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PROJECT TITLE
ABSTRACT
The main purpose of pump seating is to place the pump while maintaining the function
of the pump. This study is concerned with the development of an efficient method for the
analysis of performance pump seating. The objectives are to predict the performance and
behavior of the design under static loading, to predict the performance and behavior of the design
under vibration loading and to predict the performance and behavior of the design under cyclic
loading. This project is planned to use finite element analysis by using Abaqus software. The
model is designed according to the industry that are familiar with the pump seating. The safe
design in vibration is when the applied frequency will not cause resonance or high amplitude
response. Furthermore, by comparing the analytical/theoretical calculations obtained with the
simulation using Abaqus software, the reliability of the finite element model is analyzed. The
expected result for this project is the simulation can predict the performance of the pump seating
under various loading.
CHAPTER 1
INTRODUCTION
1.1
Project Background
A pump is a hydraulic device which is used to move fluids such as liquids, gases and semiliquid
mixture. The pump converts mechanical energy into hydraulic energy. It also increases the
kinetic energy and / or pressure energy of the fluid. Roto-dynamic action or Positive
Displacement action can increase the energy of the fluid. Nowadays, centrifugal pumps are
perhaps the most common type of pump in operation. With many different configurations
available, centrifugal pumps are widely-used because of their design simplicity, high efficiency,
wide range of capacity and head, smooth flow rate and ease of operation and maintenance.
Pumps are widely used in various industries like petrochemical, textile, chemical, based on
application.[1]
Pump need to be placed by using a pump seating. Pump seating come in as many designs
and styles as there are pumps. No matter the design, the main purpose of the pump seating, is to
placed the pump, while maintaining the function of the pump.[2] When designing and fabricating
a pump seating, it is expected that the complete unit is robust enough so it can withstand the
pump for a long term.
In many industry, usually the material chosen for pump seating is steel ASTM A36. The
reason why this material is chosen is because ASTM A36 plate is a low carbon steel that exhibits
good strength coupled with formability. Furthermore, it is easy to machine and fabricate and can
be securely welded. A36 is a common structural steel plate that can be galvanized to provide
increased corrosion resistance.
A properly designed pump seating is essential for optimal functioning of a centrifugal
pump. One of the way to analyze the pump seating is by using a traditional approach which is
based on the direct testing of prototypes. This trial and error method can be effective, but
expensive and time consuming. Moreover, this method has some limitations with information
about the structure response of the pump seating. One of the possible ways to obtain this
information within a reasonable amount of time and cost is to conduct computational analysis.
1.2
Problem Statement
Pump seating is one of the important component in industry as it will receive a vibration that is
generated by pump. If the pump on the pump seating need to be change with a new pump, the
existing pump seating need to be verified whether it can withstand the new pump or not. New
design of pump seating need to be analyzed to verified it. To obtain better performance of pump
seating, different theoretical cases have been studied.
The pump seating has various loadings include static, vibration and cyclic loading. Static
loading is when the pump seating can withstand the weight of the centrifugal pump. For
vibration loading, the safe design is when the applied frequency will not cause resonance or high
amplitude response. The safe design of pump seating must be able to withstand the cyclic
loading due to pump. Stresses that are involved due to the loads are analyzed using CAE
software and calculated using analytical equations.
This study is concerned with the development of an efficient method for the analysis of
performance pump seating. The stiffness and strength characteristics of the system are greatly
affected by the thickness and size of the plate.
1.3
Objective of Study
1. To predict the performance and behavior of the design under static loading.
2. To predict the performance and behavior of the design under vibration loading.
3. To predict the performance and behavior of the design under cyclic loading.
Expected results:
1. The performance and behavior of the design under static loading is identified and
acceptable
2. The performance and behavior of the design under vibration loading is identified and
acceptable
3. The performance and behavior of the design under cyclic loading is identified and
acceptable
4. The simulation correlate well with the analytical/theoretical equation.
1.4
Scope of Work
This project is proposed to carry out Analysis on pump seating using a centrifugal pump.
