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Practical Rotordynamics For Centrifugal Pumps PDF
Practical Rotordynamics For Centrifugal Pumps PDF
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Practical Lateral Rotordynamics for
Centrifugal Pumps
Pump Symposium
Calgary November 2007
Brian Germaine
Sulzer Pumps UK Ltd.
brian.germaine@sulzer.com
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Practical Rotordynamics for Centrifugal Pumps
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Practical Rotordynamics for Centrifugal Pumps
Agenda
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Introduction
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Practical Rotordynamics for Centrifugal Pumps
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Practical Rotordynamics for Centrifugal Pumps
Single Degree of Freedom Equation of motion about the static
equilibrium position does not contain
System weight and weight balancing force.
Force is assumed to be linear to their
driving parameters
k m&x& = F ( t ) cx& kx
c
Unforced System
m
m&x& + cx& + kx = 0
x
Second-order homogenous ordinary
differential equation
F(t)
m2 + c + k = 0
Eigenvalue problem (damping
k( x + x static
) c&x neglected)
1, 2 =
k
= 0 j
k
m m m
Imaginary part of complex solution is
F( t ) mg the undamped natural frequency or
Eigenfrequency
k
0 =
m
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Practical Rotordynamics for Centrifugal Pumps
Laval (Jeffcott) Rotor Mass-less shaft with bearing stiffness (k)
Disc-like mass (m) at mid-span, supported
on rigid bearings, perfectly balanced
Unforced & un-damped system with circular
e orbit
=
Dynamic equilibrium i.e. centrifugal force =
shaft force
k( e + e )
m
static
me 2 ke = 0
me
k
me( 2 ) = 0
2
mg
m
k
2 =0
m
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Practical Rotordynamics for Centrifugal Pumps
Journal Bearings
F 2
B D
B D n
Sommerfeld Number US, S=
F
Static
2
Inlet Outlet
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Practical Rotordynamics for Centrifugal Pumps
Annular Seals Circulatory De-stabilizing Force:
The rotor as well as the fluid flowing
asymmetric pressure
through the annular seal are rotating
profile due to rotation
i.e. have circumferential velocity.
Distortion of the pressure profile due
to this rotation yields forces
perpendicular to the displacement.
These forces are non-conservative
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Practical Rotordynamics for Centrifugal Pumps
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Practical Rotordynamics for Centrifugal Pumps
Impellers Interaction Rotordynamic Coefficients
As a pump rotor is subject to vibrations by nature, reaction forces always occur at
the impeller due to the lateral movement relative to the pump casing or diffuser
The flow around the impeller becomes asymmetric and this causes unsteady fluid
forces on the impeller.
Impeller-diffuser-interaction develops as well as the side room effects.
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API 610 10th Edition Appendix I
Specification for Performing Lateral
Rotordynamics for Pumps
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Practical Rotordynamics for Centrifugal Pumps
Analysis of 1st, 2nd and 3rd dry critical speeds
Classically stiff first dry critical speed > 1.2x max. continuous shaft speed if wet running only
Analysis for new and worn (2x new) clearance conditions
Analysis at expected temperature for water (new) and pumped liquid (new and worn)
Analysis for operational speed range from 25% to 125% of rated shaft speed
Includes stiffness and damping at labyrinth type shaft seals, including bearings
Considers stiffness of bearing support structure
For both new and worn clearances the damping factor vs. separation margin to be calculated
1) Acceptable Region
2) Improvement Desired
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API 610 7th Edition Appendix I
A Specification for Compressors
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Practical Rotordynamics for Centrifugal Pumps
API 610 7th Edition; defined the analysis process completely differently
Analysis focused on unbalance response analysis only
Position of critical speed and damping level important
Procedure identical to API 617 Turbo Compressors
Damping calculated from curve shape at first critical speed position
Procedure not sensible for centrifugal pumps
Amplification factor defines damping level, log decrement etc.
