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

1. 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

2. Overview • Problem Definition • Objectives • Work Process • Conclusion • Recommendations

3. 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.

4. 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.  

5. 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. 

6. Approach • Define the scope of the project • Calculate the required work for pumping slurry • Choose a pump type • Select materials of construction based on slurry properties • Perform economic analysis on the selected design • Evaluate societal aspects • Propose final selection and recommendations

7. Work Process – Critical Characteristics and Specifications • Critical velocity (solids) • Flow rate • Type of pump • Material of construction • Approximate maintenance costs • Installation  • Replacement/backup pumps • Yearly operating costs

8. Fluid Properties Corrosion pathways

9. Corrosion Mechanisms • Stress Corrosion Cracking (SCC) • Chloride SCC • Caustic SCC

10. Work Process – Pump Materials • Pump materials must be able to withstand • Caustic environment due to basic pH • pH limit is >11 • Process fluid temperatures of 80-200°F • Flush water temperatures of 35-200°F • Chemicals in supernatant fluid RPP-RPT-15136 Final Draft

11. Work Process – Pump Materials

12. Work Process – Pump Materials

13. Work Process – Pump Materials

14. Work Process – Pump Calculations • 140 GPM maximum flow rate • 55 GPM nominal flow rate • 3-inch nominal diameter pipe • Pump work: specifications provided from DOE-ORP specifications provided from ChE 451 Team 12

15. Work Process – Pump Calculations • Fluid characteristics are interdependent, so certain parameters needed to be solidified: Solids % Density Viscosity Reynold’s Number Fanning/Darcy friction factor

16. 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/m3 • 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.

17. Work Process – Pump Calculations • Parameters to keep in mind: • Minimum pressure of 400 psig • Maximum pressure of 1,490 psig • Critical velocity for slurry of 6.0 ft/s

18. 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

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

20. Pump Types: Eddy • 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

21. 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

22. Pump Types: Positive Displacement • Piston Pump • Diaphragm Pump • Geared Twin Screw Pump • Lobe Pump

23. Piston Pump • High pressure • Can be single or double acting • May require dampeners • Cannot use due to Miller number https://www.engineersedge.com/pumps/piston_pumps_13085.htm

24. Diaphragm Pump • Self-primed • Requires dampeners • Check valves • Membrane wear • Low maximum pressure https://pumps-pumpingequipments.blogspot.com/2016/11/diaphragm-screw-pump.html

25. Screw Pump • Self-primed • Metallurgy didn't meet required specification • Concern for tolerances and wear http://www.pumpschool.com/principles/lobe.asp

26. Lobe Pump • Pump didn't produce the minimum pressure • Metallurgy didn't meet specification • Concern for tolerances and wear http://www.pumpschool.com/principles/lobe.asp

27. 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.

28. Cost summary

29. 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.

30. 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

31. 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.

32. References • 241-SY Tank Farms Waste Transfer System Fitness-for-Service Requirements and Recommendations,Rev. 0; RPP-RPT-52206 • Preoperational 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)

33. Questions?