Booster Pump Design for Transporting Slurry from SY-102 to Waste Treatment Plant (WTP) - PowerPoint Presentation

Slide1

Booster Pump Design for Transporting Slurry from SY-102 to Waste Treatment Plant (WTP)

DOE-ORP Sponsored Project

Sadiq Al Hajji

Matt Borup

Blake Bryson

Vasiliy

Kravstov

Slide2

Overview

Problem Definition

Objectives

Work ProcessConclusionRecommendations

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Slide3

Background

A project was designed and constructed starting in 1993 to replace six existing plugged and failed transfer lines. The replacement transfer system would transport tank waste between the West Area and the East Area. This design included one transfer line with the ability to transfer solids by the inclusion of booster pumps.

This booster pump system failed, and needed to be reevaluated.

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Problem

Designing a booster pump that is adequate for the current and future waste constituents in the SY Tank Farms. If needed, include additional capacity or pumping stations. 

Also, considerations of design life would have to be determined based on erosion considerations and pipe pressures would have to be evaluated to ensure the design loads are not violated.  

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Objectives

Assess the costs, pros, cons, and optimal number of additional pumping stations (if necessary).  

Assess erosion/corrosion and its effect on pumping station component operable life.  

Assess pumping station component wear based on likely pipe pressures during operation.  Assess system configuration to retrofit as necessary to improve operations and or reduce cost. 

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Slide6

Approach

Define the scope of the project

Calculate the required work for pumping slurry

Choose a pump typeSelect materials of construction based on slurry propertiesPerform economic analysis on the selected design

Evaluate societal aspects

Propose final selection and recommendations

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Slide7

Work Process – Critical Characteristics and Specifications

Critical velocity (solids)

Flow rate

Type of pumpMaterial of construction

Approximate maintenance costs

Installation 

Replacement/backup pumps

Yearly operating costs

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Slide8

Fluid Properties

Table 2 – Chemical makeup of supernatant fluid. Reproduced from RPP-RPT-52206 RO Final Draft

Compound

wt%

Molarity

KNO

3

1.31

0.17

NaNO

3

11.41

1.7

NaNO

2

7.38

1.4

Na

2CO3 3.990.5NaOH  4.611.5Al(OH)3 1.930.55Na2SO4 0.640.06NaCl 0.470.11Na3PO40.490.04NaF 0.100.03Balance of Na+1.19N/A

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Fluid Property  ValueSpecific gravity (mixture)1.5Viscosity (centipoises) 40Miller number<100Minimum pH11 Fluid temperature (oF)35-200Solid content (volume %)30Particle size (μm)0.5-4,0000 to 50 μm, % of total≈ 9550 to 500 μm, % of total<5500 to 4000 μm, % of total<1Friction factor0.404 (non-Newtonian )

Corrosion

pathways

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Corrosion Mechanisms

Stress Corrosion Cracking (SCC)

Chloride SCC

Caustic SCC

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Work Process – Pump Materials

Pump materials must be able to withstand

Caustic environment due to basic pH

pH limit is >11Process fluid temperatures of 80-200°FFlush water temperatures of 35-200°F

Chemicals in supernatant fluid

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RPP-RPT-15136 Final Draft

Table 2 – Chemical makeup of supernatant fluid. Reproduced from RPP-RPT-52206 RO Final Draft

Compound

wt%

Molarity

KNO

3

1.31

0.17

NaNO

3

11.41

1.7

NaNO2 7.381.4Na2CO3 3.990.5NaOH  4.611.5Al(OH)3 1.930.55Na2SO4 0.640.06NaCl 0.470.11Na3PO40.490.04NaF 0.100.03

Balance of Na+

1.19N/A

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Work Process – Pump Materials

Pump Material

Pros

Cons

Monel

Corrosion-resistant

Very expensive

304L SS

Corrosion resistant, cheap

Not suitable at high T

316L SS

Suitable in high T corrosive environments

More expensive than 304L SS

317L SS

Better corrosion resistance than 316L SS

More expensive than 316L SS

WCD4

Created for corrosive/erosive environments

Very expensive

Ductile Iron

High strength

Not suitable for caustic environmentsHastelloy CHigh resistance to hot NaOH solutionsSome mechanical damage possible from KNO3, Al(OH)3 and NaNO311

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Work Process – Pump Materials

Chemical

Material

Si

Tygon

EPDM

Teflon

PFA

KNO

3

A

A

A

A

A

NaNO

3

A

A

AAANaNO2 N/ABAN/AN/ANa2CO3 AAAAANaOH (dil)AAAAA

NaOH, 25%

BAAAANaOH, conc.CAADAAl(OH)3 N/AAAAANa2SO4 AAAAANaClAAAA

A

Na3PO4

D

B

A

N/A

A

NaF

N/A

C

A

D

A

Radiation

N/A

N/A

B

D

D

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Work Process – Pump Materials

Material

Pros

Cons

304L SS

Resistance to corrosion in oxidizing environments

Inexpensive

SCC in the presence of low to medium concentrations of chloride ions not likely

Not recommended for use above 800°F

316L SS

Better corrosion resistance than 304L

Good for high temperature high corrosion environments

More expensive than 304L SS

Ethylene Propylene Diene Monomer

Resistance to water and steam up to 200°F

Excellent resistance to sodium carbonate, chlorate, chloride, fluoride, sulfate, and nitrate

Suitable for abrasive environments

Poor flame resistance

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Work Process – Pump Calculations

140 GPM maximum flow rate

55 GPM nominal flow rate

3-inch nominal diameter pipePump work:

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specifications provided from DOE-ORP

 

 

specifications provided from ChE 451 Team 12

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Work Process – Pump Calculations

Fluid characteristics are interdependent, so certain parameters needed to be solidified:

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Solids %

Density

Viscosity

Reynold’s Number

Fanning/Darcy friction factor

Fluid Property

 Value

Solids volume percent

20%

Density

1250 kg/m

3

Viscosity

10 cP

Reynold’s number

18,000

Fanning friction factor

0.007

Darcy friction factor0.027

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Work Process – Pump Calculations

The solids content is specified at 20 vol%, which corresponds to the following parameters (RPP-15136):

Velocity of 6 ft/s

Density of 1250 kg/m

3

Viscosity of 10

cP

The relative elevation at points A and B are calculated via the plot plans (H-2-822201).

