Practical Rotordynamics For Centrifugal Pumps 52pp Sulzer

Sulzer Pumps
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Practical Lateral Rotordynamics for Centrifugal Pumps

Pump Symposium Calgary November 2007 Brian Germaine Sulzer Pumps UK Ltd. brian.germaine@sulzer.com
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Practical Rotordynamics for Centrifugal Pumps

This workshop will present a practical view of Lateral Rotordynamics for Centrifugal Pumps. The procedures for undertaking such investigations will be explained along with the important rotordynamic features that exist within multistage pumps. API 610 Appendix I will be presented and compared to procedures adopted for centrifugal compressors. "Stiff-shaft" and "flexible-shaft" systems will be discussed along with practical examples. This workshop will be of benefit for any Engineer involved in the specification, design or operation of Centrifugal Pumps who wants to gain a good understanding of rotordynamics and many of the myths that surround this subject.
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Agenda Introduction to the World of Rotordynamics API 610 Requirements: "Old" & "New" Definition of "Stiff Shaft" and "Flexible Shaft" The Process Damped Lateral Calculations Rotordynamic Development & Testing Instability & Unbalance Response Swirl Brake Design & Rotor Damping Practical Examples & Parameter Changes
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Introduction
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"Rotordynamics is the science of predicting the vibrational behaviour of rotors of any kind"
Rankine 1869 was the first person to perform an analysis of a spinning shaft
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Single Degree of Freedom System
Equation of motion about the static equilibrium position does not contain weight and weight balancing force. Force is assumed to be linear to their driving parameters & m&& = F ( t ) cx kx x Unforced System
x
k m F(t)
m&& + cx + kx = 0 x & Second-order homogenous ordinary differential equation
m2 + c + k = 0
k( x + x
static
)
m
c& x
mg
Eigenvalue problem (damping neglected)
1, 2 =
k k = 0 j m m
F( t )
Imaginary part of complex solution is the undamped natural frequency or Eigenfrequency
k 0 = m
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Laval (Jeffcott) Rotor
Mass-less shaft with bearing stiffness (k) Disc-like mass (m) at mid-span, supported on rigid bearings, perfectly balanced Unforced & un-damped system with circular orbit
=
)
Dynamic equilibrium i.e. centrifugal force = shaft force
k( e + e
me
static
m
2
mg
me 2 ke = 0 k me( 2 ) = 0 m
2 k =0 m
is called the critical speed and in this case is also the natural frequency
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Journal Bearings
F Sommerfeld Number, So = B D
2 Static
Sommerfeld Number US,
S=
B D n F
2 Static
Cylindrical bearings have good static properties. Where dynamic behaviour is critical, lobed or tilting pad bearings are better /9

