1. GBH Enterprises, Ltd. Engineering Design Guide: GBHE-EDG-MAC-1503 Pumps for Ammonium Nitrate Service Process Disclaimer Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the information for its own particular purpose. GBHE gives no warranty as to the fitness of this information for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

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Engineering Design Guide: Pumps for Ammonium Nitrate Service CONTENTS 1 SCOPE SECTION ONE: INTEGRATION OF PUMPS INTO THE PROCESS 2 PROPERTIES OF FLUID 2.1 Decomposition 2.2 Combustion 2.3 Detonation 2.4 Deliquescence 2.5 Density 2.6 Viscosity 2.7 Vapor Pressure 2.8 Freezing Point 2.9 Specific Heat 2.10 Surf ace Tension 2.11 Thermal Conductivity 3 CALCULATION OF DUTY 3.1 Centrifugal Pumps 4 CHOICE OF PUMP TYPE 4.1 Centrifugal Pumps 4.2 Rotary Pumps 4.3 Reciprocating Pumps 5 LINE DIAGRAMS 5.1 Centrifugal Pumps with Mechanical Seals 5.2 Vertical Suspended Cantilever Shaft Pumps for Melt Service 5.3 Horizontal Self-Priming Pumps 5.4 Reciprocating Pumps 5.5 Seal Water Supply System Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3. 6 LAYOUT 6.1 Vertical Cantilever Shaft Pumps - Tank Proportions SECTION TWO: CONSTRUCTION FEATURES OF PUMPS 7 SEALS FOR CENTRIFUGAL PUMPS 7.1 Below 30% AN 7.2 30-45% AN 7.3 45-90% AN 7.4 Above 90% AN 8 PACKED GLANDS FOR RECIPROCATING PUMPS 8.1 Below 90% AN 9 SEAL WATER SUPPLY SYSTEMS 10 CONSTRUCTION FEATURES OF CENTRIFUGAL PUMPS 10.1 Casing 10.2 Rotor 10.3 Bearing Lubrication 10.4 Coupling 10.5 Baseplate 11 CONSTRUCTION FEATURES OF VERTICAL CANTILEVER SHAFT IMMERSED PUMPS 11.1 Motor 11.2 Insulation and Jacketing 11.3 Rotor 11.4 Bearing Lubrication 11.5 Preservation Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 4. 12 CONSTRUCTION FEATURES OF RECIPROCATING PLUNGER PUMPS 12.1 Speed Limits 12.2 Casing and Gearbox 12.3 Couplings 13 MATERIALS OF CONSTRUCTION 13.1 Recommended Materials 13.2 Forbidden Materials APPENDIX A: BEARING LUBRICANTS FIGURES 2.5.1 DENSITY OF AMMONIUM NITRATE SOLUTIONS 2.5.2 DENSITY OF AMMONIUM NITRATE SOLUTIONS 2.6 KINEMATIC VISCOSITY OF AMMONIUM NITRATE SOLUTIONS 2.7.1 WATER VAPOR PRESSURE ABOVE AMMONIUM NITRATE SOLUTIONS 2.7.2 AMMONIA VAPOR PRESSURE FOR AM!MONIUM NITRATE MELT 2.8 FREEZING POINT OF AMMONIUM NITRATE SOLUTIONS 2.9 SPECIFIC HEAT OF AMMONIUM NITRATE SOLUTIONS 4 SELECTION OF PUMP TYPE Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 5. 5. 1 RECOMMENDED LINE DIAGRAM CENTRIFUGAL PUMPS WITH MECHANICAL SEALS 5.2 RECOMMENDED LINE DIAGRAM: VERTICAL SUSPENDED CANTILEVER PUMPS 5.3 RECOMMENDED LINE DIAGRAM: HORIZONTAL SELF PRIMING PUMPS 5.4 RECOMMENDED LINE DIAGRAM: RECIPROCATING PLUNGER PUMPS 5.5 RECOMMENDED LINE DIAGRAM SEAL: WATER PUMPS AND INJECTION PUMP SYSTEMS 7.2 TYPICAL ARRANGEMENT OF SEAL WITH NO INJECTION FLUSH 7.3 TYPICAL ARRANGEMENT OF CRANE TYPE 52B WITH 'J' SEAT INCORPORATING TETRALIPS INBOARD AND OUTBOARD 7.4 TYPICAL ARRANGEMENT OF LABYRINTH SEAL FOR VERTICAL SUSPENDED CANTILEVER SHAFT PUMPS 8.1 TYPICAL ARRANGEMENT OF SOFT PACKED GLAND FOR RECIPROCATING PLUNGER PUMPS FOR DELIVERY PRESSURES UP TO 10 BAR G. 12 TEMPERATURES ATTAINED ON DISSOLUTION OF ANHYDROUS CAUSTIC SODA TABLES 13.1 MATERIALS OF CONSTRUCTION CENTRIFUGAL PUMPS 13.2 MATERIALS OF CONSTRUCTION VERTICAL CANTILEVER SHAFT IMMERSED PUMPS 13.3 MATERIALS OF CONSTRUCTION RECIPROCATING PLUNGER PUMPS 13.4 MATERIALS DESIGNATIONS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 6. 1 SCOPE This Engineering Design Guide covers pump-centered systems for ammonium nitrate and its aqueous solutions. It complements the Engineering Design Guides for generalized pump-centered systems. SECTION ONE: INTEGRATION OF PUMPS INTO THE PROCESS 2 PROPERTIES OF FLUID Ammonium nitrate (NH4NO3) is colorless in liquid form and in aqueous solutions, and white in solid form. It readily dissolves in water. The hot solution gives off ammonia. 2.1 Decomposition Decomposition of ammonium nitrate gives rise to brown nitrous fumes which are denser than air. Impurities, particularly chlorides, organic materials and certain finely divided metals and metal ions (chromates, zinc, lead, manganese, copper and copper alloys) encourage its decomposition. The decomposition rate of ammonium nitrate free from contaminants is insignificantly small below 200C. On a Nitram plant the process temperature rarely exceeds 180C; therefore it is the decomposition reactions catalyzed by the above contaminants which are important. The majority of these decomposition reactions are suppressed under alkaline conditions, hence ammonia gas addition to control pH. Overheating should be avoided and for this reason isomantle electric heating elements should not be used on pump casings. 