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Balance Holes in Pumps PDF
Balance Holes in Pumps PDF
ABSTRACT
Reliability of rotating machineries, especially centrifugal pumps is defined on account of wear
rate of components and bearing durability. One of the important performance parameter for
any centrifugal pump is its bearing life, which is dependent on the hydraulic thrusts, Radial[7,9]
and Axial Thrusts[7,9]. The radial thrust prediction can be done accurately and easily with the
help of prevailing methods available in literature [7,9]. Whereas to predict the axial thrust, the
prevailing methods are not found very much reliable to use as the number of parameters
influencing axial thrusts are more than those for radial thrust. Also to contribute to it are the
variations in the impeller geometries, which are governed by the hydraulic design and keeps
on changing based on the hydraulic design of the impeller. Therefore to predict the bearing
life and select the suitable bearing for getting optimum bearing life, it is really necessary to
formulate a basis to arrive at the reliable axial thrust values and formulation of such basis,
there is no better tool than experimental analysis.
This paper talks about the experimental analysis of the axial thrust of end suction long
coupled centrifugal process pump and the findings of the analysis.
1.0 INTRODUCTION
One of the important performance parameter for any centrifugal pump is its bearing life. To
have the minimum maintenance and repairs cost, the bearing life for any centrifugal pump
must be as prolonged as far as possible. Particularly in case of process pumps, which are used
at high temperatures, high pressure and more hazardous applications with maximum
reliability, bearing life is of more importance. Bearing life [12,13]. of centrifugal pump depends
upon two hydraulic forces acting on the impeller i. e. radial thrust and axial thrust. Amongst
the two forces, radial thrust is dependant solely on pressure generated by pump. There are
proven and reliable methods available to predict the radial thrust generated. Radial thrust can
be satisfactorily reduced to harmless extents by using double volute casings or diffuser type
casings.
Whereas axial thrust is dependent on the many aspects viz. shroud and casing clearances,
peripheral shroud speeds, head developed by the pump, impeller geometry etc. due to this one
cannot arrive at the conclusion that the theoretically calculated thrust value and the thrust
experienced by the pump in practice are same. This is mainly due to the manufacturing
limitations and assembly variations. The existing methods cannot be employed in practice to
estimate the correct value of axial thrust or even the permissible variation. The available
literature on measurements of axial thrust in pumps indicates the lack of adequate and
accurate experimental results data. Axial thrust data and improved analytical methods are
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critical to the proper selection of thrust bearings due to the consequences of rapid wear,
frequent maintenance and possible pump failure due to large axial forces, it is better to predict
and minimize axial thrust for a range of pump types in a variety of applications.
2.0 NEED FOR OPTIMIZATION OF AXIAL THRUST
The life and size of the bearings in centrifugal process pumps is greatly influenced by the
axial thrust developed.
High axial thrust loads can cause rapid thrust bearing wear and either subsequent pump failure
or frequent overhauls. The axial thrust is balanced by various methods like balancing chamber
and holes, pump out vanes, balancing ring and disc and by using balancing drum. By reducing
the pressure in the space between the back shroud and the casing wall, the axial thrust is also
balanced.
The axial thrust is dependent on the many aspects viz. shroud and casing clearances,
peripheral shroud speeds, head developed by the pump, impeller geometry etc. due to this one
cannot ensure that the theoretically calculated thrust value and the thrust experienced by the
pump in practice are same. This is mainly due to the manufacturing limitations and assembly
variations. None of the existing method can currently be employed in practice to estimate the
correct axial thrust value or even the permissible variance.
The available literature on measurements of axial thrust in pumps indicates the lack of
adequate and accurate experimental results data. Axial thrust data and improved analytical
methods are critical to the proper selection of thrust bearings due to the consequences of rapid
wear, frequent maintenance and possible pump failure due to large axial forces, it is better to
predict and minimize axial thrust for a range of pump types in a variety of applications.