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Definition of "Stiff" vs. "Flexible"
Rotors
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Practical Rotordynamics for Centrifugal Pumps
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Practical Rotordynamics for Centrifugal Pumps
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The Process Damped Lateral
Rotordynamic Calculations
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Practical Rotordynamics for Centrifugal Pumps
ROTOR PUMP DATA
SULZER LATERAL-PU GEOMETRY PROGRAMS
SEAL
Bearings
Seals
HSEALM
Impellers
Finite Element Core: MADYN DATA
Oper. Data
BASE
Lubricant MADYN
Static Beahaviour
Eigenvalues
Seals Forced Response Forces
Operating data
Campbell Plot Runup
f A,
D2 A
Mb
2 D=0
T 1 D1
kB cB Bearing kB cB
FAx
n n
ms Bearing housing ms
Stress
kS cS Support kS cS Evaluation
Yielding
Fatigue
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Practical Rotordynamics for Centrifugal Pumps
Radial clearances
Journal Journal
bearing bearing
Standstill
e = Offset e
Running
at Standstill
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Practical Rotordynamics for Centrifugal Pumps
150
Frequency [Hz]
120
Speed = 3600 rpm
F= 80.42 Hz
D= 25.6 %
90
60
30
nmax
nmin
Speed = 2400 rpm Speed = 6000 rpm
nn
F= 57.21 Hz F= 125.53 Hz
0
D= 28.2 % D= 20.4 %
50
Damping [%]
40
30
20
Speed = 1200 rpm Speed = 4800 rpm
F= 35.02 Hz F= 105.53 Hz
D= 26.9 % D= 23.1 %
10
0
1200 2160 3120 4080 5040 6000
Z Rotor Speed [rpm]
orbit with max. major axis, t = 0, t = /2
X List of Symbols: Mode 1:
Mode Shape No. 1 Mode 2:
Pump State: New Pump State: New
Y Analysis.... 304122026, HPcp 350-425-8s/27m,NEW Analysis.... 304122026, HPcp 350-425-8s/27m,NEW
LATERAL Rev. 4.5A LATERAL Rev. 4.5A
LATERAL DAMPED NATURAL FREQUENCIES ANALYSIS DATE: 12.Apr.2003 EIGVC: CAMPBELL AND DAMPING DIAGRAM DATE: 12.Apr.2003
HPcp 350-425-8s/27m,NEW HPcp 350-425-8s/27m,NEW
Sulzer Pumps UK Ltd Sulzer Pumps UK Ltd
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Rotordynamic
Development & Testing
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Practical Rotordynamics for Centrifugal Pumps
Late 80's, early 90's Sulzer received a order
from EPRI to investigate a number of specific
areas of pump design with an aim of
improving BFP reliability
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Practical Rotordynamics for Centrifugal Pumps
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Instability & Unbalance Response
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Practical Rotordynamics for Centrifugal Pumps
Forced Response
Forced response is the dynamic shaft amplitude given in absolute terms due to excitation forces
(mechanical or hydraulic unbalance)
Results are presented in two ways: forced bending shape and orbits for a given shaft speed or vibration
vectors and phase angles for discrete locations along the rotor as function of shaft speed
In centrifugal pumps, the typical damped response to unbalance does not show a peak in displacement at
resonance large enough to assess the amplification factor, therefore it is restricted to comparing rotor
displacement to available clearances
The peak-to-peak displacement of the unbalanced rotor at the points of max. displacement shall not exceed
a defined percentage of the diametral running clearance (API 610 states 35%)
Bode Plot
n=const.
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Practical Rotordynamics for Centrifugal Pumps
Forced Response
The dynamic behavior of shaft
Mass [kg] 344.4
overhangs, notably the
U1 U1
X
forces.
Y
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Practical Rotordynamics for Centrifugal Pumps
Swirl Brakes Applied at
Annular Seals
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Practical Rotordynamics for Centrifugal Pumps
Swirl Brakes Applied to Balance Drum Liner
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Practical Rotordynamics for Centrifugal Pumps
Application of Swirl Brakes Swirl Brakes in Action!
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Practical Rotordynamics for Centrifugal Pumps
Case Studies
LATERAL Analysis, Ultra High Pressure Seawater Injection Pump
Option
2 4 5
5s+5s 6s+6s 8s
Impeller Back to back Back to back In line
arrangement
Speed 8494 RPM 6000 RPM 8494 RPM
Number of 10 12 8
stage
Design
Concept
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Practical Rotordynamics for Centrifugal Pumps
Case Studies
LATERAL Analysis, Ultra High Seawater Injection Pump
Evolution of First Eigenmodes from NEW- to WORN-Condition (2x Design Clearances)*
HPcp 220-5s+5s (Option 2) HPcp 285-6s+6s (Option 4) HPcp 250-8s (Option 5)
NEW
WORN
fe,1/fn = 1.10 --> 1.08 1.43 --> 1.23 1.11 --> 0.98
EIGENVECTOR Nr. 3
F= 2.2254E+01 Hz
D= 3.8533E-06
22.25 Hz
EIGENVECTOR Nr. 7
F= 9.0750E+01 Hz
D= -1.7742E-05
90.75 Hz
EIGENVECTOR Nr. 11
F= 2.0144E+02 Hz
D= -1.9899E-05
201.44 Hz
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Practical Rotordynamics for Centrifugal Pumps
Case Studies
FFT Frequency Spectra: Slave Tested Machine back-to-back design
2x Clearance Tests
Speed 6000 rpm
Flow 250 m3/h (50%)
Pump DE (x-Direction)
80
60
40
20
0
0 1200 2400 3600 4800 6000
Speed [rpm]
The diagram above shows how the Natural Frequencies of the rotor change
with speed for both New & Worn conditions.