2.2 Combustion Ammonium nitrate is a powerful oxidizing agent and is a strong supporter of combustion assisting other materials to burn even if air is excluded. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 7. 2.3 Detonation Solid ammonium nitrate can be detonated by an external shock. The required severity of the shock is greatly reduced if the temperature is high or if organic materials or chlorides are present. To cause detonation either an accelerating decomposition under confinement to a pressure of approximately 20 bar or an external initiator such as an explosive charge is required. 2.4 Deliquescence Ammonium nitrate absorbs moisture from the atmosphere and will liquefy when the relative humidity is high. 2.5 Density See Figs 2.5.l and 2.5.2 for density of aqueous solutions. 2.6 Viscosity See Fig 2.6 for kinematic viscosity of aqueous solutions. 2.7 Vapor Pressure See Fig 2.7.1 for water vapor pressure above aqueous solutions. See Fig 2.7.2 for ammonia vapor pressure of melt. 2.8 Freezing Point See Fig 2.8 for freezing point of aqueous solutions. 2.9 Specific Heat See Fig 2.9 for specific heat of aqueous solutions at 25C. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 8. 2.10 Surf ace Tension Approximate values are: The above values are from Gmelins Handbook P.104 and 120. 2.11 Thermal Conductivity K = 0.37 W/m C. from Nitram Design Manual, Evaporator Design Section, previous source unknown. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 9. FIG 2.5.1 DENSITY OF AMMONIUM NITRATE SOLUTIONS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 10. FIG 2.5.2 DENSITY OF AMMONIUM NITRATE SOLUTIONS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 11. FIG 2.6 KINEMATIC VISCOSITY OF AMHONIUM NITRATE SOLUTIONS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 12. FIG 2. 7. I WATER VAPOUR PRESSURE ABOVE AMMONIUM NITRATE SOLUTION Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 13. FIG 2.7.2 AMMONIA VAPOR PRESSURE FOR AMMONIUM NITRATE MELT Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 14. FIG 2. 8 FREEZING POINT OF AMMONIUM NTRATE SOLUTIONS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 15. FIG 2. 9 SPECIFIC HEAT OF AMMONIUM NITRATE SOLUTIONS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 16. 3 CALCULATION OF DUTY 3.1 Centrifugal Pumps The pump duty should be specified in accordance with Engineering Design Guide GBHE-EDG-MAC-1014, augmented by the following notes: 3.1.1 Limit for Suction Specific Speed Sn Pump cavitation performance for different liquids is correlated by substituting the true cavity pressure for the bulk vapor pressure, but generalized predictions of the cavity pressure for multi-component fluids are not available. A pragmatic approach for aqueous solutions is that during early growth of a cavity the vapor is predominantly water, leaving a 'skin' enriched with nitrate so that further water diffuses inward along the concentration gradient. The cavity pressure is initially reduced by evaporative cooling as for water and later reduced by the concentration change. The effect on pump cavitation performance differs little from that of water until either Sn or the nitrate content of the solution is high. (a) For nitrate solutions between 30% and 90% concentration, current practice is to calculate NPSH using the vapor pressure of water above the solution and to limit Sn to less than 0.40. (b) Melt is a multi-component liquid for which the true vapor pressure is not easily determined. For Nitram 3 melt pumps the relevant value was taken as 0.48 bar at 192C for which Sn was 0.23. At this value LM.25 aluminium impellers have not been damaged. Do not assume that this condition would hold without ammonia gas injection. 3.1.2 Submergence for Vertical Immersed Cantilever Shaft Pumps There is a minimum size of the pumping tank in order to avoid swirl at the pump inlet and surface bubble entrainment. Current practice uses a residence time not less than 100 seconds at the maximum pump flow (not the rated flow). Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 17. Note that the residence time is calculated for the pumping space alone. Another section of the tank is used for an ammonia sparge to maintain the pH above 7. 