VIBRATION MONITORING OF VERTICALLY MOUNTED PUMPS— TOOLS FOR MANUFACTURERS AND USERS by ‘Thomas J. Walter Manager, Mechanical Engineering ‘Matthew M. Marchione Project Engineer Mechanical Technology; Incorporated Shaker Research Divi Latham, New York and Gordon Shugars Project Manager Electric Power Research Institute Palo Alto, California ‘Thomas J. Walter is Manager of Mechan ical Engineering for the Shaker Research Division of Mechanical Technology, Incor- porated (MTD. He joined MTP in 1977 ‘and coordinates and maintains marketing, financial, and technical sponsibility for ‘efforts inclving fied troubleshooting and periodic vibration monitoring of machinery ‘gslems, including onsite acquisition, analy Ss, and diagnosis of data to determine ma chinery problems, {In previous positions at MT1, Mr: Waller was Manager of various ‘engineering sections here efforts ined development and appli- Cation of high speed balancing techniques, including automatic removal of material using pulied lasers. As Proect Engineer, he ‘maintained project responsibility for contracts involving vibration ‘and balancing. Prior to joining MTF, he sas a test engineer at Newport News Shipbuilding, where he was involved in nove and vibration reduction efforts velating to US. Navy submarines and surface ships. ‘Mr. Waller received his B.S. degree in Mechanical Engineering from the University of Dayton in 1971 and an MBA. from the College of William and Mary in 1976. He has authored many technical reports and has published several papers for seminars and. workshops. Maithew M. Maychione is a Projet En. agineer with the Shaker Research Dinision of Mechanical Technology, Incorporated (MT0). He is ingotved wih vibration based ‘analss and field troubleshooting of rola ing machinery problems. He also develops computer based rotordynamie models to as- Sis 0 identifying root causes of such prob- lems. His areas of involvement have in- cluded technical and financial management of several projets involving monitoring and diagnosis of vertically mounted pumps Prior (0 joining MTU in 1985, Mr. Marchione was a Field Engineer with Vibration Specialty Corporation, where he performed. % vibration based diagnosis and troubleshooting of machinery. He also performed predictive maintenance surveys for a wide variety of tlietsthyoughont the country ‘Mr. Marchione obtained his B.S. degree in General Science form ‘illancoa University in 1980, He has attended many machinery oriented seminars and has lectured om several topics. H. Gordon Shugarsisa Project Manager in the Plan Availity Progam, Nuclear Poser Division, a the Elecrc Power Re Seaveh Insite (EPRI), in Palo A, Catfrnia.He joined he ltt n 1972 ‘Ms Sugars responsible for projets dea. ng wi equipment monoring nd dag sates ond poser plant insttomendation td conta efor joing the nti, Mr: Sugars sped thee year ih the Bachil Poser Corporation. He was & Planning and Scheduling Engineer for ower plnt design in Son Franca: eotracion i Beri Pennslania; and ting in Cobyp, Montana. From 1969 to 1973, Mr Shugars wat a Projet Manager Nucear Engineer sth HeUS. Nar S. Atomic Energy Conaiicion. He was responsible for the design, caniration, teing, maintenance and operating ‘ricedues fr mice pore sibarines and surface Ships Mr Shigars recived his BS. dere in Elected! Engineering fom the University of Hints, Urbana-Chanpaign in 196%. He esa Baching Asstt in the Department of Electrical Enginer- ing athe Unters of Tinos ote aching hs MS. degree in letra Engineering in 1974. Mr Shugars he thor of many publications dealing sath poner plant sntramentation, and has freinied and published seeral popers for EPRI seminars and Soros. He's a negidered electra! engineerin the Sate of California.76 PROCEEDINGS OF THE FOURTH INTERNATIONAL PUMP SYMPOSIUM ABSTRACT. Recent efforts to develop and implement techniques to ‘monitor and diagnose problems in submerged vertical shaft pumps are summarized. Projects based on iterative analy ‘al and experimental efforts were implemented on several different types of vertical pumps typically found in power ants MAlthough modelling aspects are briefly described, the major focus is on the restlts of the experimental aspects, including the “lessons learned” in instrumenting and monitoring six vertically mounted pumps in operational power plants. INTRODUCTION For many years, uiliies and other industries have snonitored vibration to detect failures and to plan mainte: tance for horizontal achinery, Inmany instanees, however, this technique has not been succesfully applied to vertical pumps for several reasons, including lack of experience in Ineasuring vibration of submerged portions of the pumps hind lack of understanding of how sh factors unbaanee fand shatt alignment affect machinery health. In addition, imathematically modelling vertical pumps often involves {sumptions that differ from those involved in modeling horizontal pumps thus making it ifieult to predict wea oF damage from typical sibration meastrements. As‘ reslt, lures