TOPIC:

Pump and System Hydraulics for Reliability Engineers

INSTRUCTOR(S):

DETAILS:

One (1) hour presentation, including up to 15 min. Q&A

DESCRIPTION:

This presentation addresses the fundamentals of pump and system hydraulics. This includes how to read a pump curve, what the best efficiency point means, and major causes of pump reliability problems. Participants will learn how to develop a system curve and the influence of the system curve on pump reliability.

This workshop applies to you if:

• You have poor pump bearing and seal reliability

• You break pump shafts

• You need more flow in your system

• You don’t understand how the system curve interacts with the pump curve

• Your pump has high vibration

• Your pump sounds like it’s pumping gravel

• You’re responsible for pump reliability

TOPIC:

Starting Methods for Large Electrical Motors on Turbomachinery Packages

INSTRUCTOR(S):

DETAILS:

One (1) hour presentation, including up to 15 min. Q&A

DESCRIPTION:

Electric Motor Drives in the power range from 1,000 to 60,000 HP are often used for turbomachinery applications. The electric drive systems used include electric motors with variable frequency drives (VFD), electric motors with variable speed planetary gear hydraulic drives (VSHD), and constant speed electric motors.

Two issues tend to require discussion, and a significant level of expertise to avoid problems:

First, the startup has to be accomplished without exceeding the maximum permissible voltage dip limits at the point of common coupling (PCC). In case of strong supply networks, a direct online start-up usually works. However, safe start-up solutions are also available for weak supply networks by using common starting devices. Torsional transients during the starting process have to be considered.

Therefore, this tutorial presents a rough overview of proven start-up methods for direct online operating electric motor drives. Pros and cons are discussed. Based on a starting by means of a pony-motor, which is connected to a hydrodynamic variable speed planetary gear, the run-up process is discussed in detail. It can be seen that the grid disturbances are negligible especially for synchronous main motors.

Second, the choice of drive impacts the train’s torsional characteristics, shaft endurance limits and operational flexibility. Torsional integrity of the electric motor driven trains are critical to safe and reliable operation, and must be considered during the design, selection and packaging of the train’s key components (motor, gearbox, couplings and the compressors).

This tutorial outlines a methodology used to ensure torsional integrity in standardized Electric-motor-driven gas compressor packages. In addition to steady-state torsional analysis, the drive harmonics from electrical sources (steady-state pulsation) and the drive’s characteristics at fault-events such as phase-to-phase faults (transients) are incorporated into the torsional model to perform a complete torsional analysis. Shaft stresses are evaluated over a wide range of motor frame sizes, and consequently couplings and gearboxes. Couplings and gearboxes are designed to handle the mean torque and peak transient torques as appropriate.

TOPIC:

VOC Legislation and LDAR Impacts on Ageing Pump Fleets

INSTRUCTOR(S):

DETAILS:

One (1) hour presentation, including up to 15 min. Q&A

DESCRIPTION:

Regulatory requirement for VOC reduction has been in force in the USA for several decades. In Canada best in class users have voluntarily adopted similar practices.

From January 2023 facilities that produces liquid petroleum products by means of distillation of hydrocarbon compounds and associated petrochemical plants will now be subject to Canadian regulations. This now mandates Leakage detection and repair (LDAR) testing of equipment components three times per calendar year. The regulations provide LDAR exemptions for certain configurations of pump dual mechanical sealing systems, however the regulatory wording is ambiguous.

The presentation will review the impact that the regulations will have on pump fleets reliability particularly operators with older fleets of pumps. The LDAR exemption options will be discussed along with some of the challenges of the Canadian climate. A proposed improved wording that is aligned with terminology used in international standards such as API 682 & trade bodies such as the Hydraulic Institute will be offered.

Case studies form both USA and Europe will be presented, for individual applications where technology has been applied to legacy pump machinery with minimal intervention. Case studies of large fleets of legacy pump machinery have been upgraded to dual seals will be presented some of these fleets have seen little or no improvement in MTBR whereas some of fleets now enjoy best in class reliability.

TOPIC:

Machinery Grouting Best Practices

INSTRUCTOR(S):

DETAILS:

One (1) hour presentation, including up to 15 min. Q&A

DESCRIPTION:

Best practices for achieving optimum equipment performance from a machinery grout perspective. Equipment reliability is a key component of, and directly proportional to, profitability with today’s industrial producers. Our goal is to educate end users on principles for achieving optimum machinery and equipment reliability and lower operating costs using epoxy machinery grouts and focusing on best installation practices.

