MULTISTAGE HORIZONTAL BOILER FEED PUMPS:

ROTOR DYNAMIC AND STRUCTURAL ADVANTAGES

OF THE OPPOSITE VERSUS EQUIDIRECTIONAL
IMPELLERS CONFIGURATION
G. Agrati and A. Piva
Weir Gabbioneta, Sesto S. Giovanni, Italy
1.

ABSTRACT

Multistage horizontal boiler feed pumps are designed and built in two different
configurations: with equidirectional or with opposite impellers.
Advantages and disadvantages of the two design criteria are hereto analysed and
described. The study is carried out from hydraulic and structural point of view.
A particular attention is addressed to the axial load balance and to the lateral
dynamic analysis, with new and worn clearance conditions.
A complete calculation of rotor dynamic behaviour in both configurations has been
performed using the finite element method. The model of the shaft has been meshed
using beam elements, while linearised coefficients have been evaluated in order to
simulate stiffness and damping of sleeve bearings, impeller wear rings, balancing
drums and interstage seals. Undamped critical speed map, damped mode shapes and
Campbell diagrams are presented and discussed.
Calculation results are confirmed by experimental measurements carried out on an
opposite impeller multistage pump, where non contacting probes have been installed
nearby sleeve bearings locations, and order tracking method has been applied during
start-up and coast-down transients.
2.

INTRODUCTION

Centrifugal boiler feed water pumps are used in steam power plants. They are used
for feeding water to the boiler, where heat energy will be supplied and feedwater
will be changed in steam under pressure. A steam turbine will then transform part of
this energy into mechanical energy to do useful work.
Boiler feed water pumps failures are a major cause of power plant unavailability.
The operation of these machines often requires a large number of hours during
which they operate at reduced load. This undoubtedly represents a potential source
of failures, due to the presence of the onset recirculation flow. Besides they are also
required of frequent load transients and fast emergency shutdown.
For all these reasons they must be capable to operate quietly running through their
critical speeds, during the usual start-up and coast-down transient, as well as during
the continuous operation at reduced flows.
The reliability improvement on boiler feed water pumps requires a deep analysis to a
better definition of their hydraulic, mechanical and dynamic behaviours.
Both above described design criteria have several applications, and no one of the
two corresponding design philosophies has ever been considered as winner. And

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Vibration, Noise and Structural Dynamics 99

even, when one of the two has been chosen, the choice has often been determined by
historical or traditional reasons, rather than by real and proven advantages.
Advantages and disadvantages present on both configurations are hereto discussed,
considering pumps having the same impeller size, the same number of stages and the
same conditions of service. Performance curves of examined pumps are therefore
strictly similar.
3.

OPPOSITE AND EQUIDIRECTIONAL IMPELLERS CONFIGURATION

The typical cross sections of opposite impellers configuration pump (AHPB line)
and equidirectional impellers configuration pump (UHP line) are depicted
respectively in figures 1 and 2.

Figure 1 Cross section of opposite impeller centrifugal pump

Figure 2 - Cross section of equidirectional impeller centrifugal pump

First of all we can observe that from hydraulic and mechanical point of view the
UHP solution is simpler, more compact and it apparently seems more efficient. In
fact, the flow leaving the impeller outlet is conveyed into the diffuser vanes and than
to the eye of the subsequent impeller. On the contrary, in the AHPB pump, after the
first group of stages (half of the total if even, half of the total minus one if odd) the
flow is conveyed via two crossover channels to the next impeller that lies at the
opposite location of the pump. During this crossing the flow necessarily is subjected
to a non-negligible pressure drop. The hydraulic efficiency of the pump, and as a
consequence the global efficiency, is affected by this reduction in performances.
On the other hand, the UHP configuration brings to a very high axial thrust, due to
the sum of the axial thrusts of every impeller. A balancing drum is necessary to
balance the thrust and to reduce the load acting on the thrust bearing. The AHPB
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Vibration, Noise and Structural Dynamics 99

