Abstract

Sea||ess magnet|c dr|ve pumps g|ve tota| conta|nment o the

pumped process ||qu|d, wh|ch |n an |ndustry where there are
t|ghten|ng env|ronmenta| constra|nts on p|ant operat|on and
|ncreas|ng hea|th and saety requ|rements, oer rea|
advantages o re||ab|||ty and saety to users.
Th|s paper, us|ng the APl 685 standard as a bas|s descr|bes
the key des|gn eatures o magnet|c dr|ve pumps as we|| as the
potent|a| a||ure modes and the protect|ve systems and des|gn
eatures that can be put |n p|ace to mon|tor and protect the
pumps |n a petrochem|ca| p|ant env|ronment.
As w|th any p|ece o mach|nery, magnet|c dr|ve pumps have
an operat|ng enve|ope where the|r use |s to be recommended.
The actors wh|ch determ|ne e|c|ent and re||ab|e magnet|c
dr|ve pump app||cat|on are descr|bed (such as power, head,
|ow, |u|d c|ean||ness, NPSH ava||ab|e, |u|d propert|es etc.)
and the data presented upon wh|ch the cr|ter|a were
determ|ned.
Some case stud|es are then presented show|ng successu|
app||cat|ons |||ustrat|ng re||ab|||ty and saety.
The Application Of Sealless
Magnetic Drive Pumps
This paper was presented at the 2008
!NechE European Fluid Nachinery Congress.
White Paper
David Clark - Senior Engineering Manager
Alan English - Area Sales Engineer
HMD Kontro Sealless Pumps
Page 2
HMD KONTRO | Sea||ess Pumps
1} ntroduction
1.1 A brief history
1.2 Key design features
Basic design
The |rst magnet|ca||y dr|ven pumps (MDP's) were manuactured |n
1947 by HMD Sea||ess Pumps Ltd, Eastbourne, K. The 60 year
evo|ut|on o magnet|cs and assoc|ated dr|ve techno|ogy has |ed to
the ava||ab|||ty o h|gh qua||ty, h|gh |ntegr|ty, econom|ca| zero
|eakage pumps that comp|y w|th lSO, ANSl and APl des|gn
standards and oer s|gn||cant advantages over equ|va|ent
mechan|ca||y sea|ed des|gns.
The hydrau||c coverage o such des|gns |s comparab|e to sea|ed
pumps, and current|y powers o up to 300kw can be transm|tted
us|ng th|s techno|ogy.
Magnet|c dr|ve sea||ess pumps are w|de|y used |n the chem|ca|
and pharmaceut|ca| |ndustr|es or a w|de var|ety o ||qu|ds, they are
part|cu|ar|y su|ted to ||qu|ds that are tox|c, pungent, hot or corros|ve
as the comp|ex|ty usua||y assoc|ated w|th a sea||ng system or such
||qu|ds |s comp|ete|y e||m|nated. Magnet|c dr|ve pumps are a|so
now qu|ck|y ga|n|ng acceptance |n the hydrocarbon process|ng
|ndustry where abso|ute saety, |ntegr|ty and re||ab|||ty are key
actors beh|nd rotat|ng mach|nery se|ect|on.
The magnet|c dr|ve pump can be v|ewed as three parts. The
hydrau||c (cas|ng and |mpe||er), the support|ng shat and bear|ng
system and the magnet|c dr|ve.
The hydrau||c end |s undamenta||y the same as a trad|t|ona|
centr|uga| pump and as such |nvokes energy |nto the pumped
||qu|d.
At the rear o the cas|ng, a non-magnet|c conta|nment she|| |s used
to comp|ete|y conta|n the ||qu|d be|ng pumped. Th|s she|| |s rated
or the same des|gn cond|t|ons as the pump cas|ng and |s part o
the pressure boundary. lns|de the conta|nment she||, the |mpe||er
|s mounted to a shat that |s supported on |ourna| bear|ngs wh|ch
are |ubr|cated by the pumped |u|d.
Attached to the shat |s an |nner rotor wh|ch usua||y cons|sts o a
r|ng o permanent magnets or |n some cases a torque r|ng, s|m||ar
to that o an e|ectr|c motor rotor. Correspond|ng|y around the
outs|de o the conta|nment she|| |s an outer magnet|c r|ng. Th|s r|ng
o magnets |s e|ther d|rect|y mounted on a motor shat or |s
supported by some orm o externa| bear|ng assemb|y.
The outer magnet r|ng |s rotated by a standard e|ectr|c motor. The
pr|nc|p|e o operat|on |s that as the outer magnet|c r|ng |s rotated
by the e|ectr|c motor, magnet|c |ux |s transerred through the non-
magnet|c conta|nment she|| to the |nner magnet r|ng or torque r|ng,
thus caus|ng the shat and |mpe||er to rotate. [F|g. 1]
One o the key eatures o th|s des|gn o pump |s that |t comp|ete|y
e||m|nates the need or any orm o dynam|c sea||ng dev|ce. Th|s |n
turn reduces the number o potent|a| |eak paths and a|so removes
the need or any anc|||ary support systems that are assoc|ated w|th
more comp|ex dynam|c sea||ng systems.
Because there are no mechan|ca| sea|s, there are ewer potent|a|
|eak paths, no comp|ex sea| systems are necessary, they have
ewer work|ng parts and ma|ntenance |s s|mp|e.
No ug|t|ve em|ss|ons, no odours and no mon|tor|ng |s requ|red
w|th such a system. No |oss o product to atmosphere means
