Practical Rotordynamics For Centrifugal Pumps

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/1
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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
/2
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.
/3

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
/4
Introduction
/5
"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
/6

Single Degree of Freedom Equation of motion about the static
equilibrium position does not contain
System weight and weight balancing force.
Force is assumed to be linear to their
driving parameters
k m&x& = F ( t ) cx& kx
c
Unforced System
m
m&x& + cx& + kx = 0
x
Second-order homogenous ordinary
differential equation
F(t)
m2 + c + k = 0
Eigenvalue problem (damping
k( x + x static
) c&x neglected)
1, 2 =
k
= 0 j
k
m m m
Imaginary part of complex solution is
F( t ) mg the undamped natural frequency or
Eigenfrequency
k
0 =
m
/7

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
e orbit
=
Dynamic equilibrium i.e. centrifugal force =
shaft force
k( e + e )
m
static
me 2 ke = 0
me
k
me( 2 ) = 0
2
mg
m
k
2 =0
m
is called the critical speed and in this

case is also the natural frequency
/8

Journal Bearings
F 2
Sommerfeld Number, So = Static
B D
B D n
Sommerfeld Number US, S=
F
Static
2
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
Fy Axial flow in pump annular seals is
normally turbulent.
p "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
Inlet Outlet
Stiffness (k) is proportional to the pressure differential
Stiffness (k) decreases with increasing clearance h0
/ 10

Annular Seals Circulatory De-stabilizing Force:
The rotor as well as the fluid flowing
asymmetric pressure
through the annular seal are rotating
profile due to rotation
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 cross-
coupled stiffness
/ 11
Annular Seals Coefficients
/ 12

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 de-

stabilising 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.
/ 13

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
/ 14
API 610 10th Edition Appendix I

Specification for Performing Lateral
Rotordynamics for Pumps
/ 15

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
/ 16
API 610 7th Edition Appendix I

A Specification for Compressors
/ 17
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.
/ 18
Definition of "Stiff" vs. "Flexible"

Rotors
/ 19
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)
/ 20
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.
/ 21
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.
/ 22
The Process Damped Lateral

Rotordynamic Calculations
/ 23

ROTOR PUMP DATA
SULZER LATERAL-PU GEOMETRY PROGRAMS
SEAL
Bearings
Seals
HSEALM
Impellers
Finite Element Core: MADYN DATA
Oper. Data
BASE
Pre-processor: Seal Coeff.

Bearing
Rotor geometry BITER
Shaft Deflec.
Coefficient
Impeller
Pump data: Bearings Bearing load Interaction
Lubricant MADYN
Static Beahaviour
Eigenvalues
Seals Forced Response Forces
Impellers Static Deflection

and Stresses
Damped
Eigenvalues
Forced
Response
Operating data
Campbell Plot Runup
f A,
D2 A
Mb
2 D=0
T 1 D1

kB cB Bearing kB cB
FAx
n n
ms Bearing housing ms
Stress
kS cS Support kS cS Evaluation
Yielding
Fatigue
/ 24
Rotor Setting Running
Radial clearances
Journal Journal
bearing bearing
Standstill
e = Offset e
Running
at Standstill
/ 25
150
Frequency [Hz]
120
Speed = 3600 rpm
F= 80.42 Hz
D= 25.6 %
90
60
30
nmax
nmin
Speed = 2400 rpm Speed = 6000 rpm
nn
F= 57.21 Hz F= 125.53 Hz
0
D= 28.2 % D= 20.4 %
1200 2160 3120 4080 5040 6000

Synchronous Excitation Rotor Speed [rpm]
50
Damping [%]
40
30
20
F= 35.02 Hz F= 105.53 Hz
D= 26.9 % D= 23.1 %
10
0
1200 2160 3120 4080 5040 6000
Z Rotor Speed [rpm]
orbit with max. major axis, t = 0, t = /2
X List of Symbols: Mode 1:
Mode Shape No. 1 Mode 2:
Pump State: New Pump State: New
Y Analysis.... 304122026, HPcp 350-425-8s/27m,NEW Analysis.... 304122026, HPcp 350-425-8s/27m,NEW
LATERAL Rev. 4.5A LATERAL Rev. 4.5A
LATERAL DAMPED NATURAL FREQUENCIES ANALYSIS DATE: 12.Apr.2003 EIGVC: CAMPBELL AND DAMPING DIAGRAM DATE: 12.Apr.2003
HPcp 350-425-8s/27m,NEW HPcp 350-425-8s/27m,NEW
Sulzer Pumps UK Ltd Sulzer Pumps UK Ltd
/ 26
Rotordynamic
Development & Testing
/ 27

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
/ 28
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
/ 29
Instability & Unbalance Response
/ 30

