Centrifugal Carbamate Pump Failures-Improvement PDF

8th Stamicarbon Urea Symposium
6 - 9 May 1996, Amsterdam
PAPER 17
Ammonia charge & carbamate recycle centrifugal pump
technology advancements and their effect on urea plant
life cycle cost
LIST OF CONTENTS
Page:
1. Introduction 1
2. Background 1
3. Product improvement history, philosophy & objectives 2
4. Reliability and life cycle cost analysis 13
5. Summary 20
1. INTRODUCTION
This paper provides a brief history and background of high speed centrifugal pump
(HMP) implementation in the Stamicarbon urea process, field lessons learned to date,
recent HMP-3512 and HMP-5112 product technology improvements, and the positive
leverage these improvements will have on Stamicarbon urea plant operational cost.
2. BACKGROUND
In 1969, the first HMP-5112 two stage high speed centrifugal pump was placed into
high pressure carbamate recycle service. In 1985, commissioning of the first HMP-3512
two stage high speed centrifugal pump was completed at Cominco in Canada.
Introduction of the HMP-3512 signaled the start of Stamicarbon’s continuing
relationship with Sundstrand Fluid Handling. For typical Stamicarbon urea plant
capacities below 2.1 MT/D, the carbamate recycle and ammonia charge services are
well suited for the HMP-3512 pump. Figures 1 and 2 depict the products’ hydraulic
design envelopes and cumulative world wide installations. Like the standard Sundyne
LMV product line, the HMP was conceived as a low specific speed centrifugal
alternative to reciprocating or positive displacement machines. Fertilizer market
acceptance of this technological alternative was rapid.
1.
3. PRODUCT IMPROVEMENT HISTORY, PHILOSOPHY & OBJECTIVES
From 1969 through 1993, evolutionary HMP product development yielded incremental
improvements in performance and operating reliability. In 1993 the HMP-5112, and in
1995 the HMP-3512, underwent major re-design aimed at improving operating
reliability and performance. Tables 1 and 2 summarize the change in design and
performance features which resulted from these programs.
Each feature in Tables 1 and 2 was selected for its contribution toward achieving one or
more of the following quality improvement objectives:
· Improve actual field operating reliability by at least 25% as measured by Mean

Time Between Maintenance Actions (MTBMA).
· Reduce product performance and reliability sensitivity to variations in customer

operating conditions and field maintenance techniques.
· Improve product maintainability/producibility and reduce cost of quality without

increasing Total Manufacturing Cost (TMC).
As seen in Figure 2, the petroleum refining and petrochemical markets in general, and
the fertilizer market in particular, have quickly recognized the inherent reliability
advantages of high speed centrifugal designs over existing reciprocating machines.
Sundstrand’s objective is to increase that fundamental Operating and Maintenance Cost
(O&M) advantage to the benefit of our HMP customers.
The next section describes in detail, technical design and operating reliability attributes
of the product improvements summarized in Tables 1 and 2. HMP-5112 improvements
are discussed first. This is done to illustrate the synergistic flow of technology to the
HMP-3512. Improvements to the HMP-3512 are then emphasized, particularly as they
relate to the Stamicarbon urea process.
2.
Figure 1:
Performance
envelopes
HMX Product Line

Sales History
Hydrocarbon
Ammonia 9%
TPA Figure 2: Worldwide
8% Gas
10% 1% TOTAL UNITS SOLD -203 installations
Foreign - 72%
Domestic - 28%
Water 39%
13% HMP-3000
HMP-5000 - 37%
61%
HMP-5000 HMP-3000 - 63%
HMC-3000 - 1 Unit
Carbamate HMC-5000 - 2 Units
Chemical 41%
18%
3.
HMP-5112 PRODUCT IMPROVEMENTS
Value Engineering was applied to our objectives of improving reliability, minimizing