|nherent saety when pump|ng hazardous ||qu|ds. sua||y a s|ng|e,
u||y trapped contro||ed compress|on gasket orms the stat|c sea|
between the cas|ng and the conta|nment she|| and |s des|gned |n
such a way that b|ow out |s not poss|b|e.
Magnet|ca||y dr|ve pumps, because o the|r robust des|gn and the
act that they have no mechan|ca| sea|s (the pr|nc|pa| cause o
pump a||ure), w||| genera||y operate or |ong per|ods w|thout
ma|ntenance. Th|s means that costs o ma|ntenance and |ost
product|on are kept to a m|n|mum and that overa|| ||e costs are
reduced s|gn||cant|y.
S|||con Carb|de became the standard magnet|c dr|ve pump
bear|ng mater|a| |n the 1980's. Th|s mater|a| |s one o the hardest
mater|a|s ava||ab|e, has h|gh therma| conduct|v|ty and a very |ow
coe|c|ent o therma| expans|on. lt |s chem|ca||y |nert and
extreme|y abras|on res|stant. These actors make SlC the |rst
cho|ce mater|a| or the |nterna| bear|ng system, a|though |n some
cases carbon and other mater|a|s are ut|||sed.
Typ|ca||y pumps are |tted w|th two |ourna| bear|ng bushes and
correspond|ng shat s|eeves pos|t|oned beh|nd the |mpe||er to
support rad|a| |oads. Ax|a| |oads are catered or w|th the use o
thrust bear|ngs des|gned to adequate|y carry the |mposed
hydrau||c |oads across the comp|ete des|gn |ow range.
The |ntroduct|on o h|gh energy magnet|c mater|a|s |n the ear|y
1980's has cons|derab|y |ncreased the amount o power
transm|tted by the magnet|c coup||ng. Current magnet|c coup||ngs
usua||y eature one o two types o magnet|c mater|a| Neodym|um
|ron boron or Pare earth samar|um coba|t. Neodym|um has the
h|gher energy product but has a |ower operat|ona| temperature
thresho|d and thereore tends to be used on pumps eatur|ng
p|ast|c construct|on. Samar|um Coba|t, wh||st hav|ng a |ower
energy product |s ab|e to cope w|th h|gher operat|ona|
temperatures and eatures |n meta|||c magnet|c dr|ve pumps wh|ch
have the ab|||ty to operate w|th process temperatures up to 315 C.
Both mater|a|s are capab|e o operat|on at sub-zero temperatures.
SimpIicity
Zero Ieakage
Extended mean time between faiIure (MTBF)
InternaI bearings (siIicon carbide bearings)
Magnetic CoupIing
Page 3
The App||cat|on o Sea||ess
Magnet|c Dr|ve Pumps
By rep|ac|ng the |nner magnet|c r|ng w|th a torque r|ng (s|m||ar to
the squ|rre| cage rotor o an |nduct|on motor) the operat|ng
temperature o the coup||ng can be urther |ncreased to 450C
w|thout the need or any orm o anc|||ary coo||ng system.
Another s|gn||cant po|nt re|at|ng to these magnet|c mater|a|s and |n
the |ncrease |n power they prov|de has enab|ed magnet|c dr|ve
Sea||ess pumps to be manuactured to ANSl and DlN d|mens|ona|
standards.
Magnet|c coup||ngs are now ava||ab|e that are capab|e o
transm|tt|ng powers |n excess o 300kw (50 Hz) and 400kw (60 Hz).
As a consequence the hydrau||c range |s now comparab|e to most
manuacturers' ranges o ANSl and APl pumps.
As there are no dynam|c sea||ng dev|ces |n the Magnet|c Dr|ve
pump, h|gh system pressures can be eas||y catered or. H|gh
Pressure des|gns su|tab|e or system pressures |n excess o 185
Bar have been manuactured and successu||y app||ed. Typ|ca|
dut|es |n th|s area |nc|ude Crude O|| Jet M|x|ng, Samp||ng and
Hydrocarbon Condensate app||cat|ons.
o o
Low temperature to m|nus 100 C and h|gh to 450 C pumps are
ava||ab|e.
We ||ve |n a wor|d where str|ngent env|ronmenta| |eg|s|at|on |s
|ncreas|ng and where "green" |ssues are hav|ng an |mpact on us
a||.
ln the K the Env|ronment Agency |s respons|b|e or po||ut|on
prevent|on and contro|. lt promotes "Best Ava||ab|e Techn|ques" to
prevent |eakage and em|ss|ons. The Key |ssues or pump|ng
mach|nery are:
Fug|t|ve \o|at||e Organ|c Compounds (\OC's) em|ss|ons to A|r
Po|nt Source em|ss|ons o \OC's to a|r (process re|ease po|nts)
Em|ss|ons to water
Odour
Energy E|c|ency
Chem|ca| ana|ys|s & mon|tor|ng o em|ss|ons
The Env|ronment Agency has bas|c ru|es or the o||, gas, chem|ca|
and pharmaceut|ca| |ndustr|es wh|ch |nc|ude m|n|m|s|ng ug|t|ve
re|eases o ||qu|d and gaseous mater|a|s at the des|gn stage w|th a
pr|or|ty on env|ronmenta| protect|on and a orma| |eak detect|on
and repa|r program. Mon|tor|ng |n the K has been var|ab|e |n the
chem|ca| |ndustry and accord|ng to the env|ronmenta| agency |t |s
High pressure capabiIity
Temperature capabiIity
2} Environmental Considerations

