Approaches to the Rational Solution of the Problem of Creating New Pumping Equipment in the Practice of the HMS GROUP Company

Transcription

1 Available online at Procedia Engineering 39 (2012 ) XIIIth International Scientific and Engineering Conference HERVICON-2011 Approaches to the Rational Solution of the Problem of Creating New Pumping Equipment in the Practice of the HMS GROUP Company Nikolay Yamburenko a, Igor Tverdokhleb b, Gregory Vizenkov c, b* a,b,c HMS GROUP, 3rd Pryadilnaya str., 6A, Moscow , Russia Abstract The paper presents some approaches to the design process of pumping equipment, whose implementation has enabled the company HMS GROUP to optimize the designing process itself, therefore promptly supply consumers with modern highly efficient pumping equipment. The authors also review the product range and the pump designs that have been created in the last few years as well as the ones Published by Elsevier Ltd. Selection and/or peer-review under responsibility of Sumy State University Open access under CC BY-NC-ND license. Keywords: Design; pump equipment. In different branches of industry and economy, there are applied a lot of various types of the pump equipment. Today, while purchasing new pumps, Customers naturally wish to receive the pumps as much as possible corresponding to their hydraulic system, and frequently make various specific requirements as to parameters of pumps, their designs, materials, quality of manufacture, etc. In many respects, a variety of these requirements is caused by their insufficient standardization for those or other applications of pumps. In some branches of industry, the standardization problem has been fractionally solved. For example, in petroleum industry, there is a group of standards API, sometimes there are branch standards and requirements, for example, S,, there are standards ISO and HI, etc. However all these standardized requirements are often supplemented and specified at fulfilling the order, and in some cases, at various stages of realization of the contract, there are appeared new ones. As a result, at designing * Corresponding author. address: tib@hms.ru Published by Elsevier Ltd. doi: /j.proeng Open access under CC BY-NC-ND license.

2 304 Nikolay Yamburenko et al. / Procedia Engineering 39 ( 2012 ) equipment, each manufacturer of pumps works out his personal strategy. Someone designs the pump according to the Order risking thus not to be within delivery terms, someone develops the fields of the type and size rows of pumps, trying to take into account all requirements from various industries, including the hypothetical ones. Certainly, in an ideal, the second way is the best, but to follow it is a long-term and expensive process, which is presumed only by large firms and that in the availability of the experience of creation and delivery of the pumps of the specified purpose, but even on such a condition, there is no guarantee that all requirements of the concrete Customer would be taken into account. On the other hand, constantly to develop new equipment corresponding to the special Order, provide for all the preparation for manufacturing each individual product is not a less expensive process, and the main thing, it is rather long. There is only one way to solve such a problem and it consists in creating the new but standardized equipment for the specified type of application and similar Customers. That is, while analyzing the Order, it is necessary to consider its perspectives not only from the point of view as for receiving the profit at the specified stage, but also as for creating the possibility to develop the type and size row for some articles with the requirements standardized for this row, unifications with other equipment, etc. After that it is possible to start creating the pump, thus within the design limits of one of the base pumps for the parameters of the specified field. At occurrence of the Order for other parameters, but for similar purpose, the problem would be solved either within the limits of the specified design base at the expense of a replaceable flowing part, or at the expense of working out a new pump within the limits of the available type and size row. Thus, in the foreground, the correctly formulated design specifications (DS) for creating the article, to be exact, for the type and size row for a concrete application or several applications with similar technical requirements, including all the requirements of the competitiveness, inter-design unification, lowering the cost price of manufacture, etc. That is, there is need in creating such a product, which would allow a manufacturer taking the leading position among the companies creating similar equipment. Providing the future pump with the competitive advantages, in turn, imposes special requirements on the implementation of the perspective Research and Development (R & D) concerning the study and development of the assembly units, new materials, and also new engineering solutions for design and other know-how. Ability to conduct a full-fledged R & D is one of the main tasks of any company seeking to get maximum result. R & D should pursue several key goals, namely constantly to monitor all new decisions in the native industry and related ones, to take part, if necessary, in the process of creating the products and materials being perspective for these branches, as well as to develop the new equipment and explore all the ideas under consideration providing for the product of the interest the essential features that would allow it becoming more competitive. In addition, during performing R & D, it is necessary to carry out the research work as for developing and testing the new and most responsible pump assembly units and pump designs as a whole. It is especially important at growth of pressure and complicating of the operation conditions, using new materials and design schemes. For example, in HMC Group, there are conducted the R & D concerning the possibility for reducing external diameter of the guide vanes at simultaneous increasing effectiveness of the stage that would reduce the mass of the pumps by % depending on the number of the stages and rapidity factor.

