In Simcenter STAR-CCM+, solvers compute the solution during the simulation run.

Each
solver performs a specific task. Some solvers assemble the system of equations that
describe the phenomenon of interest; some solvers simply provide source terms to other
solvers.

The solvers used in this study are:

 Stead
The result of the steady simulation provides a starting point for the next phase: an
unsteady simulation from which can compute the mean flow pressure of the fully
developed flow. To ensure good noise source predictions, the physics continuum
requires an incompressible flow and a high-resolution turbulence model.
 Partitioning
The partitioning solver is responsible for controlling domain decomposition (or
partitioning) for parallel simulations. Before any physics solvers are invoked on a
given global iteration or time-step, the partitioning solver is first invoked to
ensure that the domain decomposition is up-to-date.
 Wall distance
Wall distance is a parameter that represents the distance from a cell centroid to the
nearest wall face with a non-slip boundary condition.
 Segregated flow
The Segregated Flow solver controls the solution update for the Segregated Flow
model according to the SIMPLE algorithm.
 K-Epsilon turbulence
The K-Epsilon turbulence model is a two-equation model that solves transport
equations for the turbulent kinetic energy k and the turbulent dissipation rate ε in
order to determine the turbulent eddy viscosity.
For intensity and viscosity ratio:
Calculation of k and ε from specified turbulence intensity I and viscosity ratio
3 2
μt /μ using ( IV )2 and ρC μ K
2 ¿¿¿
 K-Epsilon turbulent viscosity
The turbulent viscosity ratio is typically set in the range 10< μt /μ <100

Harmonic Response

In a structural system, any sustained cyclic load produces a sustained cyclic (harmonic)
response. Harmonic analysis results are used to determine the steady-state response of a
linear structure to loads that vary sinusoidally (harmonically) with time, therefore
enabling to verify whether or not the designs will successfully overcome resonance,
fatigue, and other harmful effects of forced vibrations. This analysis technique calculates
only the steady-state, forced vibrations of a structure, typically at a number of discrete
points within a range of frequencies. The transient vibrations, which occur at the
beginning of the excitation, are not accounted for in a harmonic response analysis.

Harmonic Response Analysis

Harmonic analyses are used to determine the steady-state response of a linear structure to
loads that vary sinusoidally (harmonically) with time, thus enabling to verify whether or
not the designs will successfully overcome resonance, fatigue, and other harmful effects
of forced vibrations.

In a structural system, any sustained cyclic load will produce a sustained cyclic or
harmonic response. Harmonic analysis results are used to determine the steady-state
response of a linear structure to loads that vary sinusoidally (harmonically) with time,
thus enabling to verify whether or not the designs will successfully overcome resonance,
fatigue, and other harmful effects of forced vibrations.

This analysis technique calculates only the steady-state, forced vibrations of a structure.
The transient vibrations, which occur at the beginning of the excitation, are not accounted
for in a harmonic analysis.

In this analysis all loads as well as the structure’s response vary sinusoidally at the same
frequency. A typical harmonic analysis will calculate the response of the structure to
cyclic loads over a frequency range (a sine sweep) and obtain a graph of some response
quantity (usually displacements) versus frequency. “Peak” responses are then identified
from graphs of response vs. frequency and stresses are then reviewed at those peak
frequencies.

From the report generated from star ccm+ for mesh diagnostics, the mesh is valid with no
negative volume cells, all cells faces are valid and min volume change is 1.000000e-03 which is
good to achieve reliable results.
 EXPERIMENTAL SETUP

After completing the work on theoretical calculations in the previous chapter, it was
necessary to apply the practical application of this experiment, and it was possible to
Procedure that experiment after providing the appropriate environment for work and
providing the measuring devices and components necessary to give the most accurate
results that prove the effectiveness of the experiment.

