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Transcript of FSRUG
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Feedwater Systems Reliability Users Group (Jan 2014)
San Antonio, TX
Stuffing Box Design & Configurations
Presenter:
Art Washburn, P.E.
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What is going on at this House?
No Driveway, No Sidewalk…
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City of Raleigh Public Utilities Water Booster StationPumps 45 Million Gallons per Day
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Virginia Beach Pump Station (Lake House)
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Pump Station (Greek Architecture)
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Office Building?...
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Electrical Sub-Station
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DISCUSSION POINTS• Two Rules to Get You Home and Plant Priorities
• Case 1: API Plan 11 – Packing Injection Flush… Exhibits Excessive Leakage During Operation and Standby (Horizontal Multi-Stage Pump in Auxiliary Service Water Service)
• Case 2: API Plan 13 – Reverse Flush System… Exhibits No Reverse Flush (Static System), Excessive Packing Leakage, Excessive Packing Sleeve Wear and Severe Stuffing Box Bearing Damage (Vertical Pump in Screen Wash Service)
• Case 3: API Plan 13 – Reverse Flush System… Exhibits Excessive Packing Leakage (Vertical Pump in Condensate Service)
• Case 4: API Plan 13 – Reverse Flush System with Bypass Port (Water Service and Hydrocarbon Service)
• Source References
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Two Rules:
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Two Rules:
Rule #1 – Make Conservative Decisions
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Two Rules:
Rule #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
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Two Rules:
Rule #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
Plant Priorities:
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Two Rules:
Rule #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
Plant Priorities:
1. Nuclear Safety
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Two Rules:
Rule #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
Plant Priorities:
1. Nuclear Safety
2. Legal Requirements
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Two Rules:
Rule #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
Plant Priorities:
1. Nuclear Safety
2. Legal Requirements
3. Efficiency
Case 1: API Plan 11 – Packing Injection Flush (Original)
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Conditions:
Excessive Packing Leakage
- In Service
- In Standby
Case 1: Horizontal Multi-Stage Pump SectionalAux Service Water Pump
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Stg 1, 260 psi
Psuction, 30 psi
Case 1: In-Board Bearing Housing Assembly
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Conditions:
Packing Leakage Sprays Directly on Bearing Housing
Water Intrusion in Bearing Housing Displaces Approx. 50% of Oil
Case 1: Stuffing Box Configuration (Original)
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Conditions:
Lantern Ring Mis-Aligned
Inner Packing Rings - What Can You Do For Me Today?
Case 1: API Plan 11 – Injection Flush System (Original)
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Stg 1 – 260 psi
Psuction, 30 psi
Pstuff box, 260 psi
Pstuff box, 260 psi
Measured Stuffing Box Pressure
Case 1: Stuffing Box Configuration (Updated)
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Case 1: API Plan 11 – Injection Flush System
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Stg 1 – 260 psi
Psuction, 30 psi
Pstuff box, 35 psi
Pstuff box, 35 psi
Case 1: Stuffing Box Configuration (Updated)
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Case 1: Stuffing Box Configuration (Updated)
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Results:
1.Packing Sleeve Diameter, 4.000 Inches
2.Required Flush for Packing or Mechanical Seal in Water Service and Fluid Temperature Less Than 150oF (1 GPM per 1 Inch of Shaft Diameter): 5 GPM
