Alexandria Engineering Journal (2017) 56, 695–707

H O S T E D BY
Alexandria University

Alexandria Engineering Journal

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ORIGINAL ARTICLE

Finite element analysis for structural modification

and control resonance of a vertical pump
Dalia M. El-Gazzar
Mechanical & Electrical Research Institute, National Water Research Centre, Ministry of Water Resources & Irrigation,
Delta Barrage, Egypt

Received 23 October 2016; revised 22 January 2017; accepted 13 February 2017

Available online 7 March 2017

KEYWORDS Abstract The main objective of this research was to evaluate and enhance dynamic performance
Vibration; for a vertical pumping unit. The original electric motor of the pump unit had been replaced by
Vertical pump; another one different in design and weights. Vibration has been increased greatly after installing
Modal analysis the new motor. Consequently, it is necessary to estimate the change in the vibration characteristics
owing to the difference in the boundary conditions of the new motor. Measured vibration levels and
frequency analysis were dangerous at 1 due to resonance problem. Finite Element Analysis was
used to model the motor structure in order to find its natural frequencies and mode shapes. The
results confirm that the third natural frequency is very close to 1 operating speed with deviation
about 1%. To solve the resonance problem, it was recommended to increase the structure stiffness.
The results after modifications confirmed that the overall vibration level decreases by 89%.
Ó 2017 Faculty of Engineering, Alexandria University. Production and hosting by Elsevier B.V. This is an
open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

1. Introduction Redmond and Hussain [2] analyzed the vibration resulting

The pumping system is the most important water system sup-
plying water for irrigation and removing subsurface water for
drainage purposes. There are more than 2000 large scale irriga-
tion and drainage pumping stations in Egypt operating under
different conditions. Pumping stations in Egypt are subjected
to many problems.
Podugu [1] indicated that the sources of vibration in pumps
can be categorized into three types such as mechanical, hydrau-
lic and peripheral causes. Imbalance and misalignment are the
major reasons for mechanical problems. Peripheral causes of
vibration include harmonic vibration from nearby equipment
or drivers, operating the pump at critical speed. Problems with
any of these issues will show up as symptoms, showing higher
than normal vibration at certain key frequencies.
E-mail address: dalia_engdalia@yahoo.com
Peer review under responsibility of Faculty of Engineering, Alexandria
University.
http://dx.doi.org/10.1016/j.aej.2017.02.018
1110-0168 Ó 2017 Faculty of Engineering, Alexandria University. Production and hosting by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
from a simple linear rotor model on isotropic supports and
showed the dominant response to be similar to that resulting
from a shaft bow. The predicted vibration response did not
contain any second-harmonic content. The reliability and per-
formance of any pump system can be directly affected by its
dynamic characteristics. Sinha and Rao [3] conducted Modal
analysis on the complete assembly of pumps and piping layout
and identified resonance as the root cause for pump failure.
DeMatteo [4] stated that modal techniques are powerful
tools that enhance an analyst’s ability to understand the
sources of vibration. A case history of the vertical pump was
investigated. Testing progression from problem identification
in route vibration measurements to resonance testing was pre-
sented. Resonance problems are difficult to solve. Modal Anal-
ysis gives a clear picture of the machine’s motion; however,
neither tool has the capability to solve resonance problems.
Marenco [5], has experimentally investigated the effect of
bearing housing design will influence the dynamic characteris-
696 D.M. El-Gazzar