3.0 HYDRAULIC THRUSTS IN CENTRIFUGAL PUMPS
During operation and working of centrifugal pumps, as mentioned earlier, the kinetic energy
of flowing liquid is converted into pressure energy. This high pressure liquid is continuously
flowing all over the circumference of the impeller and also gets entrapped inside the
clearances between impeller and casing / casing cover. This high pressure liquid exerts
pressure on the outlet passages and shrouds of the impeller resulting in generation of two
forces, one in lateral and another in longitudinal direction with respect o shaft axis.
The force generated in lateral direction is due to dissimilar pressure generation in
volute and called as Radial thrust[fig1], while another one generated in longitudinal direction is
on account of different areas of impeller exposed to trapped pressurized liquid called as axial
thrust.
3.1 RADIAL THRUST
The hydraulic radial load is due to the unequal velocity of the fluid flowing through the
casing. The unequal fluid velocity results in a non-uniform distribution of pressure acting on
the circumference of the impeller. The radial load is most influenced by the design of pump
casing. The pump casing is designed to direct the fluid flow from the impeller into the
discharge piping. In a theoretical situation at Best Efficiency point (BEP), the volute casing
has a uniform distribution of velocity and pressure around the impeller periphery. There are
proven formulas to predict the hydraulic radial thrust with fair amount of accuracy. Radial
2
thrust can be minimized by making double volute casing [fig1] or by providing the diffuser type
casing.
F2
F1
Fm
UNBALANCED
THRUST
As shown in Fig. 2 above the resultant unbalanced axial thrust is vector summation of the
following forces [1]
Force acting on front shroud due to liquid of delivery pressure entrapped between pump
casing and front shroud. (F1)
Force acting on back shroud due to liquid of delivery pressure entrapped between casing
cover and back shroud. (F2)
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Force acting in the direction of the liquid flow due to its momentum change. (Fm)
The pressures generated by a centrifugal pump exert forces on both its stationary and rotating
parts. The design of these parts balances some of these forces, but separate means may be
required to counter-balance others. Axial hydraulic thrust is the summation of unbalanced
impeller forces acting in the axial direction. As reliable large-capacity thrust bearings are not
readily available, axial thrust in single-stage pumps remains a problem only in larger units.
Theoretically, a double-suction impeller is in hydraulic axial balance with the pressures on
one side equal to, and counter-balancing the pressures on, the other Fig 6. In practice, this
balance may not be achieved for the following reasons:
The suction passages to the two suction eyes may not provide equal or uniform flows to the
two sides.
DISCHARGE PRESSURE
DISCHARGE PRESSURE
SUCTION PRESSURE
DISCHARGE
PRESSURE
SUCTION
PRESSURE
SUCTION
PRESSURE
DISCHARGE
PRESSURE
1. External conditions such as an elbow being too close to the pump suction nozzle may
cause unequal flows to the suction eyes.
2. The two sides of the discharge casing may not be symmetrical, or the impeller may be
located off-centre. These conditions will alter the flow characteristics between the impeller
shrouds and casing, causing unequal pressures on the shrouds.
3. Unequal leakage through the two leakage joints will tend to upset the balance.
Combined, these factors create definite axial unbalance. To compensate for this, all
centrifugal pumps, even those with double-suction impellers, incorporate thrust bearings.
The ordinary single-suction radial-flow impeller with the shaft passing through the impeller
eye Fig 3 is subject to axial thrust because a portion of the front wall is exposed to suction
pressure, thus exposing relatively more back wall surface to discharge pressure. If the
discharge chamber pressure were uniform over the entire impeller surface, the axial force
acting towards the suction would be equal to the product of the net pressure generated by the
impeller and the unbalanced annular area.
IMPELLER
BALANCE HOLE
REDUCTION IN
AXIAL
THRUST DUE TO
BALANCE HOLES
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cheaper and more effective than the first method. In this method the power consumed is much
less than the power loss due to leakage through balancing holes under normal conditions.
BACK VANES
IMPELLER
REDUCTION IN
AXIAL
THRUST DUE TO
BACK VANES
There are some other thrust balancing methods like Balancing Disc and ring, Balancing Drum
used specifically to reduce the axial thrust in multistage centrifugal pumps.