3.1.3 Q-H Characteristic Needs of Melt Pumps The gas content of melt may be abnormally high owing to entrainment at the pumping tank weir or to the addition of ammonia gas through spargers. The differential pressure then reduces both because of the decrease in apparent fluid density and because of a decrease in developed differential head. The pump differential head is nearly all static head and the system resistance is small; therefore a very stable Q-H characteristic is essential. The shut-off head should exceed 120% of the differential head at the capacity for the best efficiency point of the pump. 3. l. 4 Head Limit for Melt Pumps Local erosion is a function of liquid velocity relative to the metal surface. It is not a function of inlet NPSH but of the impeller head and material of construction. For Nitram 3 pumps the head/stage of 33 m is satisfactory for LM.25 aluminium alloy. 3. l. 5 Regulation of Melt Pumps Vertical cantilever pumps on melt service require the maintenance of flow within the range 50-120% of the flow at BEP. Consequently the control system should be the bypass type. A prime layout requirement is the avoidance of valves, consequently the bypass should take the form of a constant- head tank with an overflow return to the pumping tank. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 18. 4 CHOICE OF PUMP TYPE 4.1 Centrifugal Pumps The final selection of pump type depends on the AN concentration: For AN melt service specify a single unspared vertical cantilever shaft immersed pump. This configuration features: (a) Operation free from rubbing contact (b) Immersion of all the pump stages to improve temperature constancy (c) Compliance with Class 2 reliability standard so that only one installed unit is needed, with a consequent reduction in the AN inventory of the pumping tank. For AN concentrations 0 - 90% specify normal pump configurations with mechanical seals. (d) Below 30% AN concentration specify the pump and seal arrangement as for water service. (e) Between 30% and 90% AN concentration specify a seal injection flush of condensate at a flowrate of 2.4 liters/hour per mm. of seal dia. Additionally, between 45% and 90% AN concentration specify a seal water quench at a-nominal flowrate of 70 liters/hour per seal. (f) Alternatively between 30% and 45% AN concentration when a condensate injection is unacceptable, a seal with product recirculation may be specified provided that the fluid temperature is less than 80C and the rating of a PTFE faced seal is not exceeded. A seal water quench is required, at a nominal flowrate of 70 liters/hour per seal. For drain pit and allied duties where intermittent wet/dry running is expected and the AN concentration is erratic, specify horizontal self- priming pumps with a packed gland, continuously flushed at a nominal flowrate of 70 liters/hour per seal. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 19. 4.2 Rotary Pumps Rotary pumps have not so far been used in Division plants on AN service. Any proposed application needs a formal assessment. 4.3 Reciprocating Pumps Reciprocating plunger pumps have been used on sampling duties. For AN concentrations up to 90% specify a packed gland with a condensate quench flush flowrate exceeding 2 liter/hour per mm of plunger diameter. For higher concentrations specify a double diaphragm pump with condensate buffer fluid. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 20. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 21. 5 LINE DIAGRAMS 5.1 Centrifugal Pumps with Mechanical Seals. See Fig 5.1 for recommended line diagram. Check each pump installation for: (a) Temporary inlet strainer (b) Pressure gauge downstream of the temporary strainer (c) Wash out point inlet, valved and piped from supply main (d) Pump casing drain, valved and piped away to a suitable disposal point (e) Pump vent, valved and piped away to a suitable disposal point (f) Wash out point exit, in piping upstream of discharge isolation valve, valved and piped away to a suitable disposal point (g) Discharge pressure gauge (h) Non-return valve, when required, in the discharge line (i) By-pass, when required, for pump minimum flow. The bypass should be returned to the inlet vessel and not to the pump inlet line. (j) Motor trip, which actuates on failure of seal injection flush water supply. (k) For AN concentrations in the 70%-90% range, a temperature indicator with a high alarm fitted on the discharge branch boss of the pump casing or in the piping immediately downstream of the pump discharge flange. (l) For AN concentrations in the 70%-90% range, the piping is steam jacketed up to the pump isolation valves (but not the pump isolation valves). Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 22. (m) For horizontal self priming pumps, see Clause 5.3. 