Pump User's Handbook: Life Extension, Third Edition

517 Pages·2010·18.77 MB·English

by  Heinz P. Bloch

Pump User’s Handbook
Life Extension
3rd Edition
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Pump User’s Handbook
Life Extension
3rd Edition
By
Heinz P. Bloch & Allan R. Budris
Library of Congress Cataloging-in-Publication Data
Bloch, Heinz P., 1933-
Pump user’s handbook life extension / by Heinz P. Bloch & Allan R. Budris. -- 3rd
ed.
p.cm.
Includes bibliographical references and index.
ISBN-10: 0-88173-627-9 (alk. paper)
ISBN-10: 0-88173-628-7 (electronic)
ISBN-13: 978-1-4398-3740-5 (taylor & francis distribution : alk. paper)
1. Pumping machinery--Handbooks, manuals, etc. I. Budris, Allan R. II. Title.
TJ900.B648 2010
621.6’9--dc22
2009049371
Pump user’s handbook: life extension/by Heinz P. Bloch & Allan R. Budris. Third edition.
©2010 by The Fairmont Press, Inc. All rights reserved. No part of this publication may be
reproduced or transmitted in any form or by any means, electronic or mechanical, including
photocopy, recording, or any information storage and retrieval system, without permission
in writing from the publisher.
Published by The Fairmont Press, Inc.
700 Indian Trail
Lilburn, GA 30047
tel: [phone]; fax: [phone]
http://www.fairmontpress.com
Distributed by Taylor & Francis Ltd.
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487, USA
E-mail: [email protected]
Distributed by Taylor & Francis Ltd.
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Deodar Road
London SW15 2NU, UK
E-mail: [email protected]
Printed in the United States of America
10 9 8 7 6 5 4 3 2
10: 0-88173-627-9 (The Fairmont Press, Inc.)
13: 978-1-4398-3740-5 (Taylor & Francis Ltd.)
While every effort is made to provide dependable information, the publisher, authors, and
editors cannot be held responsible for any errors or omissions.
iv
Contents
Preface ................................................................................................................vii
Acknowledgments ............................................................................................ix
Chapter Page
1 Pump System Life Cycle Cost Reduction.........................................1
2. How to Buy a Better Pump—Initial Cost Issues ............................5
3. Piping—Baseplate—Installation and Foundation Issues .............33
4. Operating Efficiency Improvement Considerations......................79
5. Improved Pump Hydraulic Selection Extends Pump Life .......107
6. Improvements Leading to Mechanical Maintenance
Cost Reductions .................................................................................119
7. Bearings in Centrifugal Pumps ......................................................141
8. Mechanical Seal Selection and Application ................................179
9. Improved Lubrication and Lube Application ..............................231
10. Oil Mist Lubrication and Storage Preservation ...........................279
11. Coupling Selection Guidelines ........................................................305
12. Pump Condition Monitoring Guidelines ......................................315
13. Pump Types and Materials ..............................................................333
14. Pump Failure Analysis and Troubleshooting ..............................371
15. Shop Repair and Spare Parts Availability & Procurement .......407
16. Failure Statistics and Component Uptime
Improvement Summary ...................................................................437
Appendices .....................................................................................................451
References ........................................................................................................479
Index ...............................................................................................................489
v
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Preface to the Third Edition
Not much has changed since the second edition The assembled pump may have to be inspected and
was released in 2006. Next to electric motors, centrifu- tested; it certainly has to be properly installed. It also
gal pumps still represent the most frequently utilized needs to be serviced or maintained with appropriate
machine on earth. It has been estimated that over care and knowledge. And, it needs to be operated within
10,000,000,000 of them are in use worldwide. (Ref. I-1). the intended design envelope.
And pump life extension, maintenance cost reduction, In other words, pumps can, and usually will fail,
and safety and efficiency enhancement opportunities if one or more of seven important criteria are not met.
seem to grow. It has been proven (Ref. I-2) that:
Pumps certainly are simple machines, for quite
unlike an aircraft jet engine that consists of somewhere • The design has to be correct
• The various components have to be fabricated just right
between 6,000 and 9,000 parts, a centrifugal pump is
• Pumps must be operated within an intended service con-
made up of a rotor, two or three bearings, a few casing
dition envelope
parts, perhaps a mechanical seal and a bunch of fasten- • Pumps must be maintained as required
ers. And yet there are, in the United States alone, many • Pumps have to be assembled and installed correctly
thousands of pumps that achieve mean-times-between- • Pumps will not tolerate certain types of operator errors
• Component materials must be without defect
failures (MTBF’s) of only a year or less, whereas in
numerous other identical services MTBF values of over
eight years are not uncommon.
