PUMP TECHNOLOGY

Are we making any progress?

S. Gopalakrishnan
Flowserve Corporation
Pump Division
Vernon, California
PUMP DIVISION
ASME FEDSM May 31, 2001
LARGEST PUMP
HIGHEST HORSEPOWER
American Electric Power John E. Amos plant
Boiler Feed Pump - Multistage, Barrel
21,800 GPM
11,300 ft TDH
4160 RPM
63,200 HP
1973
LARGEST PUMP
HIGHEST CAPACITY
South Florida - Mill Creek
Flood Control
695,000 GPM
180 RPM
24 ft TDH
5000 HP
1985
LARGEST PUMP
LARGEST SIZE
Grand Coulee Dam on the Columbia River
Single Stage Vertical Volute Pump
605,000 GPM, 330 ft TDH, 200 RPM
55,200 HP
Volute Diameter ~ 21 ft
1951
0
100
200
300
400
500
600
700
800
900
1940 1950 1960 1970 1980 1990 2000
P
L
A
N
T

O
U
T
P
U
T

(
M
W
)
FOSSIL PLANT OUTPUT
(MW)
H. Ohashi: ASME FED SM 1997
POWER PLANT DEVELOPMENT
0
200
400
600
800
1000
1200
1400
1940 1950 1960 1970 1980 1990 2000
P
L
A
N
T

O
U
T
P
U
T

(
M
W
)
FOSSIL PLANT OUTPUT (MW)
NUCLEAR PLANT OUTPUT (MW)
H. Ohashi: ASME FED SM 1997
POWER PLANT DEVELOPMENT
0
5
10
15
20
25
30
35
1940 1950 1960 1970 1980 1990 2000
P
U
M
P

P
O
W
E
R

(
M
W
)

a
n
d

S
T
A
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E

P
R
.

(
B
A
R
)
0
200
400
600
800
1000
1200
1400
P
L
A
N
T

P
U
T
P
U
T

(
M
W
)
FOSSIL PLANT OUTPUT (MW)
NUCLEAR PLANT OUTPUT (MW)
PUMP POWER (MW)
H. Ohashi: ASME FED SM 1997
POWER PLANT DEVELOPMENT
0
10
20
30
40
50
60
70
80
1940 1950 1960 1970 1980 1990 2000
P
U
M
P

P
O
W
E
R

(
M
W
)

a
n
d

S
T
A
G
E

P
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.

(
B
A
R
)
0
200
400
600
800
1000
1200
1400
P
L
A
N
T

P
U
T
P
U
T

(
M
W
)
FOSSIL PLANT OUTPUT (MW)
NUCLEAR PLANT OUTPUT (MW)
PUMP POWER (MW)
STAGE PR. (BAR)
H. Ohashi: ASME FED SM 1997
P. Hergt: ASME FED SM 1997
POWER PLANT DEVELOPMENT
CUSTOMER REQUIREMENTS
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
SUPERSYNCHRONOUS RPM
PRESSURE SURGE
RECYCLING ABILITY
SUCTION ABILITY
CONTROL RANGE
NOISE EMISSION
PRICE
EMISSION FREE
EFFICIENCY
RELIABILITY
P. Hergt: ASME FED SM 1997
ECONOMICS OF
RELIABILITY
The cost of maintaining a pump
significantly exceeds the first cost.
PRICE
9%
REPAIR
COST(NPV)
27%
ENERGY (NPV)
64%
COST OF RELIABILITY
ANSI PUMP
ECONOMICS OF
RELIABILITY
The cost of maintaining a pump
significantly exceeds the first cost.
The imperative on the manufacturer is to
increase MTBR.
CHARGE PUMP FAILURE DATA
SEALS
43%
BEARINGS
13%
SHAFT
13%
AUX. SYSTEMS
31%
Source: NERI Smart NPP report Task 1
June 2000
RELIABILITY IMPROVEMENT
INITIATIVES
ROBUST MECHANICAL DESIGN
Minimizing Vibrations
Reduction of Forces
Elimination of resonances
Improving cavitation resistance
RELIABILITY IMPROVEMENT
API VIBRATION LIMITS
0
1
2
3
4
5
6
7
8
9
10
1950 1960 1970 1980 1990 2000 2010
OVERALL
FILTERED
V
I
B
R
A
T
I
O
N