The main objectives of this project is to predict the performance and behavior of the pump
seating under static loading, vibration loading and cyclic loading that are generated by the
centrifugal pump. The following steps are done to fulfill this project:
CHAPTER 2
LITERATURE REVIEW
2.1
Pump
A pump is a machinery or device for raising, compressing or transferring fluid. A fluid can be
gasses or any liquid. Pumps are one of the most often sold and used mechanical devices and can
be found in almost many industries. Due to this, there is a wide range of different pumps
available. In general, the family of pumps is separated into positive displacement and kinetic
pumps. A subcategory of kinetic pumps are centrifugal pumps which are again separated into
radial pumps, mixed flow pumps and axial pumps. A centrifugal pump is a rotodynamic pump
that uses a rotating impeller to increase the pressure of fluid. It has been designed mostly for use
in the food, dairy, beverage, pharmaceutical and light chemical industries. Centrifugal pumps
including multi-stage designs and those for high inlet pressure, can handle most low viscosity
applications. Centrifugal pumps can provide the most cost effective solution. Characteristics of
centrifugal pump include high efficiency, low power consumption, low noise level, low net
positive suction head (NPSH) requirement and easy maintenance.[3]
2.2
Pump seating come in as many designs and styles as there are pumps. No matter the design, the
main purpose of the pump seating, is to placed the pump, while maintaining the function of the
pump. When designing and fabricating a pump seating, it is expected that the complete unit is
robust enough so it can withstand the pump for a long term. To minimize the equipments Life
Cycle Costs, the proper design pump seating for the equipment and the application must be
chosen.[2]
Greg Towsley said that although manufacturers have designs and features that are
standard with their baseplates, many additional design considerations can enhance the baseplate
and assist in extending the life of the equipment.[2]
2.3.1
According to the Sami research, resonance problem leads to failure and damage for pump
stations. From the research, Sami studied and analyzed the vibration problem in Helwan
Irrigation Pump Station to define and control vibration sources due to resonance problem leading
to breakdown and failure of the concrete foundation for most pumps in the station. A finite
element model of the pump station was built to define the stresses on the various parts of the
motor and foundations affecting the structure. Vibration level was measured and frequency
analysis as done on the pump parts and on the foundations. Furthermore, the reason why doing
frequency analysis is to identify high unwanted frequencies for each element in the pump
system. Other than that, it is to define the exciting frequencies and determining the level of
vibration at each specific frequency.[4]
In Mayuresh research, it said that the present support frame has been overdesigned as per
the operational loading conditions of the pressure vessel. The further weight reduction is possible
through optimization process using FEA technique and thereby proposing a new design without
compromising the strength parameters. For the theoretical analysis, basic classical theory and
suitable FEA software stress analysis was carried out to determine the stress induced at critical
location which will be validated by experimental results. While for experimental analysis, the
support frame is fabricated and testing were carried out at actual conditions.[5]
Mayuri said that when pump is running, the unbalanced forces are induced at inlet and
exhaust of the pump. This will increase the vibrations and reducing life of pump, shaft, bearing
and other components. However, it can be solved by optimization of base frame and shaft
deflection analysis as per API standards. During the research, shaft deflection analysis will be
carried out analytically and also by using CAD/CAE softwares like CATIA/ANSYS. 3D
modelling will be done through CATIA other relevant software and meshing by using software
like HYPERWORKS/ANSYS. In this research, calculation of different theoretical cases for the
configuration at various shapes of base frame, at various cross-section of base frame and others
will be obtained. Mayuri use theoretical results to validating the results obtained from CAD/CAE
softwares like ANSYS or other else.[6]
2.4 Material
2.4.1 Steel ASTM A36
In many industry, usually the material chosen for pump seating is steel ASTM A36. This material
is chosen because ASTM A36 plate is a low carbon steel that exhibits good strength coupled with
formability. Furthermore, it is easy to machine and fabricate and can be securely welded. A36 is
a common structural steel plate that can be galvanized to provide increased corrosion resistance.
Greg Towsley explains about the various configuration design, styles and requirement of
the baseplate. When the pump and driver are extremely large, cast iron baseplates may not be the
most economical. The use of a fabricated steel baseplate may be required when the dimensions
of the baseplate are greater than 32 inches (81.3 cm) wide or 114 inches (289.6 cm) long, or
both. When reviewing the stress levels of the baseplate, the materials of construction and the type
of welding used need to be considered. After fabrication, the stress that may be caused during
skidding, transportation or lifting must also be included in the review.[2]
2.4.2
From the website, AZoM article shows the properties of the ASTM A36 steel as shown in table
below.[7]
Table 2.1: Physical Properties
As shown in the curve in Figure 2, the stress remains constant while the strain continues
to increase. In the article, it said that at that stage the elongation continues as long as the load is
not removed. The constant stress region of the curve called the yield plateau, or plastic range.