WHAT PUMP FAILURES REALLY COST
This text will explain just how and why the best-of-
class pump users are consistently achieving superior run
When pumps fail, the cost can be staggering. In
lengths, low maintenance expenditures, and unexcelled
1996, a South American refinery repaired 702 of their
safety and reliability. Written by practicing engineers
1,012 installed pumps. In that year, these pumps con-
whose working career was marked by involvement in
sumed 1,420 rolling element bearings. In 1984, a U.S.
pump specification, installation, reliability assessment,
oil refinery performed close to 1,200 repairs on 2,754 in-
component upgrading, maintenance cost reduction,
stalled pumps. Of these, 40% were done in the shop and
operation, troubleshooting and all conceivable facets of
60% in the field. Based on work order tracking, the di-
pumping technology, this text endeavors to describe in
rect charges per repair amounted to $5,380, or $6,456,000
detail how you, too, can accomplish best-of-class per-
per year. The true costs, however, amounted to $10,287
formance and low life cycle cost. Or, how your facility
per repair. Here, yearly pump maintenance expenditures
will get away from being a 1.1, or 2.7, or 3.9 year MTBF
were calculated to exceed $12,000,000 when incremental
plant and will join the plants that today enjoy a dem-
burden consisting of employee benefits and refinery ad-
onstrated pump MTBF of 8.6 and, in at least one case
ministrative, plus overhead and materials procurement
further described in Chapter 16, over 10 years.
costs were taken into account.
Statistics from a plant with 3,300 centrifugal pumps
installed indicate that 30% of the plant’s yearly repair
WHAT PUMPS DO
events are traceable to maintenance deficiencies. Neglect
Pumps are used to feed liquids from one place to and faulty procedures fall into this category. Another
another. There is no liquid that cannot be moved by refinery supplied Figures I-1 and I-2, pointing to bearing
pumps. If pumps cannot move a product, the product is failures (40%) and lubrication issues as being the main
probably not a liquid. Pumps are used in every industry culprits. Quite obviously, these illustrations show that
conceived by man and are installed in every country in considerable resources are expended on bearing and
the world. lube-related maintenance. Yet, speaking of lubrication,
But pumps are machines and machines need to a report from a Mid-Eastern refinery with 1,400 pumps
be properly designed. The parts for the pumps need to on dry sump oil mist specifically pointed out that there
be correctly manufactured and assembled into a casing. were no bearing failures in the year 2004 (Ref. I-3).
vii
• Pump failure reductions are largely achieved by
appropriate action of plant reliability staff and
plant or contractor maintenance work forces. The
pump manufacturer rarely deserves to be blamed,
although it is unfortunate that the pump manufac-
turer is not always knowledgeable in pump failure
avoidance.
In the mid-1980’s, a chemical plant in Tennessee
had over 30,000 pumps installed and a large facility
near Frankfurt, Germany, reported over 20,000 pumps.
However, the largest industrial pump user appeared to
be a city-sized plant situated on the banks of the Rhine
river south of Frankfurt. There were approximately
Figure I-1: Causes of equipment outage at a major re- 55,000 pumps installed at that one location alone.
finery by component description, years 2003 and 2004 United States oil refineries typically operate from
600 pumps in small, to 3,600 pumps in large facilities.
Assembly and installation defects are responsible Among the old refineries are some that have average
for 25% of pump failures at that facility, and 15% of the pump operating times of over 8 years. However, there
pump problems encountered were attributed to opera- are also some that achieve an average of only about a
tion at off-design or unintended service conditions. year. Some of the really good refineries are new, but
some of the good ones are also old. Certain bad perform-
ers belong to multi-plant owner “X” and some good
performers also belong to the same owner “X”. It can
therefore be said that equipment age does not preclude
obtaining satisfactory equipment reliability.
But it can also be said that facilities with low
pump MTBF are almost always repair-focused, whereas
plants with high pump MTBF are essentially reliabil-
ity-focused. Repair-focused mechanics or maintenance
workers see a defective part and simply replace it in
kind. Reliability-focused plants ask why the part failed,
determine whether upgrading is feasible, and then cal-
culate the cost justification or economic payback from
the implementation of suitable upgrade measures. Need-
Figure I-2: Causes of bearing failures at a major refin- less to say, reliability-focused plants will implement
ery by cause category every cost-justified improvement as soon as possible.