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.
/ 31

Forced Response
The dynamic behavior of shaft
Mass [kg] 344.4
overhangs, notably the
U1 U1
Mechanical Unbalance G = 2.5 x 4 coupling overhang is very

Station
Number 20 600 important.
50 175 200 220 255 315 350 370 395 550
An overhang assessment
should be made utilizing forced
U1 U1 U1 U1 U1 U1 U1 U1
response techniques.
[mm] 2275
Good rotordynamic reliability
Coupling Sensitivity Factor:
SF = 4.988E+0 can be reached only if the
Maximum Vibration Orbit coupling end of the shaft has a
t = 0
t = /2
low sensitivity to unbalance
Z
X
forces.
Y
ROTOR DEFORMATION LINE AT 6.000E+3 [rpm]

Load case... 2, WORN
/ 32
Swirl Brake Design & Rotor

Damping Benefits
/ 33

Swirl Brakes Applied at
Annular Seals
/ 34

Swirl Brakes Applied to Balance Drum Liner
/ 35

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"
/ 36
Damped Lateral Rotordynamic

Calculations Practical Examples
/ 37

Case Studies
LATERAL Analysis, Ultra High Pressure Seawater Injection Pump
Option
2 4 5
5s+5s 6s+6s 8s
Impeller Back to back Back to back In line
arrangement
Speed 8494 RPM 6000 RPM 8494 RPM
Number of 10 12 8
stage
Design
Concept
/ 38

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 %
F= 142.76 Hz F= 156.56 Hz
D= 32.2 % D= 22.1 %
WORN
Speed = 8494 rpm

Speed = 8494 rpm
Speed = 6000 rpm F= 139.21 Hz
F= 153.21 Hz
F= 122.67 Hz D= -1.3 %
D= 14.3 %
D= 12.5 %
fe,1/fn = 1.10 --> 1.08 1.43 --> 1.23 1.11 --> 0.98
* without swirl breaks at impeller suction side annular seals

/ 39

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
/ 40

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)

/ 41

Eigenfrequency
Shift with In-Line Shaft on Rigid Bearings
160
Changing Speed
140
Natural Frequency [Hz]

120 New
Worn
100
80
60
40
20
0
0 1200 2400 3600 4800 6000
Speed [rpm]
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
/ 42

Stiffness of Related Seal Stiffness In-Line Pump
Annular Seals 1000
900
new suction seal
800 new eye seal
operating speed
to shaft stiffness [%]

related seal stiffness
new interstage seal
700
new piston
600 worn suction seal
500 worn eye seal
worn interstage seal
400
worn piston
300
200
100
0
0 1200 2400 3600 4800 6000
Speed [rpm]
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.
/ 43

Static Deflection and Static Deflection and Mass vs. Shaft Diameter Increase
Increasing Shaft 300
Diameter
Deflection related to clearance

250
[%] and Mass increase [%]

200
150
100
50
0
0 10 20 30 40 50
Diameter Increase [%]
Deflection change in-line pump Deflection change back-to-back pump
Mass change in-line 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.
/ 44

Change in Critical Speed st
1 Critical Speed vs. Diameter Increase
with Increasing Shaft 4
3.5
Diameter
1 Critical speed related

3
to running speed
2.5
2
1.5
1
st
0.5
0
0 10 20 30 40 50
Diameter Increase [%]
In-line pump, dry Back-to-back pump, dry
In-line pump, wet new Back-to-back pump, wet new
In-line pump, wet worn Back-to-back pump, wet worn
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!!
/ 45
Lateral Analysis 8-stage inline Lateral Analysis 8-stage inline

API Damping Diagram - API Damping Diagram 10mm
Original Design Increase on Shaft Diameter
No change to pump rotordynamics
Diagram A Diagram A
Damping of the Individual Modes Damping of the Individual Modes
50
50
Damping %
Damping %
40
40
30
30
20
20
10
10
0
0
0.0 0.5 1.0 1.5 0.0 0.5 1.0 1.5

fe/fn fe/fn
List of Symbols: Mode 1 List of Symbols: Mode 1
Mode 2 Mode 2
Pump State: New Pump State: New

Nominal Speed = 4800 rpm Nominal Speed = 4800 rpm
Speed Range from 1800 to 5184 rpm Speed Range from 1800 to 5184 rpm
Damping Criterion: API 610 8th Edition Damping Criterion: API 610 8th Edition
Analysis.... 304122026, HPcp 350-425-8s/27m,NEW Analysis.... 611151331, HPcp 350-425-8s/27m,NEW
LATERAL Rev. 4.5A LATERAL Rev. 4.6
LATERAL DAMPED NATURAL FREQUENCIES ANALYSIS LATERAL DAMPED NATURAL FREQUENCIES ANALYSIS DATE: 15.Nov.2006
DATE: 12.Apr.2003
HPcp 350-425-8s/27m,NEW HPcp 350-425-8s/27m,NEW
Sulzer Pumps UK Ltd Sulzer Pumps UK Ltd
/ 46
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.
/ 47

