2017

STUDY AND
TROUBLESHOOTING OF
ALUM DOSING PUMP

ENGRO FERTILIZER INTERNSHIP REPORT

USAMA IJAZ
URUT-1 FIELD MAINTENANCE
UNIVERSITY OF ENGINEERING AND TECHNOLOGY LAHORE

ENGRO FERTILIZER, DAHARKI |

Table of Contents
AKNOWLEGEMENT......................................................................................................................................3
EXCECUTIVE SUMMARY...............................................................................................................................4
COMPANY PROFILE......................................................................................................................................5
INTRODUCTION...........................................................................................................................................6
BACKGROUND..........................................................................................................................................6
PROGRESSIVE CAVITY PUMP....................................................................................................................7
PROGRESSIVE CAVITY PUMPS SELECTION PARAMETERS.....................................................................7
FLOW PROBLEMS OF P 115.........................................................................................................................9
METHODOLOGY:......................................................................................................................................9
PROBLEM DEFINITION:........................................................................................................................9
FAULT TREE ANALYSIS..........................................................................................................................9
EVIDENCE...........................................................................................................................................12
CONCLUSION AND SUGGESTIONS:........................................................................................................14
BIBLIOGRAPHY...........................................................................................................................................14
D-LEVEL MEETINGS....................................................................................................................................15
OFFISTE 1 & 2 VISIT....................................................................................................................................15
PRESENTATIONS:........................................................................................................................................15
FIELD JOBS.................................................................................................................................................15
TABLE OF FIGURES:
Figure 1 Progressive cavity pump................................................................................................................5
Figure 2 Lift system......................................................................................................................................8
Figure 2 Lift system......................................................................................................................................8
Figure 3 Head system...................................................................................................................................8
Figure 3 Head system...................................................................................................................................8
Figure 4 FTA analysis chart.........................................................................................................................10
Figure 5 P115 B old rotor and stator..........................................................................................................10
Figure 6 P115 Stator wear.........................................................................................................................11
Figure 7 Hardened mud in the pump.........................................................................................................11
Figure 7 Hardened mud in the pump.........................................................................................................11
Figure 8 Wear along P117 stator................................................................................................................11

TABLE OF TABLES:

Table 1 P115 information.............................................................................................................................4

Table 2 Operating temperature limits for stator material............................................................................6

Table 3 P115 flow rate data.........................................................................................................................7
AKNOWLEGEMENT
First, I would like to thanks Engro Fertilizer for such an amazing opportunity to be part of their family
even if it was for short period of time. Then, I would like to thanks my section URUT-1 FM, my mentor
HASEEB BUKHARI (SMHB), USAMA CHAUDARY (UAC), ABDUL HAKEEM, LALA AKRAM, FAHAD and FAIZ
bhai for teaching me a lot.
At last, I would like to thanks ARSLAN NISAR, SANIA EJAZ, HAIDER ALI, ANAM SHAH for their help on my
project.
EXCECUTIVE SUMMARY
During my internship, I have to complete an intern project and besides that I got to take part in various
activities.
In my project, I have to troubleshoot alum dosing pump, the pump tag is P115 A/B and it is progressive
cavity pump manufactured by SYDEX and installed at OFFSITE-2. The pump has flow rate problems after
the FTA and RCA analysis of the pump it was found that flow problem was because of inadequate
flushing procedure.
In the end, it was suggested to improve the solution making and pump flushing procedure.
 ENGRO FERTILIZERS
COMPANY PROFILE
Engro Fertilizers Limited is a subsidiary of Engro Corporation and a renowned name in Pakistans fertilizer
industry. It is traded on the stock market under the symbol EFERT. Engro holds a vast, nationwide
production and marketing infrastructure and produces leading fertilizer brands optimized for local
cultivation needs and demand. Engro is also a leading importer and seller of Phosphate products, which
are marketed extensively across Pakistan as phospatic fertilizers.

Our extensive market development activities have ensured a sustained pull for our primary and
secondary fertilizer products and sellout productions since launch. Engro Fertilizers Limited enjoys loyal
customer base across Pakistan owing to its trusted fertilizer brands and continual farmer assistance in
training and education.

Engro Fertilizers Limited was incorporated in June 2009, following a decision to demerge fertilizer
concern from its parent company Engro Chemical Pakistan Limited. The continual expansions and
diversifications in its enterprises necessitated a broad restructuring in Engro Chemical operations and
management. To facilitate better oversight, Engro Chemical Pakistan was converted into a holding
company named Engro Corporation, and its fertilizer business was subsequently demerged to a newly
formed Engro subsidiary Engro Fertilizers Limited.