And so, again, why pumps fail and how to avoid
Improperly operated pumps constitute 12% of failures will be discussed in this text. Why the same
pump failures here. Fabrication and processing errors pump model does well at one plant and does not do
cause 8% of this plant’s pump failures; faulty design was well at another plant will be described and analyzed.
found responsible for 6% of pump failures, and 4% of Pump life extension and energy cost reduction will be
the failure population suffered from material defects. the overriding concerns and will be the collective theme
These statistics convey a number of very important of this book. This updated and expanded third edition
facts: contains experience-based details, data, guidance, di-
• Most pumps fail because of maintenance and in- rection, explanations, and firm recommendations. The
stallation-related defects material will assist all interested facilities to move from
the unprofitable repair-focus of the mid-20th century,
• Since pumps generally represent a mature product, to the absolutely imperative reliability focus of the 21st
fundamental design defects are relatively rare century.
viii
Acknowledgements
While compiling the material for this text, we • CPC Pumps, Mississauga, Ontario, Canada (process
looked at well over one thousand illustrations of pumps pumps, 6-23)
and related components. Picking the ones we did should
• DuPont Engineering Polymers, Newark, Delaware (Ves-
in no way be inferred as disqualifying similar products
pel® wear materials, 6-28, 6-29)
from other manufacturers or suppliers. We carefully
chose from readily available commercial information • Emile Egger & Co., Ltd., Cressier, NE, Switzerland (ISO-
that was judged useful for conveying the technical compliant centrifugal pumps, 2-11, 13-37, 13-38)
points we wanted to make.
With this in mind, we gratefully acknowledge the • Enviroseal Corporation, Waverley, Nova Scotia, Canada
(seal protectors, 8-75, 8-76)
cooperation of the many competent U.S. and overseas
companies and individuals that granted permission to
• ExxonMobil, Lube Marketing Division, Houston, Texas
use portions of their marketing literature and illustra-
(lubricants, 9-4, 9-7 to 9-9)
tions. These include:
• FAG Corporation, Stamford, Connecticut (rolling ele-
• Afton Pumps, Inc., Houston, Texas (process pumps, 13-4)
ment bearings, 9-2, 9-38, 9-41, 9-48)
• A-Line Manufacturing Company, Liberty Hill, Texas
• Falk Corporation, Milwaukee, Wisconsin (shaft cou-
(dial-type alignment fixtures, 3-47, 3-48)
plings, 11-2, 11-6 to 11-8, 11-13)
• Allis-Chalmers, Milwaukee, WI (pumps, 13-25)
• Flexelement Coupling Corporation, Houston, Texas (cou-
plings, 11-9)
• AESSEAL, plc., Rotherham, UK, and Rockford, Tennes-
see (mechanical seals, bearing isolators, 6-11, 6-17 to 6-21,
• Flowserve Corporation, Kalamazoo, Michigan (pumps,
8-14, 8-62 to 8-74, 8-77 to 8-79, 9-11, 9-36, 10-17 to 10-19.
seals, 8-11, 8-12, 8-18, 8-19, 8-21 to 8-24, 8-39)
• API (American Petroleum Institute), Alexandria, Virginia
(Equipment Standards, 2-1, 2-2) • Garlock Sealing Technologies, Palmyra, New York (seal-
ing products, 9-33)
• A.W. Chesterton Company, Stoneham, Massachusetts
(mechanical seals, 8-9, 8-16, 8-17, 8-25, 8-26, 8-35 to 8-45) • General Electric Company, Schenectady, New York (elec-
tric motors, 11-4)
• BaseTek® Polymer Technology, Chardon, Ohio (cast
polymer baseplate technology, 3-30, 3-31) • Hermetic Pump, Inc., Houston, TX, and Gundelfingen,
Germany (process pumps, 13-10, 13-11, 13-16, 13-17)
• Borg-Warner and parent company John Crane, Temecula,
California (mechanical seals, 8-5)
• HydroAire, Inc., Chicago, Illinois (pump repair and up-
grading, 15-21 to 15-23)
• Burgmann Seals America, Houston, Texas, and its par-
ent company Dichtungswerke Feodor Burgmann, Wol-
• Inductive Pump Corporation, Frankfort, New York (in-
fratshausen, Germany (mechanical seals, 2-7, 8-2, 8-3,
ductive pumps, 9-29, 9-30)
8-6, 8-7, 8-13 to 8-15, 8-34, 8-60, 8-61, 9-35)
• Ingersoll-Dresser, Allentown, Pennsylvania (process
• Byron Jackson Division of Flowserve Pumps, Kalama-
pumps, 9-23)
zoo, Michigan (process pumps, 15-17 to 15-19)
• Carver Pump Company, Muscatine, Iowa (process • INPRO/Seal Company, Rock Island, Illinois (bearing
pumps, 6-22) isolators, 6-15, 9-36)
• Coupling Corporation of America, York, Pennsylvania • Isomag Corporation, Baton Rouge, Louisiana (magnetic
(shaft couplings, 11-11) bearing housing seals, 6-9, 9-34)
ix