Custom Tailored Gasifier Feed Pumps

Transcription

1 Custom Tailored Gasifier Feed Pumps FELUWA Pumpen GmbH

2 Content 1. On FELUWA 2. Evolution of positive displacement diaphragm pumps 3. Requirements for Coal Slurry feed pumps 4. Beneficial pump features 4.1 Double-hose design 4.2 Valves 4.3 Gear design 4.4 Pulsation Dampening 4.5 Diagnosis Systems 5. Conclusions 2

3 1. On FELUWA 3

4 FELUWA Pumpen GmbH Quality Made in Germany 4

5 Members of the ARCA Flow Group Valves Control valves Intelligent positioners Desuperheater valves Hygienic valves ECOTROL Control valves Pressure control plants MULTISAFE double hosediaphragm process pumps Hose diaphragm piston pumps Sludge dewatering units for underground mining Municipal pumping stations Sewage pumping stations with cutter Wastewater pumping stations with solids diversion Homogenizing centrifugal pumps Control ball valves Desuperheaters Steam atomizing nozzles Steam conditioning valves Differential pressure transmitters Diaphragm valves Bottom control valves Food industry valves Sterile control valves Single seat control valves Pneumatic actuators Corrosion-resistant control valves Electro actuators Magnetic level indicators Tank level indicators Cryogenic components Stainless steel valves 5

6 Areas of Application With an extremely diverse range of control valves, pumps and level indicators the ARCA Flow Group is firmly established in the following industries worldwide: Coal gasification (coal slurry feed pumps) Power industry (fly and bottom ash disposal) Chemical industry (highly chemical aggressive media) Mining (hydro transport, tailings disposal, etc.) Oil & gas Petrochemical industry Refinery Food industry, etc. The group operates three production facilities in Germany, three in Switzerland, one each in the Netherlands and Mexico as well as joint venture companies in India, Korea and China which are supported by an efficient global sales network. 6

7 2. Evolution of positive displacement diaphragm pumps 7

8 Evolution of Hose-Diaphragm Pumps Piston Pump 8

9 Evolution of FELUWA MULTISAFE Pumps Diaphragm Piston Pump developed by FELUWA in

10 Traditional Hydraulically Actuated Diaphragm Piston Pump Design Typical diaphragm clamping method (Subject to sedimentation and damage in the clamping area.) Disadvantage: Reliability of diaphragm piston pumps with single diaphragms is somewhat limited when handling chemicals or highly aggressive media. Media that is subject to crystallisation is particularly difficult for this type of pump. For example, solids will tend to settle within the lower part of the pump between the diaphragm and the diaphragm retainer ring. This leads to premature destruction of the diaphragm. Due to the design of this type of pump, the conveyed fluid will inevitably get into the hydraulic system as a consequence of diaphragm failure. There it comes into contact with sliding seals and the cylinder face, which may result in considerable destruction (costs!) 10

11 Evolution of Pumps Hose-Diaphragm Pump 11

12 Evolution of FELUWA MULTISAFE Pumps 1970 FELUWA developed the Hose Diaphragm Piston Pump 12

13 Evolution of FELUWA MULTISAFE Pump 2002 FELUWA developed the MULTISAFE Double-Hose-Diaphragm Pump 13

14 3. Requirements for Coal Slurry feed pumps 14

15 Typical IGCC Configuration 15

16 Low Pressure and High Pressure application 16

17 Different Gasifier Configurations 17

18 Combined Know-how 18

19 What we need 1. Maximum availability 2. Uniform flow low pulsations 3. High safety and reliability 4. Low operational cost High efficiency low power consumption Maximized spare part lifetime Reduced down-time Fast and easy maintenance 19

20 4. Beneficial pump features 20

21 4.1 Double-hose design 21

22 FELUWA MULTISAFE Hose-Diaphragm Pumps Conventional Diaphragm Diverted flow path Slurry sedimentation High mechanical wear Reduced lifetime High costs for spares Flow Path Comparison MULTISAFE Hose-Diaphragm Linear flow path No slurry sedimentation Gentle pumping Long lifetime Low costs for spares 22