field maintenance, and reducing cost of quality, for the HMP-5112 pump and gearbox
(P/G) assembly.
Value Engineering
Value Engineering’s major premise is to evaluate each part in an assembly for its
individual function and contribution to the overall function of the entire assembly.
Factors evaluated on a per part basis include , producibility, maintainability, and part
life. Alternate ways of performing the particular function are also examined. Input
from engineering, manufacturing, operations, purchasing, suppliers, and customers is
used extensively.
The end result of Value Engineering is to perform the function with fewer parts by
combining functions, eliminating functions, or moving functions to other parts.
Reduced part count normally equates to lower cost, simplified maintenance and
assembly, and higher reliability.
For example:
Part --------------- Bearing Retainer
Functions---------Support bearing, support labyrinth seal, meter lube oil input to
baring, and provide return lube oil drains.
Goal---------------To combine functions, question the need for all functions, or
accomplish the function another way.
This analysis was performed on the HMP-5112 low speed (input) bearing assembly as
shown in FIGURES 3 and 4. The result of this analysis was to reduce the assembly
from 12 to 7 parts while accomplishing a new function of higher horsepower (kW)
capability.
4.
Figure 3: Figure 4:
Previous Configuration New Configuration
Refer to Figures 3 and 4 above using the balloon numbers:
1. Bearing diameter increased for higher HP (kW) capacity.

2. Shaft diameter increased for higher input HP (kW) capacity and increased shaft
safety factor.
5.
3. Lube oil labyrinth seal has larger oil pockets for better drain back to sump.
4. Larger diameter oil slinger to decrease the oil drain requirement of the labyrinth
seal.
5. Previous bearing retainer mount changed to labyrinth seal mount.
6. Previous design eliminated bearing retainer, new design added bearing clocking pin
to accommodate pump and compressor configurations.
7. Previous corner O-ring replaced by flat gasket that does the function of two O-rings
used in the prior assembly, items 7 & 9.
8. Oil metering orifice function now handled internal to bearing.
9. Labyrinth O-ring eliminated due to removal of bearing retainer item 6 in prior
design.
10. Labyrinth bolt head washer seals eliminated due to use of flat gasket.
11. Deleted rubber cover, no useful function.
12. Eliminated bearing hold down bolts, gearbox housing is now used to retain bearing.
Value Engineering was also applied to the high speed assembly. Additional design goals
included increasing the first lateral critical speed to above all design speeds, dropping
bearing pad operating temperatures, and reducing high speed shaft vibration levels.
This improved reliability of the high speed assembly, bearings, and seals. The resulting
bearing parts count decreased from 398 parts to 84 parts, a 79% reduction in
complexity!
Refer to balloon numbers in Figures 5 and 6 which are the previous and new Value
Engineered high speed bearing configurations respectively.
1. On the new configuration the bearing is bolted firmly to the gearbox housing with no
further adjustment required. The axial adjustment nut was eliminated through the
use of tighter manufacturing tolerances, eliminating the need for this bearing to be
set axially by maintenance personel.
2. The high speed shaft diameter increased and length decreased raising the 1st lateral
critical speed to about 28,000 rpm, above all design speeds.
3. The bearing pad adjustment screw has been eliminated as an adjustment point for
bearing pad clearance. This is due to the new fixed clearance flexible pad bearing
which gives control over the pad to shaft clearance. This is critical for reducing
bearing temperature and vibration levels.
6.
4. Another simplification was integration of the high speed shaft vibration probe
mounting bracket into the bearing cartridge. This reduced bracket overhang, creating
more room inside the gearbox housing for simplified assembly and maintenance.
5. This area is sized to accommodate all possible thrust bearing designs. The bearing
cartridge outside dimensions are constant for both pump and compressor
configurations. This makes one gearbox housing machining configuration, reducing
manufacturing time and cost.
7.
Other improvements
a. The entire low speed shaft assembly is now balanced instead of the bullgear alone.
b. Gear quality improved from AGMA 11 to AGMA 12 (1/3 less tolerance from true) to
reduce vibration and noise.
c. Bearing material is babbitted steel instead of bronze, yielding better corrosion
resistance to ammonia.
d. Stiffer baseplate design for improved alignment protection.
e. Laser alignment of driver to gearbox within 0.001 in. (0.025mm).
f. Changed paint from enamel to polyurethane to better resist fading and chipping.
Table 1: Summary of performance measurements
Previous New
Low speed shaft vibration levels 3 mils (76.2 um) 0.5 mils (12.2 um)
High speed shaft vibration levels 1.5 mils (38.1 um) 0.6 mils (15.2 um)
Gearbox casing vibration levels 0.15 in/sec (3.8 mm/sec) 0.08 in/sec (2 mm/sec)
High speed bearing pad temperature 225 deg F (107.2 deg C) 190 deg F (87.8 deg C)
The performance data above illustrates actual test stand measurements seen on new
P/G designs.
8.
Figure 5: Previous configuration
Figure 6: New configuration
9.
HMP-3000 PRODUCT IMPROVEMENTS
Table 2
Feature Benefit
GEARBOX
Deflection Pad Radial Bearings - Common bearing for high speed shaft radial l ocations.
- Vibration levels insensitive to operating point.
- Overall lower vibration and temperature levels.
Centered Gear Mesh - Gear loads evenly distributed to the bearings.
Tapered Land Thrust Bearings - Double the thrust capacity in all lightly loaded locations.
MECHANICAL SEALS
“Soft” Mounted SiC Rotating Faces - Optimum seal hard face material.
- Ideal encapsulated mounting configuration.
Bottom Entry Top Exit Seal Ports - Improved circulation, cooling for the mechanical seals.
New Gearbox Mechanical Seal - Keeps oil in and contaminants out.