pumps, on the contrary, are always well balanced (especially when the number of
stages is even) and the balancing drum is less critical. This fact is particularly crucial
when, after several hours of operation, all the clearances begin to increase. It can be
calculated that, supposing an uniform wear of all seals and rings, when clearances
are doubled with respect to design ones, the AHPB is still well balanced while the
UHP axial load increases from 2000 N (design thrust at rated flow) up to 20000 N.
Moreover, it must be taken into account the different flow leakage existing on drums
for both pump configurations. The UHP balancing drum is subjected to a total
differential pressure due to all stages, while on AHPB the total differential pressure
is subdivided in two balancing drums (central and side). Furthermore, the UHP drum
diameter and clearances are greater because of higher axial load to be balanced. For
these reasons the balancing drum total leakage is greater for UHP than for AHPB. It
has been calculated in fact that, for pumps operating at 3000 rpm with flow of 370
m3/h delivered at a total differential head of 1000 m, the leakage at design
clearances respectively is 11 m3/h for the AHPB and 14 m3/h for the UHP. With
worn clearances (twice design clearances) the leakage gets to 29 against 40 m3/h.
The effects on the volumetric efficiency must not be obviously disregarded. Once
again the global pump efficiency is influenced and the reduction in performances
will increase with wear.
From a rotor-dynamic point of view we can suppose that, due to the presence of
central balancing drum, the critical speeds of the opposite impellers configuration
will be higher than the equidirectional impeller configuration ones.
Aim of the following of this job is to examine closely the dynamic behaviour of
equivalent pumps related to the two design criteria, and to verify the above exposed
hypothesis.
4.

ROTOR MODELING

The method used for this analysis is the Finite Element Method. The shaft is
modelled using linear 1D (beam) elements; mass and inertia of impellers, bearings,
coupling and all rotating components are simulated with rigid body elements, the
journal bearings and seals effect is taken into account using linearised connectors,
with Cartesian coefficients of stiffness and damping.
The support bearing structure and baseplate impedance is disregarded. The reason of
this assumption lies in the fact that our aim is to compare the dynamic behaviour of
the rotor in two different configurations, but we suppose that the support structure is
very similar in the two cases. In this way we intend to separate the dynamic
behaviour of the rotor from the dynamic behaviour of the structure in order to
facilitate the interpretation of results.
On the other hand, during the experimental validation of the analysis method, the
pump under test was supported by a special very rigid structure whose stiffness was
more than two magnitudes greater than the bearing stiffness and whose natural
frequencies were far from operating speed range (Bolleter, Frei, Florjancic, 1984).
5.

MODEL EXPERIMENTAL VALIDATION

A multistage opposite impellers horizontal pump, AHP 300/200-7 seven stages, has
been tested in our test shop. Two vibration proximity probes (eddy current probes)
have been installed in radial X and Y directions, nearby journal bearing, in both
drive end and non-drive end locations.
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Vibration, Noise and Structural Dynamics 99

The electric signals, converted by a modulator-demodulator device, were analysed

by a signal dynamic analyser (see figures 3 and 4).

Figure 3 Signal Dynamic Analyser

Figure 4 Pump equipped with proximity probes

Order tracking method was used during start-up and coast-down ramping to
investigate the rotor dynamic behaviour at any speed ranging from 600 to 2980 rpm
(rated speed). The below listed speed orders were analysed, recorded and plotted.
First order, corresponding to mass unbalance frequency excitation, second order, in
relation with shaft misalignment, and seventh order, corresponding to impeller blade
passing frequency. First order tracks show that the rotor does not pass through any
critical speed during the ramping. The amplitude vibration level, in fact, gradually
increases with speed, with a very regular trend (see figures 5 and 6), which means
that no system natural frequency is encountered, or, more likely, its damping ratio is
relatively high.
180
90
0
-90
-180

180
90
0
-90
-180

2
2

1
0

500

1000

1500

2000

2500

3000

500

1000

Speed [RPM]

1500

2000

2500

3000

Speed [RPM]

Figure 5 Start-up order 1

Figure 6 Coast-down order 1

Second order, on the contrary, displays a vibration peak at about 1700 rpm, in both
start-up and coast-down transients (see figures 7 and 8).
360
270
180
90
0

360
0
-360
-720

2.5
2

1.5

1.5
1

0.5

0.5
0

0
0

500

1000

1500

2000

Speed [RPM]

Figure 7 Start-up order 2

245

2500

3000

1000

2000

3000

4000

Speed [RPM]