|mperat|ve that more cons|stency shou|d be app||ed. There |s

|nter|m gu|dance ava||ab|e and urther gu|dance |s current|y be|ng
(1)
deve|oped.
lt |s ca|cu|ated that 10% o ug|t|ve em|ss|ons |n re|ner|es and
(2)
chem|ca| |nsta||at|ons are rom sea|ed pumps. MDP's comp|ete|y
e||m|nate ug|t|ve em|ss|ons and odours by the|r zero |eakage
des|gn. Because there are no em|ss|ons there |s no requ|rement to
mon|tor them.
lt |s argued that MDP's are |ess e|c|ent than the|r mechan|ca||y
sea|ed equ|va|ents because o eddy current |osses |n the meta|||c
conta|nment she|| (though remember mechan|ca| sea|s a|so use
energy, h|gh pressure sea|s can run at h|gh temperatures). Th|s
means that more energy |s requ|red to power a magnet|c dr|ve
pump than |ts mechan|ca||y sea|ed equ|va|ent. The |eve| o |osses
exper|enced |n a meta|||c conta|nment she|| |s a unct|on o the
e|ectr|ca| res|st|v|ty o the she|| mater|a|, the th|ckness o the she||,
the |ux dens|ty o the magnet|c coup||ng and speed the coup||ng |s
operated at. Typ|ca||y h|gh strength, h|gh chem|ca| res|stant
mater|a|s are used such as Haste||oy. Losses can range rom 5
to 15% or typ|ca| app||cat|ons.
P|ast|c ||ned, non meta|||c magnet|c dr|ve pumps eature non-
meta|||c conta|nment she||s and thus the eddy currents assoc|ated
w|th a meta|||c conta|nment she|| are reduced to zero and thereore
e|c|enc|es are comparab|e to a mechan|ca||y sea|ed pump. The
restr|ct|on w|th us|ng a non-meta|||c conta|nment she|| |s that
temperature and pressure capab|||ty |s reduced when compared to
a meta|||c she||. H|gh perormance po|ymers and other mater|a|s
are s|ow|y ga|n|ng acceptance and |t |s ||ke|y that these w|||, |n t|me,
prov|de h|gher pressure and temperature capab|||t|es.
(3)
Accord|ng to HSE report |n October 2000 "To hand|e hazardous
||qu|ds and gases sae|y, part|cu|ar|y where the p|ant operates
under pressure, the who|e o the conta|nment system needs to be
bu||t to a h|gh standard. There are deta||ed codes or p|pework and
pressure vesse|s, but there |s |ess |normat|on about mechan|ca|
sea|s, a|though these are w|de|y regarded as the weakest ||nk |n
many conta|nment systems."
Magnet|c Dr|ve pumps by des|gn are |eak ree and thereore odour
ree mean|ng operators have |ess exposure to the process ||qu|ds.
L|qu|ds are conta|ned w|th|n the pump wh|ch has a des|gn
pressure rat|ng equa| to or |n excess o the p|pework, pressure
vesse|s and other anc|||ary equ|pment.
The extended mean t|me between a||ures (MTBF) means ewer
repa|rs, thereore |ess hand||ng and decontam|nat|on and d|sposa|
requ|rements.
MDP's thereore can contr|bute to a c|eaner, saer work|ng
env|ronment.
The petrochem|ca|, o|| & gas |ndustr|es have a|ways tended to wa|t
or techno|ogy to be proven beore adopt|on o the product and
th|s has been espec|a||y true o magnet|c dr|ve pumps.
S} Health and Safety Consideratio
(5
4} Overview of Api 685 Standards
4.1 Background
FI. 1
Outer magnet ring
Shaft
Inner magnet ring
Containment sheII
(5 & 6}
4} Overview of Api 685 Standards
S} Health and Safety Considerations
Page 4
HMD KONTRO | Sea||ess Pumps
The |rst magnet|c dr|ve pumps based on the w|de|y spec||ed APl
610 standard were |ntroduced |n the 1980's. Pecogn|z|ng the need
or a sea||ess pump spec||cat|on or heavy duty serv|ces |n
re|ner|es and re|ated |ndustr|es the Amer|can Petro|eum lnst|tute
|ntroduced the APl 685 standard |n 2000 some |ty years ater |ts
|nvent|on.
Th|s prov|ded urther cred|b|||ty or the techno|ogy and resu|ted |n
acceptance o MDP's by some o the wor|d's |argest o|| compan|es
who now see the opportun|ty to reduce ma|ntenance and
mon|tor|ng and to protect both the|r emp|oyees and the
env|ronment.
APl 685 (2000) recommends the use o the standard or sea||ess
serv|ces that exceed the o||ow|ng ||m|ts:
D|scharge pressures greater than 275 ps|g (1900kPa)
Suct|on pressures greater than 75 ps|g (500kPa)
o o
Pump|ng temperature greater than 300 F (150 C)
Potat|ona| speed greater than 3600 rpm
Pated tota| head greater than 400 t (120m)
Max|mum |mpe||er greater than 13 |nches (300mm)
APl recogn|zes that be|ow these ||m|ts purchasers may w|sh to
cons|der sea||ess pumps that may not comp|y w|th APl 685 or
process serv|ces.
APl does not g|ve gu|de||nes on when a sea||ess pump shou|d be
cons|dered but they are espec|a||y su|ted or app||cat|ons w|th the
o||ow|ng character|st|cs:
Carc|nogen|c
F|ammab|e
Letha|
Expens|ve F|u|ds
F|u|ds conta|n|ng d|sso|ved so||ds (|.e. Caust|c)
F|u|ds conta|n|ng H2S (Sour Water)
Heat Transer F|u|ds (Co|d and Hot)
H|gh \apour Pressure L|qu|ds
Tox|c
F|u|ds present|ng sea||ng d||cu|t|es
L|qu|ds that have em|ss|ons regu|ated
A ew examp|es o some o the typ|ca| ||qu|ds that APl 685 pumps
have been used or are:
Hydrocarbons
Sour Water
Aromat|cs (Benzene, Xy|ene, To|uene)
Anhydrous Hydro|uor|c Ac|d
Hydro|uor|c ac|d
4.2 Parameters

