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Asset Management Standard

oct/nov12

Workution nt c Exenageme Ma

Mm

maintenance management

to Pump Reliability
Tom Dabbs and Dan Pereira
compressors, mixers, fans, blowers, conveyors, etc.), spending an average of $5.5 million annually on maintenance, operation and energy. While these machines have a one-time cost of a few thousand dollars each to purchase and install, the cost to operate them exceeds $10 thousand each per year. This includes maintaining, operating and providing energy for the life of the pump. Many of our customers are in a constant struggle to lower costs and The average annual maintenance and operaimprove output of their plants, and we believe tions spending on centrifugal pumps is 50 perthat improving pump reliability is a very sound cent greater than for any other type of rotating approach for accomplishing these goals. machine (FiveTwelve Group, August 2006). The rewards for achieving pump reliability Centrifugal pumps in many plants consume are great and the effort, on the surface, seems more than 50 percent of total plant motor fairly simple. After all, most of the elements of energy (Hydraulic Institute). reliability are just common sense. But Ralph Pumps consume more energy than any othWaldo Emerson expertly put this idea into perer class of industrial equipspective when ment (U.S. Department of he said: Energy, 2005). The rewards for achieving C o m m o n A Finnish Research Center sense is as rare pump reliability are study of centrifugal pump as genius. great and the effort, on performance (Expert SysThe tough the surface, seems fairly tems for Diagnosis and Perpart is that no formance of Centrifugal simple. After all, most of matter how Pumps, 1996) found that the well conceived the elements of reliability average pumping efficiency or how well imare just common sense. was less than 40 percent for plemented, re1,690 pumps reviewed across liability efforts 20 different plants, including all market segrequire people to act in very specific and conments. The study also revealed that 10 persistent ways to sustain the effort. Furthermore, cent of the pumps were less than 10 percent it takes tremendous leadership and discipline efficient. to initiate these efforts and keep them on A large cross-section of our customers opercourse. Reliability improvement efforts also reate between 500 and 2,000 pumps in many of quire inclusion of all plant functions to be suctheir locations, as well as thousands of other cessful. We need to capitalize on our collective knowledge, experience and even our failures pieces of complex rotating equipment (e.g.,

10 Steps
to guide the efforts to improve bottom-line performance. For instance, include maintenance personnel and reliability engineers in new equipment designs and selections by bringing their knowledge and failure cause history to the table; have operators participate in performance specifications to make them as clear as possible; challenge purchasing to choose vendors and make final equipment selections based on best total cost of ownership as opposed to lowest purchase price; and consult stores personnel on existing stock of spare parts to minimize duplication and identify opportunities to standardize. There are other inclusions we can make, but you get the picture; make everyone in the business a part of your reliability efforts. Now lets get to the 10 steps to pump reliability. The top 10 steps you can take to achieve sustainable pump reliability are: 1. Proper Design and Equipment Selection. 2. Proper Installation and Commissioning. 3. Proper Flow Control. 4. Proper Operation. 5. Proper Maintenance. 6. Stock the Right Parts. 7. Monitor Efficiency. 8. Track Lifecycle History. 9. Establish a Pump Management Program. 10. Establish a Configuration Management Process. Note: Steps 6 through 10 will be discussed in the December/January issue of Uptime magazine.

Pump reliability is an old topic, but it is just as relevant today as it was the first time we heard it a few decades ago. There are some very good reasons to focus on improving pump reliability:

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oct/nov12

Part 1

Pump specifications should spell out all operating requirements and operating parameters. Some considerations are: Best efficiency point (BEP) of the selected pump; Flow; Pressure; NPSHA; Speed; Voltage; Fluid type; Specific gravity and PH; Metallurgy; Inlet and outlet pipe sizes; Operating temperature; Viscosity; Solids Present; Chemical reactivity; Vapor pressure; Entrained air/gases; Seal arrangement; Bearing lubrication method; Pipe size and configuration; Physical location and environment, etc. A complete and accurate specification is the first step to establishing a reliable pumping system. Many engineers tend to specify oversized pumps and excessive horsepower drivers on the premise that it is better to err on the side of having too much power for the application than too little. And if the flow of the system is too high coming out of the pump, it simply can be throttled in the discharge side. This approach, although very common, is a very