5.2 Vertical Suspended Cantilever Shaft Pumps for Melt Service See fig 5.2 for recommended line diagram Check each pump installation for: (a) Steam jacketing of the discharge piping from the pump support plate and of the overflow piping back to the pumping tank. (b) Pump high vibration trip (accelerometer probes) (c) Pump rotor axial movement trip (d) Pumping tank high and low level trip (e) Dry, oil-free air or nitrogen purge to the labyrinth seal (f) "Soft start" button for free rotation test before start. (g) No valves, drains, temperature indicter or strainer on the pump. 5.3 Horizontal Self-Priming Pumps See Fig 5.3 for recommended line diagram Check each pump installation for the following in addition to the requirements in Clause 5.1. (a) on/off float level switch in the effluent pit (b) Water line for filling separator (priming chamber), valved and piped from wash out inlet line. (c) Note: items (a), (b) and (e) of Clause 5.1 are not required, the suitable disposal point in items (d) and (f) is the effluent pit, the inlet vessel in item (j) is the effluent pit. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 23. 5.4 Reciprocating Pumps See Fig 5.4 for recommended line diagram Check each pump installation for: (a) Permanent strainer (b) Drain in inlet and discharge p1p1ng, valved and piped away to a suitable disposal point. (c) Discharge pressure gauge (d) Discharge relief valve piped back to the inlet piping (e) Motor trip, which actuates on failure of gland flush water (f) Gland flush water supply 5.5 Seal Water Supply System See Fig 5.5 for recommended line diagram. 5.5.1 Local to Seal Water Supply Pumps Check each pump installation for: (a) Permanent inlet strainer (b) Pressure gauge downstream of inlet strainer (c) Pump casing drain valved and piped away to a suitable disposal point. (d) Pump vent valved and piped away to a suitable disposal point. (e) Discharge pressure gauge (f) Non-return valve in discharge line Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 24. (g) By-pass line returned to the inlet vessel through the standby pump to ensure priming and also as a frost precaution. (h) Cooler, with cooling water rate controlled by a control valve (j) Seal water high temperature alarm exit the cooler. 5.5.2 Local to Process Pumps Check each pump installation for: (a) Non-return valve in common line (b) Isolation valve in line to each pump seal box (c) Flow indicator (integral orifice dP cell) with a low flow alarm fitted (d) Flow controller (Platon Flostat) (e) Pressure point (no gauge) (f) Isolation valve and restriction orifice in the water quench line, taken from the wash-out supply main (g) The outlet from the water quench is piped away to a suitable disposal point (no valve). Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 25. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 26. FIG 5. 2 RECOMMENDED LINE DIAGRAM: VERTICAL SUSPENDED CANTILEVER PUMPS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 27. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 28. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 29. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 30. 6 LAYOUT 6.1 Vertical Cantilever Shaft Pumps - Tank Proportions Current practice is to employ a multi-service tank acting as a pumping tank, an overhead tank return point and sparge point for admission of ammonia gas. A satisfactory pumping tank arrangement is shown in Figure 5.2 (details of this tank for Nitram 3 Plant are shown on Hobal drawings 0-7724-1 and 2). For a new tank at a rated flow of Q to be based on a satisfactorily operational tank at a rated flow of Q0, all the following criteria should be satisfied: (a) For the total depth h of liquid from surface to tank bottom: (b) For the tank width b taken athwart the supply flow direction: (c) The liquid velocity in the pump inlet should remain constant. (d) The supply aperture or weir should extend across the tank to ensure a uniform approach velocity to the pump. The locations of the pumps and bypass return lines relative to the tank walls and supply weirs should be geometrically similar. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 31. SECTION TWO: CONSTRUCTION FEATURES OF PUMPS 7 SEALS FOR CENTRIFUGAL PUMPS 7.1 Below 30% AN The preferred mechanical seals are Crane types 59U, 59B or 52B, all with seal group material code designation 244A, character code QR171. Flush from the pump delivery, through the seal, and back to the pump inlet via the balance holes in the impeller. No external water quench is required. 