4.3 ExampIes

4.4 API 685 Standard - some of the key points

Caust|c
A|ky|ate
Methy| Mercaptan
Aromat|cs (Benzene, xy|ene, to|uene)
Methano|
O|e|ns
Naptha
Su|phur|c Ac|d
Am|nes
lsobutane
M|n|mum Serv|ce L|e 20 years
3 years un|nterrupted operat|on
NPSH Marg|n over who|e operat|on port|on o the perormance
curve
Des|gned or rap|d ma|ntenance
Corros|on Pes|stance o ||qu|d contact components
Fu||y c|osed |mpe||ers
Ab|||ty to w|thstand the APl 610 orces & moments on the pump
nozz|es
Center||ne Mounted Cas|ng
Externa| bear|ng L10 ||e 50,000 hours
No ||p sea|s a||owed
Ba|anc|ng to G1.0 (lSO 1940), many manuacturers oer G2.5
as standard
APl 610 basep|ates
Mandatory Pressure v Temperature eva|uat|on (Heat ba|ance
ca|cu|at|on)
lmpe||er and pump case wear r|ngs
Secondary Contro| and conta|nment opt|ons
Dr|ve End and pump dr|ver removab|e w|thout d|sturb|ng
pressure cas|ng
Pump des|gn to protect the outer magnet r|ng rom contact|ng
conta|nment she|| | a shat or a bear|ng a||s.
Wh||st most o the above po|nts are se| exp|anatory the one
perta|n|ng to Pressure v Temperature eva|uat|on requ|res urther
exp|anat|on:
A heat ba|ance ca|cu|at|on |s a means o estab||sh|ng the
temperature r|se o the pumped ||qu|d as |t trave|s rom the po|nt at
wh|ch |t enters the pump, to the po|nt at wh|ch |t ex|ts the pump.
The ca|cu|at|on estab||shes the bu|k r|se |n temperature (overa||
temperature r|se rom Suct|on to D|scharge) and the r|se |n
temperature o the magnet|c coup||ng coo||ng and |ubr|cat|on |ow
as |t trave|s over the lnner Magnet P|ng (lMP) through the |nterna|
bear|ng eed system. [F|g. 2]
Why carry out the ca|cu|at|on?
L|qu|ds that are pumped that are c|ose to the|r bo|||ng po|nt need to
be checked to ensure that the temperature r|se |n the pumped
||qu|d |s not su|c|ent to a||ow the ||qu|d to change |ts state to a gas.
For such a ca|cu|at|on to be carr|ed out the user needs to supp|y
the o||ow|ng |normat|on:
\P Curve or the pumped ||qu|d
The Suct|on Pressure (or range o suct|on pressures) the pump w|||
be operate
The Spec||c Heat o the ||qu|d.
The Spec||c Grav|ty o the ||qu|d.
lt shou|d be noted that APl685 mandates the need or a heat
ba|ance ca|cu|at|on to be carr|ed out at the proposa| stage to
ensure the pump |s correct|y se|ected or the app||cat|on.
Page 5
The App||cat|on o Sea||ess
Magnet|c Dr|ve Pumps
unknown, and dr|ve bear|ng a||ure |s not usua||y catastroph|c as |t
|s w|th sea|ed pumps. ln many cases a non-spark phosphor
bronze "bump r|ng" |s |tted so that |n the event o bear|ng a||ure
the outer magnet r|ng runs aga|nst th|s and not the th|n wa||ed
conta|nment she|| hence ||m|t|ng the damage.
Shat de|ect|on |s not usua||y an |ssue w|th MDP's, as the overhang
rom the c|osest bear|ng |s very short un||ke mechan|ca||y sea|ed
pumps. Consequent|y there |s ||tt|e de|ect|on and ||tt|e damage to
the |mpe||er and renewab|e r|ngs.
A|though MDP's have an extended MTBF, they do a|| occas|ona||y
and exper|ence shows that th|s |s usua||y due to process upsets
such as runn|ng dry, runn|ng w|th a c|osed suct|on or d|scharge
va|ve, cav|tat|on/vapour |n the pump or h|gh |ow over|oad. The
extent o damage can vary rom |nterna| bear|ng a||ure to damage
o magnet r|ngs and potent|a| breach o conta|nment she||.
ln most cases the pump can be protected us|ng an |nexpens|ve
power contro| mon|tor. Th|s s|mp|e dev|ce mon|tors the actua|
power absorbed and w||| cut out the pump | |t a||s be|ow a
predeterm|ned va|ue or above |ts upper set ||m|t. Sot start dev|ces
and |nverter dr|ves oten have th|s eature.
Th|s method has e||m|nated most o the catastroph|c a||ures
exper|enced by some users |n past years. An a|ternat|ve or
add|t|ona| method o pump protect|on that can app||ed to meta|||c
MDP's |s to use a temperature measur|ng dev|ce |ocated on the
outs|de o the conta|nment she||. A r|se |n temperature |nd|cates a
reduced coo||ng eect o the magnet|c dr|ve coo||ng and bear|ng
eed stream thus s|gna|||ng a potent|a| |ssue w|th operat|on. [F|g 3]
5.3 Pump protection
FI. 2
IIcaI constructIon of manetIc drIve um
Neck P|ng [Front]
Neck P|ng [Back]
Coup||ng Washer
lmpe||er
Front Thrust Washer
Back Thrust Washer
Bush Ho|der
Bush
Thrust Pad
Cas|ng Gasket
'O' P|ng
Conta|nment Shroud
Pear Bush Hous|ng
Coup||ng Nut
lnner Magnet P|ng
Support Gasket
Cas|ng
Coup||ng Hous|ng
Bump P|ng
Outer Magnet P|ng
Bear|ng Hous|ng
Dr|ve Shat
Front Cap
Back Cap
Labyr|nth Sea| [K|t]
Sec. Conta|nment Sea|
Shat S|eeve
Breather
Pace
F|x|ngs [K|t]
10
10A
50
60
70
80
90
100
130
170
170B
200
220
360
370
390
410
430
440
510
610
620
670
680
700
700A
860
890
5020
****
5} Why Pumps Fail
5.1 Pumps fitted with mechanicaI seaIs