3.1. Experimental setup

This chapter shows the effect of change any input at vibration behavior. Experiments
were done on a system shown in (Fig.3.1) composed of centrifugal pump (QB-60). The
centrifugal pump vibration is detected by 3D accelerometer sensors kit, the TE
Connectivity Model 4030[12]. The kit is fixed on shaft case with position and directions of
measuring shown in (Fig.3.2). The accelerometer kit is connected to National Instrument
data acquisition [13] (NI USB-6001) (Fig.3.3). The centrifugal pump has single stage with
maximum flow rate 25 liter/min., maximum head 25 meter and rotating speed 2850 rpm.
Electric motor (0.5 HP, 220V 50 Hz) is used to drive the pump to study the effect of the
defects and the flow rate. The working fluid is water, firstly; stored in the tank shown in
(Fig.1). The system has two gate valves one at tank exit and the other at the pump outlet.
The system is considered a closed system. The system is designed with a moving frame
to be easily transport. LabVIEW is used in signal conditioning. The LabVIEW block
diagram for this experiment is shown in (Fig.3.4). Vibration measurements were
made for the cases shown in (table3.1).

As shown in (Fig.5.29) and from (Table 5.5) the highest amplitude take place at
frequency (34.2 and 61.616) that mean at full load of the pump the highest amplitude fall
at 1X.

The equation used to determine the moment at each flow rate:

flow rate × pressure ×36.77

Torque=
RPM

Where: pressure =14.8 N /m2

From (Fig 5.31) and (Table 5.6) the highest amplitude at frequency (34.2Hz) because
suction and discharge recirculation, which happens when the fluid does not flow through
the pump properly

The highest amplitude takes place at frequency (34.2 Hz) due to the unbalance that
happened because rotor instability at low flow operation, see (Fig 5.33) and (Table 5.7).

As mentioned earlier; at a very low flow rate, the power input is converted to thermal
energy, causing a rapid temperature rise and the liquid will vaporize and cause thermal
expansion of the pump internal parts like that shown in (Fig.5.35) and (Table 5.8). The
highest amplitude takes place at frequency (34.2 Hz).

When the pump runs dry without water, the pump will be overheated and damage the
bearings, shaft and impeller. As shown in (Fig 5.37) and (Table 5.9) the amplitude
increased from frequency (34.2 Hz) till the damage takes place at any time.

As mentioned before; the vibration caused by unbalance may destroy critical parts of the
machine, such as bearings, seals, gears and couplings. From (Fig 5.39) and (Table 5.10)
the highest amplitude is at frequency (200 Hz).

As predicted above in experimental results that the highest amplitude will take place at
frequency (350 Hz) due to damaged 7 teeth, the numerical result confirmed that the
highest amplitude take place at the same frequency.

5.1. Results of measurements

For each case the spectral domain, time domain and waveform are studied in vertical,
axial and radial (x, y and z) directions respectively. The spectral domain is the most
significant indicator that indicates at which frequency the highest amplitude will take
place. Time domain can be also investigated for every critical case to show the time
corresponding to the highly vibration frequency. From the time domain and spectral
domain the high amplitude can be determined at certain frequency and time. Since the
time is independently available parameter so at any time the amplitude can be estimated,
whenever, the critical time, corresponding to highly amplitude, can be avoided. The most
efficacious and important results will be displayed and taken care of. By examination, the
rotating speed of the pump should be less than 2850 rpm so that the most vital frequency
to take care of should be less than (47.5Hz) and the results that showed below will be
selected based on the most dangerous and influential cases.
5.1.1. Balance mode without flow in x-direction
The system will run in balance mode without any additional flow or faults. When the
pump runs dry without water, air is the working fluid which does not act as a coolant.
So the pump will be overheated and damage the bearings, shaft and impeller. It is
shown in (Fig.5.11) that there are small peaks at (47Hz and 100Hz) but the highest
amplitude is (0.054g) at frequency (200Hz) because the pump started to collapse.
 5.1.1. Balance mode with flow rate of 8 L/min. in z-direction
When the pump runs at a very low flow rate, the power input is converted to thermal
energy, causing a rapid temperature rise and the liquid will vaporize and cause thermal
expansion of the pump internal parts like that shown in (Fig.5.12). There are small
peaks at (100Hz and 200Hz) but the highest amplitude is (0.049g) at frequency (47Hz)
due to the unbalance happened at 1X frequency.

