By

Stephen E. Smith, P.E.

Ingersoll-Dresser Pump Co. SES MP-0500
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• Plant And Operator Safety.
• Production Throughput And Equipment Availability.
• Cost Control.
– Capital Equipment
– Maintenance
– Inventory Management SES MP-0500
– Energy 2
(The Beginning)

SES MP-0500
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• Mechanical Seals Leakage (41%).
• Bearing Life (19%).
• Shaft Overpressure And Fatigue.
• Coupling and Misalignment.
• High Wear Rates.
• High Vibration Levels.

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• Root Causes
– Lack Of Lubrication Of Seal Faces.
– Abrasive Wear Of Seal Faces.
– Flashing Of Product Across Seal Faces.
– Coking Of Seal Leakage.
• Failure Indicators
– Excess Mechanical Seal Leakage.
SES MP-0500
– High Seal Operational Temperature. 5
• Goal - Achieve 99% Mechanical Seal Reliability.
• Reviewed Application With Various Seal Vendors.
• Recommendations By All Vendors
– Double Mechanical Seals.
– Seal Flush System With Filtration And Cooling.
– Seal Flush Flow And Temperature Monitoring. SES MP-0500
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• API 682 Double Mechanical Cartridge Seal.
• Longer Box Design.
– Alternate Seal Types and Suppliers.
– Optimum Seal Designs And Suppliers.
• Material Options.
– Soft/Hard Has Reduced Flush Requirements. SES MP-0500

– Hard/Hard Seal Flushing Is Required. 7

• Double Motor/Pump System.
• Flush Fluid Filtration With Bypass.
• Air/Oil Heat Exchanger.
• Simple Flow Control To Split Flows.
• Relief Valve Protection Of System. SES MP-0500

• Pressure, Flow And Temperature Instrumentation. 8

• Root Causes
– Bearings Loads Are Excessive (Including Shock Loads).
– High Pump Speed.
– Lubrication Method Insufficient.
• Failure Indicators
– High Vibration And Bearing Temperature Levels.
– Screws Contact Bore Causing Extensive Pump Damage.
SES MP-0500
– Short Bearing And Mechanical Seal Life. 9
• Larger Bearings And/Or Alternate Bearing Arrangement.
– Convert Four Bearing Pumps To Six Bearing Design.
• Eliminate Axial Loads
– Change Helical Gears To Spur Or Herringbone.
• Lubrication Systems - Oil Circulation Or Mist.
• Status Monitoring.
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• Double Motor/Pump System.
• Flush Fluid Filtration With Bypass.
• Air/Oil Heat Exchanger.
• Simple Flow Control To Split Flows.
• Relief Valve Protection Of System. SES MP-0500