5.2 Magnetic drive pumps

lt |s est|mated that 80% o pump break downs are due to
mechan|ca| sea| a||ure resu|t|ng |n pumped ||qu|d escap|ng to
atmosphere or to the sea||ng system |n the case o doub|e sea|s.
The rema|nder are due to bear|ng a||ure or gasket |eaks.
Mechan|ca| sea| a||ures can be caused by:
Punn|ng Dry
Loss o sea| |ush/coo||ng or barr|er |u|d on doub|e sea|s
Shat m|sa||gnment or bent shat
Shat de|ect|on caused by operat|ng at |ow or h|gh |ow
Wear o sea| aces
Fa||ure o e|astomers due to heat or |ncompat|b|||ty w|th |u|d
Gasket a||ure
Fau|ty |nsta||at|on o sea|s
Bear|ng a||ure
Excess|ve v|brat|on, |ow NPSH
Hang up caused by crysta|||sat|on
The a||ure modes o MDP's are somewhat d|erent rom the|r
mechan|ca||y sea|ed equ|va|ent. Gasket a||ure |s v|rtua||y
Page 6
HMD KONTRO | Sea||ess Pumps
6} Reliability
lt |s reasonab|e to assume that | a pump does not have
mechan|ca| sea|s, then |t w||| be more re||ab|e and magnet|c dr|ve
pumps certa|n|y have an extended MTBF est|mated at 2 to 3
t|mes that o an equ|va|ent mechan|ca| sea| pump.
lt |s very d||cu|t to get cons|stent re||ab|||ty data or pumps each
s|te has d|er|ng exper|ences or both types o pump. Ava||ab|e
sea| data rom |nternet research and customer eedback suggests
MTBF o approx|mate|y 2 years or an unba|anced sea| on ANSl or
lSO Chem|ca| serv|ce pump and up to 4 to 5 years or an APl
spec||ed pump w|th ba|anced sea|s.
APl 682 states that mechan|ca| sea|s shou|d "have a h|gh
probab|||ty o meet|ng the ob|ect|ve o at |east three years o
(2)
un|nterrupted serv|ce wh||e comp|y|ng w|th em|ss|on regu|at|ons
MTBF var|es w|de|y depend|ng upon the nature o the product
be|ng pumped.
Theoret|ca| Mean T|me Between Fa||ure can be ca|cu|ated or
(4)
magnet|c dr|ve pumps. The methodo|ogy used |s to stat|st|ca||y
exam|ne the h|stor|c ||e o the ma|or components w|th|n the pump
whose a||ure can cause ma|or pump prob|ems/pump a||ure. The
var|ous h|stor|c ||ves are then ed |nto the o||ow|ng equat|on to g|ve
an overa|| pump MTBF:
2 2 2 2 0.5
1/MTBF ~ [(1/L1) (1/L2) (1/L3) (1/L4) ]
Where
L1 ~ lnterna| Bear|ngs (S|C est|mated at 25 years)
L2 ~ Ant| Fr|ct|on Bear|ngs (est|mated at 15 years)
L3 ~ Wear r|ngs (est|mated at 25 years)
L4 ~ Shat (est|mated at 30 years)
On a c|ean ||qu|d the |mpe||er |s not cons|dered to be a wear|ng
part and the magnet|c coup||ng | correct|y app||ed shou|d never
a||. Th|s |s based on a correct|y app||ed, |nsta||ed & ma|nta|ned
pump.
Actua| customer eedback rom MDP users suggests MTBF o 8 to
10 years or both ANSl and APl pumps .|||c0| o|e.en|a||.e
ma|n|enance.
Th|s extended MTBF means that when L|e Cyc|e Costs are
cons|dered the enhanced re||ab|||ty w||| |n many cases g|ve a |ower
cost or the MDP, together w|th |ncreased product|on, |ess
ma|ntenance and downt|me.
7} Factors Determining The
Correct Selection Of Magnetic
Drive Pumps

