Vertical Pump (Turbine) Design Considerations PDF

Type VS1 and VS6 Vertical Turbine Pumps
Wet Pit and Double Casing
Marc Buckler
Flowserve Corporation
Calgary Pump Symposium 2013

Product Manager - Vertical Pumps
Marc Buckler Flowserve Corporation
Taneytown, MD, USA

Topics
Configurations & Construction
Pump Features
Design & Analysis
Sump Design

Configurations
&
Construction
Engineered Flexibility

Open or Enclosed
Lineshaft Construction
OR
Open – Product Enclosed – Oil

Lubrication Lubrication

Discharge Head Configurations
Cast Discharge Head Fabricated Discharge Head
OR

Suction & Discharge
Configurations
Above Ground
Discharge
Above Ground
Suction Below Ground
Discharge
Below Ground
Suction

Impeller Constructions
 Maintains efficiency by close running

clearances between lower shroud and bowl
Enclosed Impeller
 Provides an increase in efficiency over

enclosed impellers
 More suitable for services with solids
 Limited in number of stages
Semi-Open Impeller

Impeller Constructions
Semi-Open Enclosed

Impeller Mounting
Configurations
 Provides interference fit between bowl

shaft and impeller
Colleted Impeller
 Positively locked to shaft

 Stainless steel slotted keys prevent
radial movement
 Stainless steel split ring keys prevent
axial movement
 Commonly used for extreme
temperature applications
Keyed Impeller

Wear Ring Construction
 Available on enclosed impellers

and most bowls
 Installed with interference fit
 Roll pins positively lock the rings

in place

O-Ring Construction
 Provides a positive seal of all

flanged joints
 Located at rabbet fits on bowl

and column joints
 Also included at discharge head

to suction can fit

Sealing Configurations
 Various Mechanical Seals

 Single, dual, split seals
 Balanced or unbalanced
 Piping plan 13 minimum
 Stuffing Box (Packed Box)

 Low, high, extra high packed
boxes
 Plan 13 required for 100 psi
or greater

Driver Configurations
 Motors, Solid or Hollow Shaft

 Variable Frequency Drives
 Engines with Right Angle Gear

Drives
 Steam Turbines

Question:
I have an application where the
pumping liquid is municipal water.
What pump configuration do I select?

Answer:
Consider a Wet-Pit VS1
with Product Lubrication

VS1
Standard Features
Product Lubrication

VTP Standard Features
Open-Product Lubrication
• Basket Strainer (Optional)

 Prevents unwanted debris from entering pump
 Design exceeds HI standards
• Bell Bearing
 Provides maximum shaft support
 Permanently grease lubricated for reliability
• Suction Bell
 Provides efficient flow into eye of first stage
impeller
• Sand Collar
 Prevents grit from entering into bell bearing
• Wear Rings (Optional)
 Renews clearances and efficiency

 Lock Collet
 Provides interference fit to hold impeller to bowl shaft
 Impellers - Enclosed & Semi-Open
 Designed for maximum coverage of all applications
 Bowl Bearings
 High length to diameter ratio on both sides of the
impeller to provide rigid support for the bowl shaft
 Discharge Case or Bowl/Column Adapter
 Hydraulic adapter ensures efficient transfer of flow to
various column sizes

• Open Lineshaft Construction

 Allows lineshaft bearings to be lubricated by pumped
liquid
• Bearing Bracket with Rubber Lineshaft Bearings
 Fits integrally between column sections to maintain
alignment
 Spaced to provide adequate shaft support
• Column Pipe
 Available threaded as shown to minimize well casing
diameter

 Discharge Head
 ASME 125# or 250# flat face flange
 Provides smooth transition of pumped liquid to
discharge piping
 Functions as mounting base for driver
 Pre-lubrication Connection
 Allows external lubrication for deep set pumps
 High Pressure Stuffing Box
 Allows working pressures up to 20 bar (300 psi)
 Vertical Hollow Shaft Motor
 Extends head shaft through the motor
 Provides impeller adjustment with an adjusting
nut at the top of the motor

Question:
What if my pumping liquid contains
some abrasives?