• Pressure, Flow And Temperature Instrumentation. 11

• Root Causes
– Fundamental Pump And Screw Design.
– Use Of Shell Screw Design.
– System Pressures Exceed Design Pressure.
– Shock Loads Within System.
• Failure Indicators
– High Vibration Levels.
– Broken Shaft, Screw Shells Or Gears.
– Short Bearing And Mechanical Seal Life.
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– Uneven Gear Wear. 12
• One-Piece Stronger Integral Screws.
– Increased Shaft Diameters.
– Reduction In Stress Risers Of Shaft.
– Shorter Bearing Span.
• Bore And Screw Coatings To Allow Incidental Contact.
• Convert Four Bearing Pumps To Six Bearing Design.
• Alternate Screw Materials For Increased Strength And
Fatigue Resistance.
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• Status Monitoring. 13
Four Bearing Six Bearing
Design Design
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• Root Causes
– Insufficiently Stiff Pump/Motor Foundation.
– Fundamental Equipment Design.
– Improper Initial Alignment.
– Pipe Loads.
• Failure Indicators
– Fretting And Wearing Of Shaft And Coupling Bore.
SES MP-0500
– High Vibration Levels.
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• Rigid, Grouted Baseplate Design.
• Use Of Component Design Tools Such As Finite
Element Analysis.
• Coupling Selection (All Metal, Flexible Disk).
• Tapered Pump Shaft.
• Training Of Installation Personnel. SES MP-0500
• Vibration Monitoring. 16
Case And Liner Displacement
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Case And Liner Stress Levels
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• Root Causes
– Abrasives In Pumped Fluid Wears Pump.
– Corrosive Fluid Attacks Pump.
– Excessive Pump Speed.
• Failure Indicators
– Loss Of Screw Seal With Resulting Blow Back At High Gas
Volume Fractions (GVF).
SES MP-0500
– Low Flow. 19
• Selection Of Materials.
– Hard Tipping Of Screws For Increased Abrasion Resistance.
– Chrome Coated Bores For Increased Hardness.
• Longer Bore Length
– Additional Locks To Prevent Blow Back.
– Longer Pitch Screw At Slower Operational Speed.
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• Root Causes
– Increasing Screw Pitch, Pressure And GVF.
– Fundamental Pump Design.
– Failing Component.
– Improper Alignment or Insufficiently Stiff Foundation.
• Failure Indicators
– High Vibration Levels.
– High Temperature Levels.
– Short Bearing And Mechanical Seal Life. SES MP-0500
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• Screw And Bracket Design.
– Shorter Screw Pitch Gives Mores Locks.
– Modified Screw Profile At Last Seal Point To Allow
Compression In Second To Last Lock.
– Brackets Under Compressive Load.
• Failure Analysis, Trouble Shooting And Root Cause
Analysis.
• Monitoring Equipment To Determine Root Cause.
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• Selected Continuous Monitoring Of Critical Items.
• Active Identification Of System Status With Preset
High/Low Warning.
• Positive Actions Taken Immediately.
– Automatic Actions Taken To Counter Identified Problem.
– Notification Of Selected Personnel. SES MP-0500
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• Pressure Transmitters
• Pressure Gauges
• Temperature Transmitter
• Temperature Gauges
• Suction Low Pressure
• Suction Strainer Delta Pressure
• Discharge High Pressure
• Pump Bearing Temperature
• Pump Bearing Vibration
• Motor Bearing Temperature
• Motor Bearing Vibration
• Auxiliary System Pressure Transmitter
• Auxiliary System Delta Filter Pressure
• Auxiliary System Level Indicator
• Auxiliary System Low Level Switch
• Auxiliary System High Level Switch
• Auxiliary System Flow
• MPP Bearing Lube Flow
• MPP Bearing Lube Temperature
• Electrical System Performance/Status
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• General
– API 676 Compliant Design.
– Non-Contacting Design.
– Simple Design With Minimum Components And Keyed Or
One-Way Simple Assembly Requirements.
– Common External Envelope With Different Size Internals.
• Bore Length Compromise
– Long Bores Maximizes Locks To Prevent Blow Back.
– Long Bores Maximizes Pitch And Reduces Pump Speed.
– Short Bores Minimizes Shaft Bending.
– Short Bores Minimizes Pitch And Reduces Vibration.
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• Inner Case (Liner)
– Replaceable Inner Case (Liner) In A Cartridge Design.
– Bore Coating To Increase Abrasion Resistance And Tolerate
Incidental Screw/Bore Contact.
– Repairable Bores Through Coating Replacement.
• Screws
– Integral Design Using Fatigue Resistance Material.
– Hard Tipping To Increase Abrasion Resistance And Tolerate
Incidental Screw/Bore Contact.
– Repairable By Welding, Machining and Coating Replacement.
– Modified Profile At Last Lock To Allow Pre-Compression.
– Tapered Coupling Connection. SES MP-0500
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• Mechanical Seals
– 99% Seal Reliability
– API 682 Double Seal To Maximize Flexibility And Options.
– Flush System With Filtration, Cooling And Instrumentation.
• Bearings
– Six-Bearing Design.
– Eliminate Axial Bearing Loads.
– Lube System With Filtration, Cooling And Instrumentation.
• System Monitoring
– Bearing Temperature And Vibration.
– System Pressure And Temperature.
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– Continuous Active System. 27
 (The Results)

SES MP-0500
Model MP1 28
 Stephen E. Smith, P.E.
Ingersoll-Dresser Pump Co. SES MP-0500
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