V
E
L
O
C
I
T
Y

(
M
M
/
S
E
C
)
RELIABILITY IMPROVEMENT
DSHF
RELIABILITY
IMPROVEMENT
SR ratio
RMS
(in/sec)
Static
Deflection
(mils)
Double Suction Process Pump
Vi brati on Data Map
3
2
1
0
1.8
1.5
1.2
0.9
0.6
0.3
0.24
0.21
0.18
0.15
0.12
0.09
RELIABILITY IMPROVEMENT
Increase foot thickness
Decrease bearing span
Robust bearing adaptors
EXISTING
DSHF
BEARING
ADAPTER
DESIGN
NEW DSHF
BEARING
ADAPTER
DESIGN
INCREASE OF
GAP B
IMPELLER VANE
STAGGER
RELIABILITY
IMPROVEMENT
DSHF Pump Vibration Data
MAXIMUM BEARING HOUSING VIBRATION VERSUS FLOW RATE
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Q/Qbep (ratio)
New 360 degree Bracket
Staggered Impeller
Thicker Pump Feet
Flex in/ out
0.156
0.120
API LIMIT
x 1.30
CURVE FIT
PUMP DIVISION
R
M
S

i
n
/
s
e
c
RELIABILITY IMPROVEMENT
0
10
20
30
40
50
60
1996 1997 1998 1999 2000
1
2

m
o
n
t
h

r
o
l
l
i
n
g

M
T
B
R

M.L. Fontaine and E. Haflich, Developing Fixed-Fee Seal
Arrangements to Improve Pump Reliability - 18th Texas A&M
Pump Symposium, March 2001
NPSH REQUIRED
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
0.8 1 1.2 1.4 1.6 1.8
FLOW (m^3/sec)
N
P
S
H

(
m
)
INCEPTION
3 % HEAD DROP
DAMAGE FREE
REDUCTION OF CAVITATION
DAMAGE
0
0.001
0.002
0.003
0.004
0.005
0 0.5 1 1.5 2 2.5 3 3.5
BUBBLE LENGTH (IN)
R
E
L
A
T
I
V
E

E
R
O
S
I
O
N

R
A
T
E
316 STEEL
NITRONICS 50
DUPLEX
REDUCTION OF CAVITATION
DAMAGE
0
0.01
0.02
0.03
0.04
0.05
CAST IRON CA 15 CAST
CARBON
STEEL
CA6NM 17-4 PH
(H1150)
X
CAVALLOY
M
P
D
R
REDUCTION OF CAVITATION
DAMAGE
REDUCTION OF CAVITATION
DAMAGE
We still need a way to assess damage
potential at factory testing stage.
PRICE
9%
ENERGY (NPV)
83%
REPAIR
COST(NPV)
8%
PRICE
9%
REPAIR
COST(NPV)
27%
ENERGY (NPV)
64%
ECONOMICS OF EFFICIENCY
API PUMP
ANSI PUMP
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4 4 4 3 4 4 4 2 1
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1. Power in one annual cycle
2. Cost of energy
Sour ce: P. Wurzburger, Energy - A basic element of Life Cycle Costing - Einfhr ungsvortrag,
Pump User s International Forum - Karlsruhe - October 2000
3. No. of years
ENERGY COST CALCULATION
MODEL
4. Net present value
ECONOMICS OF EFFICIENCY
A project funded by the European Commission
(SAVE) has concluded:
Pump efficiencies can be improved with present
technology by 3 points.
If all EU pumps are upgraded, a total of 1.1
TWhr of energy can be saved. At 5 c/kWhr, this
amounts to about 50 million $ saving per year
Basic infrastructure issues are the impediment
to this upgrade.
THEORETICAL EFFICIENCY
0.4
0.5
0.6
0.7
0.8
0.9
1
100 1000 10000
SPECIFIC SPEED
E
F
F
I
C
I
E
N
C
Y

THEOR. MAX
PRACTICAL MAX.
AVERAGE
FLOW = 800 GPM
European Association of Pump Manufactureres No. 2 (1999):
Attainable Efficiencies of Volute Casing Pumps
BASELINING WITH CFD
H. Goto: ASME FED SM 1997
CRYOGENIC EXPANDER
EFFICIENCY IMPROVEMENT
CALCULATED EFFICIENCES (%)
SINGLE STAGE MULTI-STAGE
Hydraulic Net
8RL (Baseline) 92.1 89.2 85.0
8RH Design #1 91.7 86.8 84.9
8RH Design #2 94.5 89.6 87.9
8RH - Final 94.6 89.7 88.1
HIGH PERFORMANCE
EXPANDER
0
Flow (l/sec)
0
50
100
150
200
250
300
350
400
450
500
20 40 60 80 100 120 140 160 180 200 220 240 260 280
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
1800 RPM
Efficiency
Total Turbine Output
Head
E
f
f
i
c
i
e
n
c
y
T
o
t
a
l

T
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r
b
i
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O
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t
p
u
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(
k
W
)
N
e
t

H
e
a
d

(
m
e
t
e
r
s
)
Motor stator embedded
and sealed into rear
casing cover
Rotor Assembly
with Shaft
Pump Casing
ASSEMBLY OF SCAMP
CONCLUSIONS
Pump Technology is driven by customer
requirements
Reliability: Significant improvements in MTBR
Efficiency: CFD techniques are producing good
results
Emission: Novel mechanical designs are being
introduced