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Safety factor of pump vibrations on ships based on the natural frequency of

pump vibrations according to ISO 10816-3

Article in Journal of Mechanical Engineering Research and Developments · January 2020

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Journal of Mechanical Engineering Research and Developments
ISSN: 1024-1752
CODEN: JERDFO
Vol. 43, No. 7, pp. 180-192
Published Year 2020

Safety Factor of Pump Vibrations on Ships Based on The Natural

Frequency of Pump Vibrations According to ISO 10816-3
Damora Rhakasywi†*, Amir Marasabessy‡, Mohammad Rusdy Hatuwe†, Sjaiful
Kotahatuhaha‡†
†
Faculty of Engineering, Mechanical Engineering, Universitas Pembangunan Nasional Veteran Jakarta, Jl. Limo
Raya No.80, Limo, Kec. Limo, Kota Depok, Jawa Barat 16514.
‡
Faculty of Engineering, Naval Engineering, Universitas Pembangunan Nasional Veteran Jakarta, Jl. Limo Raya
No.80, Limo, Kec. Limo, Kota Depok, Jawa Barat 16514.
‡†
PT. SKF Industrial Indonesia, Gedung Talavera Lt.09. Jl. TB Simatupang Jakarta.
*
Corresponding Author E-mail: rhakasywi@upnvj.ac.id

ABSTRACT: Maintenance of ships to support operational aspects on an ongoing basis is very important from
operational cycle management or life cycle management. In this case the engines on the ship, especially in the
engine room which is a machine with a safety factor is quite high, so that if there is a damage can be known
immediately. One type of machinery referred to here is the pump system as a single pump or groups pump. The
purpose of this research is to develop a vibration monitoring system for centrifugal pumps on the ship by
placing sensors on the pump. The research method was carried out experimentally by installing 6 units of
accelerometer sensor connected to DAQ (Data Acquisition) and computer. The results of the study explain
pump vibrations at frequencies of 24.7 Hz have been categorized as exceeding the threshold value of the natural
pump frequency of 20 Hz or 1200 rpm. The value of pump vibration frequency greater than the natural
frequency of the 20 Hz pump according to ISO 10816-3 standard can cause cracks in the pump system on the
pump structure or pump components.

KEYWORDS: Safety Factor, Pump Vibration, Abnormality, Natural Frequency, Data Acquisition, Ship

INTRODUCTION

It is generally understood that the machining maintenance methods are as follows: damage treatment where
repairs are carried out directly on the spot, periodic maintenance, predictable maintenance and proactive
maintenance. The engines that exist on the ship, especially in the engine room are engine systems that have a
critical level high enough if there is damage must be repaired immediately. One type of machinery referred to
here is the pumping system individually or pump group. Vibration is one of the main problems considered in the
design and manufacture of pumps in this case the radial force and impeller vibration induced by the fluid in the
centrifugal pump is investigated at different flow rates using numerical simulations and the vibrations in the
volute are tested by experimental means [1]. New axial dynamics models including the transient force of the
balance disc were studied to predict the vibrational characteristics of a multilevel pump rotor system, the
distribution of pressure in axial distances and the dynamic forces suitable for nonlinear reduction in which the
axial gap increases from 0.2 mm to 1 mm then space pressure the inside is more sensitive to the inlet pressure
than the rotating speed, especially when the axial gap is 0.2 mm [2]. Multistage pumps for improved design with
low vibration and noise features in industrial applications. In this research, it becomes very important to fully
understand the vibration patterns of complex types of machines.

The study was to examine the vibration and stability of cantilevered centrifugal pumps under different flow
rates. The results showed the effect of operational conditions on the vibration of multilevel cantilever centrifugal
pumps. The vibration velocity is caused by mass imbalance at the flow rate point, the main type of vibration
frequency for the inlet and outlet is high frequency [3]. Monitoring of machine condition is a primordial field of
study aimed at avoiding downtime in industrial plants which results in financial and time loss. The research uses
internet of things (IoT) technology to classify pump vibration signals, as identification of normal operation
stages, new cavitation stages and severe cavitation stages, using vibration signals, which are collected on the
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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

MEMS sensor. The results of these studies show that the Hu moment combined with KNN has the best accuracy
(99.47%) with a score time of 17 ms. Thus, the approach is reliable and efficient for detecting cavitation in
pumps [4].