1. Proper Design and Equipment Selection

inefficient and very costly way to design a system. It increases energy costs for operating the pumping system, reduces the operating life of the equipment and will most likely increase the frequency of failure. To understand why this is true, you have to understand the basics of how a pump works. Centrifugal pumps operate with a rotating impeller that imparts velocity energy to a liquid. The impeller accelerates the liquid and discharges it into the casing and, as the casing area increases, the velocity energy is converted to pressure. Higher velocity brings higher pressure. Pumps are designed for specific flow ranges. When a pump is sized properly and is operating optimally, or at its best efficiency point (BEP), liquid flow is constant and radial forces acting on the impeller are at a minimum. This allows the pump to experience the highest efficiencies and lowest vibration. If the pump runs off-BEP at an increased or reduced flow rate, an imbalance of pressure will occur inside the pump. This imbalance can cause shaft deflection, excessive loads on bearings and mechanical seals, excessive vibration and heat, all of which significantly reduce the life of the pump and increase the likelihood of premature fail-

ure. Because the majority of pump operating conditions are dynamic and actual flow and pressure requirements fluctuate, it makes it extremely important to size the pump to operate at or near its BEP. Pumps operating away from BEP display a myriad of issues, none of which contribute to good reliability or efficiency. BEP occurs when the angle of the fluid entering the eye of the impeller is parallel to the impeller blade. Operating away from BEP changes the angle of the fluid to the inlet vane and increases the possibility of premature or catastrophic failure of the pump. By causing suction or discharge recirculation, or cavitations, this leads to excessive vibration, increased shaft deflection, increased bearing loads and reduced seal life.

Basic Hydraulics

When a pump is delivered to a site, its important to take time to inspect it to ensure it matches the order information and has not been damaged. If the pump is stored for less than six months, you only need to store it in a clean, dry environment that is free from contamination and excessive heat and vibration to keep it in good condition. If the pump is stored for more than six months, continue to follow these same guidelines and also begin to rotate the shaft Cavitation by hand at least every three months to prevent brinelling of the bearing surfaces. It is important to provide a rigid and flat concrete foundation that weighs two to three times as much as the pump. This will absorb any type of vibration and should prevent strain and distortion when you Vane tighten the foundation bolts. There Bubble Collapse is much detail to preparing a proper foundation and the vendors installaBubble Formation tion manual is a good reference for keeping things on track.

