Materials of Construction [-z Building a Better Boiler Feed Pump Robert Aronen, Boulden International; Dennis Plaizier and Dave Sinclair, Hydro-Scotford, Inc. Say goodbye to concerns about pump seizure: By properly applying composite materials to a troublesome boiler feed water pump, this large process facility in Alberta can now run one pump during full-rate operation with very low vibration and higher efficiency. he reliability and eficiency impacts of close-clearance | ‘wear components — wear rings, inter-stage bushings, throat bushings, and pressure-reducing bushings have been well documented, In 1985, Bloch and Geitner cited the Following poten: tial problems associated with excessive wear ring clearance: cffciency losses, loss of rotor stability, shaft breakage, driver overloading, bearing overheating or failure, unequal load sharing in parallel pump operation, noise and damage typi cally associated with cavitation, and possible coral pump destruction (p. 31-36) ‘One application for which the wear components are particularly importanc is boiler feed water. In the typical process plant, the boiler Feed water pump is a multistage horizontally-spit, beoween-bearings design that is heavily dependant upon the wear components for rotor stabilicy Material selection is very importane to ensure long-term reliability in this service. The value of proper application and installation of modern composites is demonstrated by che results from a ‘9-seage boiler feed water pump from a large process facility in Centra Albert Why Wear Components are Important The close clearance wear components in 4 centtifugil pump perform similar func- | #001 ~5.000 in( tions. They separate high pressure areas | 5.001 ~ 6.000 in(t within che pump from lower pretext |” 9017.00 int viaa minimal clearance between aotating | o55 5 oop nq and stationary member. Due to the differential pressure across 26 NOVEMBER = these components, there is substantial flow from the high pressure to lower pressure regions of the pump ~ recirew lation flow. If inadequate clea components, the rotating and stationary elements could possibly seize and lead to substantial pump damage (Bloch, 1988), ‘Conversely, as the clearance beeween rotating and sta nce Ties between wo metal tionary components increases, the recirculation flow within the pump increases and efficiency drops (Bloch and Ge 1985). Over time, this will become evident to the pump ‘operators as recitculation flow increases to the point where the pump can no longer operate at design capacity What the operators may not notice is that che wear ‘components also contribute substantially to rotor stabilicy (Lobanoff and Ross, 1992, p. 440-451), Increased clearance at the weat components can lead to higher vibration, shorter bearing life, and the pocental for high-energy failure modes such as shale breakage Furthermore, recirculation flow atthe first-stage impel ler eye increases the effective inlet luid temperature, pos sibly 90.97). The net result is that a pump with increased clear- ading to cavitation damage (Lobanoff and Ross, p. ance at the wear components is not as reliable or efficient as (Gabel oe Ot 27152 mm) | 0.017in(0.43 mm) | 0.008 in(0.20 mum) | 21mm) | 0018 @aemm) | 00m in023 mm) | Table 1 Typical clearance values for metal and composite wear rings. PUMPS & SYSTEMS“Thermal Expansion Coefisient(X-Y plane) “Thermal Expansion C ent (Z-iretion) to 300°F Dynan Coetfisiont of Friction (25 fin) 020 Liming PV Hardness 75 Water Absorption “Temperature Limit Table 2. Composite material properties, 4 pump with reduced clearance The Composite Advantage Composite materials have advanced ro the degree chat wea components can now be the source of reliability improve- ment Modern composite wear mateals duce the risk of pump secure and can therefore be installed with dighrer clea fncs than thoge listed inthe API 610 standard for config pumps be Table 1) One material that has been widely applied is a com presion-molded composite of fuoropolymer resin and long carbon fibers oriented in a directional matrix, This directional sults in an anisotropic material with different proper ties in the X-Y plane compared to the Z-axis. For a typical pump wear component, the X-Y plane is perpendicular to the axis of rotation. ‘The properties for this ‘material ae shown in Table 2 The overall combination of properties available in modern composites (sce Table 2) set the stage for rliabilcy improve rmcnts, The coeicient of thermal expansion, coefficient of ic tion, and limiting PV (pressute velocity ratio) are all importane factors to reduce the rsk of material seizure ‘More importantly, these prop material 10 survive the normal contact that occurs becween rotating and staionary components without weating out oF faling prematurely, particularly during process upsets such as low flow operation, cavitation, or fundry events. ties are essential for the Because composite materials reduce the risk of seizure or damage during normal contact, running clearance at the wear ‘components can be reduced, typically vo 50 percent ofthe APL ‘components. Reduced clearance improves eliability and efficiency, as demonstrated both under controlled conditions and during field studies (Komin, 1990: Pledger 2001), Ina recent study of 61 pumps in an oil refinery; conversion 610 recommended value for metal we to composite wear materials with reduced clearance reduced the failure rate by 45 percent, and overall vibration levels fll by an average of 25 percent (Aronen, Boulden, Russek, 2007). With this growing history of suecess, no wonder pump users are eurning to composite materials for some of theit roughest applications POWPS & SYSTENS 1.8 X 10° inin*F 180 X 10° iin’ 155,000 Rimin 0 Shore D S00°F @6rO) ‘ww pumpzane com Figure 1. The 9-stage boiler feed water pump. The Pump that Couldn't large process facility in Central Alberta was having problems with their boiler feed pumps. The original 12 chrome metal ‘wear components caused several pump seizutes. Even though the mecal components were designed with differential hardness, the original design clearance of 0.016-in (0,406-mm) between rotating and stationaty wear components was increased to pre vent seizure. The increased clearance led to production prob- Jems. When running a fll rates, the plant needed to run to pumps in parallel Plant reliability and maintenance personnel needed a solution thar would allow one pump to meet production needs during full rate operation without increasing the risk of scinure. After consultation with eheit local repair facility, ehey decided to overhaul one of heir pumps using all composite stationary wear components (case wear rings, in bushings, throat bushings, and center-stage bushing) wich reduced clearances. The pump involved is a common design for a process rage case plane boiler feed water pump: 9.stage, horizontally-spit berween-beatings design (se Figure 1) This design includes a doublesuetion first-stage impeller with wear eings, an eyeside wear ring and inter-stage bush ing ac each of the other cight stages, ro throat bushings, and a pressure reducing bushing between the Sth and 9th stages The impellers are 9.125-in (232-mm) diameter, with 5-in Figure 2 Rotor configuration. NOVEMBER 200727Is of Construction mm) diameter wear rings. are aro This pump des Section Pressure | 26 psig (182 KPa) pig (7936 KPa) “Temperature Discharge Pressure | 1 Rated Power [317 hp @37kW) Speed 38501 long, thin shaft (se Fi the wear rings for rotor stabiliy While the pump is idl sn ereates unique challenges which are particulary suited to the application of composite wear components, The rotor configuration ~ a re 2) suspended berween bearings ~ relies heavily upon there is substantial rotor sag (about 0.008- ‘a ______|_—_in/,2-mm) at the center bushing. The rotor sag goes away only when the Table 3. Process conditions for boiler feed pump. DICKOW Pump Company Dictow Pump Company has mantactored centtags! pumps ‘or mre tan 5 years, aways wih an emphasis 0 precision Inge in sevice and htralicaMciancy Today we ater the brandes and most technological advanced range of magnet taive pumps, 0d have sod npn expenance Erg Ded Heron Cantal Pe “Clee Cale win cantare 800-880-4442 Dickow Pump Company a 1738 SANDS PLACE SE» MARIETTA. GA 30067 USA "TEL: (770) 952-7903 » FAX (770) 933-8846 EMAIL. salex@dickow.com 28 wovEMBER www.dickow.com [ay| pump is running and hydrodynamic forces at the wear rings are established. During alignment of the pump to the driver, slow-roll (if coupled to a steam turbine driver), or at start-up, there will be contact at the center stage bushing. and other wear components. During full speed operation off de- sign conditions like low-flow operation, dry-tunnin ‘contact between rotating and stationary ‘components, potentially leading to s sure. The service conditions, shown in Table 3, were typical for a process plant boiler feed pump. Pump Retrofit Details To optimize the performance of this pump during the available repair time the repair facil selected a composite material forall of the stationary. wear components. The existing. 12 percent clarome meal rotating components were used in combination with the compos- J. Running clearance between rotating and stationary components was reduced t0 0.008-in (0.203-mm), 50 percent of the original design values, Instead of fabricating new compo- rents with complex geometry for the stationary composite components, the ‘existing components were used as hold crs for composite “inserts.” The existing metal bores were increased, and thin- radial-wall composite inserts were mi ufactured and pressed into the metal holders Additional design detail was needed for the split int shown in Figure 3. Usin age bushings, as the existing ‘components as “holders” for the com: posite reduced the required machining nating the nced for milling slots and other details on the outside diameter of the components To prevent axial movement of the PUMPS & SYSTEMSFigure 4. Line ‘boring the » r TIME FORA | ia NEW PUMP A oe Figute 3. Composite