Answer:
Consider a Wet-Pit VS1
with Enclosed Lineshaft /
Oil Lubrication

VTP
Standard Features
Enclosed Lineshaft
Oil Lubrication

Enclosed-Oil Lubrication
 Tension Bearing Assembly with Oil

Tank
 Holds the enclosing tube and lineshaft
bearings in alignment
 Provides a chamber for the lubricant to
as it enters the enclosing tube
 Oil tank provided with shut off valve,
sight feed regulator and lubrications lines

 Enclosing Tube Stabilizer

 Maintains rigidity and alignment of the
enclosing tube
 Enclosing Tube
 Provides protection from the pumped liquid
 Used with metal lineshaft bearings

 Discharge Case with Bypass Port

 Allows positive flow of the lubricant
into the enclosing tube to lubricate
lineshaft bearings

Optional Standard Features
Enclosed Lubrication
 Fresh Water Injection Lubrication

 Uses injection assembly with packing in lieu of tube tension assembly
 Flush Line to Suction Bearing (up to 20 feet)

 Provides fresh water flush to bowl bearings
 Rifle Drilled Pump Shaft

 Provides fresh water flush to bowl bearings

Question:
What if my application has limited
NPSH available?

Answer:
Consider a Double Casing VS6

Standard Features
Non-API VS6 Pump

VPC Standard Features
Non-API Can Pump
 Solid Shaft Motor with Thrust Bearing

 Shaft extension allows motor to be coupled to pump
 Includes thrust bearing to withstand the total
hydraulic thrust as well as the rotor weight
 Motor Alignment
 Precision rabbet fit aids in the alignment of the
motor to the pump shaft
 Pumps with larger motors are supplied with motor
alignment screws
 OSHA Non-Spark Coupling Guards
 Provides safety while allowing visual inspection of
the coupling without guard removal

Non-API Can Pump
 Fabricated Discharge Head

 Fabricated with ANSI 150# or 300# slip-on flanges
 Functions as a mounting base for driver
 0.50” NPT discharge pressure gauge, suction vent,
and drain taps
 Lifting Lugs
 Permits economical two point lifting method of
pump during installation and maintenance
 Rigid, Adjustable Flanged Coupling
 Provides the proper impeller clearance adjustment
 A spacer coupling allows access to the mechanical
seal without removing the motor
 High Pressure Seal Chamber
 Accommodates low, high and extra high packed
boxes or mechanical seal arrangements

Non-API Can Pump
 Fabricated Suction Can

 Creates optimum hydraulic conditions through the
suction flange inlet into the suction bell
 Threaded or Keyed Lineshaft Couplings
 Positively locks sections of lineshaft together
 Open Lineshaft Construction
 Allows lineshaft bearings to be lubricated by the
pumped fluid
 Flanged Column Assembly
 Utilizes precision rabbet fits to ensure proper
alignment of each section
 Provides transition from bowl assembly to discharge

Non-API Can Pump
 Bearing Retainers with Bearings

 Provides shaft support in column assembly
 Retainers are spaced between column sections
 Pumps with larger column sizes ( >16”) are supplied
with integral retainers
 Enclosed or Semi-Open Impellers
 Cast to provide smooth passageways for more
efficient fluid flow
 First stage impeller available with low NPSH design
 Colleted or Keyed Impellers
 Provides method of fasting impeller to shaft with an
interference fit or a positive locking design

Question:
What if my application has limited
NPSH available and compliance to
API specifications are required?