The strain hardening of the stress-strain curve begins at a strain of approximately 12 times the
strain at yield. At that stage, additional stress is required to further extend the material until a
maximum stress is reached, after which the stress decreases with increasing the strain, and then
fracture occurs. Ductility is the behavior as exhibited by the curve which allows the steel
material to largely deform before fracturing. The stress on the curve that lies between the
proportional limit and the upper yield point is the elastic limit of the material.
The article also state that if the material is loaded to a stress lower than this value,
unloading will not induce any permanent deformations. Unloading before elastic limit will
follow the linear path developed during loading the material. Unloading from a point beyond the
elastic limit will follow a path parallel to the linear part but it would produce a permanent
deformation.[8]
2.5 Loadings
2.5.1
Static loading
Loi Cheng studied the behavior of impact loading on an elevator car frame using static structural
analysis and explicit dynamic analysis under different assumptions of boundary conditions.[9]
In the research, the stresses of the static and dynamic analysis were almost similar, which
indicates that both the static and dynamic methods are consistent in calculating stresses of the car
frame under buffer impact. The behavior of the system over the duration of impact can be study
in dynamic analysis. A single snapshot of the systems behavior can be provided by the static
method.[9]
Xiaobo Wang developed a finite element models for the specimen tested and performed a
nonlinear analysis using ABAQUS software. A prediction of the behavior of these girders under
static load can be proposed by FEA. The actual dimensions of the beam were used in order to get
the accurate results.[10]
2.5.2
Vibration loading
Sami said that the pump base plate is the interface between the casing feet and the foundation.
The baseplate and foundation are often a key factor in establishing the so called reed
frequencies of a pump, the vibration motion that particularly vertical pumps often exhibit near
running speed.[4] The installation and qualification of new pumps is often overlooked by civil
engineers and mechanical contractors when they design and construct a new or revised pump
installation. Stiffness of base plate effect on improving the dynamic characteristics of the pump
assembly.
Scheffer has conducted an experiment to monitor pump condition through vibration
analysis. Vibration from their sources may be small but excite the resonant frequencies of the
rotating parts such as the rotor shaft and set-up considerable extra dynamic load on bearings.[4]
Simmons argues that the cause and effect reinforce each other and the machine progresses
towards ultimate break down.[4]
Chris Harper discussed the issues and approaches involved in frame design for vibrating
loads such as reciprocating compressors and pumps, also discusses industry best practices in
frame design, including optimized design techniques. The majority of compressor packages are
now mounted on steel frames or base plates. Designing a frame for a new machinery package
can be challenging because of these factors: The frames must be designed to avoid resonance
and vibration (from dynamic machinery forces and couples).[5]
2.5.3
Cyclic loading
Amin and Hasan said that buckling of structural steel columns under cyclic loading has a great
space in literature. The main aim here is to establish a better understanding and improve the
techniques in the evaluation of buckling of steel structural columns subjected to repeated
loading.[11] Kumar and Usami presented a damage model which is developed and established
for cyclic loading tests of hollow box columns forming bridge piers. In the experiment, the box
columns were checked under a firm axial load and repeated lateral loads.it was found that the
degree and kind of damage allowed depend on parameters of the structure the loading history.
[11]
Amin and Hasan proved that the monotonic nonlinear buckling analysis was seen to give
results that were in very good agreement with the corresponding experimental tests and slightly
different with the Load and Resistance Factor Design (LRFD) formula results.[11] For obtaining
the accurate results, the inclusion of both material and geometrical nonlinearities is very
important. The cyclic behavior was harder to be fully captured using the nonlinear transient
dynamic analysis, where the accuracy of the results inaccurate slightly compared to monotonic
simulation. Both isotropic and kinematic strain-hardening rules gave good approximate outputs
compared with experimental results. Overall, Amin and Hasan proved that the nonlinear finite
element shows good capabilities in simulating the buckling behavior of a steel column under
cyclic loading.[11]
CHAPTER 3
METHODOLOGY
3.1
INTRODUCTION
Methodology for a simple meaning is a theoretical analysis from the method used to conduct an
experiments and principles related with a branch of knowledge. This chapter will cover the
details explanation of methodology that is being used to make this project complete and working
well. Many methodology or findings from this field mainly generated into journal for others to
take advantages and improve as upcoming studies. The method is used to achieve the objective
of the project that will accomplish a perfect result. The flowchart below shows the summary of
procedure taken in this study, phase of actions, type of software used to obtain data.