3 Nikolay Yamburenko et al. / Procedia Engineering 39 ( 2012 ) D of the case Actual design of the multistage pump section Design of the multistage pump section with the diminished guide vanes Fig. 1. Design of the multistage pump section As a result of performing the above said (R & D), the competitiveness of the newly developed articles will increase. There is a possibility of upgrading the serially produced multistage pumps of different purposes. The other R & D being in the company s focus are directed to the refinement of the original design schemes, assembly units and parts of the pumps. As a result, there is appeared a scientific and technical reserve for the further perfecting the pump equipment of the company. Taking into account that the pump is only a part of the hydraulic network wherein it operates, it is important to consider the operation of the system as a whole. Thus today in the whole world, there is clear understanding that the basic reserves of increasing efficiency and reliability of the pump equipment are concentrated in collaboration with the hydraulic network of the Consumer [1]. Pump Pumping aggregate with System Control auxiliaries Control Discharge Consumer load Discharge Suction Coupling Frequency converter Discharge Frequency Suction Electric Coupling Tank converter Motor Suction Electric Suction Coupling Electric Motor Motor Foundation plate Foundation plate Foundation plane -Creating pumps of maximum possible effectiveness; - Increasing efficiency of existing pumps with interchangeable rotors, cutting impellors, etc.; - Reducing energy consumption -3 %. - Regulation of pumps operating modes by means of a variable frequency drive; - Creation of intellectual monitoring and control systems; - Reducing energy consumption- 20 %; - Improvement of the quality of installation, commissioning service; - Reducing energy consumption - 3 %; - Optimizing the whole system; - Reducing energy consumption- 10 %.; - Coordination of the network and the pump parameters; - Reducing energy consumption - 4 %. Fig. 2. Main directions for decreasing power consumption

4 306 Nikolay Yamburenko et al. / Procedia Engineering 39 ( 2012 ) Significant increase of temperature. 2. Decreasing resource of operation as a result of vibration, because of: 2.1 Possible cavitation; 2.2 Availability of recycling the flow at the impeller inlet and the outlet. 3. Decreasing resource of operation as a result of vibration caused by the flow separation in the flowing part. 4. Cavitation, electric motor overload. Fig. 3. Influence of various factors on reliability In this regard, an important question is the question of proper organizing the interconnections with the Consumer, both at the stage of the new hydraulic systems design and analysis, and at the stage of modernizing the existing ones. The pumps are often operated not taking into account the modern possibilities for regulation and optimization of pumping conditions, and such a situation results in unnecessary energy losses (Fig. 2), sometimes in reducing resource of the equipment operation (Fig. 3), etc. The solution of these problems can and should be performed by the pump Manufacturer together with the operating organizations. Thus, the constant working interconnections with the Customer provides not only reducing its operating costs for pumping units, but also gives the chance to the Manufacturer correctly to form DS and to design pumps taking into account the capabilities of the entire system. This fact in turn increases the Manufacturer s competitiveness in the market. To confirm the above said conclusion, recently HMC Group has carried out a lot of studies on creating and upgrading the pump equipment. 1. Unique pipe line pumps for oil pipelines with an ultimate pressure up to 10 P and a driver power of 12 W. There are provided the full-scale tests and the delivery of the aggregates completed with the standard driving engines, hydraulic couplings or frequency converters, systems for maintenance of the thermal condition and locking mechanical seals, etc. ) b) Fig. 4. ( ) Oil transfer pumping station layout; (b) Test stand (N=14 W)