often oveur without warn ‘Atempis to more thoroughly measure vibration on the submerged portion of vertical pumps have often rested lata that cannot be readily interpreted When compared to horizontally mounted pumps, vertical pumps can exhibit high vibration levels and yet contin to Sperate satisfactorily. The pumpsotten operate wit signs ot Aistable operation large misiligoments nd other chara teristics et would dicate immediate shutdown in mo thachinery. Many of these phenomena go sndetected at ‘raditional vibration sensor lations (ege on drive motor Housings). Experiments have ko shown that significant thanges to the mechanical properties of the pump (e.g lange changesin (unbalance) donot avaysresultin expected Changes in bration level, Experimental data, have also Shown that some changes in the wbration level may be associated with the pump hydraulic load {1} “Toaldress these problems, projects have been undertak en to develop analytical techniques to interpret vibration Ieasurements, verify these techatiguesby in-plant test, and develop recommendations for application of submergible vibration sensors “The projects combined both analytical and experimental efforts Following an nial survey of available iterature and inquires with puinp manufactarers and users regerding modeling and vibration analysis of vertical pumps, three {ypesof vertical pumps were selected for stacy ata grsctred power plant on the Pacific Coast in northern Cahiforna Eibsequenty additional circulating pumps have Been st ied atan oibfired plant on the Headson River near Pough- teepaic, New York DISCUSSION Project Methodology Each of the selected pumps was studied under analytical and experimental efforts through iterative and interactive processes. In general, an intial mathematical moclel of the pump was made, and a computer program was used to predict natural frequencies and mode shapes. Thisinforma- tion was used to selec the types and lotions of tensors. Each’ pump wis hen opened and inspected, and’ precise mmeaaurementsof fis and dlearances were made and ted to Update the model. Following reinstallation, vibration and performance parameters from the instrumented pimp Mere continuously monkored. Resulting information was tsed to tine the model to reflect actual operation. ‘The tmodel was then used to predict the effect oft given change ine pump. All pumps were to be removed from service, inspected, and alodified ie, changes made in unbalance, malign: ment, hydraulic loading). ‘The pumps were then to be feinwalled and run for several additional months andthe esting test data used io une and simply the mel Test data were used to refine the sensor types and. locations needed to adequately monitor pump vibration The inital intent was to implement on subsequent pump types those modelling and sensor techniquet that were Successful onthe fist pump. Availability ofthese pumpunits for sty was limited however, because all pups are in inthe planned schedule were necessary namely the need to instrument and monitor several pumps, simultaneously rather than ‘sequentially. Plant power requirements ad tverhaul schedles also limited the number af pup remov- Ste secomplihed Analytical Efforts A basicobjective was to evaluate the ability of rotordynam- ic analysis to predict the vibration performance of vertically mounted submerged shaft pumps. However, the overall goal was not 10 prodiice a complex moclel that duplicates the actual performance of the pump being analyzed), but rather to develop a modelling technique that ineludes only those clements pertinent to predicting the general vibration per formance. Although the techniques may not be sufficient 10 accurately simulate precise operation of the units, a primary “objective was to develop guidelines, so an interested vertical pump manufacturer or user will beable o adequately model vertically mounted pump to reliably predict its operational ‘bration characteristics, ‘perimental Efforts ‘The analytical model initially provided important direc- mn for determining optimum sensor locations on the pump. However, experimentally acquired data were re- quited co both verify and, when necessary, tune the model The tuned model, in turn, provided further direction t0 ‘modify the experimental seuup, An important objective was to develop recommendations for proper application of submergible vibration sensors, ‘The work was not intended to develop new types of sensors but to evaluate the ability of existing sensor types to measure vibration reliably while they were submerged The experimental efforts were directed toward establish ing guidelines forthe selection and use of sensors to monitor vertical pump vibration. Sensor survivability, practicality, and ease of use were parameters considered for instrumen- tation selection, Pumps Studied The following pumps were studied: + Heater Drip Pump (7 stages, 13-fe long shaft, 40 hp, 8600 ‘cpm, 210 gpm, 500-f total head), This pump normally runs ‘continuously with load varying as a function of plant