23 Double Hose-Diaphragm Pumps - Flat vs. Hose-Diaphragm - Flat diaphragm Double hose-diaphragm Pump head volume about 40% smaller 3 times higher filling ratio About 5% higher efficiency Pumped medium is in contact with diaphragm housing filling ratio = pumped volume max medium volume Pumped medium is in contact with diaphragm, only 23

24 Comparison of Fluid Wetted Items Weight of wetted parts: 6,400 kg Weight of wetted parts: 150 kg -97,7% 24

25 4.2 Valves 25

26 Valve Types - Corner vs. Linear Valves - Angle Valve Linear Flow Valve 26

27 Ball Valve vs. Cone Valve Valve ball Ball guide Ball Valve Guide bush Cone top guide Compression spring Rubber ring Cone Valve Valve seat (reversible) Cone valve disc Valve seat Cone guide 27

28 Quick Change Device for Valves 28

29 4.3 Gear design 29

30 Triplex Crank Drive 30

31 Comparison modern Crank Drive vs Traditional Design Today Traditional Design 31

32 Different configurations Number of pump heads Triplex Design (3 pistons / single acting) Quatroplex Design (2 pistons / double acting) Quintuplex Design (5 pistons / single acting) 32

33 Kinematic Irregularity low pulsations 33

34 4.4 Pulsation Dampening 34

35 Pulsation Dampener - Adjustable Air Vessel System - Air cushion Prefilling before pump is started: 80% of working pressure During operation: Pressure in air vessel is equal to working pressure Medium Pressure Inlet Outlet Pressure 35

36 Pulsations and Control Pressure (bar) Pulsation with constant precharging in case of varying pressure Q = 100 m³/h 20 MPa Pulsation (%) Time Discharge Pressure (bar) Prefilling Pressure (bar) Pulsation (%) 36

37 Dampening with Pulsation Dampener Automatic dampener pressure adjustment 37

38 Dampening with Pulsation Dampener Pulsation with dynamic precharging in case of varying pressure Pressure (bar) Q = 100 m³/h 20 MPa Pulsation (%) Time Discharge Pressure (bar) Prefilling Pressure (bar) Pulsation (%) 38

39 4.5 Diagnosis Systems 39

40 Valve Performance Monitoring System Check Valve with Leakage Sensor The structure-borne sound sensor is fixed to the outside of the valve casing. For the acoustic coupling, a suitable plane surface at the casing is to be provided. The filtering and evaluation of the leaktypical frequencies is effected in a separately installed device. Transmission of the status message can be effected by a binary or digital signal. The system is able to detect leaks even if the loss of volume is still below 1.5%. 40

41 Identifying Nonconformities Acoustic Frequency Range a (mm/s) Frequency Spectrum Condition Monitoring Mechanical gearboxes Anti-friction bearings Cavitation (depending on fluid & pressure) f (khz) 41

42 Condition Monitoring of Double Hose-Diaphragm (Hose Diaphragm Guard) Check Valve Pressure Switch Condition monitoring of hose-diaphragms Early detection of faults (before failure occurs) by means of pressure switch Air Bleed Valve 42

43 Overall Pump Condition Guard Pre-Compression Hydraulic Temperature Valve Wear Suction Pressure Local Monitoring System Hose-Diaphragm DCS Gearbox Temperature/flow Frequency Converter Motor Bearing/Winding Temperature Temperature/flow of Intermediate Gearbox SIMATIC S7-300 Remote Service 43

44 Today Know How of the technican See, Hear, Understand Overall diagnostic system for permanent condition monitoring of essential components and parts Past today Run until fault Preventative maintenance Predictive maintenance 44

45 5. Conclusions 45

46 Conclusions 1. PD diaphragm pumps represent a long time proven reliable system for coal slurry feed, achieving high availability 2. Process stability and safety by minimizing pulsations (uniform flow) can be achieved by effective pulsation dampening systems and overall diagnostic systems 3. Operational cost can be reduced by: Reducing down-time by predictive fast and easy maintenance High pump efficiency by design reducing energy consumption 4. Beneficial additional pump features can enhance all of the above 46

47 Thank you for your attention. If you have questions, please do not hesitate to contact me.