PRESENTER

Monroe Voyles

Monroe Voyles is a mechanical engineer with 23 years of experience; 7 in a chemical plant, 3 in a refinery, 9 as a pump improvement engineer for Flowserve, and 4 as a Solutions Engineer for ITT Goulds Pumps. Experience with large electric motors, gas turbines, centrifugal compressors, reciprocating compressors, steam turbines, large API pumps, ANSI pumps, high pressure boiler feed water pumps, non-contacting gas seals, high temperature bellows seals, mag-drive pumps, liquid ring compressors, cooling tower fans/gear boxes, and large compressor gear boxes. Work included RCFA, Vibration analysis, performance testing, and upgrading systems/equipment to resolve problems. Proficient with finite element modeling (CREO/Simulate).

SUMMARY

Most centrifugal pumps create vane-pass pressure pulsation and vibration as a normal reaction to head generation. In some cases the resulting vane-pass vibration amplitudes can be excessive. The cause of high vibration amplitudes can be related to large pressure pulsation forces; resonance can also amplify the vibration response in some cases.

This case study describes excessive vane-pass vibration amplitudes that were caused by structural and possibly acoustic resonance. The solution involved pump modifications to decrease vane-pass pressure pulsation amplitudes and a speed change to increase frequency separation margin between vane-pass frequency and natural frequencies. ODS and Modal data was used to evaluate the natural frequencies and mode shapes. Modal data was also used to calibrate a finite element model. Finite element analysis was used to evaluate the pump/piping system. Several previously planned (costly) actions were also shown to be ineffective; therefore, a planned outage scope was changed due to this analysis. The result was a dramatic reduction in vibration amplitudes and noise with minimal cost.

PRESENTER

Wally Bratek

Wally Bratek is a principal consultant in Wood’s vibration, dynamics and noise group. His more than 20 years’ design and field experience include acoustical (pulsation) and mechanical vibration analysis, machinery dynamics, field testing and troubleshooting, alignment, high-speed balancing, lateral rotordynamics, piping flexibility and flow-induced pulsation. Wally has presented multiple papers at industry conferences, is a member of the GMRC Gas Machinery Conference Planning Committee, and is an active member of the API 618 6th Edition task force or pulsation analysis.

SUMMARY

Technologies and hardware for the measurement and diagnosis of vibration on machinery and piping systems continue to evolve. Multi-channel data acquisition systems (48 or more) have become commonplace whereas simple one- or two-channel systems have been the standard for many years. More-efficient software is available to analyze and visualize the mountain of data that is collected. However, the use of advanced tools is not a substitute for careful examination of basic factors that might cause increased vibration levels. In many cases, basic observations and analysis can lead to the identification of causes without having to resort to more costly field measurements or advanced analyses. Sometimes a “back-to-basics” analysis approach is all that is required to solve a problem.

This presentation is intended for plant engineers, operators and millwrights who are often the first to identify vibration problems and asked to solve them. The goal of this lecture is to present the fundamentals of vibration, typical causes for vibration issues and common remedies. Techniques for visual inspections are presented.

Case studies involving pumps and compressors will be discussed to show how seemingly complex issues can be solved based on knowledge of basic vibration principles. Attendees will gain valuable knowledge of vibration basics and simple approaches for solving problems.

PRESENTER

Christopher Ewald

Christopher Ewald joined ITW Engineering Polymers in 2015. His primary responsibilities include technical support and educating personnel in engineering, construction, operations and maintenance on best practices and recommendations for epoxy design and installation. His primary focus is on Industrial applications and US Military Marine installations, and a secondary focus on all marines applications. He holds a degree in Civil & Environmental Engineering from the Georgia Institute of Technology.

SUMMARY

Proper consideration for the design and installation of anchoring of rotating machinery is key to the long-term integrity and reliability for the entire foundation system. As a key component in the foundation system, bolt or adhesive failures result in a loss of connection to the foundation that will cause a significant increase in operating vibrations of equipment, leading to a decreased life span and reduced mean time between failures.

This presentation will discuss potential failures that may occur in the connection of the equipment to the foundation, methodology for diagnosis of potential failures, best practices and techniques for remediating failures after occurrence, and prevention recommendations for avoidance of issues. Bolting configurations and specific methodology for ensuring proper bolt tensioning and anchoring will be discussed. Finally, a case study showing the diagnosing and remediation of a failed anchor system that was conducted without necessitating the removal of the machinery is presented.