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Horizontal Joint Gasket Failure

Learn how Finite Element Analysis was used to resolve split case gasket failure in an Ingersoll Rand pump, increasing reliability and reducing downtime. Presented by Kurt J. Weis from Rotating Equipment Repair, Inc.

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Horizontal Joint Gasket Failure

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  1. Horizontal Joint Gasket Failure • Feedwater Systems Reliability • Users Group • Presenter: • Kurt J Weis • Rotating Equipment Repair, Inc.

  2. Finite Element AnalysisTo resolve split case gasket failure Ingersoll Rand 12 Stage Split Case Pump 4X10-12DAH-E

  3. Equipment Analyzed • Ingersoll Rand 12 stage spilt case pump • 4X10-12DAH-E • 3000-3600psi operating range

  4. Failure Mode: Internal RecirculationMTBF: <2500 hours

  5. Previous Repair Solutions • Different Gasket materials • Increased Stud Preload (Use of “Super Studs”) • Beveled or Tapered Joint

  6. Analyzing the Failure Mode • Gasket has minimal contact pressure between stages causing internal recirculation • Contact pressure can be analyzed with FEA • Accurate full casing model required to perform FEA

  7. Creating Accurate Model • White Light Scanner/Digitizer gathered 3D point cloud data needed to create a model.

  8. Creating Model • Using point cloud data, a Pro-E solid model-assembly was created.

  9. Model Constraints • CA6NM Material, a 400 series stainless steel cast material • Feet restricted to horizontal movement only • Internal pressures

  10. Pressure Distribution

  11. Analysis 1 • Standard Casing, 75% stud preload, (original design) to establish baseline.

  12. Analysis 2 • Standard Casing, 112% stud preload

  13. Beveled Casing, Analysis 3

  14. Analysis 3 • Beveled or Tapered Casing, 75% Stud Preload

  15. Additional Row of Studs, Analysis 4

  16. Analysis 4 • Additional Row of studs, 75% Stud Preload

  17. Analysis 5 • Additional Row of studs and beveled joint, 75% Stud Preload

  18. The final design choice: Additional row of studs with no joint bevel

  19. Manufacturing

  20. Manufacturing

  21. Completed Product

  22. Completed Product

  23. Completed Product

  24. Results • Three pumps rebuilt with this modification. No pumps have been removed from service yet. • First installed pump has over 17000 hours on it, with no degradation in performance.

  25. Reverse Engineering • The same technology can be used for reverse engineering impellers

  26. ExampleCirculating Water Pump Impeller Failure

  27. Large Horizontal Circ Pump Impeller • Impeller was scanned and modeled using same technologies

  28. Pattern Fabrication using Model

  29. Casting Poured with CA6NM

  30. Machining

  31. Old to New Impeller Comparison

  32. Old to New Impeller Comparison

  33. Deviation Report

  34. Completed Product

  35. Completed Product

  36. Completed Product Installed

  37. Questions?

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