7.2 30 - 45% AN (a) The preferred mechanical seal is the Crane type 52B with seal group material code designation 244A, character code QR171 and an extended surface seat, 'J' type. Provide an injection flush of condensate from an external source, through the seal and back to the pump inlet via tetralip rings and balance holes in the impeller. No external water quench is required. The normal rate for the seal injection flush to each process pump should be 2.4 liters/hr/mm sleeve diameter with the low flow alarm set at 60% normal flow. The balanced seal is recommended as it generates less heat and so reduces the risk of decomposition of AN upon inadvertent failure of the injection flush water supply. See Fig 7.3 for typical arrangement but note quench provisions should be excluded. (b) For duties where condensate injection is unacceptable and the AN liquor is below SOC, the preferred mechanical seal is Crane type 59B seal group material code designation 255A, character code QW!Cl. Provide a recycle flush from the pump delivery, through the seal, and back to the pump inlet via the balance holes in the impeller. Stuffing box neck bushes/restrictors should not be fitted in order to improve circulation in the event of inadvertent failure of the recycle flush. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 32. Provide a water quench on the outboard side of the mechanical seal, sealed by a tetralip. The water quench rate should be 50 to 90 liters per hour per seal. A restriction orifice sized for 70 liters per hour per seal should be fitted between the water quench isolation valve and the gland seal plate. On horizontal pumps, the water quench inlet should be at the bottom of the seal plate and the outlet at the top. See Fig 7.2 for typical arrangement. 7.3 45 - 90% AN The preferred mechanical seal is the Crane type 52B and an extended surface seat; 'J' type. Provide an injection flush of condensate from an external source, through the seal and back to the pump inlet via tetralip rings and balance holes in the impeller. The normal rate for the seal injection flush to each process pump should be 2.4 liters/hr/mm sleeve diameter with the low flow alarm set at 60% normal flow. Provide a water quench on the outboard side of the mechanical seal sealed by a tetralip. The water quench rate should be 50 to 90 liters per hour per seal. A restriction orifice sized for 70 liters per hour per seal should be fitted between the water quench isolation valve and the gland seal plate. On horizontal pumps, the water quench inlet should be at the bottom of the seal plate and the outlet at the top. The water quench should be supplied continuously on all pumps, including standby pumps. The balanced seal and extended surface seat provide a cooler running seal and reduce the risk of decomposition of AN upon inadvertent failure of the injection flush water supply. See Fig 7.3 for typical arrangement. 7.4 Above 90% AN For the vertical, cantilever shaft, immersed pump, a double labyrinth seal with air or nitrogen purge should be provided where the shaft passes through the tank and mounting plate. The air or nitrogen should be absolutely free of oil or organic particles. See Fig 7.4 for typical arrangement. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 33. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 34. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 35. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 36. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 37. 8 PACKED GLANDS FOR RECIPROCATING PUMPS 8.1 Below 90% AN Specify a soft packed gland having a lantern ring. See Fig 8.1 for typical arrangement. The packing material should be braided PTFE without oil or graphite additions or impregnation, and selected from the size range 6, 8, 10 and 12.5 mm square section. Both the lantern ring and the backing ring should be in glass-reinforced PTFE. Provide a condensate flush, inlet at the bottom of the lantern ring and outlet at the top, with a flowrate exceeding 2 liters/hour per mm of plunger diameter. 9 SEAL WATER SUPPLY SYSTEMS Warm clean condensate should be used for seal injection flush duty to prevent the ammonium nitrate from crystallizing. The condensate cooler should be designed to cool the condensate from 100o C to about 70o C. The cooling water control valve should control the condensate temperature at 70o C with the high temperature alarm exit the cooler set for 75o C. The seal water pump duty should be calculated using the highest shut-off pressure of the ammonium nitrate pumps. The capacity should be based on all the ammonium nitrate pumps running including standby pumps. The setting of the extra low pressure trip (that trips all the process pumps) should be the highest operating pressure in any process pump stuffing box. The standby seal water pump should start up when the pressure has reduced to midway between the normal operating pressure and the extra low pressure trip setting. The seal water flow indicator in each process pump line is normally the integral orifice dP cell type. The flow controller is normally a Platon Flostat set for the correct flow when the pump is operating at its design duty point. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 38. 10 CONSTRUCTION FEATURES OF CENTRIFUGAL PUMPS The construction features should conform to the appropriate Engineering Design Guide in the GBHE-EDG.MAC.12 Series, augmented and amended by the requirements of this Design Guide. 10.1 Casing All gaskets should be fully trapped. For duties handling AN solutions in the 70% - 90% range a thermocouple should be fitted on a boss on the pump discharge branch. The boss should be tapped t" BSP. Vent and drain connections should be flanged and have a socket weld type flange. 10.2 Rotor Specify that impellers are cast in one piece without coring so that there is no possibility of confining a quantity of ammonium nitrate. Minimum acceptable running clearances, based on modified tolerances from BS 4SOO, are as follows:- Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 39. Minimum acceptable radial clearances are 0.3 of the above values. The shaft or shaft sleeve should be hard coated under the wedge ring of the mechanical seal and under the tetralips. The hard coating should be ceramic. To avoid leakage to the atmosphere an 'O' ring seal, sleeve to shaft, should be located near the outer end of the sleeve. Three symmetrically disposed relief holes should be drilled in the sleeve immediately below this '0' ring to communicate with the seal quench system. 10.3 Bearing Lubrication Grease lubrication is preferred. Pumps employing oil lubrication should have a constant level oiler fitted with glass reservoir bottle and mild steel body. The oil grade should be Fomblin - see Appendix A. The bearing housing should be positively sealed at the non-drive end to prevent ingress of process fluid or loss of lubricant. Labyrinth type seals are NOT acceptable in this location. A Weston Impax seal CRZ type or a Garlock PS lip seal should be used on grease lubricated systems. When the Garlock PS lip seal is fitted, the seal contact zone should be to a finish of 0.2 to 0.4 microns Ra and be hard coated with stellite or ceramic. 10.4 Coupling The coupling should be of the spacer type Metastream M/S series (single membrane unit). The membranes should be stainless steel and the bolts type 605 M36 condition T; all other components, ie hubs, spacer, guard rings and retainer rings may be carbon steel. Rubber element type couplings should not be used. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 40. 10.5 Baseplate All mild steel baseplates should be grit blasted and then painted on all surf aces with one coat of etching primer 568 and two coats of Dulux chlorinated rubber paint. 11 CONSTRUCTION FEATURES OF VERTICAL CANTILEVER SHAFT IMMERSED PUMPS The construction features should conform to Engineering Design Guide GBHE_EDG.MAC12.Series, augmented and amended by the requirements of this Design Guide. 11.1 Motor Sensotherm over-temperature detectors should be fitted to the drive motor with the leads brought out to a separate terminal box and connected to the starter so that the motor will trip at a predetermined temperature. A 'soft-start' facility should be fitted to apply a low initial torque for testing that the pump rotor is free to rotate before the true start-up. This is because local solidification of the melt in a cold pump upon initial pump commissioning may jam the rotor. The transient torque should not exceed 20% of the motor FLT. Inching by immediate start-stop action should be avoided because the torque can exceed 300% FLT; LM25 aluminum impeller material has been sheared in this way. 11.2 Insulation and Jacketing The pump discharge piping inside the pumping tank should NOT be steam jacketed. The discharge piping outside the pumping tank should be steam jacketed. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 41. 