Annular Seals
The main difference between bearing and annular seal is the axial pressure differential axial flow Axial flow in pump annular seals is normally turbulent. "Lomakin" effect: Bearing capability due to axial through flow, without any contribution from rotor or fluid rotation, leads to restoring radial forces if the rotor is laterally displaced.
resulting force proportional to area
Fy
Inlet
Outlet
Stiffness (k) is proportional to the pressure differential Stiffness (k) decreases with increasing clearance h0
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Annular Seals
asymmetric pressure profile due to rotation Circulatory De-stabilizing Force: The rotor as well as the fluid flowing through the annular seal are rotating i.e. have circumferential velocity. Distortion of the pressure profile due to this rotation yields forces perpendicular to the displacement. These forces are non-conservative Fluid rotation in annular seals has two origins: 1) fluid pre-rotation at entrance u1 and 2) shear forces at the surface of the rotating part. For short seals with L/D << 1, the destabilizing force is proportional to u1 and is expressed by the crosscoupled stiffness
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Annular Seals Coefficients
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Impellers Interaction Rotordynamic Coefficients
As a pump rotor is subject to vibrations by nature, reaction forces always occur at the impeller due to the lateral movement relative to the pump casing or diffuser The flow around the impeller becomes asymmetric and this causes unsteady fluid forces on the impeller. Impeller-diffuser-interaction develops as well as the side room effects. These forces are destabilising forces and counteract the available modal damping If they are not included in a damped lateral rotordynamic analysis, modal damping will be higher than actual.
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Campbell & Damping Diagrams
Investigation of dynamic system behavior For pump rotors, Eigenfrequencies are a function of shaft speed Critical speeds are the intersection points of natural frequency curves with 1x n line Natural frequencies depend on shaft speed, critical speeds do not Damping is "modal" damping
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API 610 10th Edition Appendix I Specification for Performing Lateral Rotordynamics for Pumps
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Analysis of 1st, 2nd and 3rd dry critical speeds Classically stiff first dry critical speed > 1.2x max. continuous shaft speed if wet running only Analysis for new and worn (2x new) clearance conditions Analysis at expected temperature for water (new) and pumped liquid (new and worn) Analysis for operational speed range from 25% to 125% of rated shaft speed Includes stiffness and damping at labyrinth type shaft seals, including bearings Considers stiffness of bearing support structure For both new and worn clearances the damping factor vs. separation margin to be calculated
1) Acceptable Region
2) Improvement Desired
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API 610 7th Edition Appendix I A Specification for Compressors
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API 610 7th Edition; defined the analysis process completely differently Analysis focused on unbalance response analysis only Position of critical speed and damping level important Procedure identical to API 617 Turbo Compressors Damping calculated from curve shape at first critical speed position Procedure not sensible for centrifugal pumps Amplification factor defines damping level, log decrement etc.
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Definition of "Stiff" vs. "Flexible" Rotors
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Definition of "Stiff Shaft" Design ISO 13709 (API 610) requires all 1 and 2 stage (OH, BB1 and BB2) pumps to have their first critical speed in air to be at least 20% above operating speed. "Stiff Shaft" or "Large Shaft" machines have lower static deflection under no rotation than the radial clearance (statically stiff) Duncan & Hood 1976, define "stiff shaft" pumps when the first Eigenfrequency in air is higher than the running frequency i.e. fe/fn > 1 (dynamically stiff)
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Definition of "Flexible" Design "Flexible" or "slender" rotors have their first lateral critical speed in air, below the operating speed. "Flexible" rotors typically will have contact between stationary and rotating wear parts at start-up and shut-down. During operating the center and throttle bushings act as product lubricated bearings and add significant stiffening and damping making for a very "stiff" rotor in operation.
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Duncan & Hood Guidance Chart Often the feeling is "The thicker the shaft the better" and pumps are praised (or cursed) based on the shaft thickness. Concerning hydraulic behaviour, it is undisputed that thinner shafts tend to increase efficiency, head coefficient and improve suction performance. In general, multistage centrifugal pumps are dynamically flexible.
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The Process Damped Lateral Rotordynamic Calculations
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SULZER LATERAL-PU Finite Element Core: MADYN Pre-processor: Rotor geometry Pump data: Bearings Lubricant Seals Impellers Operating data
ROTOR GEOMETRY PUMP DATA PROGRAMS SEAL HSEALM DATA BASE Bearings Seals Impellers Oper. Data
BITER Shaft Deflec. Bearing load
Seal Coeff. Bearing Coefficient Impeller Interaction
MADYN
Static Beahaviour Eigenvalues Forced Response
Forces
Static Deflection and Stresses
Damped Eigenvalues
Forced Response
Campbell Plot f Mb 2 T 1 FAx D1 D2

D=0
Runup A, A
kB
cB
Bearing Bearing housing
kB
cB
n n
ms
kS cS
ms
kS cS
Stress Evaluation Yielding Fatigue
Support
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Rotor Setting
Radial clearances Running
Journal bearing
Standstill
Journal bearing
e = Offset
Running at Standstill
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Frequency [Hz]
Speed = 3600 rpm F= 80.42 Hz D= 25.6 %
30
60
90
120
150
Speed = 2400 rpm F= 57.21 Hz D= 28.2 %
Speed = 6000 rpm F= 125.53 Hz D= 20.4 %
nmin
1200 50
2160
3120
4080
Synchronous Excitation
5040 6000 Rotor Speed [rpm]
Damping [%]
Speed = 1200 rpm F= 35.02 Hz D= 26.9 %
Speed = 4800 rpm F= 105.53 Hz D= 23.1 %
10
20
30
40
1200
Z
2160
3120
4080
Mode Mode
5040 6000 Rotor Speed [rpm]
orbit with max. major axis,