The increasing industrial productivity has resulted in major breakthroughs in the field of centrifugal pump
maintenance to ensure optimal operation under different conditions, one of the important mechanisms affecting
the stable and dynamic operation of the pump is the cavitation conditions, from the results of these studies
indicate that the characteristics of the impeller geometry affect the development and cavitation behavior [5].
Other research conducted sea water piston pumps using the main power components for underwater equipment,
pulsation and low-pressure vibration are the main requirements of high-quality sea water piston pumps to
improve stability, underwater reliability. The simulation results show that the pressure pulsation rate reaches
17% [6]. Diagnostic method using vibration analysis for pump error detection by means of Fast Fourier
Transform (FFT) in the form of a vibration signal received by the sensor [7].

Cavitation is an important problem that occurs in all pumps, in this study it detects and diagnoses the
phenomenon of cavitation in centrifugal pumps using vibration. The results obtained from time and frequency
vibration signals are analyzed to provide an understanding of cavitation detection at the pump. The method used
is Fast Fourier Transform (FFT) to perform frequency domain analysis (FDA) [8]. Other studies have conducted
a diagnostic process using vibration sensors to monitor the phenomenon of cavitation in gerotor pumps used for
automotive applications [9]. Another study reports a Vibration-based Electromagnetic Energy Harvester (VEH)
designed to power wireless sensors so that they can be used in industrial centrifugal pumps. The design consists
of two independent moving parts; the middle and the outside. The experimental results are in accordance with
the simulation results because the average error percentage is within the acceptable range of 6.15%. A case
study is also presented in which the Zig Bee transceiver was successfully powered from the output produced by
VEH [10].

The phenomenon of fluid-induced instability is one of the common problems as large amplitude sub-
synchronous vibrations from the pump shaft and pump structure due to vortex flow. When the pump is not
operated at its best efficiency point, some of the mechanical energy is transferred to the fluid that produces the
vortex. The vortex flow has a very low pressure at its center and forms steam bubbles at a very high speed, the
formation of vapor bubbles (cavitation) produces a hammer effect that can cause vibrations and sounds this must
be avoided because it can cause engine damage due to fatigue [11]. This research investigates the vibrations of
fluid flow from centrifugal pumps using computational fluid dynamics (CFD) and cyclostationarity signals,
pump vibration models are set as amplitude modulation (AM) models. The results of the comparison between
CFD and cyclostationarity signal show convergence results [12].

Two sources of vibration in the pump using three screws, studied to provide a basis for vibration control, an
experimental test model was carried out to obtain the vibration response of three pump threads, from the test
results explained that the screw contact force is more dominant than the fluid tensile force [13]. Another study
used a simulated vertical mount configuration in which an electric motor was bolted over a twin screw pump in
an unsupported manner, the natural frequency of the pump / motor structure could be very low, resulting in
destructive vibrations. Resonance can occur when a driving force is not balanced on the motor or pump. In this
study, a finite element analysis software simulation is used to calculate the natural frequency of the pump
structure and then create a potential modification model to determine its impact in eliminating harmful
resonances [14].

Other studies explain the results obtained on measuring centrifugal pump vibrations by measuring the pressure
pulses, which are generated in the pipe system. More than 9 different operating modes are used on 1,000
m3/hour centrifugal pumps during the process of measuring vibration and pulsation pressure. From the results of
this study obtained in the booster pipe and main pump, 1.31 bar to 0.68 bar, by only running a booster pump, the
pressure pulse is reduced significantly to the value of 0.63 bar [15]. Vibration analysis on a pump assembly with
four positions can be very dangerous for the operation of a total pump pool. Vibration can affect the pumping
aggregate segment, so it needs to be done vibration analysis. From these results it was found that in an electric
motor, it is possible to determine bearing damage and other mechanical damage such as incorrect clutch position
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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

[16]. Other research conducted by [17], the value of the change in relative pressure and vibration is measured
using 14 pressure sensors and 2 vibration sensors mounted inside the axial pump, it is concluded that horizontal
and vertical vibrations with twice the frequency have little relationship with the pulsating pressure for the inlet
impeller.