2. Proper Installation and Commissioning

Centrifugal Pump Characteristics TDH

Centrifugal Pump Characteristics

EFFICIENCY

BEP

BEP

105%

BEP

70%

BEP
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Another good practice is to never draw pip- Ensure that no part of the suction piping ex- stances should the pump flow be adjusted from ing into place by using force at the flanged contends below the suction flange of the pump, the suction side of the pump. In doing so, the nections of the pump. This can introduce signifiis adequately below the surface of the liquid risk of pump damage far exceeds any possible cant strains on the unit and cause misalignment source and is level or sloping downward from benefit. Modifying the flow from the suction between the pump and driver. Pipe strain adside of the pump will result in reduced pump the liquid source. versely affects the operation of the pump, which Net positive suction head available (NPSHA) life and unsafe conditions that could destroy the may result in physical injury and/or damage to equipment and cause serious injury or death. must always exceed NPSH required (NPSHR). the equipment. When checking rotation prior to start-up, dis- 4. Proper Operation Installation and commissioning represent connect the pump from the driver to prevent During operation of the pump, critical pera very small portion of the overall total cost of the pump from operating in reverse rotation. formance elements like flow, pressure, temownership (TCO). However, improper installaReverse rotation can result in the direct con- perature, vibration, current load and cleanliness tion and commissioning will result in problems tact of metal parts, excessive heat generation should be continuously monitored to ensure that significantly reduce the reliability of the and catastrophic failure. the pumping system is operating efficiently and pump. These problems often do not surface for effectively. a period of time and can 3. Proper As noted before, it is crucial that pumps are require significant time During the design phase, Flow Control sized properly and operate at the optimum and cost to resolve (e.g., Flow control is a speed to meet the flow and head requirements variable frequency drives redesign, base plate very important ele- while remaining at the BEP for the majority of or foundation replace(VFDs) should be evaluated ment for optimiz- run time. Additionally, it is extremely important ment, piping modificafor flow control. VFDs cost ing the efficiency to operate the pump properly to guarantee tions, etc.). Often these more to purchase and install and lifecycle cost of that the equipment will reach its useful design issues are not resolved a pumping system. life and for the safety of plant personnel. Pump and arent feasible for due to the time and Controlling flow by damage (bearing/seal) is cumulative. Regardcost required to solve every situation, but in many throttling a valve in less of the level of damage, it remains with the them, thus resulting in cases, smaller horsepower the discharge line components until the parts are ultimately rereduced life and higher is a widely used ap- placed. Multiple episodes of improper operarequirements and increased cost of ownership. proach for control- tion will cause the pump to fail prematurely. energy efficiency can offset Here are some wise ling the flow, but is Some pump operation rules to follow are: rules to follow during the initial cost. generally very inef- The suction valve is 100 percent open at all installation to avoid preficient and costly in mature failure: times. the long run. Pump Locate the pump as close to the liquid source Discharge flow is adjusted to ensure that there ing fluid against a partially closed control valve as possible. is adequate back pressure to eliminate water consumes tremendous amounts of energy and hammer or running out to maximum flow. Make sure there is adequate space around and can cause premature pump failure. This method above the pump for safety, ventilation, inspec- of flow control modifies the point in which the Pump is primed and air vented prior to start up. tion, installation/removal and maintenance. system curve intersects the pump curve and, if Seal flush systems are operational prior to Protect the unit from weather and water it is significantly away from BEP, pump life will start up. damage due to rain, flooding and freezing be diminished. Lubrication is at proper level and meets specitemperatures. During the design phase, variable frequency fied quality standards. Do not install and operate the equipment drives (VFDs) should be evaluated for flow con- Pump must be operated at a speed to mainin closed systems unless the system is con- trol. VFDs cost more to purchase and install and tain adequate flow through the pumping sysstructed with properly-sized safety devices arent feasible for every situation, but in many tem. (Above minimum flow rate stated by the cases, smaller horseand control devices. manufacturer). Take into consideration the occurrence of un- power requirements Pumps should not As noted before, it is crucial and increased energy wanted noise and vibration. be operated for long efficiency can offset the that pumps are sized periods of time at Follow all safety, installation, alignment, startinitial cost. The utilizamaximum flow rate. up, shutdown and operating procedures outproperly and operate at the tion of a VFD allows the lined in your vendors manual. Do not operate pump to remain close optimum speed to meet the the pump without Utilize API 686 Standards/Tolerances, or at a to BEP over a range flow and head requirements coupling guards corminimum the Hydraulic Institutes standards/ of flow by varying the rectly installed. tolerances, where applicable. while remaining at the BEP speed of the driver. The Pumps should not Ensure that the distance between the inlet VFD allows the pump for the majority of run time. be operated with the flange of the pump and the closest elbow is curve to be adjusted discharge valve comat least five pipe diameters. This minimizes along the system curve pletely closed for extended periods of time. the risk of cavitation in the suction inlet of the as opposed to the use of a control valve that pump due to turbulence. Do not allow the pump to rotate in reverse. modifies the system curve. Ensure that elbows in general do not have Another method of flow control is the use of a Failure to follow these rules may result in sharp bends and that the suction piping is bypass line with a fixed speed driver. This meth- elevated temperatures, excessive vibration, one or two sizes larger than the suction inlet od allows the flow through the pump to remain potential flashing of liquid, cavitations and exof the pump. constant, hopefully at BEP, while modulating cessive pressure build-up, which may lead to The suction piping must never have a smaller the flow rates downstream and diverting some catastrophic or premature equipment failure, of the fluid back to the source. Under no circum- personnel injury, or death. diameter than the suction inlet of the pump.