The title chosen for this research is Analysis on Pump Seating using a Centrifugal
Pump. From the title chosen, it is proposed to carried out an analysis on pump seating by using
ABAQUS software. Firstly, 3D CAD modelling will be done through CAD software called
SolidWorks. This is because SolidWorks CAD is one of the best 3D modelling software which
helps to design a product easily and improved productivity as compared to another CAD
softwares. The CAE software used for this research is ABAQUS software. ABAQUS software is
one of the finite element analysis modules. The main objectives of ABAQUS are the analysis
modules, ABAQUS/Standard and ABAQUS/Explicit, which are complementary and integrated
analysis tools.
The information on pump seating and the type of pump seating in industries has been
studied in order to predict the performance and behavior of the design. A good understanding of
project objectives is important in order to plan the flow of the project research.
3.2
SUMMARY OF STEPS
The summary of steps present by the Figure 3.1 below, the flowchart describes the steps taken to
conduct this study, starting from the identification of problem with several factors considered
until the end of preparation where the data used to write a report. The procedure taken steps by
steps to ensure the study is carried out properly and in appropriate way.
PLANNING
To identify all the information and requirement such as hardware and software, planning must be
done in the proper manner. The planning phase have two main elements namely data collection
and the requirements of hardware and software.
3.3.1
DATA COLLECTION
Data collection is a stage in any area of study. At this stage I planned about the projects resources
and requirements, literature studies and schedule to get more information in this study. All the
materials are collected from journal, texts book and research papers gathered from libraries and
Internet.
Within the data collection period, I do some research about the project related. Then, I
tried to find out the materials and some of equipment to be used.
3.3.2
SOFTWARE REQUIREMENT
3.3.2.1 SOLIDWORKS
SolidWorks mechanical design automation software is a feature-based, parametric solid
modeling design tool which takes advantage of the easy to learn Windows graphical user
interface which can create fully associative 3D solid models with or without constraints while
utilizing automatic or user defined relations to capture design intent.
A solid model is the most complete type of geometric model used in CAD systems. It
contains all the wire frame and surface geometry necessary to fully describe the edges and faces
of the model. In addition to the geometric information, it has the information called topology that
relates the geometry together.
3.2.2.2 ABAQUS
ABAQUS FEA (Finite Element Analysis) is a software that highly usable for finite element
analysis and computer aided engineering. The name of this software is based on the abacus
calculation tool. The Abaqus software consists of five core software products which are:
Abaqus software is highly used in automotive, aerospace and industrial industries. This
software is popular with academic and research institutions due to the wide material modeling
capability and the ability of the program to be customized. Abaqus software also provides a good
collection of Multiphysics capabilities which makes it more attractive for production levels. For
this study, Abaqus software will be used to make the simulation for both static and vibration
state.
The software can be related with other Windows applications like CAD software,
spreadsheet calculators, GIS database and also word processor. The Abaqus software is used to
get the strength of the pump seating prediction for this study and it can be shown by following
this several steps:
1. The pump seating should be drawn in SolidWorks software and will be save in
dxf file format or other types of file format provided.
2. The dxf file then will be imported to be open in Abaqus software.
3. The software also has the application box which provide many features that
can be choose.
3.4
3.4.1
Static loading
Static load is a mechanical force applied to the object. The load usually will cause stress,
deformation and displacement in structure. Bending and moment also occurs in the static load. In
this static loading, the shear and bending moment method are used to analyzed the pump seating
structure. It is important to determine the shear and bending in static load to withstand the
loading without failure.
In this research, the weight of pump is assumed as a distributed load as the weight is on
all the surface of the pump seating.
Figure 3.3
For this research, the pump seating used is rectangular cross section with width b and height h,
the moment of inertia is
I=
b h3
12
The maximum bending moment in the pump seating occurs at the midpoint. The stresses
in terms of the bending moment can be determined. Bending stresses are directly proportional to
the bending moment M and inversely proportional to the moment of inertia I of the cross section.
The stresses vary linearly with the distance y from the neutral axis.
3.4.2
My
I
Vibration loading
Forced vibration is when external forces, usually as F(t) = FoSint or FoCost, are acting on the
system during its vibratory motion. At force vibration, the system will tend to vibrate at its own
natural frequency as well to follow the frequency of the excitation force. In the presence of
friction that portion of motion not sustained by the sinusoidal excitation force will gradually die
out. As a result, the system will vibrate at the frequency of the excitation force regardless of the
initial condition or the natural frequency of the system. That part of sustained vibration is called
steady state vibration or response of the system. Very often, the steady state response is required
in vibration analysis because of its continuous effects.