The dynamic model of axial piston pump is modeled as a dynamic system with four masses and 19 degrees of
freedom (DOF). Dynamic excitation force is calculated using piston chamber pressure which is simulated with a
three-dimensional computational fluid dynamics (CFD) model. The results show that the moment of excitation
force has a major contribution to most vibrations, vibration can be reduced significantly by optimizing the bolt
mounting position [18]. Experimental studies that focus on monitoring vibration based conditions and fault
diagnosis of centrifugal pumps, two types of interrelated errors, namely: blockage of flow in the inlet pipe and
the formation of impending bubbles in the pump are considered, centrifugal pumps are installed in the Machine
Fault Simulator (MFS) settings for experimental purposes [19]. The reversible pump turbine prototype at the
hydroelectric power station was investigated experimentally, the vibration performance and its physical origin,
the pump valve was opened (48 - 90) %. From the results of the analysis, it was found that valve vibrations were
mostly caused by fluid flow inside the pump turbine [20].

Analysis of experimental and numerical hydraulic vibrations in pipe systems under multi-excitations, from the
results of this study obtained by the FEM (finite element method) can predict the vibration characteristics of the
pipe with sufficient accuracy, and can see the dangerous phenomena caused by these vibrations [21]. Vibration
analysis and experimental studies on water piston pumps using liner-motor-driven on marine vessels to provide
an effective method of detecting vibration characteristics as well as a reference for the design and optimization
of linear motor-driven piston water pumps [22]. Experiments of pump vibration on ship propulsion using
damper bearings, the results show that in order to improve the safety and reliability of navigation, the hull
deformation, especially the horizontal hull deformation excitation, so that the rotation speed and resonance
frequency are required to be designed properly at the excitation frequency of the hull deformation [23]. Other
studies regarding vibrations that occur in pump impellers using numerical simulations and experiments, from the
results of these studies resulted in deviations in the value of the pressure that occurs in the hydraulic pump of
5% [24,25].

This research has only been carried out on ships to read the vibrations that occur in the cooling pumps of the
main engine of the ship in operation. The research objective is to apply a technological approach through the
development of a centrifugal pump monitoring system on ships continuously by placing sensors in the pump to
read the vibration value that occurs in the centrifugal pump in safe conditions, as well as providing an
explanation of the natural frequency vibration of a centrifugal pump if the vibration exceeds the natural
frequency vibration of the pump it can cause damage to the pump components. The problem that often arises in
centrifugal pumps is that they often experience cracks caused by pump vibrations, so it is necessary to monitor
the operating centrifugal pump. The purpose of this research in the future is to apply the industrialization
technology approach 4.0 where the operation of the centrifugal pump cooling for ship propulsion engines is
monitored online by placing sensors on the pump. The method used is FFT (Fast Fourier Transform), for online
reading of pump operation with a vibration analysis approach to understand the pump operating conditions, both
normal and abnormal conditions to prevent unscheduled or unpredictable operating failures.

METHODOLOGY

Set Up Sensor

This research was conducted experimentally pairing 3 sensors in the stuffing box and 3 sensors in the electrical
motor in the main engine centrifugal pump, the experimental setup that will be used in this research activity is as
follows. Figure 1 show accelerometer sensor 100 mV/g, sensors to be installed in the stuffing box and electrical
motor components are as many as 6 units with an accuracy level of up to 10,000 Hz (60 - 600,000 CPM)
frequency response.