Larger Seal Drain Area - Reduces back pressure on gearbox seal.
WET END HARDWARE

Titanium Impellers Made From - Increased vane integrity. Eliminates all welding.
Barstock
For Ammonia Feed Pumps - Guarantees operation below the first critical speed.
SEAL FLUSH AND BUFFER SYSTEM

Double Seals For Ammonia, Stage 1 - Reduces ammonia/water contamination by 50%.
Larger Seal Flush/Buffer Pump - Reduces RPM to mid range of speed envelope.
Larger Pulsation Dampeners - Reduces pressure fluctuations in seal supply lines.
Common System For - Provides redundant system hence higher reliability.
Both HMP Pumps
The items listed in TABLE 2 which improve reliability and reduce operating cost are
elaborated on in this section.
10.
GEARBOX
Multiple oil entry ports, characteristic of tilting pad bearing construction, allow the use
of a common bearing for all high speed shaft radial locations. This reduces inventory
requirements and simplifies maintenance. A separable bearing in both motor side
positions also reduces the cost for this smaller, replaceable component.
A wide range in hydraulic load direction when combined with the gear load vector
causes low resultant bearing loads at certain operating points. The tilting pad design is
less sensitive to these variables as shown by the vibration plots in FIGURE 7 for the
same carbamate recycle pump operating at the same flow rate. Also, centering the gears
between the bearings evenly distributes the gear load.
Tapered land thrust bearings, interchangeable with the previous bearings, double the
load capacity in lightly loaded positions due to the increased oil film.
MECHANICAL SEALS
Silicon Carbide has proven to be a superior material for bearings and seals in many
pump applications. Its high hardness creates an inherent brittleness which necessitates
precaution against thermal and mechanical shock. Mechanical seal development on the
HMP-5112 product line lead to significant enhancement of the HMP-3512 rotating hard
faces using Alpha Grade Silicon Carbide. FIGURE 8 illlustrates these changes.
Previously, the HMP-3512 used a solid Tungsten Carbide rotating face or Silicon
Carbide pressed into a metal retainer. The new “soft” mounted Silicon Carbide rotating
seal face is suspended between lapped surfaces while all the impeller torque is
transmitted underneath through the metal carrier. A special, low thermal expansion
metal ring keeps the Silicon Carbide in compression through the full range of operating
temperatures. Stress concentration at the anti-rotation points is evenly distributed to this
metal shield. Double o-rings in the carrier provide seal face stability under normal or
upset (reverse) pressure situations.
Uniform temperature gradients around the mechanical seal decrease the possibility of
thermal shock during operation. Side entry bottom exit of the seal buffer fluid has been
changed to a bottom inlet top discharge arrangement. This maximizes cooling and
lubrication capability and prevents gas accumulation at the seal faces for longer life.
11.
A completely new gearbox face seal has been developed and qualified for the
HMP-3512. This unique I.D. pressure configuration takes advantage of the normally
low pressure in the gearbox and is designed to function as a conventional O.D.
pressurized mechanical seal under adverse conditions caused by excessive process seal
leakage. Gearbox damage from process seal leakage is further reduced by a 67%
increase in seal drain capability.
WET END HARDWARE