3.Stuffing Box Pressure: Maintains Positive Pressure, Easier to Adjust Packing, Reduced Frequency of Packing Adjustments, Eliminate Risk of Packing Spray Impingement on Bearing Housing
Case 1: Stuffing Box Configuration (Updated)
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Analysis Process:
1.Simplify Equation of State to 2 Pressure Drop Devices or Less
2.Iterate Pressure Drop Determination for Both Devices to Share the Total Pressure Until a Mass Balance is Achieved (in GPM)
3. Result: Highly Predictable System Behavior
Water Intrusion – Traditional Oil Deflector vs. INPRO Deflector
See EPRI NMAC Lube Notes, November 2004, Bearing Operation with an Oil-Water Mixture
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Case 2: API Plan 13 – Reverse Flush System (Original)
Conditions: Screen Wash Pump
Pdischarge, 85 PSI
Lantern Ring, Grease Filled
Packing exposed to pump discharge pressure
Bearing, High Pressure Breakdown Device(Static, melts)
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Case 2: API Plan 13 – Reverse Flush System (Original)
Conditions:
ExcessivePacking Wear
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Case 2: API Plan 13 – Reverse Flush System (Updated)
Conditions:
Screen Wash Pump
Pdischarge, 85 PSI
Replaced Bottom Packing with Spacer (Controlled Clearance)
Lantern Ring, Leak Off Thru Tubing (Orifice) to Sump
Bearing dP, 82 PSITubing dP, 3 PSIPacking, 3 PSI
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Case 2: API Plan 13 – Reverse Flush System (Updated)
Analysis Seeks Mass Balance Thru the Bushing and Orifice:
Bushing:
Orifice:
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Case 3: API Plan 13 – Reverse Flush System (Original)
Conditions:
Condensate Pump
Excessive Packing Leakage
Pdischarge, 515 PSI
Pabove bushing, 170 PSI
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Case 3: API Plan 13 – Reverse Flush System (Original)Conditions:
Condensate Pump
Bottom Lantern Ring Significantly Blocking Plan 13 Return to Suction
Lantern Ring Annulus Area too Small – Region Under Packing Does Not Depressurize
Packing Sleeve Wear Excessive
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Case 3: API Plan 13 – Reverse Flush System (Updated)
Conditions: Condensate Pump
Bottom Lantern Ring Resized to Assure Plan 13 Return is Not Blocked
Lantern Ring Annulus Area Increased to Allow Depressurizing Region 360 Degrees Around Shaft
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Case 3: API Plan 13 – Reverse Flush System (Updated)
Conditions:
Condensate Pump
Interstage Pressure Acting on Packing Rings is Low, Gland Water Injection Maintains Positive Pressure on Packing to Prevent Air In-Leakage
Packing Leak-Off Easily Controlled and Sleeve Wear Low
Condensate Pump
Interstage Pressure Acting on Packing Rings is Low, Gland Water Injection Maintains Positive Pressure on Packing to Prevent Air In-Leakage
Packing Leak-Off Easily Controlled and Sleeve Wear Low
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Case 4: API Plan 13 – Reverse Flush System with Bypass Port(s)
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Case 4: API Plan 13 – Reverse Flush System with Bypass Port(s)
Conditions:
Bypass Port(s) may Not be Required for Water Service
Bypass Port(s) are Required for Hydrocarbon Service (Low Specific Gravity Product)
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Case 4: API Plan 13 – Reverse Flush System with Bypass Port(s)
Conditions:
Bypass Port(s) may Not be Required for Water Service
Bypass Port(s) are Required for Hydrocarbon Service (Low Specific Gravity Product)
SOURCE REFERENCES:• Centrifugal Pumps: Design & Application, Lobanoff and Ross
(practical application)• Centrifugal and Axial Flow Pumps, Stepanoff (theory)• Centrifugal Pumps, Gülich
• Vertical Turbine, Mixed Flow & Propeller Pumps, Dicmus• Centrifugal Pump Handbook, Sulzer• Pump Handbook, Karassik• Centrifugal Pump Clinic, Karassik• Centrifugal Pumps Selection & Operation, Karassik• Centrifugal Pumps, Karassik• In-Tandem 3.0 for Windows, EG&G Sealol (John Crane)• ABZ Inc, Design Flow Solutions Software
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WHO IS THIS SYSTEM ENGINEER?
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TAYLOR SMITH – Comanche Peak
THE (HAPPY) END
QUESTIONS ?
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