTALLATION AND OPERATING PROBLEMS ‘The operational problems diseussed herein will concentrate ‘on those associated with high temperatures Each pumping wnit was arranged (as is typical) with two pamps—one operational and ane spare (hot standby). Suetion and discharge piping Was oriented at the top of the pump (top. nozzles) with hangers and supports to reduce nozzle loads. The suction pipe, at about 10 pipe diameters from the pump nozele (ange) tured 90 degrees and ran parallel to axis of the pump shaft. In this particular instance, the distance of the 90 degree turn from the suction nozzle was probably suiicient to at least rninimize distortion ofthe flow into the suction nozzle~and thus tothe impellerinlets. However, normally, itis critical that atten- tion be given to suction piping (and flow distebution) on double suction pumps (impellers) to ensure that flow is equal to both sides ofthe impeller to prevent poor suction performance, totor unbalance and axial rotor shutling-especially at flow less than design flow. ‘The mechanical performance of the first unit, which was started cold and brought up to design temperature slowly with the process, was satisfactory. Major probleuns arose, however, when the “hot” standby pump rotor would not gen by hand without experiencing internal rabbing (hard contact) after ap- proximately 180 degrees of twin. After an elapsed period of abi ur minutes, the rotor could undertake a futher rotation (0 180 degrees before contact Was experienced again. Thus, hot standby startup could not be achieved Tavestigation revealed several possible factors contributing to this inability to rotate the pump rotor freely on hot standby: * The warmup flow to the pump case (Figure 2) cousisted of 4 singular pipe to the discharge piping of the standby wnit suel. that uniform distribution of the warmup liquid through the pomp easing and around the rotor was not being achieved. In view of the large physical size of the pump and the thermal strabifeation eects, the location of the Warmup line, andl prob- ably the quantity ofwarm-up liquid aswell, was inadequate [2]. * Coupling alignment was changed significantly from the “coldta the "hot standby” condition (as muich a 0.020 in- 0.080 in) It was suspected that nozzle loads were moving the pump relative to the drive. It was also suspected that the pump was tuying to expand axially and transversely and was being re: stricted, and that the shaft was moving independently of the pump casing.DESIGN AND OFERAHION OF PUMPS FOR HOT STANDBY SERVICE m DISCHARGE ume, SUCTION Figure 2. Warmup Piping Showing Top Warmup Connection INVESTIGATIONS io evaluate the influence ofthe original warmup fxs to the pump easing, a finite element model (Figure 3) of a portion of the nearly'symmetrial pressure containment vessel was created such that thermal gradients could be studied and distortions {movements} could be evaluated relative to known measure ‘ments (Figure 4), When we imposed known deflections on the madel, the total displaced geometry could be viewed and studied. Te vas found that the otiginal warmup low atvangement was doing very little good, Ie appeared tobe short-crcuiting (Figure 5} and simply going in and out ofthe top of the pump ease. Tt ‘as, in fact, adding tothe distortion (Figure 6) ‘The configuration of the easing was also reviewed to deter ‘mine if changes in construction ceinforeing ribs. ete.) could add significantly to strvctural rigidity and add resistance to thermal distortion, Aftec reviewing the finite element model, this was jected in favor of maintaining a sinoath casing profile. Thermal oP ‘COUPLING, END, BOTTOM Figure 3. Finite Element Model ofa Porton ofthe Nearly Sym- ‘metrical Pressure Containment Vessel EXTERNAL ViEW uNpispLaceo ‘GEOMETRY pisPLaceo GEome TRY (EXAGGERATED) Figure 4. Model Showing deflection resulting from Original Warmup Flow into Top Connection Figure 5. Top Warmup Flow Connection Besults in Short C ‘cult. Warmup Flow Simple Goes in and out of the Top of the Fump Case, Resulting in Severe Thermal Gradients. gradients in major reinforeing ribs could actually ereate higher levels of distortion, and stress, ifnot precisely located and sized, Originally the pump was dnwelled securely to its mounting pedestals withont provision for expansion in any disection. This 's routinely done on smaller unis ofthis type to maintain pump position on its bedplate and maintain alignment with the driver With such a large pump, however, it appeared that “planned” ‘expansion, partculatly inthe radial