X
t = 0,
t =
/2
List of Symbols: 1: 2:
Mode Shape No. 1 Pump State: New Analysis.... 304122026, HPcp 350-425-8s/27m,NEW
LATERAL Rev. 4.5A DATE: 12.Apr.2003
Pump State: New Analysis.... 304122026, HPcp 350-425-8s/27m,NEW
nn
LATERAL DAMPED NATURAL FREQUENCIES ANALYSIS
EIGVC: CAMPBELL AND DAMPING DIAGRAM
HPcp 350-425-8s/27m,NEW
Sulzer Pumps UK Ltd
HPcp 350-425-8s/27m,NEW
Sulzer Pumps UK Ltd
nmax
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Rotordynamic Development & Testing
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Late 80's, early 90's Sulzer received a order from EPRI to investigate a number of specific areas of pump design with an aim of improving BFP reliability
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EPRI Tasks included; full dynamic testing of annular seals and development of new computer code Impeller/diffuser interaction coefficients Full verification testing of a 3-stage pump
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Instability & Unbalance Response
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Forced Response
Forced response is the dynamic shaft amplitude given in absolute terms due to excitation forces (mechanical or hydraulic unbalance) Results are presented in two ways: forced bending shape and orbits for a given shaft speed or vibration vectors and phase angles for discrete locations along the rotor as function of shaft speed In centrifugal pumps, the typical damped response to unbalance does not show a peak in displacement at resonance large enough to assess the amplification factor, therefore it is restricted to comparing rotor displacement to available clearances The peak-to-peak displacement of the unbalanced rotor at the points of max. displacement shall not exceed a defined percentage of the diametral running clearance (API 610 states 35%)
Bode Plot
n=const.
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Forced Response
Mass [kg] U1 344.4 U1
Mechanical Unbalance G = 2.5 x 4

Station Number 20 600
50
175 200 220
255
315
350 370 395
550
U1
U1 U1
U1 2275
U1
U1 U1
U1
[mm]
Coupling Sensitivity Factor: SF = 4.988E+0
Maximum Vibration Orbit t = 0 t = /2 Z X
The dynamic behavior of shaft overhangs, notably the coupling overhang is very important. An overhang assessment should be made utilizing forced response techniques. Good rotordynamic reliability can be reached only if the coupling end of the shaft has a low sensitivity to unbalance forces.
ROTOR DEFORMATION LINE AT Load case...
6.000E+3 [rpm]
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2, WORN
Swirl Brake Design & Rotor Damping Benefits
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Swirl Brakes Applied at Annular Seals
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Swirl Brakes Applied to Balance Drum Liner
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Application of Swirl Brakes Swirl Brakes in Action!
Radial slot Swirl Brakes were applied to a 5-stage BFP to reduce shaft vibration at full speed, leak-off flow condition. Shaft vibration and response was considerably "damped"
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Damped Lateral Rotordynamic Calculations Practical Examples
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Case Studies
LATERAL Analysis, Ultra High Pressure Seawater Injection Pump
Option 2 5s+5s Impeller
arrangement
4 6s+6s Back to back 6000 RPM 12
5 8s In line 8494 RPM 8
Back to back 8494 RPM 10
Speed Number of stage Design Concept
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Case Studies
LATERAL Analysis, Ultra High Seawater Injection Pump
Evolution of First Eigenmodes from NEW- to WORN-Condition (2x Design Clearances)*
HPcp 220-5s+5s (Option 2) HPcp 285-6s+6s (Option 4) HPcp 250-8s (Option 5)
NEW
Speed = 8494 rpm F= 156.26 Hz D= 22.9 %
Speed = 6000 rpm F= 142.76 Hz D= 32.2 %
Speed = 8494 rpm F= 156.56 Hz D= 22.1 %
WORN
Speed = 8494 rpm F= 153.21 Hz D= 14.3 %
Speed = 6000 rpm F= 122.67 Hz D= 12.5 %
Speed = 8494 rpm F= 139.21 Hz D= -1.3 %
fe,1/fn =
1.10 --> 1.08
1.43 --> 1.23
1.11 --> 0.98

* without swirl breaks at impeller suction side annular seals
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Case Studies
FFT Free Vibration in Air: Verification of Analysis 100Hz Operation
Rotor Tap Test in Vee Blocks
EIGENVECTOR Nr. 3 F= 2.2254E+01 Hz D= 3.8533E-06
22.25 Hz
EIGENVECTOR Nr. 7 F= 9.0750E+01 Hz D= -1.7742E-05
90.75 Hz
EIGENVECTOR Nr. 11 F= 2.0144E+02 Hz D= -1.9899E-05
201.44 Hz
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Case Studies
FFT Frequency Spectra: Slave Tested Machine back-to-back design
2x Clearance Tests
Speed 6000 rpm Flow 250 m3/h (50%)
Pump DE (x-Direction)
Pump NDE (x-Direction)

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Eigenfrequency Shift with Changing Speed
Natural Frequency [Hz]
In-Line Shaft on Rigid Bearings

160 140 120 100 80 60 40 20 0 0 1200 2400 3600 4800 6000 Speed [rpm]
New Worn
The diagram above shows how the Natural Frequencies of the rotor change with speed for both New & Worn conditions. From Dry to Operating, frequencies can change by a factor of 4
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Stiffness of Annular Seals
related seal stiffness to shaft stiffness [%]
Related Seal Stiffness In-Line Pump