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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

Figure 1. Accelerometer sensor 100 mV/g

Table 1. Sensor specifications

Specifications Standard Metric

Part Number AC 150 M/AC 150
Sensitivity (± 15 %) 100 mV/g
Frequency Response (±3dB) 60-600,000 CPM 1,0-10000 Hz
Dynamic Range ± 50 g, peak
Electrical
Settling Time < 2.5 seconds
Voltage Source (IEPE) 18-30 VDC
Constant Current Excitation 2-10 mA
Spectral Noise @ 10 Hz 14 μg/√Hz
Spectral Noise @ 100 Hz 2.3 μg/√Hz
Spectral Noise @ 1000 Hz 2 μg/√Hz
Output Impedance < 100 ohm
Bias Output Voltage 10-14 VDC
Case Isolation >108 ohm
Environmental
Temperature Range -58 to 250oF -50 to 121oC
Maximum Shock Protection 5,000 g, peak
Electromagnetic Sensitivity CE
Sealing Welded, Hermetic
Submersible Depth (AC150-
200 ft 60 m
2C/3C)
Physical
Sensing Element PZT Ceramic
Sensing Structure Shear Mode
Weight 3.2 oz 90 grams
Case Material 316L Stainless Steel
Mounting 1/4-28
Connector (non-integral) 2 Pin MIL-C-5015
Resonant Frequency 1,380,000 CPM 23000 Hz
Mounting Torque 2 to 5 ft. lbs 2,7 to 6,8 Nm
Mounting Hardware 1/4-28 Stud M6x1 Adapter Stud
Calibration Certificate CA10

Table 1 sensor specifications used in centrifugal pumps to read pump vibrations that occur during operation. The
test is carried out for 1 week to get the vibration data of the main engine centrifugal pump during operation with
variations of the valve open 0%, 4%, 11% and 46%.

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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

Next figure 2 shows the connecting sensor cable with a length of ± 8 meters connected to the Data Acquisition
(DAQ) Unit can directly read the vibration chart of a centrifugal pump using a computer.

Figure 2. Cable connection DAQ

Then Figure 3 shows the Data Acquisition Unit (DAQ), in this study the instrument used is the vibration
measurements IOtech 672u engineering specification model and accuracy are described in table 2.

Figure 3. Vibration gauge DAQ

Table 2. Vibration gauge DAQ specifications

Features IOtech 672u

Channel Capacity 20
A/D Resolution (bits) 24
IEPE Current Source 4 mA
Programmable Input Ranges ± 40V
Accelerometer Inputs yes
Filter Type Linear Phase
Coupling AC, DC
Maximum Sample Rate 105 kHZ/ch
Simultaneous Sampling yes
Analog Trigger Source single channel
Digital I/O – Included 8
Other Supported I/O volts
PC Connectivity USB

Figure 4 shows the flowchart of the research conducted to obtain vibration data of the main engine centrifugal
pump on a 30 GT fiberglass fish ship. This research was conducted at PT. Proskuneo Kadarusman for collecting
centrifugal pump data.

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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

Start

Field survey at the shipyard of PT. Proskuneo Kadarusman

Collecting data:
- Sensor installation in centrifugal pump system
- Data Acquisition Unit (DAQ) settings on the pump
- Data is collected when the ship is operating at a fishing ground for
one week

Data processing:
Vibration data recorded
on IOtech 672u No
vibration measurements
are transferred to a
computer for analysis

Yes

Data analysis:
The results of the centrifugal pump vibration data are then analyzed
based on the ISO 10816-3 standard

Recommendation:
Make recommendations to make decisions on the results of
centrifugal pump vibrations

Finish

Figure 4. Research flow chart

Experimental pump

Table 3 explains the specifications of the centrifugal pump used in the study. The pump used has a rotational
speed of 1200 RPM with water as a working fluid.

