Faisal Salman and Nick Dagres of Hydro, Inc report how performing new design modifications on two critical safety-related charging pumps have extended their lifespan and reduced maintenance.
Written by: Faisal Salman & Nick Dagres Published by: World Pumps
Setting up the pump at Hydro’s Hydraulic Institute Certified Test Lab.
A Western European nuclear power plant was having difficulty meeting the necessary hydraulic performance at runout for two centrifugal charging pumps. The system needed 30 ft of Net Positive Suction Head required (NPSHr).
The pumps are safety-related pumps, which pump bore-rated water (water mixed with boric acid) into the reactor to kill nuclear fission. What water is to fire, bore-rated water is to nuclear fission. Bore-rated water kills nuclear reaction.
The two pumps are each about 15 ins in diameter and about 100 ins in length. They were shipped from the Western European site to Hydro, Inc.’s Chicago, IL facility to conduct analysis, redesign, manufacturing, and testing.
A 5-day emergency testing turnaround for a nuclear pump proved no problem for this world-class testing facility.
Written by: Nick Dagres & Faisal Salman Published by: Nuclear Plant Journal
When a vertical safety-related residual heat-removal pump failed its required surveillance performance test at a nuclear power plant, it created the need for emergency hydraulic performance and vibration testing. The plant required the pump back in operation within one week, to prevent shutdowns that could cost the facility up to $1 million per day.
Background
During a routine check by the regulator, a safety-related heat removal pump failed its required in-house surveillance pump performance test. With a safe shutdown of the unit, the plant entered an LCO (Limited Conditions of Operation) period. The power station shut down the unit but wanted to avoid a full shutdown of the facility. This created an emergency situation for the plant.
According to the regulator’s strict standards, if performance requirements are not fulfilled immediately, the plant can be shut down completely. The LCO allows the plant to continue to operate as long as the problem is being resolved in a limited time frame. In this case, the time frame was seven days. To allow for shipping to and from the facility, Hydro had only five of those days to complete the project. The plant was concerned that the repair time might exceed the LCO. Other similar pumps remained in operation performing the same function, however the unit was shut down because there were no spare pump store place it while testing was being
performed. The original equipment manufacturer could not schedule the required tests in the abbreviated time span; therefore the Chicago service company was commissioned. Under normal conditions the scope of work would generally take about six to eight weeks to complete.
Pump as received
Identifying the Problem
In such cases, the regulator requires that a third party inspect the equipment to discover whether the issues were with the instrumentation or with the pump itself. As a result, immediate testing was required to determine whether the pump was functional.
The phenomenon occurs when a system experiences extreme vibration caused by excessive pump pressure and pulsation.
Written by: Greg Matteson & Jeff Johnson Published by: Pumps & Systems
A North American natural gas liquids pipeline company was experiencing an acoustic resonance issue that cost up to $35,000 a month in maintenance and repair. A six-week project resulted in rerating three American Petroleum Institute (API) designation between-bearing (BB3) horizontal multistage split-case mainline pumps and performing extensive and specific vibration analyses to identify the problem. The project involved designing and manufacturing new impellers using exclusive milled vane technology, conducting API hydraulic performance tests, and returning the pumps into service.
This midcontinent pipeline gathers, processes, stores and transports natural gas—in this case, propane. Because of its geographic location, extreme temperatures and conditions are a factor in the selection of major equipment and components. The pumps operate at 2,917 gallons per minute with 2,926 feet at 1,500 horsepower and 3,560 revolutions per minute (rpm).
The Problem
The pipeline company was experiencing an acoustic resonance vibration problem at the pump crossover, causing major maintenance and repair issues. Acoustic resonance occurs when a system experiences extreme vibration due to excessive pump pressure and pulsation, with frequencies loud enough for humans to hear. This can happen with the use of variable speed drives.
The pulsations are caused by a non-uniform flow from turbulence, sudden change of flow structure, direction or cross-section.
The acoustic resonance had existed since the pumps were installed more than five years ago. Rather than repairing or replacing them, the company performed continuous unscheduled maintenance that cost as much as $35,000 in a single month.
Hydro Middle East has a state-of-the-art manufacturing and service facility for comprehensive pump maintenance and rebuilding needs.
Hydro Middle East Inc. will provide aftermarket support for maintenance, rebuilds, retrofits, upgrades, re-rates, provide engineering support, conduct field service, and manufacture spare parts for PDO‘s entire centrifugal pump portfolio. Hydro Middle East has a state-of-the-art manufacturing and service facility for comprehensive pump maintenance and rebuilding needs.
Last year, Hydro Middle East and its agent Global Pavilion LLC were awarded a major 10 year contract by Petroleum Development Oman (PDO), the leading exploration and production company in Oman which is majority owned by the Government of Oman with Royal Dutch Shell, Total and Partex being the minority shareholders.
Hydro Middle East, the Dubai branch of Hydro Inc. group of companies having worldwide operations and headquartered in Chicago USA, has entered into a contract with PDO. With this contract, Hydro Middle East and its local partner Global Pavilion LLC will be responsible for a complete range of pump aftermarket services for both PDO’s high and low energy centrifugal pumps. In addition to the vital expertise that Hydro Middle East will provide to PDO, this contract also serves and supports the government’s initiatives to train young Omani engineers and utilize local resources within PDO local facilities.
Thomas Arakal, managing director of Hydro Middle East, noted that prior to Hydro’s arrival in the region, a need for high-level niche aftermarket engineering was not being served to industry here. “Hydro’s considerable engineering capabilities, along with ready and affordable access to our pool of experienced aftermarket engineers from our worldwide locations allow us to offer quick turnaround.”
George Harris, CEO of Hydro Inc. added, “With this new contract, Hydro looks forward to serving PDO’s needs while making an impact on young engineers in the region and helping to spread cutting-edge pump-engineering technology to this crucial region of the world.”
Hydro Middle East was established in Dubai’s National Industries Park with a state-of-the-art manufacturing and service facility for comprehensive pump maintenance and rebuilding needs. They are also licensed by American Petroleum Institute for drilling services (manufacture, service, testing, inspection of well control, pressure control and rig and drilling equipment, onshore and offshore).
Hydro has carved out a niche as the premier engineering and solutions based company for the oil and gas, power utility, nuclear, desalination, mining and petrochemical industries in the region.
Hydro Inc. has a strong engineering capability and an expansive global reach in the pump industry, especially in aftermarket services. Pump Engineer had the pleasure of speaking with George Harris, Chief Executive Officer and Founder of Hydro Inc., where he discussed the company’s recent research initiatives, reliability support for customers, customized designs and the significance of upgrades and health audits.
Written by: Deirdre Morgan Publisher: Pump Engineer / December 2016
“We were very fortunate that early in the company’s development we had the good fortune to work closely with Dr. Elemer Makay, a foremost consultant to the power generation industry and a specialist in troubleshooting multi-stage, high energy pumps”, states Harris. “Engineering combined with meticulous observation and analysis in the field were key to his troubleshooting process. As a result of his training over a twenty year period, engineering became the focus and strength of Hydro Inc.’s aftermarket services”.
According to Hydraulic Institute statistics, 85% of the critical pumps in industries, such as power, refineries and pipelines, are custom designed for the specific application intended. In order to properly rebuild, upgrade or troubleshoot these installations requires a solid aftermarket engineering capability and experience. Not only must the engineer understand pump fundamentals, but also the application and system in which the pump is being used, as well as the changes that may have occurred in plant operating conditions since the pump was originally installed.
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The Problem