tics of the system. In this paper, an attempt was to study the
effect of the base plate stiffness on improving the dynamic char-
acteristics of the pump assembly. Scheffer [6], conducted an
experiment to monitor pump condition through vibration anal-
ysis. This research illustrates the typical steps required to solve
resonance problems. This paper describes the use of operational
deflection shape (ODS) and modal analysis testing for problem-
solving.
Kumatkar and Panchwadkar [7], carried out a modal anal-
ysis of a vertical turbine pump to determine its dynamic charac-
teristics such as its natural frequencies and corresponding mode
shapes. They have analyzed the rotor assembly of VT Pump
theoretically, numerically and experimentally. The system is
modeled as a lumped mass structure to theoretically determine
its torsional natural frequencies and as a continuous system to
determine its transverse natural frequencies. The numerical
model is validated with the results of the theoretical analysis.
Nikumbe et al. [8] discussed the modal analysis of vertical
turbine pump. Natural frequencies of a vertical turbine pump
are calculated by performing a modal analysis using the Finite
Element Method (FEM). They founded total six modes of
vibration for this analysis. Experimental analysis is defined
as the study of dynamic characteristics of a mechanical struc-
ture. Experimental analysis is done by using Fast Fourier
Transform (FFT) analyzer. During this analysis, exciter mech-
anism is done by using an instrumental hammer, as this mech-
anism requires a minimum amount of hardware and provides
shorter measurement times. Comparison between natural fre-
quencies with an operational frequency of vertical turbine
pump ensured the safe working of the pump.
de Souza [9], has used Operating Deflection Shape (ODS)
technique to analyze the dynamic behavior of the machine or
structure, by determining the existing strains and their probable
causes. Measurements of phase and of the amplitude of vibra-
tion at predetermined points were carried. The cause of high
levels of vibration of the centrifugal pump was determined
and the recommendations for correcting the problem were
achieved.
Dupac and Rahman [10], have developed and used ODS
procedure to monitor relative in-service planar or orbital dis-
placements of vertical pump for any signs of excess or incom-
patible displacements. In such cases, the system is taken out of
service for full dynamics analysis and subsequent design mod-
ification. A combination of ODS, Modal analysis and FEA
has been used to verify any design improvements. The undesir-
able structural dynamics is the root cause of poor reliability.
Prajapati [11], found out the solution for reducing vibration
in vertical turbine centrifugal pump. He enumerated some
methods of identifying vibration in pump and some possible
cause of vibration. He found out that the possible cause of
vibration in pump is due to its structure and it is due to either
weight of the motor placed at higher cause maximum vibration
or due to improper misalignment between upper and lower
base part of pump.
is of discharge 1.5 m3/s, head 11.6 m, 992 rpm, and motor
power 1000 kW. The vibration problem on Pump unit (1)
began after its original motor (a 1000 kW, BROWN BOVERI.
Type: SOV560wb) was replaced with a new Hungarian motor.
The old motor was in service for many years. The old motor is
987 RPM and weighs 6200 kg. The new motor is 992 RPM and
weighs 8600 kg. Since the new motor was installed, the vibra-
tion on the machine has been extremely rough. Therefore, the
decision was to modify the motor setup by supporting its base
plate with reinforcing concrete supports at the sides of the
base. After supporting, the measured vibration level had been
duplicated especially on the motor upper and lower bearings
and reached a danger value. So the task was to determine
the source of the high vibrations and the method to overcome
this problem. in the final motor setup, a part of metal has four
webs of 15 mm thickness and each is added by welding to the
lower motor base to increase the stiffness to overcome the pro-
blem of high vibration due to resonance.
3. Results of vibration measurements tests
Overall vibration levels and vibration spectra are measured at
the motor running speed (16.53 Hz) at different locations on
the whole pumping unit parts to determine the dynamic per-
formance for such huge machines installed at the heavy base
plate and located at class I according to ISO 1-10861. This
class defines that up to 2.8 mm/s is a good level, up to
4.5 mm/s is an allowable level, up to 11.2 mm/s is just tolerable
level and what exceeds this value is not permissible and dan-
gerous. Measurements were done during no load condition
where the motor was disconnected completely from the pump
via the coupling and full load condition. Vibration measure-
ments were done on 9 locations on the motor upper and lower
bearings and pump bearing in the axial, vertical, and horizon-
tal directions as shown in Fig. 1.

2. Problem description & task

In this research, dynamic measurements are evaluated for an

axial pumping unit at El-Shabab Pumping Station in the area
of El-Salhiya. This pumping station is used to irrigate
9000.5 feddans and consists of 6 pump units; each pump unit Figure 1 Measurement locations at the pump unit.
Structural modification and control resonance of a vertical pump 697

Vibration measurements were taken before and after sup- vibration levels are decreased on the motor upper bearing
porting the motor base at full load and no load conditions about 24% in the vertical direction and 50% in the horizontal
as shown in Table 1. Firstly the measurement results before direction, while they decreased on the motor lower bearing

Table 1 Overall vibration measurements on the pump unit.