Titanium impeller/inducer material is required for high head ammonia feed services to
guarantee the first lateral critical bending mode is a safe margin above maximum
operating speed of the pump. Machining these critical components from barstock
eliminates the inherent Alpha layer found on the surface of cast titanium components
and provides full strength in vane and root areas.
SEAL FLUSH AND BUFFER SYSTEM

The low pressure first stage of amonia feed pumps is well within the pressure capability
of double seals. Since the pressure between the seals is higher than process pressure, no
ammonia contamination occurs. A separate condensate buffer discharge port allows the
effluent from Stage 1 to be plumbed back to the condensate system instead of the
ammonia/water treatment system. This reduces operating costs associated with water
treatment by 50%.
Using larger seal flush and buffer pumps allows them to perform at lower speeds. The
reduction in operating speed translates directly into increased operating life.
Larger pulsation dampeners on the positive displacement seal flush and buffer pumps
reduce pressure pulsations and mechanical shock in the system.
A separate seal flush and buffer system on its own base plate with two pumps, two
filters, and two pulsation dampeners, allows it to be placed conveniently in the facility.
More importantly, it creates redundant seal flush and buffer systems. Either seal system
can operate with either HMP pump thereby increasing overall reliability.
12.
Figure 7: Previous Vibration Level 0.774 mils (19.7 µm), New Vibration Level 0.226 mils
(5.7 µm)
Figure 8: Previous and new rotating seal face configurations
13.
4. RELIABILITY AND LIFE CYCLE COST ANALYSIS
Model evolution
The Life Cycle Cost (LCC) math model used in the following analysis, evolved from
models employed by Sundstrand Aerospace, their airframe manufacturing customers,
and end-users including the U.S. Air Force. It is a simplified combination of two
proprietary models used as standards in commercial and military systems analysis. The
authors have modified it for use in studying industrial machinery applications. In its
simplest form, it combines standard system reliability prediction methods with
discounted cash flow analysis techniques to perform relative comparisons between
competing alternatives.
There are a wealth of excellent publications on the subjects of reliability,

maintainability, and LCC available in the Engineering and Operations Research
communities. The authors recommend Chapters 11 and 13 of Reference 1 for a more
detailed assessment of reliability and cost effectiveness in complex systems.
The math model used in the following example is based on two assumptions which
simplify the analysis.
1) The subsystem or component failure rate is constant. This means the equipment
evaluation pertains only to the mature portion of its life. Failures associated with
commissioning such as improper component sizing or installation, manufacturing
defects, inexperienced maintenance and operations personnel, and system
uncleanliness are excluded from the analysis. Therefore, the exponential failure
law applies:
R(t) = e-t/M = e-λt
14.
Where:
R(t) = The Reliability Function For Some Specified Time t.
M = Mean Time Between Failures = 1/λ
λ = Failure Rate = Number of Failures/Total Operating Hours
15.
Using the improvements listed in TABLE 2 and applying increased life factors to those
items, the increased reliability of a new HMP-3512 pump is shown in TABLE 3 below.
Values are normalized to one year of operation and calculated according to the
assumptions given at the beginning of this section.
Table 3: HMP-3512 pump
Previous Configuration New Configuration
MTBF, Operating Years R(t) MTBF, Operating Years R(t)
Coupling 20 .951 20 .951

Shafts 25 .961 25 .961
Gears 25 .961 25 .961
Oil pump 15 .936 20 .951
Input bearings 14 .931 14 .931
Output bearings 10 .905 15 .936
Oils seals 1 .386 3 .717
Process seals 0.8 .287 1.2 .435
Impellers 15 .936 15 .936
Pump cases 25 .961 25 .961
Total 0.386 .066 0.630 .204
The changes made to the HMP-3512 itself result in a 87% life improvement, from 4.4
months to 7.6 months. The analysis is illustrative only. Results will vary from one
operator to another according to their installation and practices.
The complete system reliability is calculated in TABLE 4. In the original configuration,

each main driver, lube system, seal system, and HMP is arranged in series then
combined with the other in parallel. The block diagram and associated equation from
FIGURE 11 yield the complete system reliability improvement shown for the new
configuration in TABLE 4.
18.
Table 4: HMP-3512 pump and system
Original Configuration New Configuration
MTBF, Operating years R(t) MTBF, Operating years R(t)
Main driver 6 .846 6 .846