Engros fertilizer manufacturing facility at Daharki has been experiencing ongoing expansion. This,
coupled with distinct dynamics of highly nuanced fertilizer industry warranted an independent and
dedicated business entity and approach. The demerger of fertilizer concern was approved by High Court
of Sind on December 9th, 2009, making it effective as of January, 1st 2010.

Engro Fertilizers is poised to become the leading urea manufacturer in the country following major
upgrading of its manufacturing capabilities. ENVEN 1.3a tremendous expansion in Engros urea
manufacturing facility went into production in November 2010 and looks set to end Pakistans near-term
urea imports, leading to benefits of an expanded local urea base and savings in national exchequer.

Engro is a dynamic company driven by a vision to improve productivity and lifestyle for thousands of
farmers across Pakistan. Engro Fertilizers Limited has earned itself a distinguished name by continually
striving to uphold its tradition and trust of its loyal consumer base.
 STUDY AND TROUBLE SHOOTING
OF ALUM DOSING PUMP
INTRODUCTION
BACKGROUND
P115 A/B are positive displacement rotary type helical rotor pumps also called Progressive cavity pumps.
The pumps were supplied by SYDEX 1 and installed at offsite-22 facility to pump Alum solution
(coagulant) into the flash mixing chamber where it is mixed with water in specific quantity (in ppm) to
carryout coagulation and flocculation.
Pump performance:
The P115 A/B is motor driven with the capacity and speed ranges from 400-1950 l/h and 125-635 rpm,
respectively. The suction side of the pump is flooded (filled with pumping fluid) which avoid any type of
cavitation and design pressure of pump is 5 bar. The pump has the power requirement of 0.4 MW and its
duty cycle is 12 hours each day.
Pump Metallurgy:
P115 A/B belongs to the k-range series of pc pumps manufactured by Sydex. Pump casing is cast iron
GG20, rotor is made of duplex steel and stator is made of nitrile. The base plate of pump mild steel base
plate.
Pump Driver:
P115 A/B is motor driven pump. The motor is provided by the pump SIEMENS and has the power
requirement of 0.5 KW. Gear based speed reduction mechanism is used in the pump with speed
reduction of 1:5. The drive service factor is 1.3.
Table 1 shows the basic information of pump.

Table 1 P115 information

1
Sydex is a modern, global manufacturer of progressing cavity pumps, grinders and macerators.
2
Offsite-2 is the water treatment facility used for canal water treatment.
PROGRESSIVE CAVITY PUMP
The progressive cavity pump is a positive displacement rotary pump. The pump has an internal threaded
rotor with double thread and externally threaded rotor with single threads. The meshing of two forms a
series of cavities 180 degrees apart, which progress along the axis of the rotor as it rotates. As one cavity
increase in volume the opposing cavity decrease in volume at the same speed. Therefore, the sum of the
discharge at the constant volume. The result is a continuous flow from the pump.
A PC pump is shown in figure 1.

Figure 1 Progressive cavity pump

Being a positive displacement pump, a certain volume of fluid is discharged with each revolution of the
rotor. Unlike centrifugal pumps, the pump does not develop pressure or a head but will attempt to
deliver the same volume of fluid regardless of the pressure (resistance) that must be overcome in the
discharge line. With a fluid, such as water (1cP viscosity), and with zero discharge and suction pressures,
the displacement or quantity of fluid delivered of the pump is only dependent on the revolutions per
minute.
As the pressure increases, a small amount of the fluid displaced slips back through the elements to the
suction side. This slip is the fluid that leaks across the sealing lines of the cavities from the higher-
pressure discharge back to the lower pressure suction side of the elements. Slip is measured in units of
flow such as gallons per minute (gpm). The amount of slip or leakage becomes greater as the discharge
pressure increases. To minimize the amount of slip at high pressures, more cavities are added in series by
lengthening the rotor and stator. This is called staging, analogous to multi-screw pumps, as discussed in
earlier chapters. Increasing the number of stages decreases the amount of slip experienced by the pump
by distributing the pressure differential over a greater number of pump stages. Staging is also used to
obtain higher differential pressures for a given flow design. Past practice was to limit pressure per stage
to 75 psi.
PROGRESSIVE CAVITY PUMPS SELECTION PARAMETERS
Abrasion
The progressing cavity pump is one of the best pumps available for handling abrasive slurries. However,
there are some considerations in pump size that need to be made in order to achieve maximum
performance. It is necessary to minimize the slip and internal velocities to achieve good results. Most
progressing cavity pump manufacturers limit these items by publishing reduced maximum speeds and
pressures for pumps handling abrasive materials.
Determining the degree of abrasion is largely judgmental; however, the makeup of the particles will offer
some clues as to how it is to be classified. A closer look at what causes abrasion may be helpful in
determining its classification. The components of abrasion are the particle, the carrier fluid, and the
velocity.
I. Particles
Size Wear increases with particle size.
Hardness Wear increases rapidly with particle hardness when it exceeds the rotor surface
hardness.
Concentration The higher the concentration, the more rapid the wear.
Density Heavier particles will not pass through the pump as easily as lighter ones.
II. Carrier Fluids
Corrosivity Surfaces attacked by corrosion will set up a corrosion-erosion effect.
Viscosity A high viscosity fluid will tend to keep particles in suspension
and not be as abrasive.
Velocity Low fluid velocity, or pump speed, will minimize abrasive effects. For a heavy
abrasive fluid, it is recommended to keep the average velocity in the elements between 3 to
5 ft/sec. A medium abrasive fluid should be limited to 6 to 10 ft/sec, and a light abrasive
should be limited to 10 to 15 ft/sec. These velocity limits are usually listed in catalogs as
pump rpm limits for various size pumps in conjunction with the abrasive nature of the fluid.
Temperature
The fluid temperature will affect the pump performance in two different ways. First, since the stator is an
elastomeric material, the thermal expansion is roughly ten times greater than that of the metal rotor
which is usually steel or stainless steel. This will cause a tighter fit for the elements, and higher starting
and running torques. When the temperature reaches a certain limit, it is then advisable to use an
undersized rotor which compensates for the difference in size. Second, the life of the elastomer is
greatly affected by heat. Table 2 shows limits from one manufacturer for elastomers which are being
worked such as in a stator, and will differ from other published information on elastomers used in a static
state such as O-rings and gaskets.

