Frequency Detuning in Vertical Pumps

by Carlos Moreno, Flowserve

04/24/2012

Detuning devices solve high vibration problems in power station water

circulating pumps.
Mechanical resonance—the buildup of a large vibration amplitude when something is excited
at its natural frequency—comes in many forms. In its most desirable state, it occurs in music.
Instruments and acoustics are nely tuned to produce dramatic and beautiful resonant e ects.
In its most undesirable state, mechanical resonance has extremely dramatic e ects.They can
cause bridges, structures and machinery to break or malfunction, resulting in dangerous and
expensive failures.

Engineers work diligently to ne-tune mechanical structures and machinery to reduce or

eliminate the e ects of mechanical resonance before construction or installation. Engineers
must account for the following factors when designing pumping systems to avoid mechanical
resonance:

Operating speed
Foundation sti ness characteristics
Drive reed critical frequency
Bearing span
Bearing damping coe cients
Bearing sti ness coe cients
Drive mass and distribution
Pump mass and distribution 
Pump uid
Geometry of the rotor and structural components

When assumptions are wrong or the actual installation does not mirror the engineering
models, the potential for mechanical resonance could exist if the system’s actual natural
frequency is too close to the operating speed. Issues do arise, often from unexpected
foundation conditions or inaccurate drive reed critical frequency data. 
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Natural Frequency in Pumps

A mechanical system’s natural frequency is a function of its weight and sti ness, most
commonly expressed as:

ωn = √(k/m)

Where: 

ωn = natural frequency

k = sti ness

m = mass

For horizontal pumping systems, the solution to resonance issues has generally involved
simple modi cations that increase system weight, reducing natural frequency as a result and
creating an adequate margin from the operating speed.

Resonance issues can be much more di cult to address with large vertical circulating water
pumps. Typically found in power generation, steel manufacturing, water intake and ood
control applications, these massive, expensive pump installations can be di cult and costly to
modify once installed. Because of these di culties, engineers are forced to employ more
sophisticated techniques that alter system sti ness as a means of changing natural frequency
once pumps are installed. 

Often, this can be accomplished by adding frequency detuning devices to the pump system
structure. In principle, the addition of these devices reduces system sti ness, lowering its
natural frequency away from potential points of excitation. While this practice has been around
for decades, advances in testing and modeling techniques have made design and application
of detuning devices extremely reliable, avoiding the unnecessary and costly trial and error
previously associated with this technique. 

Frequency Detuners for Vertical Pumps

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Axial and mixed- ow vertical circulating water pumps (see Figure 1) are wet-pit installations
with these main components:

Suction bell
Rotor assembly (impeller, shaft, bearings, couplings and drive rotor)
Column
Discharge head
Drive (not shown)

In this type installation, one of the easiest and most inexpensive places to a ect a change in
natural frequency is at the interface between the discharge head and the driver. A detuning
device for this type pump system consists of two carbon steel plates (sometimes called spring
plates) mounted between the driver ange and the pump driver support ange of the
discharge head. A gap between the cantilevered portions of these plates adds exibility to the
system—like a pair of springs acting in series—reducing system sti ness. To illustrate the
engineering and application of detuning devices, consider the following circulating water
pump application at a Midwest U.S. power station. 

Figure 1. Typical vertical circulation pump /

Frequency Detuning in Practice
Despite careful engineering, two vertical circulating water pumps exhibited higher than
expected vibration levels shortly after installation (see Figure 2). Engineers performed
thorough vibration analysis on both units, revealing high amplitudes in both systems, the most
severe being in Unit 1B. Measurements for Unit 1B are shown in Table 1. To identify and con rm
a resonance issue, consulting engineers engaged in the following eld testing and analysis.

Figure 2. Original pump installation at the power generation plant

Impact Testing with a Calibrated Hammer

In this method, engineers strike the pump system at multiple locations using an instrumented
hammer and use a vibration sensor and a vibration analyzer for measurement. This method of
striking a system with a mass and measuring its response is common for determining natural
frequencies in mechanical structures. Best practice requires that the impact testing take place
at multiple locations on the structure to identify several resonant frequencies. This test must
be performed with the pumping equipment o . The recorded rst and second natural
frequencies are shown in Table 2. 

Table 1. Solo run vibration data, original installation

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Table 2. Impact test results, original installation

Peak-Hold Coast down Test

To con rm the resonant frequency issue, engineers performed a second test known as a peak-
hold coast down test. In this test, the driver is decoupled from the pump, started and allowed
to coast down from its normal rotational speed. Engineers record the maximum vibration
amplitude at each spectral line during coast down, noting rises in amplitude. The speeds at
which the amplitudes increase can indicate a natural frequency. In this case, the maximum
amplitude occurred at 600 cycles per minute (cpm), which varied from published reed critical
frequency data. This testing con rmed the impact test results (see Figure 3).

Figure 3. Motor peak-hold coast down test, original installation

Applying Detuning Devices

Taking into account the acquired data, the assumption was made that the high vibration levels
were the result of mechanical resonance, as indicated by the low margins between the
required operating speed (590 rpm) and the measured natural frequencies. Accordingly, the
application of detuning devices to reduce system sti ness and, subsequently, natural
frequency was determined to be an e ective course of action.
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Using advanced mechanical and sti ness analysis techniques, consulting engineers
determined the appropriate size, thickness and gap widths for the plate assemblies. An
engineering model of the modi ed system was developed to con rm the maximum de ection
levels to assure that the cantilevered portions of the mating plates would not touch under any
condition. Finite element analysis (FEA) was performed to con rm system parameters—the
predicted system natural frequencies and mode shapes at operating conditions. This analysis
considered:

The base geometry of the motor support, discharge head, bowl and suction bell
The mass of the uid in the pump, sump and discharge head
An equivalent model of the driver (by mass and center of gravity), including reed
frequency
The sump geometry and mass, including concrete properties

Figure 4. Arrangement drawing for detuning devices

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Figure 5. Installed detuning devices

Figures 4 and 5 show the detuning devices in the pump assembly. Once installed, engineers
repeated the impact and peak-hold coast down tests to validate that the natural frequencies
of each pump system had been su ciently reduced to eliminate resonance issues. Field test
results for Pump 1B are shown in Table 3 and Figure 6. Testing showed that the margin
between the system’s natural frequency and operating speed was increased to a comfortable
35 to 40 percent, signi cantly better than the accepted minimum standard of +/-25 percent.

Of course, con rming reductions in actual vibration levels once the system was operating
again was the most important measure of success. A thorough analysis was performed under
normal operating conditions, and the results con rmed the e cacy of the detuning plates, with
all vibration measurements well within established acceptance criteria (see Table 4).

Table 3. Impact test results with detuning devices

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Table 4. Solo run vibration data with detuning devices

Figure 6. Motor peak-hold coast down test with detuning devices

A Predictable, Reliable Solution to Mechanical Resonance

While the practice of frequency detuning has been understood for decades, advances in
diagnostic techniques, engineering models and mechanical analysis have made the design
and application of detuning plates extremely predictable. This is important for large, critical,
continuous-duty installations in which modi cations must be made quickly, inexpensively and
with minimal disruption to plant operations. The application of frequency detuning devices has
been known to bring harmonious resonance to the ears of plant operators—in the form of low
vibration and worry-free vertical pump operation.

Pumps & Systems, May 2012

Carlos Moreno is principal engineer for Flowserve. He can be reached at

cmoreno@ owserve.com. For more information about Flowserve, visit www. owserve.com.
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