Secondary ControI or Containment

As descr|bed ear||er, magnet|c dr|ve pumps are su|tab|e or many
serv|ces, but there are st||| many m|sconcept|ons regard|ng the|r
use. Apart rom the tox|c dut|es a|ready suggested they are a|so
su|tab|e or many other ||qu|ds and rom exper|ence we g|ve the
o||ow|ng parameters:
L|qu|d C|ean||ness up to 5% so||ds, 150 m|cron |n s|ze. By
|nsta|||ng a se| c|ean|ng d|scharge |ange mounted ||ter th|s can
be |ncreased to 250 m|cron. Th|s |s s|m||ar to the ||m|ts o other
c|osed |mpe||er pumps. Externa| ||trat|on and c|ean sacr||c|a|
|ush can be cons|dered or some app||cat|ons. However,
cons|derat|on shou|d be g|ven to the abras|ve nature o the
so||ds or examp|e no more than 0.5% s||t/sand shou|d be
pumped w|th a standard c|osed |mpe||er pump, but the h|gher
||m|ts wou|d app|y to soter crysta|||ne so||ds o the type regu|ar|y
encountered |n the pharmaceut|ca| |ndustry.
NPSH Ava||ab|e th|s |s cr|t|ca| to any pump|ng app||cat|on and
care shou|d be taken to ensure that there |s an adequate marg|n
between th|s and the NPSH requ|rement o the pump. Th|s w|||
ensure cav|tat|on w||| not damage the pump, or |nterere w|th the
|ow o ||qu|d to the pump |nterna| bear|ngs. There are no hard
and ast ru|es or de|n|ng th|s marg|n, but |t |s good pract|ce to
ensure a m|n|mum o 0.5m or non cr|t|ca| dut|es and o 1.0m or
cr|t|ca| serv|ces.
Sae M|n|mum and Max|mum |ow rate Manuacturers a|| have
d|erent gu|de||nes or th|s and aga|n there |s no |ndustry
standard. Gu|de||nes are thereore genera||y based on pract|ca|
exper|ence, test|ng and |ndependent research. Two energy
dependant actors determ|ne a pumps sae m|n|mum |ow. F|rst,
the mechan|ca| eects o |ncreased v|brat|on |eve|s at a |ow
|ow. Second, on |arger pumps as |ow through the pump
decreases other hydrau||c actors become more dom|nant, such
as suct|on and d|scharge rec|rcu|at|on, wh|ch can cause h|gh
v|brat|on and shorten pump ||e.
On vo|at||e and |ow spec||c heat ||qu|ds the mechan|ca| sae |ow
shou|d be ad|usted to ach|eve the sae therma| m|n|mum |ow, to
ensure the ||qu|d does not change state to gas.
Pump protect|on opt|ons shou|d a|so be cons|dered when
se|ect|ng MDPs as prev|ous|y |nd|cated. The pr|me
recommendat|on |s or a power contro| mon|tor to be |ncorporated
|nto the pump contro||er as descr|bed above. Cons|derat|on
shou|d a|so be g|ven to Temperature probe wh|ch can measure the
temperature at the conta|nment she|| an |ncrease |n usua|
temperature can |nd|cate part|a| b|ockage wh|ch wou|d not be
detected by the mon|tor.
Some orm o Secondary contro| or Conta|nment shou|d a|so be
cons|dered when pump|ng part|cu|ar|y hazardous ||qu|ds. By
secondary, we reer the un||ke|y s|tuat|on that the pr|mary
conta|nment she|| |s breached, and the ||qu|d then comes |nto
contact w|th the secondary system. The bas|s o th|s 'secondary
system' o ||qu|d retent|on |s ach|eved by |tt|ng the externa| dr|ve
bear|ng hous|ng w|th some orm o sea||ng dev|ce. D|erent
manuactures oer d|erent opt|ons rang|ng rom ||p sea|s to dry
runn|ng gas sea|s.
FI. 3
The purpose o a Secondary Contro| system |s to contro| any
|eakage that may occur |n the event o the pr|mary pressure
Conta|nment She|| a||ure. Th|s |s done by contro|||ng the |eakage |n
such a way that |t can be d|verted away rom the pump |n a
contro||ed and sae manner whereby |t can be dea|t w|th
appropr|ate|y.
A Secondary Conta|nment system |s ab|e to conta|n any |eakage
that may occur. Once conta|ned sae|y, the |eaked product shou|d
have a means o be|ng dra|ned away rom the Secondary