Table 2 Operating temperature limits for stator material

Mounting and vibration

The progressing cavity pump is inherently an unbalanced machine due to the eccentric rotation of the
rotor. The vibration which occurs is dependent on the size of the element, the offset, and the speed of
rotation. For this reason, the speed of the pump is limited with typical limiting speeds reaching 1200
RPM for small pumps (.02 gal/rev and lower), decreasing to limits of 300 RPM for large pumps (3 gal/rev
and larger).
FLOW PROBLEMS OF P 115
METHODOLOGY:
Based on the data available on the pump, we will go in a systematic way from the definition of problem
to FTA analysis, then evidence and conclusion.

PROBLEM DEFINITION:
After its installation in 2008, P115 A/B have suffered severe flow problems and required continuous
overhauling over the years. The P 115 is supposed to pump alum into the static mixer where it is mixed is
with the canal water and then transported to the flash mixer and then clarifier. The most common
problems that the pump has is the clogged suction and stator wear that we will see in the further
analysis.
The P115 A/B flow rate data is shown in the table 3 below:

Table 3 P115 flow rate data

FAULT TREE ANALYSIS

There can be several reasons that can cause low or no flow rate problems in the progressive cavity
pumps we will do our FTA analysis and see which reasons are more plausible than others. Now the pump
manufacture data shows that the flow problem can occur from the following reasons shown below:
1) Wrong rotor rotation direction
2) Pump and system characteristics does not match
3) Suction Lift too high
4) Leaked inlet or Suction line
5) Back Pressure too high
6) Rotor or Stator Wear
7) Clogged inlet, Suction Line or Cavity
Now there is no reason to believe that these are all the problems that can happen with the pump but
the most common one has been listed above no we will go through these reasons one by one to find the
actual cause of the problem.
Wrong rotor rotation direction
Wrong rotor rotation can be the reason for no flow rate. The reason for wrong rotor direction can be
related to electrical circuit of the pump. But the problem is that flow problem is repetitive and the
electrical problem cannot be reason for failure of the pump again and again. So, we can rule this reason
safely without any doubt.
System and pump are incompatible
It is possible that the pump speed and flow doesnt match with system characteristic and the operating
point of the pump is not at the optimum location but from the manufacture data available as shown
above in table 1 and 3 the system and pump are quite compatible and there is no reason to believe that
pump is failing because of this reason.
High suction lift
The progressive cavity pumps do not create pressure across its ends It only transfer the fluid from one
end to the other and that is why they have low or no lift at all. Most of progressive cavity pumps has a
suction side that is always filled with fluid to keep the cavities with liquid. Also, the system for alum
dosing is the head system not a lift system (see figure 2 and 3).

Figure 2 Lift system

Figure 3 Lift system

Figure 4 Head system

Figure 5 Head system

as you can see from figure 3 the suction side in the head system is flooded so the problem of high
suction lift cannot occur. So, we can also rule out this possibility too.
High back pressure
High back or discharge pressure can also cause slip in the pump and result in the backward flow of the
fluid. Now there is not enough data to safely rule out this possibility but later evidence show that the
root cause of the problem is not high discharge pressure as we will see as we further go on.
Leakage at inlet section
Leakage at the inlet is can also be the reason for pump failure as high suction pressure can cause leakage
through unions or joints but the pressure at the suction is not very high is not high enough to cause such
failure at least no repetitively.
Clogged inlet or suction
Clogged inlet, suction or strainer can cause pump to fail and the reason can be suspended solids in the
fluid that is undissolved alum or other impurities that might be present.
Rotor and stator wear
Wear at the rotor and stator can also be reason for flow rate problem as the clearance between the rotor
and stator increases the pump slip increases and discharge flow rate increases.

Now, after the first stage of FTA analysis the following reasons for pump failure are more reasonable then
the others.
1) Rotor or Stator Wear
2) Clogged inlet, Suction Line or Cavity

Now Rotor wear can occur because of several reasons:

i. High Temperature
High temperature can cause the swelling of the stator as it is an elastomeric material which
results in decrease in internal diameter of the stator and when the pump is running it will result
in high wear of stator. But the operating temperature of the pump is well within materials
working range.
ii. Highly abrasive fluid
If the solution is highly abrasive in nature because of any of the factors discussed before then it
may cause rotor wear.
iii. High fluid velocity
If the fluid velocity is high, it may cause erosion effect but as discussed before progressive cavity
pumps are low speed pumps and P115 is operating well within its speed range so that cannot be
the case.
iv. Corrosion
If the fluid is corrosive to the stator, then stator will wear rapidly but alum solution is not
corrosive to the stator material.
v. Inadequate flushing procedure
Inadequate flushing procedure can cause serious damage to the pump as after the shut down if
the pump not flushed properly it may cause the sludge to be formed in the rotor path as liquid
evaporates and on startup it will cause serious damage to the pump
ROOT CAUSE FOR P115 FLOW PROBLEM:
After the detail FCA analysis done be the maintenance, process, operation engineers the root cause for
the pump low flow rate was stated to be inadequate flushing procedure. The final FTA analysis chart can
be shown as below in figure 4:

Figure 6 FTA analysis chart

EVIDENCE
I. Findings of recent overhauling of P115 B
Recently, in Jun 2017 P115 B was overhauled and excessive of rotor and stator wear was found
that caused slip in flow. See the figure 5, 6 below:

Figure 7 P115 B old rotor and stator

II.

Figure 8 P115 Stator wear

Findings of overhauling of P117 and P118
The root cause for repeated failure of stator is the inadequate flushing procedure. The water
evaporates from the solution leaving thick slurry during off-duty, if not flushed before shutdown,
which damage the stator when it is restarted. The more severe case is seen in P117/118. See
figure 7, 8 below;

Figure 9 Hardened mud in the pump

Figure 10 Hardened mud in the pump

Figure 11 Wear along P117 stator

 III. Inadequate alum solution making procedure
From the report issued by the process on P115 it was said that the alum solution making procedure was
inadequate and that is why solid is the solution resulted in line choking and pump wear.

CONCLUSION AND SUGGESTIONS:

From FTA analysis and evidence above we can conclude and suggest following recommendation.
Proper flushing of pump at shutdown should be carried out.
Proper alum solution facility should be installed.
Alum dosing can be replaced with liquid coagulant.
Strainer should be cleaned and checked for damage.
Discharge pressure should be handled properly.

BIBLIOGRAPHY
a) ALI, H. (n.d.). RCA REPORT OF P117/118.
b) NELIK, L. (n.d.). Centrifugal and rotary pump.
c) PROCESS, E. (n.d.). TEST RUN OF BULAB 5082 AT OFFSITE-2.
 OTHER ACTIVITIES
Beside the project, I took part in various activities and got to see various jobs in the field. List of these
activities are as follow:

D-LEVEL MEETINGS
During my internship, I attended 3 D-Level meeting and got to learn a lot of things about safety
management, procedures, etc.

OFFISTE 1 & 2 VISIT

During my internship, I got to visit canal water treatment facilities and got to see the treatment
procedures.

PRESENTATIONS:
I got to attend three presentations at URUT-1
1) STUDY OF MECHANICAL SEAL
2) INTRODUCTION TO HRSG
3) INTRODUCTION TO SIX SIGMA AND MUDA

FIELD JOBS
I got to watch various field jobs like,
1) Surveillance of pumps
2) Surveillance of Cooling towers
3) Surveillance of SG blowers
4) Hydrotesting of hypo pumps
5) Changing of suction and discharge lines of acid dosing pumps
6) Valve checking of hypo pumps, etc.