5 Nikolay Yamburenko et al. / Procedia Engineering 39 ( 2012 ) The type and size rows of vertical booster pumps of VBN type with feed to 5000 m3/h. In comparison with pumps, which had been created earlier, the new pumps were developed with rotational speed of 1000 rpm that made it possible to increase their reliability and also to increase the range of possible head pressure values due to their multistage performance. Fig. 5. Pumps of VBN type 3. The type and size rows of horizontal booster pumps of NHBN-M type with feed to 5000 m3/h. The pumps are equipped with replaceable rotors to provide for various combinations of parameters. Their low rotational speed ensures their highh reliability and applying the screw-type centrifugal stages provides the high anti cavitations performances (fig. 6). ( ) ( 80 ) Fig. 6. Pumps of NHBN-M Type 4. There have been modernized type and size rows of the pipe line pumps of NM type with feed to m3/h. The essence of modernization consists in implementation of the saved up long-term experience and knowledge that allowed increasing both their profitability and reliability indices.

6 308 Nikolay Yamburenko et al. / Procedia Engineering 39 (2012) Fig. 7. Modernized Pumps of NM Type 5. New pump of D12500 type has been created for irrigating systems, and on its base, in Turkmenistan, there was developed, manufactured, mounted and started up in maintenance the irrigating station, being vital for this country (fig. 8). The created pump has also found wide application in other industries. Fig. 8. Pump of D12500 Type At the present time, there have been being developed new type and size rows of the competitive pumps of type D with feed to 10000m3/h and mastered at two enterprises of the group. 6. There were created feed non-booster one-threaded electropumps for blocks of the atomic power station, 2006 (fig. 9). ɉɨɞɚɱɚ = 1840 ɦ3/ɱ; ɇɚɩɨɪ = 910ɦ; ɑɢɫɥɨ ɨɛɨɪɨɬɨɜ = 2980 ɨɛ/ɦɢɧ; Ⱦɨɩɭɫɤɚɟɦɵɣ ɤɚɜɢɬɚɰɢɨɧɧɵɣ ɡɚɩɚɫ = 15ɦ; Ɍɟɦɩɟɪɚɬɭɪɚ ɩɟɪɟɤɚɱɢɜɚɟɦɨɣ ɫɪɟɞɵ = 164 ɋ; Ʉɨɥɢɱɟɫɬɜɨ ɧɚɫɨɫɨɜ, ɭɫɬɚɧɚɜɥɢɜɚɟɦɵɯ ɜ ɛɥɨɤɟ 4 ɪɚɛɨɱɢɯ, 1 ɪɟɡɟɪɜɧɵɣ. Fig. 9. One-threaded feed pump of PEA type

7 Nikolay Yamburenko et al. / Procedia Engineering 39 (2012) There have been being created feed non-booster two-threaded pumps of new generation with w reference to the standardized optimized informaational project for atomic power station (APS SOI). In the above mentioned pump, the flow is separated into two ones and the screw-type centrifugal stagees are applied o to ensure that allow combining in it the functionss of two pumps, namely: a booster pump and a main one, high cavitations properties and reliabiliity (fig. 10.) Fig. 10. Two threaded feed pumps Comparison of the proposed pumpp aggregate with the aggregates of leading foreign fiirms (fig. 11) hereby confirms the possibility of refusing the booster pumps, multiplier, transferring pipe, filter, and the opportunity of reducing its dimensions,, mass and price, etc. Fig. 11. Comparison of the schemes for installatiion of pump aggregates in the atomic power station blocks 309

8 310 Nikolay Yamburenko et al. / Procedia Engineering 39 (2012) For water supply and water removal, there has been designed a new type andd size row of e and submersible well pumps with a "tightt" engine [2]. At the same time there increased its efficiency reliability (12). Fig. 12. New generation pumps of ECV type 8. There is designed a new type andd size row of the pumps of NOU type for leakage pum mping out with head pressures to 1000 m that allowss applying these pumps for the systems of oil pipellines with an ultimate pressure to 10 ɆPɚ (fig. 13).