direction, eould help elim- nate distortion and shaft movement at the coupling Because ofthe volatile nature of the pumpage, the single ba- Janiced mechanical seals were arranged with cold gas oll Mush to each seal chamber from an extemal source API-610 Seal Piping lan 32/63) (Figure 5), This flush was injected into the seal ata single point. Since the lush has to he on the ile standby pump asall times (for safety purposes), it has the ellect of cooling the shaft and seal chamlter area while the restafthe pump was being heated, Actually, the casing was being heated nonuniformly with the single point warmup flow in the discharge pipe and the Shad aod seal chamber area were being cooled sonuniformly12 PROCEEDINGS OF THE PIFTH INTERNATIONAL PUMP USERS SYMPOSIUM VERTICAL UNbISPLAcED ‘eomerer oor L, 1982 INCH pispuacen. (EEACCERATED) Figure 6, Model Shows Gasing Displacements Resulting from Top Warmup Flow Which Actually Added to Distortion. ‘vith the single point injection ofthe cold gas oil lush, Further nonuniform cooling took place asthe spent cold gas oil stratified inthe bottom ofthe pump casing adjacent to the seal chambers. ‘The net result was severe “hogging” of the shat, bowing ofthe casing, and binding ofthe rotor. CORRECTIVE ACTIONS ‘The finite element model was constructed such tat field mea- surements of pump cising surface temperatuies top to bottom) could be used as input. When this was done, resulting distortions \were in close approximation to those values actually experi enced on the hot standby pump. The distorted model with ac- tual measurements of deflections imposed is shown in Figure 6. The finite element analysis showed that multiple point warm up injection would be required to uniformly heat the easing With single point injection, the bearing housing brackets were actually moving and twisting relative tothe close running clear ance diameters in the easing, thus esasing rotor contact as well asbeaving misalignment, By replacing single 34 inch injection Figure Z.lmproved Warmup Flow Piping into the Bottom of Each Casing Passage point at the top ofthe pump with three one-inch connections on the bottom of the easing fone in the volute and one in each of the suction passages, adjacent to the seal chambers and bearing brackets Figure 7), it was predicted thatthe flow of warm-up liquid would be substantilly increased and would flow more aniformly throughout the pump casing, resulting in uniform eas ing growth (Figure 8). Infact, by this means, the original approx imately 250°C differential across the easing was veduced to an acceptable 25°C. The ways easing temperatures were distri ibuted and inputted to nite element program are shown in Fig- ture 9. Another displacement output to evaluate effect of 360 degree bearing bracket is shown in Figure 10. In arranging for injection into the suction passages, it was determined that eon veetive upward flow should be controlled so as not to impinge ‘on the pup shat. The concern sas that such impingement con- tributed to additional bowing of the shaft. Agnin studying casing thermal growth, itwas decided that the pump, because ofits physical size and near eube-tike overall di ‘mensions, should not be dowelled, in order to avoid any possible internal distortion. Instead, keys were fitted at the centerline of Doth pump feet to allow free radial expansion and axial expan- sion toward the drive (Figuve 11) VERTICAL —feanne UNoisPLAceo cEoMETRY + o201NcH piseuaceo GeoMerRY (EXAGGERATED) Figure 8. Model Shows Improvement in Casing Displacements tuithInproced Bottom Warmup Connections 650 \ | jpeooe 500 500 1400: 500 bor .600 Figure 9. Distribution of Casing TemperaturesDESIGN AND OPERATION OF PUMPS FOR HOT STANDBY SERVICE us. VERTICAL ARIAL UNDISPLACED SEOMETAY 939 INCH DispLaceo. GEOMETRY (EXAGGERATED) Figure 10. Effect of 960 Degree Bearing Support on Distortion. Compare to Figure 8. Figure 11 Keys Fitted o Allow Free Radial and Axial Expansion tchile Mininizing Distortions Caused by Restricted Movement In addition, a key block was wed to the lower centerline of the pump easing to mate with a block on the baseplate. By pro- viding these sliding features to allow the pamp to expand both axially and transversely, alignment with the driver could be as- sured while avoiding any restrictions whieh could add to the dis- tortion problem. The coupling alignment is maintained by the transverse key fitted at the bottom ofthe pump. The keys were fitted with 0.005 in side clearance {maxintum) to limit angular movement. To