1000 900 800 700 600 500 400 300 200 100 0 0 1200 2400 3600 4800 6000 Speed [rpm]
new suction seal new eye seal new interstage seal new piston worn suction seal worn eye seal worn interstage seal worn piston
operating speed
The diagram above plots "annular seal" stiffness with increasing speed. The piston stiffness is more than 6x that of annular eye or hub side labyrinths. For back-to-back pumps, this means that the centre bush acts as an additional hydrodynamic bearing, not so heavily influenced by worn clearances.
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Static Deflection and Increasing Shaft Diameter
Static Deflection and Mass vs. Shaft Diameter Increase
300 Deflection related to clearance [%] and Mass increase [%] 250 200 150 100 50 0 0 10 20 30 40 50 Diameter Increase [%] Deflection change in-line pump Mass change in-line pump Deflection change back-to-back pump Mass change back-to-back pump
The above diagram shows the shaft deflection related to the seal clearance. With an increase of 50mm (+27%), the static deflection is reduced by a factor of 2 for inline pump. For back-to-back this increases by a factor of 3, with a diameter increase of about 45%. This shows that the inline machine remains statically stiff but back-to-back design would have to see a 40% increase to make the rotor statically stiff.
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Change in Critical Speed with Increasing Shaft Diameter
1 Critical Speed vs. Diameter Increase
4 1 Critical speed related to running speed 3.5 3 2.5 2 1.5 1 0.5 0 0 10
In-line pump, dry In-line pump, wet new In-line pump, wet worn
st
st
20
30
40
Back-to-back pump, dry Back-to-back pump, wet new Back-to-back pump, wet worn
50
Diameter Increase [%]
The above diagram shows the change in the first critical speed with increasing shaft diameter. Dry critical speeds do not change that much and according to the "old" criteria remain dynamically flexible. Shaft size has an effect on the wet critical speed but even at the original diameter they are well above running speed frequency. Notice large difference between wet and dry critical speeds for back-to-back pumps. The secret is the centre bush!!
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Lateral Analysis 8-stage inline API Damping Diagram Original Design Lateral Analysis 8-stage inline API Damping Diagram 10mm Increase on Shaft Diameter No change to pump rotordynamics
Diagram A
Damping of the Individual Modes
50
Damping %
Damping %
Diagram A
Damping of the Individual Modes
50 0 0.0 10 20 30 40
10
20
30
40
0.0
0.5
List of Symbols: Mode Mode 1 2
1.0
1.5 fe/fn
0.5
List of Symbols: Mode Mode 1 2
1.0
1.5 fe/fn
Pump State: New Nominal Speed = 4800 rpm Speed Range from 1800 to 5184 rpm Damping Criterion: API 610 8th Edition Analysis.... 304122026, HPcp 350-425-8s/27m,NEW
Pump State: New Nominal Speed = 4800 rpm Speed Range from 1800 to 5184 rpm Damping Criterion: API 610 8th Edition Analysis.... 611151331, HPcp 350-425-8s/27m,NEW
LATERAL Rev. 4.6 DATE: 15.Nov.2006
HPcp 350-425-8s/27m,NEW
Sulzer Pumps UK Ltd
HPcp 350-425-8s/27m,NEW
Sulzer Pumps UK Ltd
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Pump Selection Chart
2-1 1-1
2-2 1-2 2-3
Region 1-1: In-line pumps that do not require any swirl brakes Region 1-2: In-line pumps that require radial holes at balance drum entrance Region 2-1: Back-to-back pumps that do not require any swirl brakes Region 2-2: Back-to-back pumps that require radial slots at centre bush Region 2-3: Back-to-back pumps that require swirl brakes at all annular seals and throttle bushes.
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Rotor Design
For high speed pumps shrunk on components is key for good rotordynamic performance, balance and repeated build quality (>4000rpm)
Shrunk on coupling, oil press fit, parallel stepped or taper fit
Shrunk on balance drum,Shrunk on thrust oil press fit collar, oil press fit
Shrink disk for mechanical seal sleeve
Impellers are shrunk on, have keys for torque transmission and use split ring for thrust loading
Advantage shrunk on parts allow for high rotor balancing quality shrunk on parts avoid fretting corrosion and minimize stress concentrations shrunk on parts avoid loose parts on shaft during operation and result in lower vibration
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A Last Look at the 30 Year Old Chart
back to back
K-Factor Guideline Chart - Duncan & Hood

