A Lecture is a presentation of a technical paper detailing cutting-edge, emerging technology. Two lectures are presented consecutively in one 90-minute time slot.
Lecture P1: Operational Problems in Pumping Shear Thinning Slurry Resolved Using Laminar Flow Fitting Loss Model
| Tuesday, September 25, 2012 |
10:30 AM |
Level Three, Room 372A |
Instructors:
| Daniel Wood (DuPont, Wilmington, DE) and Trey Walters (Applied Flow Technology, Colorado Springs, CO) |
Description:
A case history is presented pertaining to five pumping systems that operated satisfactorily until a new production requirement was imposed. A new slurry product initially developed at lab scale was introduced into the production plant for an initial trial run. Problems began to surface immediately on three out of five batch process pumping systems when the slurry could not be pumped through the plant at contract rate. Additionally, significant "heels" (unwanted fluid levels) were left in some of the suction vessels that were unable to be pumped out, resulting in considerable yield losses. This manufacturing problem had not been anticipated by the team, and without quick resolution, a loss of customer confidence and a significant delay in the new product would have resulted.
Investigation and analysis of the system revealed two major problem areas in pumping non-settling slurries in laminar regimes:
- Initial prediction of head losses through suction piping fittings was flawed using traditional hydraulic loss methods. The original calculations for NPSHA values for the pumps predicted adequate NPSH margin. The fluid was non-Newtonian and was operating in the laminar regime. Upon further investigation, a weakness was revealed in predictions of fitting losses for laminar flow through the pipe fittings. An improved model for predicting losses through pipe fittings was identified and implemented. The improved model matched operational data much better and provided the critical insight needed to resolve the operational problems and get the facility operating.
- Piping arrangements that allow for features such as clean-out ports (e.g., branch flow tees) can be counterproductive to unrestricted flow of the process liquid in systems with non-settling slurries operating in laminar regimes. Tees, elbows, diameter changes, and other fittings can introduce significant head losses in the pumping system.
The authors present an improved method for analyzing fitting losses in pumping systems when dealing with non-settling slurries operating in the laminar regime. In addition, design considerations are presented to minimize the impact that piping has on the pumping system when handling non-settling slurries operating in the laminar regime. |
Lecture P2: If You Install a Pump Subsea, Leave Nothing to Chance
| Tuesday, September 25, 2012 |
10:30 AM |
Level Three, Room 372A |
Instructors:
| Pierre-Jean Bibet and Bernard Quoix (TOTAL, Paris, France) |
Description:
| In 2011, for the first time, Hybrid Multiphase Pumps have been deployed on the seafloor. This was Offshore Angola, at 800m Water Depth, to ensure the full field development of Pazflor Deep Sea Project by pumping the viscous oils of the Miocene fields. Through the example of these Pazflor subsea pumps, this paper invites the reader to discover, step by step, the thorough acceptance tests program that was put in place to mitigate as much as possible the risks before installation. This paper relates how, after 15 months of Acceptance tests, the eight Hybrid Pumps were declared Ready for Deployment. |
Lecture P3: New Advances in Pulse Width Modulated (PWM) Slip Power Recovery Drive for Pumps
| Tuesday, September 25, 2012 |
2:00 PM |
Level Three, Room 372A |
Instructor:
| Stephan Bondy (TMEIC, Houston, TX) |
Description:
| Since its invention by Nikola Tesla in 1888, the alternating-current (AC) motor has been a critical driver for the industrial age. One of his original three patents was the wound rotor induction motor (WRIM). Later, Westinghouse refined the design of the wound rotor motor to permit control of the speedtorque characteristics of the machine. This paper discusses a new advancement in Pulse Width Modulated slip power recovery drives (PWM-SPR) application for pumps. By using sophisticated adjustable speed drive control, a significant amount of slip power can be fed back to the utility line, hence resulting in energy savings. Also, application examples are discussed to enhance understanding. |
Lecture P4: New Advances in Pulse Width Modulated (PWM) Slip Power Recovery Drive for Pumps
| Tuesday, September 25, 2012 |
2:00 PM |
Level Three, Room 370D |
Instructor:
| Eric Vanhie and Benjamin Weiss |
Description:
| Since 2007, the hot-filament Chemical Vapor Deposition (CVD) technology for crystalline diamond thin-film coatings has found its way into the mechanical seal market to combat the problems of dry running, corrosion and abrasion. This new technology has proved successful in hundreds of pumping applications in a wide range of services and duties. The reliability and lifetime of mechanical seals are improved by using diamond-coated faces. One such application involved the sealing of large boiler feed and steam generator pumps in power plants, which operate under high pressure, RPM, and temperature conditions. Consequently, the mechanical seal faces are highly loaded in a fluid with less than ideal lubricating qualities. These applications are technologically challenging for mechanical seal manufacturers not only from a tribological perspective but also from a corrosion viewpoint when the feed water has a low electrical conductivity or is free of impurities. This paper discusses a new seal-face treatment using hot-filament CVD manufacturing technology tested in a lab for 16,000 hours and currently used in feed pump operations in several power stations in the USA and Europe. |