Answer:
Consider a Double
Casing API VS6 Pump

Standard Features
API VS6 Pump

API Can Pump
 Motor Alignment Screws

 Provided for use with motors over 500 pounds
 Aids in the alignment of the motor to the pump
shaft
 Solid Shaft Motor with Thrust Bearing
 Motor shaft runout of 0.001 inch total indicated
runout (TIR) contributes to the low vibration and
overall pump and motor rotor balance
 Precision, Rigid Adjustable Spacer
Coupling
 Provides easy rotor lift adjustments for renewing
critical impeller clearances and pump efficiency
 Allows seal removal without disturbing the motor

API Can Pump
 Cartridge Mechanical Seal with Plan 13

 Seal chamber is suitable for single or dual seals
 Plan 13 provides continuous seal chamber venting
 Seal Chamber with Jackscrews
 Used to separate mating parts easily during disassembly
 Weld Neck Flanges
 Used for suction and discharge connections
 Increase maximum allowable working pressure
 Provide higher nozzle loading capabilities then threaded
or slip-on welded flanges
 Flanged Vent Connection (Not Shown)
 Allows pump to be vented upon initial operation
 Can be pressurized to purge liquid from suction can
when a suction can drain is supplied

API Can Pump
 Lineshaft Bearing Spacing

 Optimized to ensure long bearing life, low
vibration and increased mechanical
seal life
 Separate Sole Plate (Optional)
 Allows removal of suction can without
disturbing the foundation
 Internal Suction Can Drain (Optional)
 Allows the suction can to be drained of
pumping liquid prior to removing the pump
 Studs & Nuts
 Prevent thread damage common with
capscrew removal

API Can Pump
 One Piece Shaft

 Eliminates threaded shaft couplings which cause
increased shaft runout, higher vibration and
weaker joints
 Available up to 6 m (20 ft)
 Open Lineshaft Construction
 Keyed Impellers
 Key and split-ring design positively locks the
impeller to the shaft, eliminating undesired
movement
 O-Ring Construction
 Provides a positive seal of all flanged joints
 Located at rabbet fits on bowl and column joints
 Also included at discharge head to suction can fit

API Can Pump
 Pressure Casing
 Consists of suction can and discharge head
 Designed to ASME standards
 Able to withstand API’s specified corrosion
allowances
 Dynamically Balanced Impellers
 Enclosed impellers balanced to ISO 1940-1
Gr G2.5
 Bowl & Impeller Wear Rings
 Provide a quick and easy way to renew
clearances and pump efficiency
 Roll pins positively lock the rings in place
 Impeller wear rings are integral as standard

Pump Intake
Design

Hydraulic Institute Standards
Section 9.8
• Provides guidelines for
• Sump design
• Model studies
• Remedial measures

Sump Design
• Recommended design

Intake Model Study
• Model study recommended for:
• Single pump with flow > 40,000 gpm
• Total station flow > 100,000 gpm

Acceptance Criteria
• No organized free surface and/or subsurface

vortices should enter the pump
• Pre-swirl limited to 5° from the axial direction
• Velocity fluctuations at the impeller less
than 10%
• Time averaged velocities within +/- 10% of
the mean velocity (Turbulence)
Model Pump

Baseline Test
Sidewall Vortex Surface Vortex
Floor Vortex

Remedial Measures
Modifications at entrance to pump bay Modifications in pump bay
Curtain Wall
Grating
Splitter
Baffles Fillet

Remedial Measures
Vane grating baskets

Final Testing
Flow along floor with modifications
Flow streamlines entering pump
Flow streamline along sidewall fillet

Suction Can Design
• Guidelines for:
• Can length
• Suction flange location
• Flow vanes
• Can diameter

Summary
• Potential problems identified and corrected using physical modeling
• The approach of using HI Standards with physical modeling provides the
best chance for success
• The approach minimizes performance problems, O&M costs, and outages

Pump Analysis
• RotoDynamic Analysis
 Includes:
 Torsional
 Lateral
• Structural Analysis
 Includes:
 Reed Critical Frequency (RCF)
– Above Ground • Thermal Analysis
– Below Ground
 Elongation and stresses
 Nozzle Load Calculations  Temperature gradient
 Foundation Load Calculations
 Seismic Calculations
 Anchor Bolt Calculations
 Lifting Lug Calculations

Pump Analysis
Reed Critical Frequency Analysis
 Why is it done?
 Determine the natural frequency of the combined motor & pump system
 Prevent excessive vibration