The efficiency of the pump is assumed to be 70%.

Assumed a 50% margin of error.

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Work Process – Pump Calculations

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Requirement

Variable

Value

Power Supplied to Pump

137 kW (185 hp)

Total Head

H

1,944 ft

Friction Loss

h

f

1,053 psi

Requirement

Variable

Value

Power Supplied to Pump

137 kW (185 hp)

Total Head

H

1,944 ftFriction Losshf1,053 psiParameters to keep in mind:Minimum pressure of 400 psigMaximum pressure of 1,490 psigCritical velocity for slurry of 6.0 ft/s

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Pump Types

Centrifugal - 

Magnatex

 MAXP Series, A9 ANSI Chemical Pump, HD Slurry Pump, C 3400 Commercial Slurry Pump Eddy

Peristaltic - LD 127 

Rotho

, JT 3500 

Reciprocating – GEHO Piston Pump, Versa Matic Diaphragm Pump, Geared Twin Screw Pump, TORNADO Rotary Lobe Pump

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Pump Types: Centrifugal

Can pump chemicals, slurry, water, etc.

Impeller is backed by a disk for fluids w/ solids

Impeller is connected to a drive shaft with multiple impellers in series to increase discharge pressure

Flows at constant pressure

High speed rotation of the impeller is a disadvantage

Must initially be primed

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http://www.oempanels.com/vfd-variable-frequency-drive-and-centrifugal-pump

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Pump Types: Eddy

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Uses eddy principle for moving the fluid

Doesn't need tight clearances

Less maintenance than the centrifugal pump

Requires at least 30% solids

Does not generate high enough pressures for this application

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Pump Types: Peristaltic

EPDM tube

Doesn't come in contact with metallurgy

Requires dampeners to reduce pulsations

Doesn't generate enough pressure for this application

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Pump Types: Positive Displacement

Piston Pump

Diaphragm Pump

Geared Twin Screw PumpLobe Pump

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Piston Pump

High pressure

Can be single or double acting

May require dampeners

Cannot use due to Miller number

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https://www.engineersedge.com/pumps/piston_pumps_13085.htm

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Diaphragm Pump

Self-primed

Requires dampeners

Check valvesMembrane wear

Low maximum pressure

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https://pumps-pumpingequipments.blogspot.com/2016/11/diaphragm-screw-pump.html

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Screw Pump

Self-primed

Metallurgy didn't meet required specification

Concern for tolerances and wear

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http://www.pumpschool.com/principles/lobe.asp

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Lobe Pump

Pump didn't produce the minimum pressure

Metallurgy didn't meet specification

Concern for tolerances and wear

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http://www.pumpschool.com/principles/lobe.asp

Slide27

Economic analysis

Based on a correlation from

Analysis, Synthesis and Design of Chemical Process

book. Parameters in the calculation: (pump type, material of construction, discharge pressure, shaft power, CEPCI)All costs considering a back up pump Utility cost based on (133 transfers for 30 years, hours of operation)Chemical Engineering Plant Cost Index (CEPCI) is 601.3 for 2018.

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Slide28

Cost summary

 

Centrifugal

Peristaltic

Purchased Equipment Cost ($)

277,000

220,000

Bare Module Cost ($)

467,000

784,000

Total Module Cost ($)

550,000

940,000

Annual Utility Cost ($)

3,370 3,370

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Slide29

Regulatory Compliance & Societal Considerations

The Resource Conservation and Recovery Act (RCRA)

The Comprehensive Environmental Response, Compensation and Liability Act (CERCLA)

The Tri-Party Agreement between the U.S. Department of Energy, the U.S. Environmental Protection Agency, and the State of Washington Department of Ecology

The public review process for Hanford projects.

Political positions that could alter the funding allotted Hanford.

Future funding allocations from the Federal budget.

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Slide30

Conclusion

Minimum work required by the pump is 137 kW (185 hp).

Based on this requirement,

a 200 hp centrifugal pump is chosen.

The pump will be 304L stainless steel, with EPDM soft goods.

The Total Module Cost of the pump is $ 550,000

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Slide31

Recommendations

In order to ensure and maintain 20 vol% solids in the system, jumpers could be utilized to provide critical velocity prior to slurry addition.

A back up unit could be installed in parallel, to prevent downtime.

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Slide32

References

241-SY Tank Farms Waste Transfer System Fitness-for-Service Requirements and Recommendations

,

Rev. 0; RPP-RPT-52206Preoperational Test Report, Cross-Site Transfer System Integrated Test (POTR-007)

; HNF-2504

System Design Description for the Replacement Cross-Site Transfer System Between 200 West and 200 East Tank Farms

, Rev 4; RPP-15136

Civil Site Plan, Rev 2 (1997); H-2-822201

The

Audiopedia

. What Is MONEL? What Does MONEL Mean? MONEL Meaning, Definition & Explanation. (

https://www.youtube.com/watch?v=myHm-cdLf5g)

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Questions?

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