Conta|nment area |n a sae and contro||ed manner.
S|xteen sea||ess pumps based on APl 610 |nsta||ed |n 1994
pump|ng propane and butane. Each pump runs 4 months |n
rotat|on. There have been no mechan|ca| a||ures to date.
lnspect|on carr|ed out |n 2006 showed ||tt|e wear w|th the pump
bear|ngs st||| w|th|n to|erance.
The Huntsman Corporat|on have now used magnet|c dr|ve pumps
s|nce the m|d 1990's when they were |nsta||ed dur|ng a ma|or
|nvestment programme. The Huntsman product|on ac|||ty at W||ton
|n the K, now use sea||ess pumps, as the|r preerred un|t, to
pump a who|e range o potent|a||y tox|c and exp|os|ve ||qu|ds.
lnc|uded w|th|n these are An|||ne, Benzene, N|tro Benzene, Am|ne
Water and Pheno|s. For a|| o these app||cat|ons, the magnet|c
dr|ve ensures that the pumps conta|n ||qu|ds w|th|n the process,
ensur|ng saety and stab|||ty o the operat|on at a|| t|mes.
Or|g|na| Equ|pment Manuacturers, J|skoot Auto Contro| (n|ted
K|ngdom), bu||d and supp|y Dens|tometer Sk|ds to the O|| Supp|y
lndustry. The|r customers |nc|ude many o the wor|ds |argest O||
corporat|ons such as She|| K.
Pr|mar||y, Dens|tometer Sk|ds prov|de |normat|on on the qua||ty
and character|st|cs o the crude o|| be|ng extracted. Th|s
|normat|on prov|des deta||s or the re|evant taxat|on author|t|es.
Sea||ess magnet|c dr|ve pumps extract o|| rom the p|pe||ne and
pump through the dens|tometer and back to the p|pe||ne. Work|ng
pressure |n these app||cat|ons can be up to 185 bar.
Case Studies
8.1 BP Grangemouth
8.2 Huntsman Group
8.3 SheII UK
8.4 SpaIIation
8.5 StatoiI
9} Summary
References:
The Spa||at|on Neutron Source pro|ect |n the SA needs to keep
careu| contro| on the temperatures w|th|n the neutron beam ac|||ty.
|tra-c|ean De-lon|sed water, |n coo||ng |oops, |s the med|um used
but th|s becomes act|vated dur|ng operat|on necess|tat|ng pumps
o h|gh saety and |ntegr|ty. Magnet|c dr|ve pumps were chosen
because o zero |eakage and enhanced re||ab|||ty.
Stato|| |n Norway use |teen APl 685 sea||ess pumps on |ts
Onshore P|ch MEG Feed system. The un|ts are used to pump
re|ux water and mono ethy|ene g|yco|. Further h|gh system
pressure pumps are used on the Tro|| A p|atorm on methane
condensate app||cat|ons. One pump on the p|atorm was recent|y
|nspected and showed ||tt|e or no wear. A recommendat|on was
made to |nspect every our years.
Fo||ow|ng 60 years o evo|ut|on magnet|c dr|ve pumps can now be
treated as mature techno|ogy. Because o zero |eakage they are
env|ronmenta||y sound and |nherent saety bene|ts are exce||ent.
The|r se|ect|on and app||cat|on |s very we|| understood by the
manuacturers and the exper|ence ga|ned over many years |s
cons|derab|e. They can be very cost eect|ve due to the|r |ong,
un|nterrupted serv|ce ||e and now prov|de a rea| a|ternat|ve to
doub|e sea|ed pumps.
(1) Gu|dance Notes - Env|ronment Agency, K.
(2) European Sea||ng Assoc|at|on Sea||ng Techno|ogy BAT
gu|dance notes
(3) HSE Peport TD5/021 "Mechan|ca| Sea|s On Process P|ant"
A. Ty|des|ey
(4) "Downt|me Prompts pgrad|ng o Centr|uga| Pumps" Art|c|e
rom "The Chem|ca| Eng|neer" by He|nz P. B|och Exxon
Chem|ca|s.
(5) APl Standard 685 2000, "Sea||ess Centr|uga| Pumps or
Petro|eum, Heavy Duty Chem|ca|, and Gas lndustry Serv|ces",
F|rst Ed|t|on, Amer|can Petro|eum lnst|tute, Wash|ngton DC,
SA.
(6) APl 685 Tutor|a| Shawn L. Bennett, Sundyne Corporat|on,
Arvada and J|m Bryant, KBP, Houston, Texas.
Page 7
The App||cat|on o Sea||ess
Magnet|c Dr|ve Pumps
For the Know-How about HMD Kontro seaIIess pumps,
pIease request a copy of our free guide by
contacting us using the detaiIs opposite.