Pump Analysis
Design Standards
• When is it required?
 All VFD applications
 To meet Hydraulic Institute and API 610 vibration limits
 Motors > 260 kW (350 HP)
 Design speeds ≤ 900 rpm
 Design speed ≥ 3000 rpm AND > 7.5 m (25 ft)
 Customer request
• Inputs required  Required Modifications

 Motor Outline Drawing, Weight  Discharge head wall thickness
 Motor RCF (+/- 10%), CoG
 Ribs/gussets
 Foundation stiffness / spring rates
 Discharge head size  Customer foundation
 Discharge head type (TF, HF, etc)  Possible lockout speed range
 Pressure rating (wall thickness, etc)

Pump Analysis
Design Standards
• Operating Speed Range
 From a hydraulic standpoint, 30% of the operating speed can be
considered a reasonable operating speed range
 Greater than 30% should allow for lockout speeds
 The predicted lockout speed will be defined in a +/-20% range; however, the
actual lockout typically only requires a +/-5% speed range to be avoided.
 Need to avoid sub-synchronous whirl (below ground instability)
 Typically 30%-50% of maximum design speed
 Critical for pumps with hard bearings
 Need to avoid second critical frequency
 Issues typically occur on high speed pumps with TF style discharge heads
• Separation Margin
 Minimum of separation factor above and below the running speed range is
standard for the reed critical analysis
 +/- 20% separation for speeds 1200 rpm and greater
 +25% / -20% separation for speeds 900 rpm and less
 This is not a guaranteed factor or operating speed range

Pump Analysis
Flexible System (With Lockout Speeds)
Operating Speed Range
Predicted
RCF Range
Actual
Blockout
Range
Speed

Pump Analysis
Flexible System (No Lockout Speeds)
Predicted
RCF Range
Actual
Blockout
Range
Speed

Pump Analysis
Rigid System
Predicted
RCF Range
Actual
Blockout
Range
Speed

Pump Analysis
Design Factors
• System frequency varies by:
 Motor manufacturer
 Base Diameter
 Frame Size
 Weight
 Center of Gravity
 Reed Critical Frequency

Pump Analysis
Cases To Avoid
• Cast Heads have limited use for VFD applications.

 Cast heads always have a system natural frequency below the
operating speed (flexible system)
 Better for higher RPM applications (1800-3600rpm)
 Not much can be done to stiffen the system
• 100% of Operating Speed Range

 Must have system natural frequency higher than the operating speed
(rigid system)
 Requires proper selection of the motor to even be physically possible

Pump Analysis
Special Case
• A standard RCF analysis

is only on the above
ground portion
• Below ground analysis

performed only on special
case basis
 Ex. Can pump, 35’
long, small pump size

Pump Analysis
Nozzle Load Calculations
• Why is it done?
 Limit deflection at the stuffing box
 Reduce stresses in the discharge head

Pump Analysis
Nozzle Load Calculations
• Inputs Required:
 Pump loading
 Foundation design NOTES:
 Motor weight  More difficult to obtain higher loads on
 Customer imposed loads  TF style heads vs HF heads.
 Discharges heads with 3-piece elbow
• When is it required? design.
 If the imposed reaction forces or  Pumps in a flexible system
moments exceed the allowable load
 When nozzle position differs from
standard (PRM)
• Required Modifications:
 Add ribs to the discharge head
 Thicken the discharge head riser

Pump Analysis
Foundation Load Calculations
 Why is it done?
 Determines load imparted on
foundation.
 Allows proper sizing of anchor bolts,
foundation, etc.