Lube system 6 .846 6 .846
Seal pump system 1.5 .513 2 .607
HMP-3512 0.368 .066 0.630 .204
Total 0.330 .048 0.685 .232
The overall system reliability has increased 108%. Note that if the seal pumps were still
applied in series with the rest of the systems, the resulting reliability for the new
configuration would only be .169. This translates to an MBTF of 0.563 years
(6.8 months), and an overall system life improvement of 71%.
Although the reliability numbers seem small, they transform into large amounts of
savings in operating time and maintenance costs. To estimate maintenance costs, we
must first convert MTBF into MTBM or Mean Time Between Maintenance:
MTBM = 1/{1/MTBMu+1/MTBMs}
Where: MTBMu = Mean Time Between Unscheduled Maintenance

MTBMs = Mean Time Between Scheduled Maintenance
And: MTBMu = MTBF

MTBMs = C * MTBF, where C < 1
Therefore:
MTBM = 1/{1/MTBF+1/(C*MTBF)} = MTBF * C/(C+1)
Where: C is operator defined.
19.
A typical limiting case occurs when operators establish scheduled maintenance intervals
to coincide with unscheduled maintenance actions, or: C = 1. The above expression
reduces simply to:
MTBM = 0.5 * MTBF
This practice is not recommended when the cost of complete production loss (both
pumps down) can be extremely high even though the probability of such an event is
extremely low (<0.25%). Typical urea plant operators find that they can significantly
increase MTBMu by selecting a scheduled maintenance interval MTBMs between 30 to
50% of MTBF (i.e. C = 0.3 to 0.5). In most cases, the time and cost of maintanence for
scheduled actions is far lower than for unscheduled maintenance. This is particularly
true when scheduled actions are planned to coincide with periodic scheduled plant shut-
downs.
HYPOTHETICAL LIFE CYCLE COST EXAMPLE

The reliability and maintainability improvements from TABLES 3 and 4 were input to a
simplified version of the LCC model described earlier. The economic factors assumed
for this example are shown below:
Useful Asset Life = 25 years

Cost Of Capital & Inventory = 10%
Annual Price Inflation = 4%
Annual Urea Plant Utilization = 8760 hours/year
Annual Operating Hours Per Pump = 4380 hours/year
Mean Maintenance Down Time For P/G = 8 hours
Scheduled Maintenance Labor Rate = $25/hr
Unscheduled Maintenance Labor Rate = $50/hr
Market Urea Price = $175/mt FOB bulk
Stamicarbon Urea Plant Capacity = 1.8 MT/D
Electric Power Cost = $0.15/kW-hr
Overall HMP Efficiency = 55%
To properly compare the previous and new designs, operating and maintenance (O&M)
costs were emphasized. All future cash flow streams were translated into NPV (Net
Present Value) dollars by the LCC model to preserve validity of the comparison.
20.
FIGURE 12 shows the comparative LCC for the two designs, with the values
normalized to the total LCC for the previous design. Normalizing comparisons in this
way allows the data to be used as a relative measure for other installations. The example
results show an approximate 40% improvement in LCC for the system evaluated.
Figure 12: Life Cycle Cost Comparison
EXAMPLE LCC COMPARISON

O&M COSTS ONLY - OLD vs. NEW
1.0
0.8
Normalized LCC
0.6
0.4
0.2
0.0
PREVIOUS NEW
Main Oil Pump Impellers High Speed Shafts
Radial Bearings Gearbox Oil Seal Process Seals
The dominant cost factors are related to seal reliability. As expected, increasing the
gearbox oil seal life by a factor of three, and improving process seal life by 50%,
provides the greatest contribution to overall LCC improvement. For the system
described, in the previous configuration, all seal faliure rates account for roughly 60%-
70% of O&M related LCC. This is consistent with customer feedback in Stamicarbon
urea plants. Seal reliability improvements are largely attributable to: process seal re-
design, vibration reduction, increased capacity pulsation dampeners reducing pressure
pulsation amplitude to seals, and seal housing port refinements.
By improving LCC to the operators without increasing initial capital cost, the analysis
can illustrate the magnitude of immediate financial benefits available to customers who
place the new design into service. Within the economic assumptions set forth in the
example, users can roughly estimate the savings achievable from the improved design
by taking 40% (1 - 0.60) of their existing HMP-3512 O&M expenditures for all 4
machines (2 carbamate plus 2 ammonia).
21.
Depending upon the installation, upgrading the previous design to the new configuration
may be able to save existing plant operators up to 40% of their HMP O&M costs for the
25 year life of the machine. In Net Present Value (NPV), this saving can easily exceed
the purchase price of a new P/G assembly, or an entirely new system.
5. SUMMARY
Sundstrand has made dramatic improvements to the HMP high speed centrifugal pump
designs used in Stamicarbon’s urea process. Each feature in Tables 1 and 2 was selected
for its contribution toward achieving one or more of the following quality improvement
objectives:
· Improve actual field operating reliability by at least 25% as measured by MTBMA.

