A Reasonable Approach to Pump Design While Avoiding Resonance

For the majority of pump application, the growing use of variable speed operation has increased the likelihood of resonance conditions that can cause excessive vibration levels, which can negatively impact pump performance and reliability. Mechanical resonance is the tendency of a mechanical system to absorb more energy when the frequency of its oscillations (external excitation source) matches the system’s natural frequency of vibration more than it does at other frequencies. To avoid vibration issues, potential complications must be properly addressed and mitigated during the design phase.

Some of the factors that may cause excitation of a natural frequency include rotational balance, impeller exit pressure pulsations, and gear couplings misalignment. The effect of the resonance can be determined by evaluating the pumping machinery construction. All aspects of the installation such as the discharge head, mounting structure, piping and drive system will affect lateral, torsional and structural frequencies of the pumping system. It is advised that the analysis be conducted during the initial design phase to reduce the probability of reliability problems and the time and expense associated.

Natural frequencies of a pump and motor can be calculated by performing a modal analysis using the Finite Element Method Analysis (FEA). The finite element modelling and analysis techniques provide an understanding of the mechanical system behaviour, including the natural frequency values during design phase.

Understanding the predicted natural frequency values allows an evaluation of the expected separation between the pump natural frequency and excitation frequencies, such as pump operation speed. The separation is established by the pump manufacturer to avoid mechanical resonance.

The boundary conditions assumed during FEA are essential to the accuracy of predicted results. In some cases, the final as-built conditions (such as foundation stiffness) significantly affect the analysis accuracy if they differ from those conditions assumed during the analysis. In such case a pump test is recommended. Tests like that indicate that increasing the natural frequency of the system is the best solution. This increase in natural frequency could be accomplished by modifying two of the pump system’s physical characteristics, reducing mass or increasing stiffness of the system.

It is therefore important to know the type of acceptable solution that will provide the best pump operation. And this is where AxSTREAM adds significant value at the design process. Using SoftInWay fully integrated engineering platform the customers are able to optimize the pumping machine, and next to perform all the necessary structural analysis using AxSTRESS, our express structural, modal and harmonic analysis FEM solver with a customizable, automatic turbomachinery-specific mesh generation.




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