load‘VIBRATION MONITORING OF VERTICALLY MOUNTED PUMPS—TOOLS FOR MANUFACTURERS AND USERS 77 + Condensate Pumps (2) ( stages, 15-4 long sha, 150 hp, 1770 cpm, 760 gpm, 520-0 total head). These purnps normally cycle on'a weekly basis with load varying asa function of plant lad. The pumps ae identical excep one Contains an inner shaft spider” bearing near misao the pump sha; the second pump has no such bearing + Main Circulator Pumps 2) (1 stage, 194{long shaft, 125 tp, 880 cpm, 12.900 gpro- S0-f tua head). These units pimp seawater and normaly operate continuously at ely onstant load. Tidal scion is nominally 5 fc * Rw Water Pump (1 stage, 41-f¢long shaft, 2250 hp, 240 pi, 160,000 gpm, 30 total head). This unix pumps tidal influenced freshwater and nominally operates continuously 4 uniform loa. Tidal action is nominally = 3 fe These pumps ae all located at operational power plans ‘This aspect was important, because many’of the problems usually associated with laboratory tests the difficlty in $pplying suck results to actual in-plant pumps were avoided through onsite testing Results of Research Efforts Recent work [2] has resulted in a number of “lessons earned that may be applicable in future efforts to monitor aand diagnose problems in submerged vertical pumps. The following isa summary of some ofthe findingson the pumps studi Modelling Computer simulation of a pump’ rotordynamic charac teristics has provided valuable insight into understanding the vibration performance of vertically mounted pumps. Modelling is especially useful in: + Determining initial sensor types and locations. + Identifying the source of unknown frequencies in the pump’ vibration signature. + Assessing “what if" scenarios to help determine “sensi- tive" modes and in correcting pump vibration problems Modelling guidelines [2] have been developed to assist the interested user, manufacturer, oF diagnostician assess vert- cally mounted pumps. Together with an existing computer program,* these guidelines** have been effective in pre- dieting the behavior of the pumps studied. The models do not have to be overly complex to achieve results with sufficient accuracy to determine natural frequencies, mode shapes, and approximate damped response of the pump. ‘The work accomplished has demonstrated that only a reasonable amount of care is needed to develop a pump ‘model that realistically simulates the vibration modes that are of primary interest (0 users and manufacturers of variety of submerged shaft vertical pumps * The Finite Element Analysis Tol for Utility Rotordy ‘namic Evaluation (FEATURE) computer program [3] performs linear critical speed, damped response, and Stability calculations fora wide range of rotor geometries, including multiple, concentric, counter rotating spools and large, mullspan, rigidly coupled rotors. A faite «lement formulation gives the program numerical stabil ty. Acompanion program [4] provides fui film bearing properties. Zote, etal, (5] further describe the FEA FURE program. "= These. guidelines incorporate applicable concepts from seal and Mid film bearing theory as part of the techniques for medeling submerged shat vertical pumps [6.7.8.9] Iisimportant to note that pumps with shafts exceeding 40 feet and those with many intermediate bearings have not teen studied at this ime. Therefore, the capability ofthe computer program and the modelling guidelines to accu Tate sate response of this type of pump has not been ested Monitoring without Modelling Even though computer modeling can provide valuable asssacein determining the probable source of many types af vibration in verical pumps itisnotan essental ingredient ff monitoring project. AKhough ones prognostic ability mnay be limited, many vertical pumps can be effectively monitored for trends and changes in bration without the Hsitance of computer model, The remainder of the discussion wil focus on recom experience in inatrumentin Sid monitoring several types of vertically mounted pumps, Allof the pumps studied were modelled partofthe overall ‘ffort. Some of the findings are based an the modelling Sccomplshed; others are independent ofthat work. Impact Ts Impacting structures and measuring their response con- stitutes a good method of identifying the sources of some of | the frequencies that may be observed in the vibration spectrum of the operating pump. The opportunity to ac- quire such data on intermediate tubes, bearing support structures, assembled pump casings, ete, should not be missed. However, “hang and bang” responses of a pumps rotating elements should not be expected to coincide with those observed in the running pump. The frequencies measured on the rotating elements of a multistage pump during impact tests and during operation are shown in Figure 1. The differences are mainly due to the stiffening ceffectof the bearings and wear rings (water lubricated) in the pump, V a ' Figure 1. Comparsion of Natural Frequencies and Mode Shapes for Impact and Dustalled Configuration of a Nertical Pump.