Table 3. Main engine coolant centrifugal pump specifications

Type Pump UC2110

Certification CE, ATEX
Maximum power hp (kW) 80.46 HP (60 kW)
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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

Maximum working pressure to 435 psi (30 Bar)

Maximum viscosity Over 200 cP
Type driving motor Tyrone
Output power 16.09 HP (12 kW)
Voltage 380V/50 Hz
Maximum speed 1200 RPM

Figure 5 shows the position of the sensors installed in the 2 main components of the centrifugal pump on the
stuffing box and the electrical motor, with horizontal (H) and vertical (V) positions. The installed sensor
position will store vibration data during the centrifugal pump operation, the test is carried out for 1 week with
the data stored 1 day for 9 hours. Description of the numbers 1H, 1V, 2H, 2V, 3H, 3V and 3AV (axial vertical)
indicate the number of vibration points to be measured as shown in Figure 5 and Figure 6. The installation
stages of the sensors are carried out by means of a soft drill based on the standard screw sensor then the sensor
is mounted using a screw.

Figure 5. Sensor position placement

Figure 6. The actual position of the sensor installation

RESULTS AND DISCUSSION

Pump Vibration Analysis

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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

The results of measurements using DAQ IOtech 672u obtained vibration data on the centrifugal pump of the
ship engine cooling in table 4, centrifugal pump experiments for ship engine coolers using variations of the
discharge valve opening to obtain vibration values based on safety factors is 11% according to ISO standards
[26], when opening the valve as described in figure 7.

Table 4. Centrifugal pump vibration measurement results

Discharge valve opening

Part Sensors point
0% 4% 11 % 46 %
1H, 1V - 5.785 4.949 5
1V, 1V - 6.682 3.193 3.118
Electrical motor
2H, 2V - 4.881 2.166 2.210
2V, 2V - 4.661 1.312 1.335
3V, 3V 15.315 12.679 9.515 5.193
Pump Stuffing Box 3H, 3V 16.804 11.808 9.864 4.840
3A, 3V 11.456 5.91 5.252 3.147

Figure 7. Pump vibrations are based on Standard ISO 10816-3

Figure 7 displays the stuffing box is a component home of a centrifugal pump impeller, Mtr DE is the part of the
motor that is connected to the pump clutch and Mtr NDE is a part that is not connected to the pump clutch. The
position of the sensor is placed on these components. Information table 4, displays the value of each vibration
point on the electrical motor versus pump stuffing box when compared to the percentage of the discharge valve
opening, the horizontal or vertical position of the pump vibration value is higher at the point of pump stuffing
box.

Table 5. ISO Standard 10816-3 [27]

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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

Complicated vibration chart reading takes time for technicians to understand, so a simple method for reading
charts using color display needs to be developed [27]. The display of the color indicates for certain conditions
such as, green with a safe meaning, yellow with the meaning that there is already an abnormality indication and
red with the meaning of danger, in accordance with ISO-10816-3 Standards, vibration standard values with
various categories are shown in table 5. This simplification method is by building certain algorithms that can be
processed from the vibration sensor output to produce graphical readings as desired. These sensors are attached
to the centrifugal pump so they can be read in real time. The natural frequency possessed by the pump casing
during vibration testing is explained in Figure 8 and Figure 9. Random frequencies in addition to the blade pass
frequency (BPF) line can produce turbulence flow disturbances thereby creating random frequencies in other
parts, this gives an indication that it can stimulate the natural frequency of the natural frequency of the pump
casing (24.7 Hz). Based on data from the pump specifications in table 3.1, the value of the natural frequency of
the pump is (1200rpm)/(60 minute) = 20 Hz, so that the resonance generated can create several impacts such as
the phenomenon of cracking in the pump casing.

Figure 8. The results of natural centrifugal pump frequency measurement

Figure 9. The natural frequency of the pump when collecting data

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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

The results of the data obtained explain that the natural frequency is approaching the same value as the
maximum speed motor output, the natural frequency value of the centrifugal pump is obtained from the
measurement results shown in figure 9. By using the explanation in figure.3.5, lower boundary (1132.8 CPM-
1185.6 CPM) and Upper boundary (1699.2 CPM-1778.4 CPM) can be explained that the natural frequency is in
the lower limit and the upper limit of each area of resonance. Figure 9 explains that the operational speed is in
the area of resonance and the natural effect of this phenomenon is that the vibrational amplitude produced is
quite high. To reduce vibrations caused by the resonance effect, the pump operating speed must be ± 25% below
the natural frequency limit value of the pump. In this case, the increase in natural frequency or resonance area
must not occur due to the influence of the rotating speed of the pump engine.