Options

C|ose Coup|ed - F|ange Mounted on Sub-Base Des|gn

Separate Mounted - Foot Mounted on Basep|ate Des|gn
So||ds Hand||ng - \ar|ous ||trat|on opt|ons ava||ab|e
Secondary Conta|nment - \|a Gas Sea|
Cas|ng Heat|ng Jackets
Coup||ng Hous|ng Heat|ng Jackets
Secondary Contro| - \|a, Magnet|c Sea| /
F|anged Dra|n \a|ve
Pump Parameters

o
Temperatures - Down to m|nus 100 C
o o
p to 450 C / 840 F Torque P|ng Des|gn
o o
p to 315 C / 600 F Synchronous Des|gn
3
F|ow - 1500m / Hour 6600 SGPM
Heads - 350m / 1140' D|erent|a|
\|scos|ty - Max|mum 200cps
Power - 315kW 50hz / 400kW 60hz
System Pressures p To 185Bar / 2600 PSl
Comp||ance to APl 685 / ANSl B73.3 / DlN EN 22858
Th|s pape| was p|eseuled al lhe 2OO8 lNechE Eu|opeau l|u|d Nach|ue|y Coug|ess, p|oceed|ugs pub||shed by Chaudos Pub||sh|ug,
lSBh 978-1-84884-492-G. P|ease see lhe webs|les www.|meche.o|g aud www.chaudospub||sh|ug.com lo| lu|lhe| |ulo|mal|ou.
Sundyne HMD Kontro
SeaIIess Pumps
HMD Sealless Pumps Ltd
Hampden Park !ndustrial Estate
Brampton Road
Eastbourne
East Sussex
BN22 9AN
United Kingdom
Phone: +++ (0) 1323 +S2000
Fax: +++ (0)1323 S03369
E-mail: info@hmdkontro.com
www.hmdkontro.com
2009 HND Sealless Pumps Ltd
All Rights Reserved
HND Kontro GSP 1.0 2f09 Eng.
Sundyne Corporation
1+8+S West 6+th Avenue
Arvada
Colorado
USA
Phone: +1 303 +2S 0800
Fax: +1 303 +2S 0896
E-mail: pumps@sundyne.com
www.sundyne.com
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