Measurement locations Overall velocity before supporting Overall velocity after supporting
Full load No load test Full load No load test
test without coupling test without coupling
Motor Upper Bearing (MUB) Axial Point (1) 1.87 0.398 2.80 0.669
Vertical Point (2) 6.91 5.21 35 14.9
Horizontal Point (3) 9.84 4.9 19.7 8.11
Motor Lower Bearing (MLB) Axial Point (4) 1.5 0.394 1.45 0.670
Vertical Point (5) 5.27 0.838 7.54 3.94
Horizontal Point (6) 4.72 0.96 8.22 4.78
Pump Bearing (PB) Axial Point (7) 2.19 2.75
Vertical Point (8) 1.57 2.32
Horizontal Point (9) 1.87 1.40

supporting during full load condition indicated that the over-
all vibration levels are extremely rough. On the motor upper
bearing, the overall vibration level reached 6.91 and
9.48 mm/s in vertical and horizontal directions. On the other
hand, the overall vibration level reached 5.27 and 4.72 mm/s
vertical and horizontal directions at the motor lower bearing.
These levels of vibration are a danger to the machines and
structures where it transmits to the foundations and struc-
tures. After that, the motor was disconnected completely from
the pump via the coupling to check and confirm that the main
source of high vibration level is from the motor. The overall
about 84% in the vertical direction and 79% in the horizontal
direction.
Frequency analysis is used to define the exciting frequencies
and determine the level of vibration at each specific frequency.
Also, it is used to determine the sources of vibration, to control
vibration levels and solve vibration problems. Results of fre-
quency analysis shown in Fig. 2 indicated that, there is a high
vibration occurs from the mechanical defect at 1 rotational
speed. Structural modifications were done by adding rein-
forced supports to the motor base in order to decrease and
control the vibration level.

Figure 2 Vibration spectrum measured during full load at motor upper and lower bearings before supporting.
698
Results of the overall vibration level after supporting are
extremely increased and reached a danger level according to
ISO 10816. In the case of full load, the overall vibration level
at the motor upper bearing increased about 400% in the vertical
direction and 100% in the horizontal direction. On the other
hand, the overall vibration level at the motor lower bearing
Figure 3 Vibration spectrum measured during full load at motor upper and lower bearings after supporting.
D.M. El-Gazzar
increased about 43% in the vertical direction and 74% in the
horizontal direction. Results of frequency analyses in the case
of full load indicated that the vibration amplitude reached a
danger value about 26.3 and 15.7 mm/s in the motor upper bear-
ing in the vertical and horizontal directions respectively as
shown in Fig. 3. In the case of no load, the overall vibration level
Motor upper bearing
Motor lower bearing
Structural modification and control resonance of a vertical pump 699

at the motor upper bearing increased about 180% in the vertical On the other hand, the overall vibration level at the motor lower
direction and 65% in the horizontal direction as shown in Fig. 4. bearing increased about 300% in the vertical direction and

Motor upper bearing

Motor lower bearing

Figure 4 Vibration spectrum measured during no load at motor upper and lower bearings after supporting.
700 D.M. El-Gazzar

500% in the horizontal direction. Results of frequency analyses upper bearing in the vertical and horizontal directions respec-
in the case of no load indicated that the vibration amplitude tively. Vibration level change during full load and no load con-
reached a danger value about 11.32 and 6.75 mm/s in the motor ditions before and after supporting is shown in Fig. 5.

Figure 5 Vibration level during full load and no load conditions.

Structural modification and control resonance of a vertical pump
4. Run-up test
A common Way to identify resonances empirically is to oper-
ate the equipment across its range of operating speeds while
measuring the vibration it exhibits. Run-up or coast-down
tests, which monitor vibration from standstill to maximum
speed and back down, are a quick way to see whether trouble-
some resonances are present in the system. As shown in Fig. 6,
a waterfall plot of the spectral data is used to identify a peak
vibration level at a certain speed during the run-up a test of
Figure 6 Run-up test data.
701
the pump unit. This plot consists of the 1 vibration ampli-
tude being collected simultaneously with a 1 rpm phase read-
ing as the machine coasts to a stop running speed. It could be
seen that during the pump starting up, there is a discrete peak
in the magnitude at 1 and it’s a good indication that a reso-
nance exists there. The speed range includes 10 Hz, 12.5 Hz,
13.75 Hz, 15 Hz, 16.5 Hz, and 17 Hz, 18 Hz and the amplitude
at this speed frequency is 0.0479 mm/s, 0.2077 mm/s,
0.488 mm/s, 0.659 mm/s, 0.17 mm/s, 0.301 mm/s, 0.15 mm/s.
It could be seen that the amplitude increases until the rotor
702 D.M. El-Gazzar