5.0 EXPERIMENTAL ANALYSIS [14].
The actual thrust induced on the impeller with back vanes will be measured by virtue of an
experimental test rig. This will include direct measurement of the thrust exerted on the
impeller by employing suitable transducer. The methods of measuring the unbalanced
hydraulic axial thrust experimentally are
Providing tapping in pump casing and casing cover for obtaining the pressure values
between the clearances of impeller and casing.
[14]
Finally the results obtained experimentally and those obtained by theoretical analysis were
compared to draw a conclusion.
5.1 Experimental analysis procedure[14].
The method of orthogonal array was used to conduct this experiment instead of making
simple iterations (conventional method) of predefined parameters. For conducting this
experiment conventionally it would have required 81 different trials based on three variations
of four parameters each, but by utilizing the orthogonal array method, the same results can be
obtained in three trials. With orthogonal array method, it is possible to analyze the effect of
influencing parameters on the axial thrust development quickly and with fewer trials.
In this technique it is proposed that an experiment organizes consecutive small series of trials
in each of which all the factors are simultaneously varied according to a definite rules. The
series are such arranged that after mathematical processing of a proceeding, it will be possible
to analyze the effect of each influencing parameters on the response value. For this project
following four parameters are chosen
1. The number of back vanes,
2. The back vane radius,
3. The back vane height,
4. Clearance between casing cover and back vanes.
All the above factors have three variations each as given in Table-1.
Experiment
no
No of back
vanes
(Z)
Back vane
diameter
(D) mm
Back vane
thickness
(T) mm
107.00
6.00
5.00
87.00
3.50
3.00
67.00
1.00
1.00
107.00
3.50
1.00
87.00
1.00
5.00
67.00
6.00
3.00
107.00
1.00
3.00
87.00
6.00
1.00
67.00
3.50
5.00
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load application, the graph-1 shows the response of the load cells output voltage with respect
to the known load applied.
LOAD CELL
(front)
DRIVER SIDE
PUMP SIDE
-r12/2)2}
(kg)
-S12)-B2 (b2-S12/2)2}
(kg)
= (Force on back shroud considering back vanes pressure force on front shroud
momentum thrust)
= FB - FR - Tm
(kg)
(Rad/s)
(Rad/s)
= Density
(Kg/m3)
= Pump head
(meters)
Ho
r1
Cd
u2
(Rad/s)
(mm)
= Vane width
(mm)
(s-t)
=Vane clearance
(mm)
Re
=Reynolds number
= Kinematic viscosity
(m2/sec)
S1
=Radius of shaft
(meter)
= Discharge
(m3/hr)
= speed in
(rpm)
A1
(m2)
Where,
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(Kg)
2) From graph it is observed that as number of back vanes increases the back vane force
developed also increases since the increase in number of back vanes increases the
angular velocity of the fluid between the back shroud of impeller and pump casing.
But after some limit, if no. of back vanes increased that will not be served. In these
experiments the optimum number of back vanes was found to be 8 [graph 2].
3) From graph-3. it is observed that back vane force increases as the radius increases. The
increase of radius results in increasing the rotation of the fluid. (Over a radial length).
A small increase in back vane radius affect the back vane force for a great extent. If
full diameter back vanes are provided it will rotate the total water trapped in the axial
gap. There by increasing the angular velocity of the fluid over the whole region of
impeller. If the back vanes provided are less than the impeller diameter, the fluid
trapped in the region of back vanes and casing will have the angular velocity higher
than the angular velocity of fluid trapped in the remaining region of the impeller
diameter. In this case the back vane force developed will be due to combined effect of
the two angular velocities which will result in the lower back vanes force.
4) If the axial gap is very small, the angular velocity of the fluid in the gap will be high
and hence the back vane force as well. Back vane height also helps to increase the
rotation of the fluid in the axial gap. The optimum value has been found to be 5 mm
from these experiments.
10
(Kg)
5) Graph 5 shows that the back vane force developed is higher for low clearance values
as well a with very high clearance values, when the clearance is very low the angular
velocity of the fluid is higher in this small gap. This will result in decrease in pressure
on the impeller shroud. As the clearance increases a very large value the eddy of
recirculatory flow will start through the axial gap. This will result in equalization of
pressure behind the impeller at the outer diameter and at the inner most diameters
naturally increasing the total back vane force.