From Dry to Operating, frequencies can change by a factor of 4
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Practical Rotordynamics for Centrifugal Pumps
Stiffness of Related Seal Stiffness In-Line Pump
Annular Seals 1000
900
new suction seal
800 new eye seal
operating speed
200
100
0
0 1200 2400 3600 4800 6000
Speed [rpm]
The diagram above plots "annular seal" stiffness with increasing speed.
The piston stiffness is more than 6x that of annular eye or hub side labyrinths.
For back-to-back pumps, this means that the centre bush acts as an additional
hydrodynamic bearing, not so heavily influenced by worn clearances.
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Practical Rotordynamics for Centrifugal Pumps
Static Deflection and Static Deflection and Mass vs. Shaft Diameter Increase
Increasing Shaft 300
Diameter
150
100
50
0
0 10 20 30 40 50
Diameter Increase [%]
Deflection change in-line pump Deflection change back-to-back pump
Mass change in-line pump Mass change back-to-back pump
The above diagram shows the shaft deflection related to the seal clearance.
With an increase of 50mm (+27%), the static deflection is reduced by a factor
of 2 for inline pump.
For back-to-back this increases by a factor of 3, with a diameter increase of
about 45%.
This shows that the inline machine remains statically stiff but back-to-back
design would have to see a 40% increase to make the rotor statically stiff.
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Practical Rotordynamics for Centrifugal Pumps
Change in Critical Speed st
1 Critical Speed vs. Diameter Increase
3.5
Diameter
to running speed
2.5
2
1.5
1
st
0.5
0
0 10 20 30 40 50
Diameter Increase [%]
In-line pump, dry Back-to-back pump, dry
In-line pump, wet new Back-to-back pump, wet new
In-line pump, wet worn Back-to-back pump, wet worn
The above diagram shows the change in the first critical speed with increasing
shaft diameter. Dry critical speeds do not change that much and according to
the "old" criteria remain dynamically flexible.
Shaft size has an effect on the wet critical speed but even at the original
diameter they are well above running speed frequency.
Notice large difference between wet and dry critical speeds for back-to-back
pumps. The secret is the centre bush!!
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Practical Rotordynamics for Centrifugal Pumps
Diagram A Diagram A
Damping of the Individual Modes Damping of the Individual Modes
50
50
Damping %
Damping %
40
40
30
30
20
20
10
10
0
0
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Practical Rotordynamics for Centrifugal Pumps
Pump Selection
Chart
2-1
1-1
2-2
1-2
2-3
Region 1-1: In-line pumps that do not require any swirl brakes
Region 1-2: In-line pumps that require radial holes at balance drum entrance
Region 2-1: Back-to-back pumps that do not require any swirl brakes
Region 2-2: Back-to-back pumps that require radial slots at centre bush
Region 2-3: Back-to-back pumps that require swirl brakes at all annular seals
and throttle bushes.
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Practical Rotordynamics for Centrifugal Pumps
Rotor Design
For high speed pumps shrunk on components is key for good rotordynamic
performance, balance and repeated build quality (>4000rpm)
Shrink disk for Impellers are shrunk on, have keys for torque
mechanical seal sleeve transmission and use split ring for thrust
loading
Advantage
shrunk on parts allow for high rotor balancing quality
shrunk on parts avoid fretting corrosion and minimize stress concentrations
shrunk on parts avoid loose parts on shaft during operation and result in lower vibration
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Practical Rotordynamics for Centrifugal Pumps
A Last Look at the 30 Year Old Chart
back to back
300,355 6s
R eco mmend ed d esig n line 300,355 7s
600 f o r slend er shaf t wet r unning
Holstein
Halfdan
p ump s
Chirag 8 stage 300,355 8s
ELF Angola Troll Eldfisk
500 Armada AIOC
R eco mmend ed
Er skin e
T ot al dun bar
Schiehallion M aersk Gorm Gorm 395,405 4s
Zakum Hutton
d esig n line f o r lar g e Dorood
shaf t wet r unning Girassol M iller Dev
395,405 5s
400 Fulmar El Furrial
Cusiana Mars Buckland White Tiger
Hutton SWI 395,405 7s
R eco mmend ed up p er Yibal 4 stage Sleipner Bonga
limit s f o r p ump wit h Nimar 2,3
300
d r y r unning cap ab ilit y Alba plb
395,405 8s
Brage plb
ALBA SWI plb
Bragr plb
515
200
100 430
0
2000 3000 4000 5000 6000 7000
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Practical Rotordynamics for Centrifugal Pumps
Typical "Flexible" Back-to-Back Pump Designs
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Practical Rotordynamics for Centrifugal Pumps
Conclusions
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Thank You for Your Attention
For further details, contact:
Brian Germaine
Engineering Director
Sulzer Pumps UK Ltd.
Manor Mill Lane
Leeds
LS11 8BR
Tel. +44 113 272 4528
E-Mail: brian.germaine@sulzer.com
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