Pump Practices & Life

Presented by:

Paul Barringer, P.E.

Barringer & Associates, Inc.
Reliability, Engineering, and Manufacturing Consultants P.O. Box 3985 Humble, TX 77347-3985

Phone: 281-852-6810 hpaul@barringer1.com

FAX: 281-852-3749 http://www.barringer1.com

Reliability measures the capacity of equipment or processes to operate without failure for a specified interval when put into service and used correctly.
Barringer & Associates, Inc. 2004

Pump Curve Practices & Life-ANSI

ANSI Pump Curve Sensitivity For Pump Reliability
Lower Impeller Life Discharge Recirculation

Weibull Characteristic Life ~MTBF

Barringer & Associates, Inc. 1999

Optimum

Low Flow Cavitation High Temperature Rise Low Bearing & Low Seal Life Suction Recirculation

Best Practice = -10% to +5% of BEP

0.92 0.53

% Head

Best Efficiency Point

Better Practice = -20% to +10% Good (Commercial) Practice = -30% to +15%

Reliability Curve

Cavitation

% Reliability

+Reconsider!!+

Low Bearing & Low Seal Life

Avoid!!

+
Pump Curve

0.1

% Flow
Barringer & Associates, Inc. 2004

Pump Curve Practices & Life-API

API Pump Curve Practices And Effects On Pump Life From Variability About BEP
Lower Impeller Life Discharge Recirculation

Weibull Characteristic Life ~MTBF

Barringer & Associates, Inc. 1999

Optimum

Low Flow Cavitation High Temperature Rise Low Bearing & Low Seal Life Suction Recirculation

Best Practice = -10% to +5% of BEP Better Practice = -20% to +10% of BEP
Low Bearing & Low Seal Life Cavitation

1.00 0.98 0.90 0.75

% Head

Best Efficiency Point

Life Based On Best Practices For Installation And Use For All Features Except How Close The Pump Operates To BEP

Avoid!!

Good Practice = -30% to +15% of BEP

Reliability Curve Pump Curve

% Flow
Barringer & Associates, Inc. 2004

% Reliability

+ Reconsider!! +

Pump Curve Practices & Life?

High Speed & High Head Pump Curve Practices And Effects On Pump Life From Variability About BEP
Lower Impeller Life Discharge Recirculation

Weibull Characteristic Life ~MTBF

Barringer & Associates, Inc. 1999

Optimum

Low Flow Cavitation High Temperature Rise Low Bearing & Low Seal Life Suction Recirculation

Best Practice = -10% to +5% of BEP Better Practice = -20% to +10% of BEP
Low Bearing & Low Seal Life Cavitation

? ?? ??? ????

% Head

Best Efficiency Point

Life Based On Best Practices For Installation And Use For All Features Except How Close The Pump Operates To BEP

Avoid!!

Good Practice = -30% to +15% of BEP

Reliability Curve Pump Curve

% Flow
Barringer & Associates, Inc. 2004

% Reliability

+ Reconsider!! +

Reliability Practices On Weibull Life,

Pump Curve % Off BEP Resulting eta Multiplier 0.9726 0.8547 0.8719 0.9533 0.8719 0.9801 1.0000 1.0000 1.0000 1.0000 + 5% to -10% of BEP 98% 86% 98% 98% 98% 98% 99% 100% 99% 100% L/D Suction Straight Runs L/D = 10 to 12 Rotational Shaft Alignment 0.001 inches/inch error Piping Alignment Rotational Balance Foundation Design 5 Times Equipment Mass 100% 100% 100% 100% 100% Rotational 100% Shaft 100% Alignment 100% 100% 0.003 100% inches/inch error Grouting Monolithic And Adhesive Epoxy 100% 100% 100% 100% 100% 100% Piping 100% Alignment 100% 100% 100% 0.010 inch Best Practices Impeller Housing Pump Bearings Mech. Seal Bearing Seal Shaft Coupling Motor Bearings Replacement Mtr. Motor Starter 0.003 inch error 100% 100% 100% 100% 100% Pump 100% Curve % 100% Off BEP 100% 100% + 10% to 100% -20% of BEP Smooth at 0.0198 ips 100% 100% 99% 100% 100% L/D 99% Suction 100% Straight 100% Runs 100% 100% L/D = 100% 100% 100% 99% 99% 100% 100% 100% 100% 100% Better Practices 100% 100% 100% 100% 100% 100% 99% 100% 99% Resulting 100% eta Multiplier

Barringer & Associates, Inc. 1999

Rotational Balance Foundation Design 3.5 Times Equipment Mass 95% 95% 90% 90% Rotational 90% Shaft 90% Alignment 90% 90% 0.009 99% inches/inch 100% error
90% 83% 58% 58% 40% 58% 65% 55% 100% 100%

Grouting

6 to 8

error

Good at 0.0448 ips 95% 95% 90% 90% L/D 90% Suction 90% Straight Runs 95% 95% 100% L/D = 100% 1 to 3
75% 80% 60% 60% 60% 60% 80% 80% 100% 100%

Slightly Pourous But Adhesive 98% 95% 90% 90% 90% Piping 90% Alignment 91% 90% 99% 0.125 100% inches error
69% 64% 40% 40% 40% 40% 71% 80% 100% 100%

Impeller Housing Pump Bearings Mech. Seal Bearing Seal Shaft Coupling Motor Bearings Replacement Mtr. Motor Starter

0.6583 0.5163 0.3950 0.4314 0.3950 0.5705 0.6036 0.9776 0.6036 1.0000

88% 95% 95% 94% 73% 95% 95% 92% 79% 90% 88% 88% 88% 90% 90% 84% Pump 88% 90% 90% 84% Curve % 79% 90% 88% 88% Off BEP 92% 95% 90% 94% 94% 93% 94% 97% +15% to Resulting 100% 100% 100% 100% -30% of Good Practices eta 100% 100% 100% 100% BEP Multiplier

Avoid

Rotational Balance

Foundation Design

Grouting

Rough at 0.248 ips 81% 79% 61% 61% 64% 61% 78% 75% 100% 100%

Reliability practices must be connected with costs to find the lowest long term cost of ownership calculated by net present value.

Impeller Housing Pump Bearings Mech. Seal Bearing Seal Shaft Coupling Motor Bearings Replacement Mtr. Motor Starter

0.1949 0.1438 0.0151 0.0095 0.0151 0.1149 0.0737 0.8625 0.0737 1.0000

68% 70% 65% 65% 51% 65% 76% 78% 100% 100%

0.5 Times Cementitous Equipment & Low Mass or StiltAdhesion Mounted 88% 88% 78% 80% 50% 55% 50% 55% 55% 55% 50% 55% 70% 75% 60% 60% 100% 100% 100% 100%

Barringer & Associates, Inc. 2004

Summary
Important impacts on life involve:
Equipment grade Installation grade Operation grade Maintenance grade
Remember effects of abuses are cumulative! You may try to hide your atrocities but the equipment accumulates the history and someone pays in the end

No free lunchessomeone pays for everything Think about the life cycle cost of your actionsengineer the results
Barringer & Associates, Inc. 2004