evaluate the effectiveness of corrective actions, the pump as warmed up with the coupling spacer removed and sufficient time allowed for the pumnp toreach stabilization. Pump to motor alignment was determined with the pump in the hot condition using a “three clock” method. Three dial indicators were at tached tothe motor coupling hub with one indicator registering ‘pump coupling hub rim runout and tww indicators registering ‘pump coupling hub face runout. Two indicators were necessary for the face measuteinent to compensate for pump shaft axial rmovernent dusing tation, Indicator support arins Were suf ciently rigid to avold sag over the Aste between the to hhobs. Alignment (to less than 0.009 in) was achieved by adjust ing the motor position and shimming under the motor feet. A *oftfoot” check was performed on the motor after aligament. Pump casing skin temperatures were obtained by the use of ten thermgoouples attached statically tothe casing by spot ‘welding. Thermocouples were also attached to the warmup line {0 monitor the warmup liquid temperature and tothe sea of feed line to monitor the sel ol temperature. allthermocouples were connected 10a chart recorder which reisteved each tem- peratute every 60 seconds “The rate offlow'to each warmup injection point was contelled by avalve such hata warmup rte not exceeding Cimin and 4 maximum differential temperature at any. point in tae be tween al pump thermocouples of 30°C could be achieved. Tt was found thatthe maximum diferential objective was atan ble, but is was not posible to maintain the 3*C/min vse at all Poinis inthe ver inital stages of warmup. A steady sate tem: peratuse was reached after approximately two hous of ntrodce tog hot liguid. Ultimately, the warmup Tiquié contol valves weve to be replaced by sized orifices Shaft to casing relative movement could be monitored only where the shaft extended from the coupling end bearing hous- Jing, because of insuificient space between the seal glands and Yiebearing housings. A single dial indicator was attached tothe coupling end bearing housing Yo resister the telative vertical ‘movement of the shaft during warmup. Te was shown that this indicator was a dependable guide tothe extent of bowing of the Shaft at the coupling, the dtletion at that peint being approx ‘nately half that atthe coupling, Ths deflection couldbe ver ‘ducing shaft rotation alter warmup. A lint of. 005in was placed on the acceptable shaft unoot or tatsip, knowing that the shaft ‘would fully straighten very shortly aftr startup. “To minimize any possible etvor arising ftom the growth of structures in close proximity tothe hot pump easing, al dial Gicator supports were carefully insulated. Care was taken to en- Sure that support structures themselves were sufficiently rigid to withstand reasonable accidental knocks, The axial movement ‘ofthe pump suction line relative toa fxed poi was also mi tored to establish its posible effect on the pump esing move- snent during warmup, In adition tothe continuous monitoring oftempratares al nestor eadigs wer recorded 1 in “These medications resulted in a sigaticant improvement. The shaft was now capable of being rotated continuously through full 360 degrees. However, an unacceptable upward Shaft bowing atthe coupling prevented automate startup from the hot standby condition. Coupling malignment vias more than was desived prior to startup. Further testing clearly ind sated a telitionship to the old flash ol injetion. Shat move ment a the coupling could be roodied significantly by altering the rate of Bow of the cold fash oil injection, obviously aot at acceptable situation. Teas determined that the shaft bowing resulted fiom the cold oil fish impinging onthe shaft overa restricted cicumer fence due tothe single point sel injection (Fig 12). In con- fonction with the seal manisactucer, the seals were modiied to ‘simplified multipoit injection. At the same time, an attempt ‘was rade to avoid dvect impingement of the ht warmup” lig uid on the underside of the shat at the coupling end of the pump. However, these modifications resulted in ony limited To abtain further improvement and minimize the effects of the cold fhish off smpinging on the shalt, arangements were nade to preheat the as ofl to approsimately 100°C (212"F) ina4 PROGEEDINGS OF THE FIFTH INTERNATIONAL PUMP USBRS SYMPOSIUM Figure 12, Bottom Warmup Connections in Each Pump Passage Improves Distribution of Warmup Liquid and Results in More Uniform Casing Growth steam heater, By this means, bowing ofthe