reaches its critical speed (16.5 Hz) and then decreases to the
normal level as the speed continues to change. So the speed
at 16.5 Hz which the amplitudes decrease is a possible natural
frequency. The run-up data identified a natural frequency 1
at 16.5 Hz. The resonance is coincident with 1 rotational
speed. Vibration from this mechanical defect at 1 rotational
speed is exciting a natural frequency of the pump structure.
As a result of operating the pump with its 1 at a resonant
frequency, there was an experience excessive vibration and it
will wear prematurely. Corrective actions should be taken to
move the resonant frequency away from the 1 frequency,
through the addition of stiffness (to increase the resonant fre-
quency) or mass (to lower the resonant frequency) to the struc-
ture. Another solution is to use a ‘‘tuned absorber” or a ‘‘tuned
mass damper”. These devices greatly reduce the amount of
vibration observed at the natural frequency.
All the previous results confirmed that characteristics of the
problem are listed below:

 The foundation is not rigid enough (weak) to support the

new motors.
 The new motors are heavier than the old one affected the
natural frequency of the foundation leading to high vibra-
tion levels due to resonance.
 Vibration from a mechanical defect at 1 rotational speed
is exciting a natural frequency of the pump structure.
Therefore it is mandatory to perform dynamic structure
Figure 7 Geometrical dimensions of motor and base plate
study to determine the exact stiffness needed. The study
structure.
determines the type and the method of re-enforcing the
structure. The study includes the following:-
 build a numerical model of the structure,
 determine its dynamic characteristics,
 Design of the re-enforcement to ensure safe and normal 6. Model results
operation of the pumps.
Natural frequencies of a symmetric structure occur in orthog-
5. Finite element analysis onal pairs as shown in Table 2. The physical significance is that
the motor can actually vibrate (bend) in any direction based on
Finite element analysis (FEA) was used to model the motor the direction of the applied excitation. So it is recommended to
structure to estimate the dynamic characteristics using ANSYS increase stiffness results in the high natural frequencies. The
WORKBENCH 14.5. The FEA model was built for the orig- results of the model indicated that the low stiffness of the
inal motor structure and simulation is made to find its natural motor base contributed to the relatively high oscillatory
frequencies and mode shapes. The model consists of a motor motion of the motor. Add stiffeners as proposed will decrease
weighing 8700 kg, a steel base, and a concrete foundation. the amplitude of vibration; however, it will not eliminate the
Concrete is assumed to be a homogeneous and isotropic source of vibrations. The predicted mode shapes are shown
material and to behave in a linear elastic manner. The mechan-
ical properties of the concrete are assumed to be modulus of
elasticity: 32 GPa, Poisson’s ratio: 0.2, and weight density:
2400 kg/m3. Steel is assumed to be a homogeneous and isotro-
pic material behaving in a linear elastic manner. The mechan- Table 2 Predicted natural frequencies.
ical properties are assumed to be modulus of elasticity: Modes Description Frequency (Hz)
200 GPa, Poisson’s ratio: 0.3, and weight density: 7800 kg/
1 1st bending 7.908
m3. A simple geometrical structure was designed using SOLID 2 1st bending 7.908
WORKS 2010 to simulate the motor structure as shown in 3 2nd bending 18.35
Fig. 7. When a 3D model of solid volumes is generated, solid 4 2nd bending 18.35
modeling is generally more convenient compared to direct gen- 5 2nd bending 50.71
eration. Solid modeling is tedious and too much time consum- 6 2nd bending 50.71
ing. The boundary conditions assumed that the concrete 7 Horizontal extension 35.47
foundation is fully clamped in the two cases including modified 8 Horizontal extension 35.47
and final motor structure setup.
Structural modification and control resonance of a vertical pump 703

in Fig. 8. The possible cause of this problem is due to that, all precision of fits at upper thrust bearing could create high unbal-
these motor applications have a high thrust bearing design con- ance due to eccentricity, besides that insufficient down thrust
sisting of 3 angular contact bearings (2 down and 1 up). Lack of causing improper loading of the bearing and affecting stiffness.