(1)
and
(2)
Equations (1) and (2) is expressed in non-dimensional term that enables a concise graphical
presentation of these results. By dividing the numerator and denominator of Equations (1) and
(2) by k, we obtain:
(3)
and
(4)
These equations can be further expressed in terms of the following quantities:
determined from,
Depending on the damping constant value, c, the solution for the roots reveal three cases of
vibrating mode:
a). overdamped the value of the damping constant large enough to prevent the mass from
vibrating
b). underdamped the value of the damping constant is small enough to allow the mass to
oscillate.
c). critically damped the borderline case between case a and b
The free response of vibrating system as shown.illustrates the three modes of vibration.
3.4.3
Cyclic loading
When the stress alternates between equal positive and negative peak stresses sinusoidally during
each cycle of operation, it called a purely reversing or cyclic stress. Cyclic stress is developed in
many rotating machine parts that are carrying a constant bending load.
When a part is subjected cyclic stress, also known as range or reversing stress (Sr), it has
been observed that the failure of the part occurs after a number of stress reversals (N) even it the
magnitude of Sr is below the materials yield strength. Generally, higher the value of Sr, lesser N
is needed for failure.
Figure 3.5
A generalized stress condition, can be defined as combine purely reversing stress (Sr)
superimposed on a steady stress (Savg). The following stress-time graph shows this combined
reversing and steady stress condition. If the stress is varying between Smax & Smin, then the
Steady stress = Savg =
Reversing stress = Sr =
S max + Smin
2
S maxS min
2
Figure 3.6
3.5
The loads on the pump seating will be determined, the weight on pump seating and constrains
will applied for fixing the pump seating. The CAD model will imported to be meshed with
suitable element size and checked for quality criteria. The boundary conditions determined are
applied. Results of stress obtained will correlate well with the stress calculated using analytical
equation.
3.6
The applied frequency on the pump seating will be determined, the weight on pump seating and
constrains will applied for fixing the pump seating. The CAD model will imported to be meshed
with suitable element size and checked for quality criteria. The boundary conditions determined
are applied. The applied frequency will not cause resonance or high amplitude response.
3.7
The cycle of the pump seating will be determined, the weight on pump seating and constrains
will applied for fixing the pump seating. The CAD model will imported to be meshed with
suitable element size and checked for quality criteria. The boundary conditions determined are
applied. The pump seating must be able to withstand the cyclic loading due to pump.
References
[1]
[2]
W. Li, H. Lu, Y. Zhang, C. Zhu, X. Lu, and Z. Shuai, Vibration analysis of three-screw
pumps under pressure loads and rotor contact forces, J. Sound Vib., vol. 360, pp. 7496,
2016.
[3]
[4]
[5]
[6]
[7]
T. Covered and C. Composition, ASTM A36 Mild / Low Carbon Steel. pp. 13, 2012.
[8]
[9]
P. Adviser, Finite Element Simulation of Elevator Car Frame Buffer Crash Using ANSYS
, Altair HyperMesh and RADIOSS, 2011.
[10]
[11]
Preliminary Outcome
Figure 2 shows the 2D of pump model that is used to placed on the pump seating. From the table
in the figure, it shows all the specifications of pump. All the specification of pump are important
as it involved in the calculation and analysis. The specifications of pump has been studied in
order to analyzed the parameters of the pump as shown in Figure 1. By using the parameters
from the industry, the weight of pump has been identified which 235kg.
3D CAD modelling of the pump seating has been done through CAD software called
SolidWorks. SolidWorks CAD is one of the best 3D modelling software which helps to design a
product easily and improved productivity as compared to other CAD softwares. All the
dimensions of the pump seating for 3D CAD modelling are used according to the dimension of
pump seating in industry. Figure 11 shows the complete 3D CAD modelling in SolidWorks.
The theoretical calculation that manage to be done in Final Year Project 1 is stress under static
loading. Unfortunately, the calculations need to be improvised in Final Year Project 2. The
calculations has been done by key in all the formulas in excel. Shear force and bending moment
diagram are also used during the calculations as shown in Figure 4. The calculations under static
loading are done as shows below.
#1
#2
b(m)
0.125
b(m)
0.01
h(m)
0.01
h(m)
0.247
I2(m4)
1.26E05
I1(m4)
1.04E08
I(m4)
1.26E05
y(m)
0.16667
9
F(N)
10000
L(m)
0.26
(Pa)
8620330
RA
F
M(Nm
)
650
(Pa)
862033
0
5000
0.1705
MA
0.1705
-5000
0.3005
MB
650
0.3005
RC
5000
0.4305
MC
: 10mm
Yield stress
: 379.02 MPa
Figure 4
0.4305