371
HAZARDS OF
REVERSE PUMP
ROTATION
_
ROBERT TALBOT FIELD ENGINEER SULZER PUMPS,
372
PROBLEM SYNOPSIS
High pressure water flood injection pump with
customer concern for potential reverse rotation in the
event of a discharge check valve failure. Previous
valve failure had caused some pump damage.
Pump is an API BB3, 10 stage
Pump is driven at a constant speed by 1500 BHP
horizontal induction motor
2 pumps main and standby piped in parallel
arrangement
2
373
Requested
Questions to be answered are:
In the event of a check valve failure
will the pump and motor realize
reverse rotation?
Will reverse rotation damage pump,
motor, seals, coupling, etc?
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374
Considerations
System configuration
Available reverse flow rate at pump
Head drop expected across the
pump
Break away torque and running
resistance of the pump/motor train
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375
Considerations
System configuration
Normal Flow
Failed Check Valve
Discharge Valve Discharge
PUMP 1 Failure PUMP 2
Flow
OPERATING ON STANDBY
Suction Suction
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376
Considerations
Available reverse flow rate to the pump
Head drop expected across the pump
BEST EFFICIENCY
HEAD 4100 FT
CAPACITY 975 GPM
4100 FT
FULL RANGE
HEAD 5000 TO 3000 FT
CAPACITY 0 TO 1350 GPM
975 GPM
PUMPS 1 AND 2 NORMAL PERFORMANCE
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377
Initial Checks
Will the pump rotate in reverse direction?
Consider the factors.
Seal drag
Bearings
Rotor inertia
Driver inertia
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378
TOOLS
2.5
2
Single Suction
nro/n @ 100% hBEP
1.5
Double Suction
1
0.5
0
0 2 4 6 8 10 12 14 16 18
Specific speed - US units
Pump OEMs sometimes
HI Reverse Runaw ay Ratio
provide four quadrant curves
also known as Knapp or total
Hydraulic Institute provides
performance curves
guidance using a ratio
See publications by A. J.
Stepanoff and R.T. Knapp for
additional information.
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379
Initial Checks
260 lb-ft
Case study pump Speed/Torque curve shows 260 lb-ft breakaway.
Assume motor breakaway at 50% of pump for a total of 390 lb-ft
Pump full speed power per performance curve = 1300 BHP @ 3577 RPM
100% torque = 5252*1300/3577 = 1909 lb-ft
Breakaway torque = 20% of full load torque. 9
380
Four Quadrant
ENERGY
DISSIPATION
+T
-H
H
F c 6 - ENERGY
~iSSIPATiml
(
-H
ENERGY
I ~
DISSIPATIO'I
-T
+H
PUMP CIRCLE DIAGRAM 10
381
Impending Rotation
20% impending rotation
40% capacity
Estimate 20% torque line on Quadrant curve and plot on the zero speed
line.
In this case we can see that the flow rate will be at about 40% (390 gpm) in
the worst case before the pump will start to rotate. 11
382
PERFORMANCE
40% looks
reasonable
when we look
and a typical
hydraulic
turbine curve
(Pump
running in
reverse)
44% flow
Characteristics of a similar
hydraulic turbine.
With assumption of 100% flow, the question is what rotational speed
will the pump achieve? 12
383
Speed From Hydraulic Institute 1.4
QUICK Single Suction
SIMPLE
GOOD APPROXIMATION Double Suction
1.16
SPEED = DESIGN * RATIO
SPEED = 3577 * 1.16
NS= 1225
= 4142 RPM Hydraulic Institute provides
Quick speed check
NOTE: The higher the pump specific speed the higher the ratio !
Higher speeds are a result given the flow and head availability !
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384
Speed From Four Quadrant Curve
Once the pump starts to rotate what final speed will be achieved.
67% flow
100% Constant head line
118% speed
Assume available pump back flow head at 100%
Speed will increase until the head crosses the zero torque line.
Follow to both horizontal and vertical axis 14
385
Speed From Four Quadrant Curve
HEAD = 100% = 4100 Ft
CAPACITY = 67% = 975GPM*0.67 = 653 GPM
SPEED = 118% = 3577*1.18 = 4221 RPM
POINT IS BELOW THE CURVE!!