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5. Proper Maintenance

ning and scheduling cannot be emphasized Maintenance is the second highest cost ele- enough. After all, the issues that are resolved ment of TCO at 20 percent, aside from energy before they evolve into breakdowns are the at 32 percent, so it is extremely important to returns from the CM/PM investment. Another important element of a good mainestablish and follow a rigorous maintenance program to keep pumps in good operating con- tenance program is employing sound reliability engineering techniques aimed at eliminatdition and maximize their useful life. ing failure. Stanley Maintaining pumps Nowlan and Howard is fairly straightforward; Heap, the pioneers of you generally do the Stanley Nowlan and reliability-centered same things you do Howard Heap, the pioneers maintenance (RCM), to any rotating equipment. In our experiof reliability-centered main- concluded that to improve the reliabilence, the highest cause tenance (RCM), concluded ity of a machine, you of pump failure is improper operation that that to improve the reliabil- had to understand how it could fail and causes seal failure and ity of a machine, you had provide a means to improper lubrication eliminate the failthat causes premature to understand how it could ure. Eventually, you bearing failure. fail and provide a means to would eliminate all The first order of the ways it could fail eliminate the failure. business is to establish and end up with a a condition-monitoring more reliable ma(CM) program that inchine. As it turns out, they were right. Manucludes as many technologies that can be justified. Conditions that should be considered that facturers of aircrafts and automobiles, and many others, have used these techniques require some investment in technology are: very well to significantly improve reliability of Flow; their products. Pressure; If you have included these steps in your Temperature; pump management strategy, you are well Vibration; on your way to optimizing cost and plant output. This may seem like a lot of effort to Ultrasound; keep pumping systems running reliably, but Amp Draw. when you compare the effort to the cost of Acceptable ranges should be established for continuous inefficiency and repeat failures, it each of these parameters with actual readings makes it all worthwhile. Remember, all that compared each time they are taken. Readings you learn about keeping pumping systems should be trended over time to identify any running effectively and efficiently can be ditrends that require further analysis. Many comrectly applied to all other assets, making this puterized maintenance management systems investment even more valuable. Please read are capable of having these conditions directly the upcoming conclusion of this article, Ten entered into the system electronically and will Steps to Pump Reliability (Part 2), in the upprovide trend charts for timely analysis. coming December/January issue of Uptime Other conditions that should be considered magazine. by more traditional time-based preventive maintenance (PM) activities are: Lubrication (manufacturers specifications); Tom Dabbs, CMRP, is a Program Manager Seal water flow or packing integrity; for Asset Management with ITTs Plant Performance Services Group. He has Cleanliness; an Electrical Engineering degree from Proper air flow; Clemson University, with more than 35 years experience delivering behavior-based reliability Foundation or base plate issues; solutions working with clients to reduce cost and Piping system hangers and support integrity; improve business effectiveness. www.ittpps.com Inspect coupling guards; Dan Pereira has worked for ITT - Goulds Loose bolts. Pumps for 25 years. He began his career as an applications engineer and moved Professional planning and scheduling techon to sales engineer with a focus on the niques must be employed to ensure all condichemical/petrochemical, pulp and paper, tion-monitoring and preventive maintenance engineer contractor and energy markets. Over the past 15 years, Dan has brought his expertise to the activities are properly planned and scheduled. classroom, teaching general hydraulics, pump operaTo ensure the right actions are performed at the tion, pump maintenance, and pump optimization right frequency and action is taken to resolve for the petro chemical, pulp and paper, and energy industries. any issues resulting from the routines, plan-

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