5.1.1. Balance mode with flow rate of 12.5 L/min. in z-direction

Rotor instability that occurs at low flow operation can lead to shaft failures, premature
packing wear and mechanical seal failures. There are small peaks at (100Hz and
200Hz) but the highest amplitude is (0.056g) at frequency (47Hz) due to the unbalance
happened at 1X frequency see (Fig.5.13)

5.1.1. Balance mode with flow rate of 16 L/min. in z-direction

The subsynchronous vibration also takes the same shape that appears at 8 liter/min.
and 12.5 L/min. spectral domain graphs. The highest amplitude is (0.056g) at
frequency (47Hz) as shown in (Fig.5.14) because suction and discharge recirculation,
which happens when the fluid does not flow through the pump properly. This can lead
to catastrophic failure of the pump when portions of the impeller inlet or discharge
vanes fatigue and fail by breaking off.

5.1.1. Balance mode with flow rate of 25 L/min. in z-direction

The system will run at full load (full flow) 25 L/min. The smallest peak appeared at
frequency (100Hz) and the highest amplitude is (0.067g) at frequency (47Hz) like that
as shown in (Fig.5.15).

5.1.1. Unbalance mode with flow rate of 25 L/min. in x-direction

Unbalance is the most common cause of machine vibration, an unbalanced rotor
always causes more vibration and generates excessive force in the bearing area and
reduces the life of the machine. Most of the rotating machinery problem can be solved
by using the rotor balancing and misalignment adjustment. The vibration caused by
unbalance may destroy critical parts of the machine, such as bearings, seals, gears and
couplings. There are many sources of unbalance. In the current study, unbalance is
simulated by making a defect in the cooling fan showed in (Fig.5.16). As shown in
(Fig.5.17) there are some peaks take place at (47Hz and 100 Hz), also the
subsynchronous vibration takes place which means that the system experiences
unbalance. The highest amplitude is (0.048g) at frequency (200Hz) because of the
unbalance external force, fan defect.

5.1.1. Pedestal looseness mode without flow in y-direction

In a rotor bearing system, the loosened bolt of the pedestal will reduce pedestal
stiffness and mechanical damping. This will lead to violent vibration of the whole
system. When the looseness fault is serious, it may cause other faults such as rub
impact fault of the rotor-stator. This may even lead to disastrous accidents. Therefore,
the research on pedestal looseness is significant in engineering practice for the safe
 operation of rotating machinery. It affects service life and work efficiency. It is shown
in (Fig.5.18) that some peaks appeared at (100, 150 and 200) Hz. The highest
amplitude took place (0.076g) at frequency (47Hz) due to dry run which causes
overheating and damages the bearings, shaft and impeller in axial and radial
directions.

5.1.1. Pedestal looseness mode without flow in z-direction

It is shown in (Fig.5.19) that a small peak appeared at frequency (100Hz) and the
highest amplitude took place at (0.077g) at frequency (47Hz).

5.1.1. Pedestal looseness mode with flow rate of 25 L/min. in z-direction

The system will run with full flow, this is the most dangerous case in the current
study. There are some peaks appeared at (100Hz and 200Hz) and the highest
amplitude is (0.104g) at frequency (47Hz) as shown in (Fig.5.20). This is because the
system runs with full load and all forces affect the pump without any fixation. This
results in system instability. The highest amplitude will be at 1X.

5.1.2. Pedestal looseness and unbalance mode with flow rate 25 L/min. in x-
direction
This case combines between unbalance and pedestal looseness as shown in (Fig.5.21).
There are a lot of peaks appear at spectral domain graph. The highest amplitude is
(0.06g) at frequency (50Hz) because all the system move due to the pedestal
looseness. The pump vibrates due to fan defect so the frequency for highest amplitude
is 1X.

5.1.3. Fault impeller mode with flow 25 L/min. in x-direction

Finally the impeller is malfunctioned by breaking 7 blades as shown in (Fig.5.22) and
the system runs with full load.

From (Fig.5.23) and (Fig.5.24), it is shown that the system has subharmonic response
and the amplitude massively increased to high values.
The frequency that has major amplitude could be determined by blade pass frequency
equation. The result compared with the frequency marked at (Fig.5.23).

5.2. Result of experimental study

All data can be collected from spectral domain by taking the amplitude at the referred
frequencies in each direction separately.
It’s possible to extract three circumstances from (Fig.5.38), (Fig.5.39) and (Fig.5.40).
Firstly, studying each case separately to illustrate where the maximum amplitude takes
place and at which frequency. Secondly, analyzing each frequency independently to
illustrate where the maximum amplitude takes place and at which case. Finally,
investigate the most dangerous case in absolute at each direction.
 At x-direction:
As shown in (Table.5.2) the highest amplitude colored in yellow and the most dangerous
case in vertical direction which colored in red is unbalance and pedestal looseness with
full flow case at frequency (50Hz) with amplitude (0.06g) because all the system move
due to the pedestal looseness. The pump vibrates due to fan defect so the frequency for
highest amplitude is 1X.