Figure 8 Coast-down order 2

Vibration, Noise and Structural Dynamics 99

This means that while the rotor is rotating at 1700 rpm the amplitude vibration
spectrum shows a high level peak at 2 x 1700 = 3400 cycles per minute, i.e. at a
frequency of about 57 Hz. On the other hand, the phase shows, crossing the same
speed, a shift of about 180. The above shown results let us suppose that, when the
pump is running at 1700 rpm, the dynamic system characterised by bearings and
seals stiffness and damping of that speed, has a natural frequency at about twice that
speed. Even a light excitation level has its effects amplified by resonance and the
increase in vibration is well noticeable. Hydraulic excitation level at blade passing
frequency was negligible; no useful information may be got from experimental 7th
order tracking.
We must clarify that, from technical point of view, with critical speed we intend not
only the coincidence between rotor natural frequency and rotor operating speed, but
also when this coincidence involves not negligible effects on vibration levels. As an
example, for the latest API 610 Standards a critical speed is associated to a Damping
Factor lower than limit values correlated to different Frequency Ratio, e.g. DF =
0.15 for synchronous frequency. Likewise, on the Amplitude Speed Plot, a critical
speed showing an Amplification Factor lower than 2.5 may be disregarded.
Standing that, a rotor dynamic analysis at these conditions has been performed.
Natural frequencies and corresponding damping ratio are listed below:
Mode Number
1
2
3
4
5
6

Damped Natural
Frequency [Hz]
24.8
33.6
34.4
62.4
99.3
112.0

Damped Natural
Frequency [cpm]
1488
2016
2064
3744
5958
6720

Damping Factor
0.807
0.831
0.546
0.450
0.067
0.322

The nearest resonant frequency is 3744 cpm corresponding to 4th mode (figure 9).
Looking at 4th mode shape, or more
precisely at three-dimensional deflected
shape corresponding to 4th damped
natural frequency, it can be noticed that
the normalised displacement in
correspondence of sleeve is large, and
therefore its contribution to vibration
may be consistent; furthermore its
th
Figure 9 4 mode shape
damping factor is relatively low.
Response transfer function of the
displacement of the drive-end bearing
node due to a force located at the
coupling node (figure 10) has been
evaluated, including in the dynamic
model the contribution of all the
calculated mode shapes (up to 150 Hz).
A peak of the transfer function for both
X and Y radial direction is located
around 58 - 60 Hz, in good accordance
with the measured data.
Figure 10 Response Transfer Function

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Vibration, Noise and Structural Dynamics 99

6.

UNDAMPED ANALYSIS CRITICAL SPEED MAP

After the validation of the mathematical model we proceeded to the comparison

between the two configurations.
The two analysed pumps are the AHPB 300/200-10 for the opposite impeller
configuration and the UHP 300/200-10 for the equidirectional impeller
configuration. Corresponding rotors are depicted respectively in figures 11 and 12.

Figure 11 Rotor of opposite impellers pump

Figure 12 Rotor of equidirectional impellers pump

The first step was the dry undamped analysis. Natural frequencies of both rotors,
supported only at the bearings, were calculated and corresponding mode shapes
were plotted. Calculation was performed with different bearing stiffnesses and
results are used to plot the Critical Speed Maps (see figure 13). According to what
suggested
by
Corbo
and
10000
Malanosky
in
their
tutorial
(Corbo,
3rd natural frequency
2nd natural frequency
Malanosky,
1998),
reference
bearing stiffness is drive end one,
1000
1st natural frequency
while non drive end bearing is
Kxx
Kyy
assumed with a stiffness in
constant ratio. Vertical and
100
horizontal
stiffnesses
are
1.0E+06
1.0E+07
1.0E+08
1.0E+09
1.0E+10
considered
as
equal.
Actual
drive
Bearing Stiffness [N/m]
end bearing stiffness curves are
Figure 13 Critical speed map
then superimposed. Critical speed
maps are very similar for the two configurations. In fact, bearing span, shaft
diameter and mass distribution (Leader, 1984) are almost the same. Calculated
bearing stiffness is cross-plotted on the critical speed map to help identify rotor
dynamic characteristics of the actual rotor-bearing system. We can deduce that it lies
in the region of flexible rotor modes. This means that for the undamped dry analysis
the considered rotors are low sensitive to variation of bearing system characteristics.
7.

