Advertisement

Journal of Failure Analysis and Prevention

, Volume 13, Issue 4, pp 489–495 | Cite as

Study on Failure Analyses and Material Characterizations of a Damaged Booster Pump

  • Ali Alavi Shoushtari
  • Khalil Ranjbar
  • Seyed Mohammad Mousavi
  • Danial Azimi Yancheshmeh
Technical Article---Peer-Reviewed

Abstract

Pumps are a key and crucial part of many industrial units which usually are endangered by metallurgical, mechanical, and chemical damages. The most important mechanisms of failure in pumps are cavitation, erosion, and corrosion which directly are influenced by pump’s materials, type of fluent, and operation condition. The aim of this study was to investigate the role of material selection in the main failure mechanisms of a power plant booster pumps. To observe the kind and micro structure of pumps optical microscopy and image analyses software were used. Morphology of the pumps’ body is investigated by scanning electron microscopy. Electrochemical tests and water analyses are done for measurement of corrosion rate as well as amount of particles in feed water. Moreover, tensile testing was carried out to compare the mechanical properties of body alloy with standard alloy. The results revealed that cavitation and erosion were the most significant mechanisms. On the other hand, the data from analyses and observations clarified that the material which chosen for pumps alloy was improper which was accompanied with lack of fabrication technology.

Keywords

Booster pump Failure analyses Cavitation Erosion Corrosion 

References

  1. 1.
    Cudina, M., Prezelj, J.: Detection of cavitation in operation of kinetic pumps. Use of discrete frequency. Appl. Acoust. 70, 540–546 (2009)CrossRefGoogle Scholar
  2. 2.
    Escaler, X., Egusquiza, E., Farhat, M., Avellan, F., Coussirat, M.: Detection of cavitation in hydraulic turbines. Mech. Syst. Signal Process. 20, 983–1007 (2006)CrossRefGoogle Scholar
  3. 3.
    Sherier, L.L., Jarman, R.A., Burstein, G.T.: Corrosion, vol. 1, 3rd edn. Heinemann, Butterworth (1994)Google Scholar
  4. 4.
    Dular, M., Stoffel, B., Sirok, B.: Development of a cavitation erosion model. Wear 261, 642–655 (2006)CrossRefGoogle Scholar
  5. 5.
    Dular, Matevz., Osterman, Aljaz.: Pit clustering in cavitation erosion. Wear 265, 811–820 (2008)CrossRefGoogle Scholar
  6. 6.
    Hart, D., Whale, D.: A Review of Cavitation-erosion Resistant Weld Surfacing Alloys for Hydroturbins, pp. 981–995. IIW Asian Pacific Welding Congress, the New Zealand Welding Committee, (1996)Google Scholar
  7. 7.
    Karassik, I.J., Messina, J.P., Cooper, P., Heald, C.C.: Pump Handbook, 3rd edn. McGraw-Hill, New York (2001)Google Scholar
  8. 8.
    Sastri, V.S., Ghali, E., Elboujdaini, M.: Corrosion Prevention and Protection Practical Solutions., p. 393. Wiley, New York (2007)Google Scholar
  9. 9.
    Sulzer Pumps Ltd: Centrifugal Pump Handbook, 3rd edn. Elsevier Ltd., Houston (2010)Google Scholar
  10. 10.
    Ariely, S., Khentov, A.: Erosion corrosion of pump impeller of cyclic cooling water system. Eng. Fail. Anal. 13, 925–932 (2006)CrossRefGoogle Scholar
  11. 11.
    Dojcinovic, M., Volkov-Husovic, T.: Cavitation damage of the medium carbon steel: implementation of image analysis. Mater. Lett. 62, 953–956 (2008)CrossRefGoogle Scholar
  12. 12.
    Ahmad, Z.: Principles of Corrosion Engineering and Corrosion Control, p. 252. Elsevier, Washington (2006)Google Scholar
  13. 13.
    Hattori, S., Ishikura, R., Zhang, Q.: Construction of database on cavitation erosion and analyses of carbon steel data. Wear 257, 1022–1029 (2004)CrossRefGoogle Scholar
  14. 14.
    Nalco Chemical Company: The NALCO Water Handbook, 2nd edn. McGraw-Hill Book Company, New York (1988)Google Scholar
  15. 15.
    Haosheng, C., Jiadao, W., Darong, C.: Cavitation damages on solid surfaces in suspensions containing spherical and irregular microparticles. Wear 266, 345–348 (2009)CrossRefGoogle Scholar
  16. 16.
    Lathabai, S., Ottmüller, M., Fernandez, I.: Solid particle erosion behaviour of thermal sprayed ceramic, metallic and polymer coatings. Sci. Technol. 221, 93–108 (1998)Google Scholar
  17. 17.
    Sun, Z., Kang, X.Q., Wang, X.H.: Experimental system of cavitation erosion with water-jet. Mater. Des. 26, 59–63 (2005)CrossRefGoogle Scholar
  18. 18.
    API STANDARD 610: Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries, 9th edn. American Petroleum Institute, Washington (2003)Google Scholar
  19. 19.
    ASM Handbook, Vol. 18: Friction, Lubrication, and Wear Technology. American Society for Metals (1992)Google Scholar
  20. 20.
    Wegst, C.W.: Key to Steel: Stahlschlussel (English Edition). Verlag Stahlschussel, Heidelberg (2007)Google Scholar

Copyright information

© ASM International 2013

Authors and Affiliations

  • Ali Alavi Shoushtari
    • 3
  • Khalil Ranjbar
    • 2
  • Seyed Mohammad Mousavi
    • 1
  • Danial Azimi Yancheshmeh
    • 4
  1. 1.Material Science and Engineering DepartmentIslamic Azad University of AhvazAhvazIran
  2. 2.Department of Materials Science and EngineeringShahid Chamran UniversityAhvazIran
  3. 3.IKA Engineering and Technical Inspection CompanyTehranIran
  4. 4.Faculty of Mechanical EngineeringK.N. Toosi University of TechnologyTehranIran

Personalised recommendations