11.3 Rotor Impeller and casing wear rings, and casing wear plates should NOT be fitted. The variation of clearances and stresses under all pump operating conditions should take into account: (a) Displacement due to thermal expansion (b) Displacement due to differential thermal expansion of different materials (c) Transient thermal gradients Alterations to the impeller/casing clearance arising from the accumulation of machining tolerances should be minimized either by the provision of means of adjustment or by self-centering methods of component location. Additionally the design radial clearance should not be less than 150% of the calculated relative displacement of impeller/casing surfaces, taking into account: (d) machining tolerances on casing and impeller diameters in the running clearance zone (e) Residual machining and assembly tolerances within the unit a the spigot locating the support tube on the casing. (f) Shaft deflection under maximum radial load (g) Shaft displacement due to bearing clearances, including the maximum wear allowance (h) Casing support unit deflection under maximum radial load, including the effect of bearing compliance. 11.4 Bearing Lubrication Polyurea grease should be used for lubrication of all bearings - see Appendix A. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 42. 11.5 Preservation In preparation for shipment, organic preservatives are prohibited. 12 CONSTRUCTION FEATURES OF RECIPROCATING PLUNGER PUMPS 12.1 Speed Limits The mean plunger speed should not exceed 0.5 m/sec. and preferably be less than 0.4 m/sec. The crank speed should not exceed 1.5 rev/s. The product of the normal differential pressure and the mean plunger speed should not exceed 5.5 bar m/sec. 12.2 Casing & Gearbox The pump inlet and discharge connections should be flanged. The gearbox and cam case housings should be positively sealed to prevent the egress of oil and the ingress of gland leaks. 12.3 Coupling Rubber element type couplings should not be used. 13 MATERIALS OF CONSTRUCTION 13.1 Recommended Materials The material types shown in table 13.1 are for centrifugal pumps having ammonium nitrate concentrations between 30% and 90% and all temperatures. The material types for pumps between 0% and 30% concentrations may also be to table 13.1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 43. The material types in table 13.2 are for centrifugal pumps between 90% and 100% concentrations. The material types in table 13.3 are for reciprocating plunger pumps between 0% and 90% concentrations. The British, American and German material designations are in table 13.4. These specifications are near equivalents, are possible alternatives to the ones quoted. 13.2 Forbidden Materials No zinc, copper or their alloys should be used in any part of pump construction. No organic material and especially no grease or oil should be used for manufacture or coating any part in contact with the pumped fluid or seal cooling fluid. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 44. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 45. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 46. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 47. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 48. APPENDIX A BEARING LUBRICANTS A.I Polyurea Grease Polyurea grease, type SRI grease 2 manufactured by: Chevron Oil UK Limited Rothchild House Whitgift Centre Croydon CR9 300 A.2 Fomblin Oil Fomblin oil Grade Y25 manufactured by: Montedison UK Limited llA West Halkin Street London SWIX 8LS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 49. DOCUMENTS REFERRED TO IN THIS ENGINEERING DESIGN GUIDE This Engineering Design Guide makes reference to the following documents AMERICAN STANDARDS ASTM A 240 Specification for heat-resisting chromium and chromium- nickel stainless steel plate, sheet and strip for fusion-welded. Unfired pressure vessels (referred to in Table 13.4). ASTM A 296 Specification for corrosion-resistant iron-chromium, iron chromium-nickel, and nickel base alloy castings for general application (referred to in Table 13.4). ASTM A 564 Specification for hot rolled and cold finished age-hardening stainless and heat-resisting steel bars and shapes (referred to in Table 13.4). GERMAN STANDARDS DIN 17440 Stainless steels: quality specifications (referred to in Table 13.4). DIN 17445 Stainless steel castings: quality specifications (referred to in Table 13.4). BRITISH STANDARDS BS 970 Specification for wrought steels for mechanical and allied engineering purposes (referred to in Table 13.4). BS 1501 Steels for fired and unfired pressure vessels (referred to in Table 13. 4). BS 1504 Specification for steel castings for pressure purposes (referred to in Table 13.4). BS 3100 Specification for steel castings for general engineering purposes (referred to in Table 13.4). BS 4500 ISO limits and fits (referred to in Clause 10.2). . Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 50. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com