Rotor Design
For high speed pumps shrunk on components is key for good rotordynamic
performance, balance and repeated build quality (>4000rpm)
Shrunk on coupling, Shrunk on balance drum,Shrunk on thrust

oil press fit, oil press fit collar,
parallel stepped or taper fit oil press fit
Shrink disk for Impellers are shrunk on, have keys for torque
mechanical seal sleeve 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
/ 48

A Last Look at the 30 Year Old Chart
back to back
K-Factor Guideline Chart - Duncan & Hood 225,290 5s

1000
225,290 6s
Karang Milne
Too slender difficult to Too slender difficulty 225,290 8s
Point
900
achieve rub-fre initial m aintaining rotor straightness
& balance. Rotor sensitive to 225,290 9s
build
unbalance possibilty of Lam inaria
800
C GY
300,355 4s
prem ature w ear at internal
clearances 300,355 5s
U p p er limit s f o r slend er
700 wet r unning p ump s
Thunder Horse
Rotor Dynamic Factor (k)
300,355 6s
R eco mmend ed d esig n line 300,355 7s
600 f o r slend er shaf t wet r unning
Holstein
Halfdan
p ump s
Chirag 8 stage 300,355 8s
ELF Angola Troll Eldfisk
500 Armada AIOC
R eco mmend ed
Er skin e
T ot al dun bar
Schiehallion M aersk Gorm Gorm 395,405 4s
Zakum Hutton
d esig n line f o r lar g e Dorood
shaf t wet r unning Girassol M iller Dev
395,405 5s
400 Fulmar El Furrial
Cusiana Mars Buckland White Tiger
Hutton SWI 395,405 7s
R eco mmend ed up p er Yibal 4 stage Sleipner Bonga
limit s f o r p ump wit h Nimar 2,3
300
d r y r unning cap ab ilit y Alba plb
395,405 8s
Brage plb
ALBA SWI plb
Bragr plb
515
200
K = (W^0.5 x L^1.5 ) / D^2 455
100 430
0
2000 3000 4000 5000 6000 7000
Max Operating Speed N
/ 49

Typical "Flexible" Back-to-Back Pump Designs
/ 50

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.
/ 51
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
/ 52

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http://boilersinfo.

Practical Lateral Rotordynamics for

Practical Rotordynamics for Centrifugal Pumps

This workshop will present a practical view of Lateral Rotordynamics for

API 610 Appendix I will be presented and compared to procedures

This workshop will be of benefit for any Engineer involved in the

Practical Rotordynamics for Centrifugal Pumps

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

Practical Rotordynamics for Centrifugal Pumps

"Rotordynamics is the science of

Practical Rotordynamics for Centrifugal Pumps

Practical Rotordynamics for Centrifugal Pumps

is called the critical speed and in this

Practical Rotordynamics for Centrifugal Pumps

Sommerfeld Number, So = Static

Cylindrical bearings have good static

Practical Rotordynamics for Centrifugal Pumps

p "Lomakin" effect: Bearing capability

Stiffness (k) is proportional to the pressure differential

Stiffness (k) decreases with increasing clearance h0

Practical Rotordynamics for Centrifugal Pumps

Fluid rotation in annular seals has

For short seals with L/D << 1, the

Practical Rotordynamics for Centrifugal Pumps

Annular Seals Coefficients

Practical Rotordynamics for Centrifugal Pumps

These forces are de-

Practical Rotordynamics for Centrifugal Pumps

API 610 10th Edition Appendix I

Practical Rotordynamics for Centrifugal Pumps

API 610 7th Edition Appendix I

Practical Rotordynamics for Centrifugal Pumps

Definition of "Stiff" vs. "Flexible"

Practical Rotordynamics for Centrifugal Pumps

Definition of "Stiff Shaft" Design

ISO 13709 (API 610) requires all 1

"Stiff Shaft" or "Large Shaft"

Duncan & Hood 1976, define "stiff

Practical Rotordynamics for Centrifugal Pumps

Definition of "Flexible" Design

Practical Rotordynamics for Centrifugal Pumps

Duncan & Hood Guidance Chart

Often the feeling is "The thicker

Concerning hydraulic behaviour, it

In general, multistage centrifugal

The Process Damped Lateral

Practical Rotordynamics for Centrifugal Pumps

Pre-processor: Seal Coeff.

Pump data: Bearings Bearing load Interaction

Impellers Static Deflection

Practical Rotordynamics for Centrifugal Pumps

Rotor Setting Running

Practical Rotordynamics for Centrifugal Pumps

1200 2160 3120 4080 5040 6000

Practical Rotordynamics for Centrifugal Pumps