Graph 5 Axial thrust Vs Clearance between casing cover and Back vane face
6) The axial thrust variation with respect to flow for all 9 tests is as given below in graph
6-
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11
700
Expt 4
600
Expt 1
Expt 3
500
Expt 8
Expt 2
Expt 7
400
Expt 9
Expt 6
300
Expt 5
200
100
0
0
20
40
60
80
100
Flow (lps)
7.0 Conclusion
12
Number of vanes
Clearance between back vanes and casing cover
3. Close control of back vane parameters is essential to maintain optimum thrust values
for mass produced pumps. The variation in thrust values due to change in the
dimensions of back vane height and clearance has been tabulated[14]
Axial Thrust at BEP
condition (kg)
Experiment
no. (Refer
table 1)
Without
back vane
With back
vane
Without
back vane
Without
back vane
With back
vane
With back
vane
Test
1
Test
2
Test
1
Test
2
Test
1
Test
2
Test
1
Test
2
Test
1
Test
2
Test
1
Test
2
640
642.5
100
101.5
815
812
295
298
82.3
82
78
78.5
630
628.5
378
377
795
794
594
592
82.3
82
78
78.5
590
588
553
552
673
674
707
580
82.3
82
78
78.5
590
588
282
283.5
673
674
497
501
82.3
82
78
78.5
640
642.5
556
551
815
812
749
748
82.3
82
78
78.5
630
628.5
510
513
795
794
690
691.5
82.3
82
78
78.5
630
628.5
545
547.5
795
794
730
733
82.3
82
78
78.5
590
588
388.5
385
673
674
547
546
82.3
82
78
78.5
640
642.5
482.5
480
815
812
688
688
82.3
82
78
78.5
References
1) K J Zanker, Experiments with back vanes used for balancing axial thrust on centrifugal
pump impellers, British Hydromechanics Research Association, Vol. 3, 5th Annual meet.
(Apr. 1962), pp.7-14.
2) George Schaefer and Eric Olson, Experimental Evaluation of Axial Thrust, Journal of
World Pumps, Issue 393, June 1999, pp. 34-37.
3) Majan Gantar, Dr. Dussn Florjancic, Dr. Brane Sirok, Hydraulic Axial Thrust in
Multistage Pumps - Origins and Solutions, proceedings of ASME FEDSM01, May 29 June1.2001, pp. 1-8.
4) Marc P. Mignolet Byeong-Keun Choi, Robust Optimal Positioning of Strain Gages on
Blades, journal of turbo machinery- transactions of ASME Vol. 125, October 2002. pp.
155-164.
5) J. Szwedowicz, S. M. Senn and R. S. Abhari, Optimum Strain Gage Application to
Bladed Assemblies, journal of turbo machinery- transactions of ASME Vol. 125, January
2003. pp. 606-613.
6) Igor J Karassik & Ray Cartor, Centrifugal pumps, Tata McGraw Hill Book company2nd Edition, 1960. pp. 3.129-3.339.
7) A.J. Stepanoff, Centrifugal and Axial flow pumps - Theory, Design & Application ,
John Wiley and Sons 2nd edition 1953. pp. 182-223.
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8) Stephen Lazarkiewicz & Adam T. Troskolanski, Impeller pumps, Pergramon Press- 1st
edition 1965. pp. 346-365.
9) Val S. Lobanoff & Robert R. Ross, Centrifugal Pumps design and application, Jaico
publishing house 2nd edition 1995. pp. 333-353.
10) Centrifugal pumps for petroleum, heavy duty chemical and gas industry services,
American Petroleum institute 610 10th edition-October 2004
11) General catalogue SKF bearings.
12) Bearings in Centrifugal Pumps Application handbook Part I &II, SKF100955_1,
SKF bearings.
13) ISO 281: Rolling Bearings - Dynamic Load Ratings and Rating Life., Second edition
1990-03-25.
14) Experimentation on suction pump for axial thrust evaluation, R&D, Kirloskar Brothers
limited, Kirloskarvadi.
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