A second point is needed to determine the pull to the curve
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386
Speed From Four Quadrant Curve
PICK A HIGHER HEAD WE WILL USE 125% HEAD LINE
76% flow
125% Constant head line
132% speed
Assume available pump back flow head at 125%
Again follow to both horizontal and vertical axis
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387
Speed From Four Quadrant Curve
HEAD = 125% = 4100 Ft * 1.25 = 5125 FT
CAPACITY = 76% = 975 GPM*0.76 = 741 GPM
SPEED = 133% = 3577 * 1.33 = 4757 RPM
POINT IS ABOVE THE CURVE!!
Speed condition is on the curve between our points
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388
Speed From Four Quadrant Curve
Pull line crosses the curve at ;
HEAD = 4630 ft = 4630 / 4100 Ft = 113%
CAPACITY = 700 = 700 / 975 gpm = 72%
4630 FT
700 GPM
The final rotational speed can now be determined.
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389
Speed From Four Quadrant Curve
Estimate head curve at 113%
72% flow
113% Constant head line
(estimated)
125% speed
From curve, estimate is 125% = 3577*1.25 = 4471 rpm
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390
AFFINITY LAW CHECK
SUMMARY FROM QUADRANT CURVE
HEAD 100% 113% 125%
(4100 FT) (4633 FT) (5125 FT)
CAPACITY 67% 72% 76%
(653 GPM) (705 GPM) (741 GPM)
SPEED 118% 125% 132%
(4220 RPM) (4471 RPM) (4757 RPM)
CURVEHEAD%
N = * QUADRANTSPEED% * ORIGINALSPEED
QUADRANT %
N=[(113/100)^0.5*1.18]*3577 = 4486 RPM
N=[(113/125)^0.5*1.32]*3577 = 4489 RPM
VALUE FROM QUADRANT CURVE = 4471 RPM
VALUE FROM HYDRAULIC INSTITUTE = 4142 RPM 20
391
What does this all mean?
The pump and motor train will not reverse rotate under low
flow conditions so no further consideration is required
Pump will accelerate to 125% over speed with unrestricted head
and flow rate.
PUMP CONSIDERATIONS
Bearings
Oil rings operate in a limited speed range
Journal bearings
Lubrication at prolonged high speed will not be
acceptable in most cases unless forced lube exists
Antifriction bearings
More tolerant of the lubrication starvation see
bearing manufacturer's catalog speed limitations.
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392
More Considerations
Seals This case has packingless boxes
Standard face seals may be adversely
affected by overspeed.
Pumping rings may be rotation sensitive
Pump internals
Slow roll in either direction can damage
Throttle sleeve pushed off
wear parts the fit and welded to throat
Reverse flow creates internal differential
pressures that were NOT considered in
the pump design. Sleeves and wear parts
can be displaced.
High runaway rotational speed
Balance issues
Impeller stresses can be exceeded Throttle sleeve thrust rings
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393
Support Equipment
High runaway rotational speed - cont'd
Low damped critical speeds not normally of interest in rotor
analysis may cause damage during runaway event
Coupling -
Most modern disk type couplings will tolerate rotation in
either direction
Runaway pumps speeds can exceed coupling rating
Possible energizing of reverse running equipment may over
stress the coupling.
Motor
Bearing considerations similar to that of the pump
Same high critical speed considerations as the pump
Rotor overspeed can cause overstressing in the motor
armature causing fits to loosen or parts to even be thrown.
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394
Final thoughts
A discharge check valve stuck wide open will result in
approximately 125% over speed with reverse rotation.
Bearing failure is a definite possibility
Seals were not rated for this rotational speed.
Internal pump components may become dislodged
High possibility of damaging vibration at over speed
Coupling is rated for the rotational speed as long as the
train does NOT become energized
Motor has journal bearings. Over speed condition in either
direction is of concern. Manufacturer should be consulted
if a runaway event occurs.
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395
QUESTIONS
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