Mode. 1 Mode. 2

Mode. 3 Mode. 4

Mode. 5 Mode. 7
Figure 8 Normal mode shapes of motor and base plate structure.
704 D.M. El-Gazzar

7. Modified model 8. Results of vibration measurements after modifications

Since the natural frequency at 16.5 Hz is at the upper end of
the motor at 1 operating speed, it is recommended increas-
ing the machine stiffness. Increasing stiffness results in a
higher natural frequency. To accomplish the change, a part
of metal has four webs of 15 mm thickness and each is added
by welding to the lower motor base as shown in Fig. 9. The
modified model produced acceptable results. Increasing stiff-
ness by adding the four web model leading to alters the natu-
ral frequencies of the motor. This modification increases the
frequency of the first pair and second bending modes. The
change at each natural frequency based on adding the four
webs model is shown in Table 3. Normal mode shapes of
motor and base plate structure after modifications are shown
in Fig. 10.
After achieving the new modifications to the pump unit, a new
measurement was done to indicate the effect of this modification
on the performance of the pump unit. Overall vibration levels
and vibration spectra are shown in Table 4 indicating that
the vibration level on the pump unit is extremely reduced.
The overall vibration level reached 3.6 and 2.631 mm/s on
the motor non-drive end in the horizontal and vertical direc-
tions. The overall level decreases about 89% and 86% on the
motor drive end in the horizontal and vertical directions
respectively. The frequency spectrum showed that the mea-
sured vibration amplitude is obviously decreased. The maxi-
mum vibration amplitude reached 0.227 and 0.294 mm/s on
the motor non-drive end in horizontal and vertical directions
respectively as shown in Fig. 11. The results after achieving

Figure 9 A four web model added to the lower motor base.

Table 3 Normal mode shapes of motor and base plate structure.

Modes Description Frequency (Hz) before adding stiffness Frequency (Hz) after adding stiffness
1 1st bending 7.908 13.51
2 1st bending 7.908 13.51
3 2nd bending 18.35 33.12
4 2nd bending 18.35 33.12
5 2nd bending 50.71 61.47
6 2nd bending 50.71 61.47
7 Horizontal extension 35.47 72.21
8 Horizontal extension 35.47 72.21
Structural modification and control resonance of a vertical pump 705

Mode. 1 Mode. 2

Mode. 3 Mode. 4

Mode. 5 Mode. 7
Figure 10 Normal mode shapes of motor and base plate structure after modifications.
706 D.M. El-Gazzar

Table 4 Overall vibration level after new modifications.

Measurement locations Overall velocity (mm/s)
Motor None Drive End (MNDE) Axial Point (1) 3.74
Horizontal Point (2) 3.65
Vertical Point (3) 2.631
Motor Drive End (MDE) Axial Point (4) 2.285
Horizontal Point (5) 2.279
Vertical Point (6) 0.300
Pump Upper Bearing (PUB) Axial Point (7) 1.165
Horizontal Point (8) 1.987
Vertical Point (9) 1.854

Figure 11 Vibration spectrum measured in horizontal and vertical direction after modifications.
Structural modification and control resonance of a vertical pump
the new modifications indicated that the overall vibration level
is in the permissible zone of ISO 10816-1.
9. Conclusion
Dynamic behavior of the pumping system is affected greatly by
the changing in the motor weight. The low stiffness of the
motor base contributed to the relatively high oscillatory
motion of the motor. Adding stiffeners as proposed decreased
the amplitude of vibration. The results confirmed that how the
dynamic characteristics of the pump structure are improved
after applying modifications. The increase in the stiffness of
the motor base moves the natural frequencies away from
forced vibrations. FEA is a useful tool to evaluate the effec-
tiveness of potential structural modifications. The results con-
firmed that the overall vibration level decreases about 89%
after achieving structural modifications.
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