Natural frequency, damping and isolator

Excessive resonance can cause cracks in the pump so it needs to be done dampers. The purpose of the damper is
to reduce excessive cracking due to high resonance, to reduce the resonance that occurs by reducing the value of
transmissibility (T) so that excessive resonance after muted will decrease in value. The mathematical equation
that can be used to reduce the value of transmissibility is as follows (1) [28]

1 + (2r )
2

T= (1)
(1 − r ) + (2r )
2 2 2


r= (2)
n

k
n = (3)
m
c
where :  = = critical damping ratio , m= mass of system (kg), k=stiffnes (N/m), c= viscous
2mn
damping (kg/s), ω = angular frequency (Hz) , ωn = natural frequency (Hz). Typical values for damping
ratio,  are 0.005 – 0.01 for steel, and 0.05 – 0.1 for rubber. The inclusion of damping has the greatest effect in
the vicinity of resonance, decreasing the vibration amplitude. A curious effect of damping is that it results in
increased amplitude at frequencies > 1.4Fn. The selection of pump bearings by taking into account the damping
factor can change the actual natural frequency of the rotor using mathematical equations 1, the actual natural
frequency can be reduced to (≤fn) from the critical natural frequency described in Table 6.

Table 6. Natural frequency value to cycle per minute (CPM) and the area that receives resonance

Natural frequency Frequency (Hz) CPM = RPM Resonance Area

Speed 19.75 1185
Natural frequency of 24.7 1482 20 %
the casing 23.6 1416 16.3 %

Natural frequency
24 1440 17.7 %
rotating components

Based on the measurement results in table 6, natural frequency value to cycle per minute (CPM) and the area
that receives resonance with a critical speed of 1185 RPM based on figure 3.5 of the natural frequency value of
a 24.7 Hz centrifugal pump so that in making good designs advising the centrifugal pump engine must be
designed not to operate beyond the 120% value of the pump critical speed or equal to 1.2 x 1185 RPM = 1422
RPM [28].

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 Safety Factor Of Pump Vibrations On Ships Based On The Natural Frequency Of Pump Vibrations According To ISO 10816-3

CONCLUSIONS

High amplitude vibrations can cause the casing frequency value of 24.7 Hz to be above the normal natural
frequency value of centrifugal pumps around +/- 20%. The large amplitude value is caused by the resonance of
vibrations received from the centrifugal pump due to the turbulence flow of water fluid in the pump. The effect
of the resonant vibration value caused a cracking effect on the pump system for the pump structure and
components. In this research, using a centrifugal pump with a maximum speed of 1200 RPM impeller rotation
with a maximum value of normal pump vibration is 20 Hz. So that if the pump vibrates beyond the value of 20
Hz, it will have a bad impact on the structure of the pump which can cause cracks and damage to the pump. In
this study, trying to characterize the pump vibrations that arise when the pump is working, by attaching the
sensor to the vibrating pump area, after it is known that the vibration of the centrifugal pump caused by the
impeller rotation and the flowing fluid flow can provide a solution to prevent pump damage. From the research
conducted, it can be concluded that the ideal pump when operating must be below the natural frequency value of
the pump vibration, which is 20 Hz, if the pump vibration value is obtained above the natural frequency value,
this will be done to reduce the vibration by installing a vibration damper in the form of a flexible spring
installation based on ISO Standard 10816-3 so as to reduce the vibration effect that causes pump damage.

ACKNOWLEDGMENTS

This work was supported within the LPPM (Lembaga Penelitian dan Pengabdian Kepada Masyarakat) –
Universitas Pembangunan Nasional Veteran Jakarta (Project number: 345/UN61.0/HK.02/2020). The author
would like to thank the Galangan Kapal PT. Proskuneo Kadarusman.

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