Pump Analysis
Foundation Load Calculations
• Inputs required
 Pump and motor weight
 Nozzle loads
 Pumpage weight
• Optional inputs
 Start-up and locked rotor torque
 Unrestrained piping
 Motor imbalance
 Other
• Required modifications
 N/A – For reference only

Pump Analysis
Seismic Calculations
• Why is it done?
 System anchorage is designed to
withstand a seismic event
• Inputs required
 Foundation loading (optional)
 Specific design code (IBC is
standard)
 Site seismic data
• Required Modifications
 Anchor bolt size or quantity
 Foundation (size, embedment,
strength)
Example per IBC
 Customer request Analyzed in X, Y, & Z directions

Pump Analysis
Anchor Bolt
• Why is it done?
 System anchorage is designed to
withstand operating loads
• Inputs required
 Pump and motor weight
 Nozzle loads
 Pumpage weight
 Anchor bolt size or quantity
 Foundation (size, embedment,
strength)
 When anchor bolts are supplied by Example per ACI
Flowserve (American Concrete Institute)

Pump Analysis
Lifting Lug
• Why is it done?
 To ensure the pump can be safely lifted using
the provisions provided
• Inputs required
 Pump weight
 Discharge head style
 Pump components (column size, etc)
 Intended installation method (fully assembled,
components, etc)
 Lug redesign
 Discharge head wall thickness
 If Flowserve standards are exceeded
 Weight and diameter dependent

Pump Analysis
Torsional Analysis
• Why is it done? • Required Modifications

 Reduce induced torques and stresses  Shaft material change
 Prevent fatigue  Increase shaft size
• Inputs required  Modify speed range
 Motor inertia & stiffness • When is it required?
 When required by API 610

Pump Analysis
Lateral Analysis (Critical Speed)
• Why is it done? • Required Modifications

 Prevent displacement  Modify speed range
 Minimize vibration  Change bearing material or
• Inputs required spacing
– Only pump data • When is it required?
 Flowserve standard
 Optional analysis method
using FEA per customer
request.

Pump Analysis
Reed Critical Frequency vs Critical Speed
Reed Critical Frequency Analysis Critical Speed Analysis

• Structural Analysis • Rotodynamic Analysis
 Determines system frequency  Determines bearing spacing
based on combination of pump,  Inputs from pump only
motor and foundation data.  No impact from motor or
 Both above and below ground foundation
frequencies exist

Pump Analysis
Thermal Analysis
• Why is it done?
 Predict temperature gradient
 Determine pump growth rates and
total elongation
• Inputs required
– Ambient conditions
– Vendor temperature limits (motor,
coupling, etc)
– Cooling provisions
– Operational conditions (temperature
cycles)
– Custom design per application
– Applications > 260 C (500 F)
– Customer request


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Type VS1 and VS6 Vertical Turbine Pumps

Wet Pit and Double Casing

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Open – Product Enclosed – Oil

Calgary Pump Symposium 2013

Cast Discharge Head Fabricated Discharge Head

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

 Maintains efficiency by close running

 Provides an increase in efficiency over

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

 Provides interference fit between bowl

 Positively locked to shaft

Calgary Pump Symposium 2013

 Available on enclosed impellers

 Installed with interference fit

 Roll pins positively lock the rings

Calgary Pump Symposium 2013

 Provides a positive seal of all

 Located at rabbet fits on bowl

 Also included at discharge head

Calgary Pump Symposium 2013

 Various Mechanical Seals

 Stuffing Box (Packed Box)

Calgary Pump Symposium 2013

 Motors, Solid or Hollow Shaft

 Engines with Right Angle Gear

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

• Basket Strainer (Optional)

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

• Open Lineshaft Construction

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

 Tension Bearing Assembly with Oil

Calgary Pump Symposium 2013

 Enclosing Tube Stabilizer

Calgary Pump Symposium 2013

 Discharge Case with Bypass Port

Calgary Pump Symposium 2013

 Fresh Water Injection Lubrication

 Flush Line to Suction Bearing (up to 20 feet)

 Rifle Drilled Pump Shaft

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

Calgary Pump Symposium 2013

 Solid Shaft Motor with Thrust Bearing

Calgary Pump Symposium 2013

 Fabricated Discharge Head

Calgary Pump Symposium 2013

 Fabricated Suction Can

Calgary Pump Symposium 2013