DAMPED ANALYSIS

The second step was a complete wet damped analysis. The model was refined with
cross stiffness coefficients and with direct and cross damping coefficients for
bearings, impellers wear rings, central and lateral balancing drum. Numerical
results, as natural frequencies in cpm and Damping Factors, are reported in
following tables.
Modes 1 and 2 correspond to high relative displacement of bearings. They are not
sensitive to impellers configuration and therefore they are not interesting for the aim
of this analysis.
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Vibration, Noise and Structural Dynamics 99

Modes 3 and 4 correspond to a mode shape where displacement is higher in the

central zone of the shaft (see figure 16). Campbell Diagrams relative to these two
natural frequencies are shown in figures 14 and 15. Speed line is superimposed in
order to identify any interference with fundamental excitation frequency. UHP
results are as expected. The natural frequencies lower considerably with wearing of
bushings, drums and impeller rings. Damping factors are low and their values
become critical with twice design clearances. On the other hand the situation is not
so clear regarding the corresponding natural frequencies of the AHPB. The effect of
wearing is less evident, and at low speeds they will even increase with wearing.
AHPB 300/200-10 opposite impellers configuration
2235 rpm
2980 rpm
3725 rpm
4470 rpm
Design Clearances
Freq. / DF
Freq. / DF
Freq. / DF
Freq. / DF
Freq. / DF
1266 / 0.883 1960 / 0.802 2758 / 0.787 4282 / 0.712 4666 / 0.661
2285 / 0.828 4120 / 0.263 4125 / 0.200 4154 / 0.137 4178 / 0.099
1683 / 0.861 2753 / 0.889 3968 / 0.892 5380 / 0.907 7268 / 0.386
1856 / 0.587 2474 / 0.598 3231 / 0.595 4082 / 0.588 4892 / 0.573
5021 / 0.192 5464 / 0.123 5642 / 0.134 5801 / 0.129 5909 / 0.119
Twice Design (worn) Clearances
Freq. / DF
Freq. / DF
Freq. / DF
Freq. / DF
Freq. / DF
1280 / 0.881 2008 / 0.792 2943 / 0.768 4446 / 0.685 5000 / 0.601
1920 / 0.836 4101 / 0.298 4105 / 0.214 4127 / 0.138 4163 / 0.098
2048 / 0.347 2629 / 0.361 3285 / 0.362 3943 / 0.362 4589 / 0.353
2084 / 0.620 2706 / 0.697 3440 / 0.727 4515 / 0.735 5411 / 0.735
5291 / 0.062 5336 / 0.090 5396 / 0.113 5464 / 0.126 5524 / 0.133
1490 rpm

Mode
1
2
3
4
5
Mode
1
2
3
4
5

Mode
1
2
3
4
5
Mode
1
2
3
4
5

UHP 300/200-10 equidirectional impellers configuration

1490 rpm
2235 rpm
2980 rpm
3725 rpm
4470 rpm
Design Clearances
Freq. / DF
Freq. / DF
Freq. / DF
Freq. / DF
Freq. / DF
1249 / 0.844 1738 / 0.841 2194 / 0.818 2695 / 0.829 3196 / 0.839
1849 / 0.846 3909 / 0.285 3920 / 0.210 4094 / 0.133 4178 / 0.098
2278 / 0.417 3067 / 0.331 3826 / 0.310 4354 / 0.298 5000 / 0.276
2967 / 0.494 3474 / 0.499 4006 / 0.525 4686 / 0.548 5399 / 0.576
4785 / 0.387 6500 / 0.114 6444 / 0.123 6341 / 0.135 6211 / 0.144
Twice Design (worn) Clearances
Freq. / DF
Freq. / DF
Freq. / DF
Freq. / DF
Freq. / DF
1255 / 0.863 1760 / 0.874 2359 / 0.826 3112 / 0.827 4242 / 0.806
1864 / 0.846 4013 / 0.297 4073 / 0.239 4126 / 0.170 4171 / 0.141
1981 / 0.253 2476 / 0.224 2938 / 0.201 3344 / 0.170 3748 / 0.143
2162 / 0.469 2774 / 0.467 3214 / 0.492 3637 / 0.495 4063 / 0.519
5021 / 0.265 6384 / 0.147 6384 / 0.122 6358 / 0.119 6313 / 0.123

7000

7000

6000

6000

5000

5000

4000

4000

3000

Freq. / DF
5660 / 0.539
4187 / 0.078
7756 / 0.341
5710 / 0.633
5973 / 0.111
Freq. / DF
5916 / 0.341
4176 / 0.077
5008 / 0.287
5999 / 0.709
5536 / 0.127

5215 rpm
Freq. / DF
3834 / 0.823
4224 / 0.073
5796 / 0.264
6060 / 0.607
6000 / 0.146
Freq. / DF
4980 / 0.759
4068 / 0.085
4272 / 0.160
4506 / 0.544
6240 / 0.128