9 Nikolay Yamburenko et al. / Procedia Engineering 39 ( 2012 ) Fig. 13. The pumps of NOU type for leakage pumping out 9. A lot of work has been done to develop new pumps of a volume principle of operation as well as to modernize the ones being produced. There has been extended the type and size row of multiphase twinscrew pumps. There have been created new single-screw submersible pumps intended for extraction of viscous oil (fig. 14,15,16). Fig. 14. Pump of NIV type Fig. 15. Multiphase pumps

10 312 Nikolay Yamburenko et al. / Procedia Engineering 39 ( 2012 ) Fig. 16. One - threaded single screw pumps 10. For State District Power Plants, there have been developed non-booster feed electropumps of PE type, which allow applying one feed pump instead of the earlier applied two ones. In addition, it is provided an (industrial) average pressure take off. The high efficiency flowing parts in a combination with the impeller vanes and guide device vanes optimal ratio have ensured their high effectiveness and dynamics of the rotor system, and applying a screw-type centrifugal stage provided high cavitations properties (fig. 17). Fig. 17. New feed pump of PE type for State District Power Plants 11. There has been developed and mastered in the series the type and size row of feed pumps for thermal power plants with steam and gas cycle (SGP) of various capacities (fig. 18). Fig. 18. Feed pumps of PE type for SGP 12. For the petroleum industry, there have been created new pumps and added the row of the pumps of CSN type for PPD systems with feed of up to 1000m 3 /h. The great number of pumps is developed for arrangement of oil deposits (fig. 19). For example, only to Vankor oil and gas deposit, there were supplied 16 types of pumps manufactured and delivered by three enterprises of the company with a total

11 Nikolay Yamburenko et al. / Procedia Engineering 39 (2012) number of pumps more than 160 articles. There have been created the pumps of various designs (fig. 20): with journal bearings operating with the use of the pumped medium, the pumps with a counter arrangement of the impellors, the pumps with high head pressure values at the expense of creating energy-intensive flowing part [3], etc. ɐɇɋ315 ( ) Fig. 19. Type and size row for pumps of CSN type ɢɹ) ɭ, ɚ) With oil bearings c) pumps of CSNz type with squeezing device Fig. 20. Pumps of CSN type b) with water bearings d) pumps of CSNp type with counter arrangement of impellers 313

12 314 Nikolay Yamburenko et al. / Procedia Engineering 39 ( 2012 ) This article only represents a few of the newly developed pump equipment of the HMS GROUP. In this case, the most significant thing is that the pumping equipment has been being systematically developed taking into account all Customer requirements. Conclusions 1. Having received an order for new pump equipment, it is necessary to consider the possibility of designing the ordered pump as one of the base ones in the type and size row of the pumps being newly developed or added with the ordered pump. 2. While providing for R & D activity, there is a possibility to receive a scientific and technical reserve for perfecting the advanced equipment and achieving the leader positions in the specified class of the equipment. 3. Close interconnection with the pump equipment Consumer makes it possible not only to help the Consumer in the process of reducing expenditures for maintenance of pump aggregates, but also gives the chance to a Manufacturer correctly and taking into account all the possibilities of all the hydraulic system, to formulate the Order DS and also to design the pump aggregates desired, that in turn raises their competitiveness in the market. References [1] V.K. Karahanyan. Ecopump-European Program of Energy Saving and Environmental Pumps. Pumps&equipment, No.3, (2008), pp [2] I.B. Tverdokhleb, A.V. Kostyuk. Modernization of Submersible Pumping Units of ECW series. Water Supply and Sanitary Engineering, No. 5, (2009), pp [3] E.O. Knyazeva. On Ways to Improve Energy Consumption of Centrifugal Pump Stages. Pumps&equipment, No. 2, (2009), pp