insert in metal case ne ring holder. pera composite, the metal holders incorpo: Re-engineered rated a small shoulder on the low pres Pump Saves Money. sue side, There were no pins or stews CC ‘composite relying upon a heavy inter La low coefficient of friction and other properties that reduce risk of seizure this method of installation b s proven, clfeccve wih this composite during the past rn years of field experience. Turning the Rotor Retrofitting a pump with composites is a fairly straightforward proposition However, as the clearance at the wear components decreases rotor concenitic ts keeping your timed screw pump alive costing too much? ity becomes more important. To ensure Call Leistritz. success with the new; tighter clearance We'll select a standard Leistritz pump cartridge that best meets the repair facility must pay attention to ie eee rey 2 few fundamental details Dt eee eae a Before the rotor is installed, the eee tai rar pump should be fully inspected. The split-line should be checked to re ea cand is true, the line bore and seal chamber Were Hest 2k Te SG bore should be checked for concentric Bree nue Ra ity (sce Figure 4), and the rotating ele ‘ment shouild have limited run-out (typi cally 0.002-in mas} Indiv checked for condition and concentric ity, For example, if using the exis dual components should be case ring as a holder for a composite insert, the metal ring should fit prop. ely within the pump case, Loose or disw "Materials of Construction Composite wear materials reduce the bo boyaeelnee be repaired risk of pump seizure and can be installed Once the rotor is in place, the case a . bolted rogether, and the bearing hous- with tighter clearances than those listed ings doweled and bolted in place, one . final check is needed. ‘The rotor should in the API 610 standard. turn freely, which requires a reasonable understanding of the pump internals. Due to the aforementioned rotor sag (along with friction from the API 685 1st Edition ene ees Canned Motor Pumps | 32% cupres Hews: which would indicate mechanical incer- Fully compliant with API 685 standards, vertical and hotonline Caned hotorPumgs ene ference berween rating and stationary fom Nikiso Furps Amarica, gt se, ~~ E===~| parts. Once the ror is curning acom- sre eee Beene repair faci will be capable of Seremarson determining whether the rotor i turn ing freely or is inhibiced by mechanical inerference, which could cause prema- cure failure of the pump. Results of Retrofit TThe boiler feed water pump in Alberta has been running since June 2007 and the retrofit has delivered everything plane personnel waneed + One pump now meets full load pro- duction demands + Risk of metal ro metal seizure is dramatically reduced. + The pump is running with very low vibration compared to previous level, As an added bonus, amperage draw on the motor has fillen by 5 per- cent, Using the rated power of 317-hp (237-4W) and assuming a power cost of $0,06/Wh (a typical price in North “America cis is worth a lot of money For this’ one pump, the plane will save roughly $6,200 for every year of Highly reliable Canned Motor Pumps in ‘operation. amazingly compact designs. world’s m Bearing Mos Conclusions The benefits of running a pump with ” NIKKISO reduced clearance at the wear rings and ~ NIKKISO Pumps America, In similarcomponentsarewell documented 500 Kenrick Drive, Sule C-1 » Houston, TX 77060 by Bld studies and pump design texts P: 281-310-6747 + F: 281-310-6771 ‘Composite materials allow pump repair www. nikkisopumpeamerica.com facilities to reduce the clearance at the Canned Motor Pumps + Metering Pumps « Power Pumps 30 NOVEMBER 2007 ‘wenwpump-zone.com PUMPS & SYSTEMSswear components to values substantially less than the recommended minimums for metal components as listed in API 610, Furthermore, the latest generation composites ha ‘material properties which process upsets, and off-design he rsk of pump failure p overhaul practices a stand up & n opera tion, reducing Quality help deliver the full benefit of compos. ite materials with reduced clearance Thorough component inspection, veri fication of rotor concentricity within the case, and proper composite installa tion methods contributed to the success of cis application, 1. Arann R., Bou Band Rash, M sibility Forward Tutor Unive Callege Staion, 9 Tit techinry Ua Publishing Compan 2, 2001 “Improving Pa Robert Aronen isthe managing director of Boulden International, Brussels, Belgium, +32-498-56-20-53, robert @bouldencompanycom, ww: bouldencompany.com. Dave Sinclair is the general manager and Dennis Plaizier is the sales manager at Hydro-Scorfrd, Ine, Range Road 215, Highway 15, Bax 3298, Fort Saskatchewan, Alberta TSL2T3, 780-992-0100, Fax: 780-992-0200, diinclair@hyaroscoford. com, dplaiier@hydvocoford com, wwu:hydroscotford.com Simsite’ Bearings Increase Bearing Life! Reduce Downtime! Simsite’ Composite Bearings * ABS Approved * US Navy Approved Use the BEST! 4-800-746-7303 _www.Simsite.com ‘Sims Pump Go,, 1314 Park Ave, Hoboken, NJ. 07030