3000
1 x speed

design clearances

design clearances

2000

2000

1 x speed

2 x design clearances

1000
1000

5215 rpm

2 x design clearances

1000
2000

3000

4000

Speed [rpm]

5000

6000

1000

2000

3000

4000

5000

6000

Speed [rpm]

Figure 14 AHPB 300/200-10 Campbell Diagram Figure 15 UHP 300/200-10 Campbell Diagram

248

Vibration, Noise and Structural Dynamics 99

Reversed considerations can be applied to the fifth natural frequency, whose mode
shape is similar to typical shaft second bending mode, showing two half waves. Its
value is higher for the UHP than for the AHPB, and, with clearances increment, it
slightly increases at higher operational speeds for UHP, and it naturally decreases
for the AHPB. This unexpected behaviour may be explained considering the
position of the central balancing drum. The role of this element is crucial especially
for first bending mode (figure
16), as its central position, just
where the modal displacement is
greater, will emphasise the
effectiveness of its damping and
stiffness. The wear reduces all
bushing coefficients. But if a
lower stiffness leads to a lower
Figure 16 First bending mode
natural frequency, to a lower
damping it corresponds a higher damped natural frequency. These effects are
opposed and the final result will depend on the balance of all coefficients.
Any way, comparing results of the two configurations we can notice that the
equidirectional impellers rotor is stiffer at design clearances. Its examined natural
frequency is higher than the one of the other rotor. This fact may be attributed once
again to the very stiff balancing drum. The UHP is more sensitive to seal wear and
its natural frequency will match the running speed after several hours of working,
while the AHPB will operate below it. Furthermore damping factors are
considerably higher for the AHPB. The presence of a central balancing drum is able
to keep the rotor stiff enough and to give a higher damping content to the system.
Even in the eventuality of a critical speed, the rotor will be able to avoid excessive
displacement amplitudes and consequent rubbing with stationary parts.
8.

CONCLUSIONS

The comparison above described between the two possible boiler feed pump
configurations points out the following. Opposite impellers configuration has the
hydraulic and technological drawback of the crossover channel, necessary to convey
the flow from the first group to the second group of impellers. On the other hand it
seems more advantageous for the balancing of axial load and for the volumetric
efficiency, mostly in worn clearances conditions. The dynamic analysis indicates
that this design criterion leads to a rotor whose behaviour is less sensitive to increase
of clearances, and whose damping factor keeps always considerably high. We can
conclude that the opposite impeller design philosophy demonstrates to increase the
reliability of multistage boiler feed water pumps.
9.

REFERENCES

American Petroleum Institute, 1995, Lateral Analysis, Centrifugal Pumps for

Petroleum, Heavy Duty Chemical, and Gas Industry Services, API Standard 610,
Eighth Edition, Appendix I, pages I-1, I-5
American Petroleum Institute, 1996, Rotor Dynamics: Lateral Critical Analysis,
Tutorial on the API Standard Paragraphs Covering Rotor Dynamics and Balancing:

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Vibration, Noise and Structural Dynamics 99

An Introduction to Lateral Analysis and Train Torsional Analysis and Rotor

Balancing, API Standard 684, First Edition, Section 1, pages 1-70
K.E. Atkins, J.D. Tison, J.C. Wachel, 1985, Critical Speed Analysis of An EightStage Centrifugal Pump, Proceedings of the Second International Pump Symposium
U.Bolleter, A. Frey, D. Florjancic, 1984, Predicting and Improving the Dynamic
Behavior of Multistage High Performance Pumps, Proceedings of the First
International Pump Symposium
M.A. Corbo, S.B. Malanoski, 1998, Pump Rotordynamics Made Simple,
Proceedings of the 15th International Pump Symposium
M. Falco, G. Mimmi, B. Pizzigoni, G. Marenco, 1984, Plain Seal Dynamic
Behaviour Experimental and Analytical Results, ImechE 1984, C303/84, pages
151-158
M. Falco, G. Mimmi, G. Marenco, 1986, Effects of seals on Rotor Dynamics,
International Conference on Rotordynamics, pages 655-661
M.E. Leader, 1984, Introduction to Rotordynamics of Pumps without Fluid Forces,
Proceedings of the First International Pump Symposium
G. Marenco, 1988, Wet Critical Speeds of Boiler Feed Water Pump beyond the
Pump Operational Range, 4th International Conference on Vibrations in Rotating
Machinery

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