· Reduce product performance and reliability sensitivity to variations in customer
operating conditions and field maintenance techniques.
· Improve product maintainability/producibility and reduce the cost of quality.
By listening to feedback from customers in the field, and by applying Value Engineering
techniques, the HMP-5112 was re-designed first. Improvements which provided
immediate synergies to the new HMP-3512 design were then incorporated along with
specific HMP-3512 changes. Although significant improvements were made to the
auxiliaries, the majority of changes directly increased P/G (Pump/Gearbox) reliability ,
resulting in an estimated improvement of 87%. This result directly benefits the end user
in terms of improvment in O&M related LCC. Sundstrand has applied simplified
relaibility and LCC analysis techniques utilized in the Aerospace industry to estimate
the magnitude of these financial benefits. An example model was presented which
illustrates that up to 40% reductions in O&M LCC can be attained.
LCC models are very useful tools in systems analysis for comparing the relative
cost/benefit ratios of alternatives. They are also valuable tools in setting priorities for
future product design and improvements. These statements are particularly true when
performed in a partnership arrangement between the equipment manufacturer, process
licensor, engineering contractor, and/or operator.
22.

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8th Stamicarbon Urea Symposium

6 - 9 May 1996, Amsterdam

3. Product improvement history, philosophy & objectives 2

4. Reliability and life cycle cost analysis 13

3. PRODUCT IMPROVEMENT HISTORY, PHILOSOPHY & OBJECTIVES

· Improve actual field operating reliability by at least 25% as measured by Mean

· Reduce product performance and reliability sensitivity to variations in customer

· Improve product maintainability/producibility and reduce cost of quality without

HMX Product Line

HMP-5112 PRODUCT IMPROVEMENTS

Value Engineering was applied to our objectives of improving reliability, minimizing

Refer to Figures 3 and 4 above using the balloon numbers:

1. Bearing diameter increased for higher HP (kW) capacity.

Table 1: Summary of performance measurements

Figure 5: Previous configuration

Figure 6: New configuration

HMP-3000 PRODUCT IMPROVEMENTS

New Gearbox Mechanical Seal - Keeps oil in and contaminants out.

WET END HARDWARE

SEAL FLUSH AND BUFFER SYSTEM

WET END HARDWARE

SEAL FLUSH AND BUFFER SYSTEM

Figure 8: Previous and new rotating seal face configurations

4. RELIABILITY AND LIFE CYCLE COST ANALYSIS

There are a wealth of excellent publications on the subjects of reliability,

R(t) = e-t/M = e-λt

Table 3: HMP-3512 pump

Previous Configuration New Configuration

MTBF, Operating Years R(t) MTBF, Operating Years R(t)

Coupling 20 .951 20 .951

The complete system reliability is calculated in TABLE 4. In the original configuration,

Table 4: HMP-3512 pump and system

Original Configuration New Configuration

MTBF, Operating years R(t) MTBF, Operating years R(t)

Main driver 6 .846 6 .846

Where: MTBMu = Mean Time Between Unscheduled Maintenance

And: MTBMu = MTBF

MTBM = 1/{1/MTBF+1/(C*MTBF)} = MTBF * C/(C+1)

Where: C is operator defined.

HYPOTHETICAL LIFE CYCLE COST EXAMPLE

Useful Asset Life = 25 years

Figure 12: Life Cycle Cost Comparison

EXAMPLE LCC COMPARISON

Main Oil Pump Impellers High Speed Shafts

Radial Bearings Gearbox Oil Seal Process Seals

· Improve actual field operating reliability by at least 25% as measured by MTBMA.

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MTBM = 1/{1/MTBF+1/(CMTBF)} = MTBF C/(C+1)