shaft was veduced toan acceptable level such that the rotor did not bind and move~ ‘ment atthe coupling was virtually eliminated. A suecessfl start- ‘up from the hot standby condition was made. However, preheating of the gascil fs not considered an accept able long term solution for many reasons, among which is the {temperature ofthe shaft at entry to the beatings (high tempera ture close to the babbitt material), ‘Other limitations have necessitated further changes. Experi= ence has shown that diferent rates of warm up flow are desirable toavoid excessive rates of temperature rise fom cold to that re- {quired to hold the pump at a sufficiently high temperature to avoid thermal shack on start up. The use of diferent orifice plates in the warm up harness to control the rate and direetion offlow would be desitable, but has been shown tobe impractical inthis particular installation beeause ofthe danger of plugging ‘Along term solution has been being pursued based an the ex: peviences gained to date (Figure 13). This will inefude the use of double mechanical seals, thus limiting the quantity of cold ffush, and containing itso that it eannot enter the pump suction passages and eause thermal stratification and subsequent distor tion. Tangential introduction ofthe hot warmup liquid (Pigure 1) will minimize the inpingement of hot liquid of the lower Figure 13. Tongential Injection of Warmup Flows Prevented Im- pingement on Shaft Figure 14. Warmup Piping Showing Tangential Injection and Temperature Control of Hot Flush Liquid. portion ofthe shaft. A natural conveetion cooler may also be in- troduced into the warmup line o provide eonttol of the pump warmup rate from ambient conditions CONCLUSION thas been enmmon practice to warmup pumps by introdue- ing hot ligatd into the discharge pipework and permitting the flow fo petmeate through the pump bad tothe pump suetion. In general, this has been perfectly satisfactory in achieving 60 vital conditions for immediate hot startup: + Controlling the warmup rate ofthe pump casing and hokd- ing the pump at a sufficient high temperature to avotd thermal shock on startup. + Holding an acceptable iffeentil temperature throughout the pump body to avotd thermal distortion and rotor binding. ‘As pumps become larger, a simple warmup flow to the dis- charge piping is not sufiient ‘Thermal gradients within the body ofa lage pump can over come the natural liguid low reslting instant ateas within the pump and extensive temperature differentials aross see- tions of the pump casing. Such thermal differentials can easy result in enough distortion to cause rotor binding (contact) and ‘The method of pump warmup must be given careful consider ation fr each pump installation. There is no universal “standard” solution. At present, i would appear that pump manufacturers arerarely consulted. twould be advantageous to manufacturers tnd users alike if more communication in this important area took place atthe initial stages ofa contract ‘Many factors come into play in the decision to use a single or double mechanical seal, but seldom is one of those factors the consideration of thermal distortion of the pump rotor or easing, Experience has shown, however, that even mechanical seal selection can be important to satsfictory pump startup fom 2 hot standby condition Both pumping temperature and pump size must be consi dered when evaluating. warmup flow requirements for hot standby pumps. Larger pamps at high pumping temperaturesDESIGN AND OPERATION OF FUMPS FOR HOT STANDBY SERVICE us demand special atention to many ofthe procedures routinely agate to males, lover ten pertie machines. Exch istalaton serves individual consideration, and it iin the best interest of both the user and the pomp manubicture to communicate on warmup arrangements early enough to avoid unnecessary start p problems: REFERENCES 1. Stepanoll, A. J., Gontrifugal and Asial Flow Pumps, New York: Jobn Wiley & Sons, Incorporated (957), 2. Nelson, W. E, "Maintenaace and Troubleshooting of Singhe Stage Pumps Freceedings ofthe First Intermationl Pury ‘Symposium, Turbemachinery Laboratories, Department of Mechaslal Engineering, Texas A&M University, College Station, Texas (1984) ACKNOWLEDGMENTS ‘The suthors wish to thank the management of the Ingersell- Rand Pump Group for permission to publish these experiences ‘They also extenda special thanks to Mr. Ron Palgrave, Chief Ent reer and Mr. Colin Ruddick, Engineering, Managet, tagersoll- Rand Company, Limited, Gateshead, England, for. their assistance.