1000
225,290 5s 225,290 6s Milne Point 225,290 8s 225,290 9s
Karang
900
Too slender difficult to achieve rub-fre initial build
800
Rotor Dynamic Factor (k)
700
U p p er limit s f o r slend er wet r unning p ump s
Too slender difficulty m aintaining rotor straightness & balance. Rotor sensitive to unbalance possibilty of prem ature w ear at internal clearances
Lam inaria
C GY
300,355 4s 300,355 5s
Thunder Horse Holstein

Eldfisk AIOC
300,355 6s 300,355 7s 300,355 8s 395,405 4s
600
R eco mmend ed d esig n line f o r slend er shaf t wet r unning p ump s ELF Angola
T ot al dun bar
Halfdan Troll Schiehallion Armada
Chirag 8 stage
M aersk Gorm Gorm Dorood Hutton M iller Dev El Furrial White Tiger
500
400
R eco mmend ed d esig n line f o r lar g e shaf t wet r unning Girassol
Er ski e n
Zakum Fulmar Cusiana
395,405 5s 395,405 7s 395,405 8s 515
Mars
Buckland Bonga
300
R eco mmend ed up p er Yibal 4 stage Sleipner limit s f o r p ump wit h d r y r unning cap ab ilit y Alba plb Brage plb ALBA SWI plb Bragr plb
Hutton SWI Nimar 2,3
200
K = (W^0.5 x L^1.5 ) / D^2

100
455 430
0 2000 3000 4000 5000 6000 7000
Max Operating Speed N
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Typical "Flexible" Back-to-Back Pump Designs
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Conclusions Pump shafts must be primarily sized for adequate stress levels, nominal torsional stress at coupling. Shaft stiffness criteria "old school" methods, are completely inadequate as these are all based on rotor frequency in air Making the shaft larger beyond the values determined for stress levels, will not generally improve the dynamic behaviour or reliability of the pump. For high speed, multi-stage pumps, labyrinth and impeller interaction forces dominate. Full damped lateral analysis using modern tools and knowledge is the only way to judge the rotordynamic design. Special care must be given to pumps operating on fluids with low density products but there are design options available such as swirl brakes to ensure these pumps remain rotordynamically stable.
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Thank You for Your Attention

For further details, contact: Brian Germaine Engineering Director Sulzer Pumps UK Ltd. Manor Mill Lane Leeds LS11 8BR Tel. +44 113 272 4528 E-Mail: brian.germaine@sulzer.com
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Practical Rotordynamics For Centrifugal Pumps 52pp Sulzer

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Sulzer Pumps

Practical Lateral Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

m&& + cx + kx = 0 x & Second-order homogenous ordinary differential equation

Eigenvalue problem (damping neglected)

Imaginary part of complex solution is the undamped natural frequency or Eigenfrequency

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Sommerfeld Number US,

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

API 610 7th Edition Appendix I A Specification for Compressors

Practical Rotordynamics for Centrifugal Pumps

Definition of "Stiff" vs. "Flexible" Rotors

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

The Process Damped Lateral Rotordynamic Calculations

Practical Rotordynamics for Centrifugal Pumps

BITER Shaft Deflec. Bearing load

Seal Coeff. Bearing Coefficient Impeller Interaction

Static Beahaviour Eigenvalues Forced Response

Static Deflection and Stresses

Campbell Plot f Mb 2 T 1 FAx D1 D2

Bearing Bearing housing

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Speed = 3600 rpm F= 80.42 Hz D= 25.6 %

Speed = 2400 rpm F= 57.21 Hz D= 28.2 %

Speed = 6000 rpm F= 125.53 Hz D= 20.4 %

5040 6000 Rotor Speed [rpm]

Speed = 1200 rpm F= 35.02 Hz D= 26.9 %

Speed = 4800 rpm F= 105.53 Hz D= 23.1 %

5040 6000 Rotor Speed [rpm]

orbit with max. major axis,

Pump State: New Analysis.... 304122026, HPcp 350-425-8s/27m,NEW

LATERAL DAMPED NATURAL FREQUENCIES ANALYSIS

EIGVC: CAMPBELL AND DAMPING DIAGRAM

LATERAL Rev. 4.5A DATE: 12.Apr.2003

Rotordynamic Development & Testing

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Instability & Unbalance Response

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Mechanical Unbalance G = 2.5 x 4

175 200 220

350 370 395

Coupling Sensitivity Factor: SF = 4.988E+0

Maximum Vibration Orbit t = 0 t = /2 Z X

ROTOR DEFORMATION LINE AT Load case...

Swirl Brake Design & Rotor Damping Benefits

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps