Piping (Nozzle) Loads.

Applying the API 610 standards To A Centrifugal Pumpset

{Pumpset = Pump + Baseplate}

Presentedby: DougIngham,SulzerPumps(US)Inc.

API610{10thEdition}Requirements
5.3.3a

The pressure casing shall be designed to operate without leakage or internal contact between rotating and stationary components while subject simultaneously to the MAWP and the worst-case combination of twice (2x) the allowable nozzle loads of Table 4 applied through each nozzle.

NOTE: The twice-nozzle-load requirement is a pressure-casing design criterion. Other factors such as casing support or baseplate stiffness affect allowable nozzle loads.
6.3.5

5.5.1

The pump and its baseplate shall be constructed with sufficient structural stiffness to limit displacement of the pump shaft at the drive end to meet values per API Table 12 when subjected to (1x) API 610 Table 4 nozzle moments. Three factors to consider: 1. Pump casing stress. Total to be within ASME allowable. (5.3.4) 2. Pump casing distortion. (5.3.3) 3. Misalignment of pump and driver shafts. (6.3.5) Annex F gives methods of qualifying nozzle loads in excess of those in Table 4. Annex F is used by the piping designer - not the pump designer.
It also goes on to say that user must be aware that the use of Annex F methods can result in 50% greater misalignment than would occur using the loads of Table 4

5.5.5

API610{10thEdition}Requirements
6.3.6

If specified, the vendor shall test to demonstrate that the pump and its baseplate assembly, anchored at foundation bolt hole locations, are in compliance with 6.3.5. The pump casing shall be subjected to moments MYC and MZC applied to either nozzle, but not both, such that the corresponding shaft displacements can be measured and recorded. MYC and MZC shall not be applied simultaneously to either nozzle. The shaft displacement measurements shall be absolute (not relative to the baseplate).

DY DZ

0.003" max

0.007" max

NozzleLoadTestatPumpVendor'sFacility
MomentsMYC&MZCareappliedviaahydraulicallyoperatedrotaryactuator. Shaftendmovementsaremeasuredviadialindicators.
AppliedmomenttosuctionnozzleforMy
Nozzle Suction Discharge Size(in) 10 6 MY(ftlb) 1800 870 MZ(ftlb) 2800 1300

Calculated Moment Loads (ft- lbs) MYc = MY (discharge) + MY (suction) = 870 + 1800 = 2670 MZc = MZ (discharge) + MZ (suction) = 1300 + 2800 = 4100

MeasuredeflectioncausedbyMy

Loading Momentapplied (ftlb) Shaftdisplacement Dialindicator (in)

MYc 2708 DZ 0.0008

MZc 4166 DY 0.0005

LoadingCondition MYc MZc

Maximumallowablepumpshaftdisplacements(in) Baseintendedforgrout DZ=0.007 DY=0.003 Ungroutedtypebase N/A N/A

Purchaser'sRequirements
To reduce the complexity / cost of the supply / return piping design layout, purchasers request that pump suppliers modify the pumpset to accommodate higher nozzle loads.
Question: Whenapurchaserspecifiesthatthepumpallowablenozzleloadsshallbetwice(2x)Table4 values Whatdoesthisactuallymean?
Option1): A2xmultipliermustbeappliedtoallparagraphsinAPI610thatpertaintoTable4nozzleloads: 5.3.3aThepressurecasingshallbedesignedtooperatewithoutleakageorinternalcontact betweenrotatingand stationarycomponentswhilesubjectsimultaneously totheMAWP andtheworstcasecombinationoffourtimes (4x) theallowablenozzleloadsofTable4appliedthrougheachnozzle. 6.3.5 Thepumpanditsbaseplateshallbeconstructedwithsufficient structuralstiffnesstolimitdisplacementofthe pumpshaftatthedriveend tomeetvaluesperAPITable12whensubjectedto(2x)API610Table4nozzlemoments. F.1.2a)Theindividualcomponentforcesandmomentsactingoneachpumpnozzleflangeshallnotexceedtherange specifiedinTable4byafactormorethan4. Option2): A2xmultiplierisonlyappliedtotheshaftdeflectioncriteria: 6.3.5 Thepumpanditsbaseplateshallbeconstructedwithsufficient structuralstiffnesstolimitdisplacementofthe pumpshaftatthedriveend tomeetvaluesperAPITable12whensubjectedto(2x)API610Table4nozzlemoments.

ChallengesForPumpVendor
Whenpurchasersmandatetheacceptanceofnozzleloadsinexcess ofAPI610 Table4thepumpvendormaybeabletomeettheserequirements,however,this provisionwillrequireadditionalanalysis,whichmayincludea3DcasingFinite ElementAnalysis(FEA)atadditionalcostandincreasedleadtime.
Thepumppressurecasingmayneedtobemodified. ASMEflangeratingsmayneedtobeincreased.{Useclass600#on apumpwithaMAWP of740psig}. Pumppedestalandbaseplatesubframedesignwillneedtobemodified. Analyticalstudiesmayfindthatitisnotpossibletomeetacceptancecriteriaforreliable operationunderthespecifiedhighnozzleloadconditions.

Non-Standard Pump Nozzle Loads = Not a simple task:

Pump Support [Baseplate] Stiffness Evaluation

Thepumpisconsideredstifffortheanalysis.
Unitloadsareindividuallyappliedtothe"stiffnesscenter"of thepump Thestiffnesscenteriswherethenozzlesmeetthepumpcasing;thenozzlescanbeconsideredtooriginatefromthispoint andconnecttothepipingforthepipinganalysis.

Locationofnozzlesfromthestiffnesscenter(APIcoordinatesystemwasused). Thebaseplatewasanalyzedwithandwithoutgrout.
Withgrout,thebaseplatewasheldattheanchorboltlocationsandattheundersideofthebaseplatesimulatingbonded epoxygrout Withoutgrout,thebaseplatewasheldattheanchorboltsonly.

FEAmodelofbaseplate&pumpwithAPIcoordinatesystem

PumpSupport[Baseplate]StiffnessEvaluationResults
Providecustomer/pipingdesignerwiththeinformationbelowandrequestrecalculation ofappliednozzleloads,consideringthenonrigidpumpsupportstiffness:

Load,Displacement,andStiffnessvaluesforBaseplate&Pump

3-Dimensional FEA of Pump Case - Example

Whenconsideringacceptabilityofnozzleloadsinexcessof2xAPI610 values,theaforementionedeffectsneedtobeinvestigated. Afiniteelementmodelofa20x24x32HSBcasingwasusedto investigatetheeffectofhighnozzleloadsontocasingstresses and deflections.

3-Dimensional FEA of Pump Case - Example

Thefiniteelementmodelwassubjectedto2,4,6and8timesAPI610Table4nozzleloads. Foreachloadingconditionthemodelwascheckedfor: Casingstresses(absoluteandchange) Casedeformationaroundrotorseals. Casetightness/potentialforleakage Pumpholddownboltstresses

3-Dimensional FEA of Pump Case - Example

Severalareasofconcernwerechosenforobservationateachnozzleloading condition.Theselocationstypicallyexhibitedhigherconcentrationofstressthan itssurroundingareas.Linearizedstresspathswereinsertedattheselocations. Stressdistributionovertheentirebodywasobservedforabrupt changesbetween nozzleloadings.

3-Dimensional FEA of Pump Case - Stress Results

CaseMaterial A216Gr.WCB

Properties(psi) 36,000Yield 70,000Tensile

Conclusion:Nozzleloadingsdonotsignificantlyinfluencestressesinthelowercasehalf.

3-Dimensional FEA of Pump Case - Stress Results

Upper Case #1

Upper Case #2

CaseMaterial A216Gr.WCB

Properties(psi) 36,000Yield 70,000Tensile

Ze ro Loa ding Internal Pressure Only (1480 psi)

psi

2X API % change

NOZZLE LOADINGS 4X API psi % change

psi

6X API % change

psi

8X API % change

UPPER CASE HALF STRESSES [Membrane + Bending] Pump Foot UpperCase#2 LowerCase#1 UpperCase#1 32,421 19,190 32,883 18,575 1.43 -3.20 32,762 19,115 1.05 -0.39 31,794 19,087 -1.93 -0.54 32,523 18,723 0.31 -2.43

Conclusion:Nozzleloadingsdonotsignificantlyinfluencestressesintheuppercasehalf.

3-Dimensional FEA of Pump Case - Deformation Evaluation

3-Dimensional FEA of Pump Case - Deformation Evaluation

Conclusion:Stationarywearringdoesnotcomeintocontactwith impellereyeringunder anytestedloadingcondition.

3-Dimensional FEA of Pump Case - Gasket Tightness Evaluation

Gasketcontactpressure mustbemaintainedwhen thecaseissubjected distortionduetointernal pressureandnozzleloads.

Pumpvendorshavespecific criteriathatneedstobe checked.

3-Dimensional FEA of Pump Case - Gasket Tightness Evaluation

Conclusion: 1.)Gasketpressuresaroundthepartingflangeboltholesandmechanicalsealboreare>=2xmaximum internalpressure.(Internalpressureis1480psi). 2.)Noleakageisexpectedfor2x,4x,6xand8xAPI610nozzleloads.Relativechangebetweenload casesisinsignificant.

3-Dimensional FEA of Pump Case - Hold-Down Bolt Evaluation

BoltMaterial SAEGr.5

Properties (psi) 58,000Yield 90,000Tensile

Conclusion:Holddownboltsdonotexperienceanysignificantchangeinstress.