At y-direction:
All cases have highest amplitude at frequency (50Hz) compared with remnant
frequencies excepting unbalance and pedestal looseness with full flow case at frequency
(150Hz) has the same amplitude (0.018g) at frequency (50Hz). It’s obvious from
(Table.5.3) that the most dangerous case in axial direction which colored in red is
pedestal looseness without flow case at frequency (50Hz) with amplitude (0.076g). When
the system run in pedestal looseness case the pedestal stiffness and mechanical damping
reduced and when run without flow the bearings, shaft and impeller damages due to
overheating and. However, when the system runs with flow, the flow creates a balance
force at axial direction that makes the system more stable.

At z-direction:
All cases have highest amplitude at frequency (50Hz) compared with 100Hz, 150Hz and
200Hz frequencies. As shown in (Table.5.4) the maximum amplitude at each frequency
colored in yellow and the most dangerous case in radial direction which colored in red is
pedestal looseness with full flow case at frequency (50Hz) with amplitude (0.104g)
because the system runs with full load and all forces affect the pump without any
fixation. This results in system instability. The highest amplitude will be at 1X.

5.4. Comparison between experimental and numerical results

5.4.1. Balance mode at flow 25 L/min
At (Fig 5.42) it’s shown that all amplitudes take the same shape at referred frequencies
and the highest amplitude at experimental and numerical work is at 1X but the amplitude
of experimental study is more skewed due to the pump at full load suddenly shocked, the
amplitudes below 1X called slow roll vector which does not take a specific form.

5.4.2. Balance mode at flow 16 L/min

All amplitudes take the same shape at referred frequencies and the highest amplitude at
experimental and numerical work is at 1X, see (Fig 5.43).
 5.4.3. Balance mode at flow 12.5 L/min
It’s shown at (Fig 5.44) that all amplitudes take the same shape at referred frequencies
and the highest amplitude at experimental and numerical work is at 1X.

5.4.4. Balance mode at flow 8 L/min

At (Fig 5.45) all amplitudes take the same shape at referred frequencies and the highest
amplitude at experimental and numerical work is at 1X.

5.4.5. Balance mode at flow zero L/min

Its shown at (Fig.5.46) that in experimental an numerical investigation the highest
amplitude take place at frequency (50Hz) and descend at (100Hz and 150Hz) and return
to increase at frequency (200 Hz) but at amplitude less than 1X.

5.4.6. Unbalance mode at flow 25 L/min

As mentioned above, in unbalance mode the highest amplitude takes place at frequency
(200Hz) but at numerical study the unbalance was symmetric but at experimental
investigation the unbalance due defected fan it is not expected what damage will happen
so the peaks at frequencies below (200Hz) will take a various and growing form.

5.4.7. Fault impeller mode with flow 25 L/min

From blade pass frequency equation it’s still expected that the highest amplitude will take
place at frequency (200Hz), the change of values at residual frequencies due to the shape
of fault at the impeller is unlike from numerical and experimental investigation.

CONCLUSION AND FUTURE WORK

This thesis presents ten cases of pump operation modes. Some defects were made to
visualize the change of vibration response. The vibration analysis reveals that the
unbalance and pedestal looseness is the most dangerous case in x-direction at frequency
(50Hz) with amplitude (0.06g). The most dangerous case in y-direction is pedestal
looseness without flow case at frequency (50Hz) with amplitude (0.076g). The most
dangerous case in z-direction is pedestal looseness with full flow at frequency (50Hz)
with amplitude (0.104g). When the impeller was broken, the frequency at which
maximum amplitude occurs can be expected from the number of defected blades. The
analytical result was validated experimentally.
The thesis lists the experimental investigation by triaxial sensor and NI data acquisition,
then the system runes at starccm+ and ansys, finally; the results clarified and compared to
illustrate how similar between the two investigation.

Vibration monitoring can be used to early detect faults during pumps operation and,
hence, save time, cost and extend the service life of the pumps.