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Axial Thrust PDF
Axial Thrust PDF
Axial Thrust PDF
ABSTRACT
Reliability of rotating machineries, especially centrifugal pumps is defined on account of wear
rate of components and bearing durability. One of the important performance parameter for
any centrifugal pump is its bearing life, which is dependent on the hydraulic thrusts, Radial[7,9]
and Axial Thrusts[7,9]. The radial thrust prediction can be done accurately and easily with the
help of prevailing methods available in literature [7,9]. Whereas to predict the axial thrust, the
prevailing methods are not found very much reliable to use as the number of parameters
influencing axial thrusts are more than those for radial thrust. Also to contribute to it are the
variations in the impeller geometries, which are governed by the hydraulic design and keeps
on changing based on the hydraulic design of the impeller. Therefore to predict the bearing
life and select the suitable bearing for getting optimum bearing life, it is really necessary to
formulate a basis to arrive at the reliable axial thrust values and formulation of such basis,
there is no better tool than experimental analysis.
This paper talks about the experimental analysis of the axial thrust of end suction long
coupled centrifugal process pump and the findings of the analysis.
1.0 INTRODUCTION
One of the important performance parameter for any centrifugal pump is its bearing life. To
have the minimum maintenance and repairs cost, the bearing life for any centrifugal pump
must be as prolonged as far as possible. Particularly in case of process pumps, which are used
at high temperatures, high pressure and more hazardous applications with maximum
reliability, bearing life is of more importance. Bearing life [12,13]. of centrifugal pump depends
upon two hydraulic forces acting on the impeller i. e. radial thrust and axial thrust. Amongst
the two forces, radial thrust is dependant solely on pressure generated by pump. There are
proven and reliable methods available to predict the radial thrust generated. Radial thrust can
be satisfactorily reduced to harmless extents by using double volute casings or diffuser type
casings.
Whereas axial thrust is dependent on the many aspects viz. shroud and casing clearances,
peripheral shroud speeds, head developed by the pump, impeller geometry etc. due to this one
cannot arrive at the conclusion that the theoretically calculated thrust value and the thrust
experienced by the pump in practice are same. This is mainly due to the manufacturing
limitations and assembly variations. The existing methods cannot be employed in practice to
estimate the correct value of axial thrust or even the permissible variation. The available
literature on measurements of axial thrust in pumps indicates the lack of adequate and
accurate experimental results data. Axial thrust data and improved analytical methods are
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critical to the proper selection of thrust bearings due to the consequences of rapid wear,
frequent maintenance and possible pump failure due to large axial forces, it is better to predict
and minimize axial thrust for a range of pump types in a variety of applications.
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15th International Conference on Experimental Mechanics
thrust can be minimized by making double volute casing [fig1] or by providing the diffuser type
casing.
F1 F2
Fm UNBALANCED
THRUST
As shown in Fig. 2 above the resultant unbalanced axial thrust is vector summation of the
following forces [1] –
Force acting on front shroud due to liquid of delivery pressure entrapped between pump
casing and front shroud. (F1)
Force acting on back shroud due to liquid of delivery pressure entrapped between casing
cover and back shroud. (F2)
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Force acting in the direction of the liquid flow due to its momentum change. (Fm)
The pressures generated by a centrifugal pump exert forces on both its stationary and rotating
parts. The design of these parts balances some of these forces, but separate means may be
required to counter-balance others. Axial hydraulic thrust is the summation of unbalanced
impeller forces acting in the axial direction. As reliable large-capacity thrust bearings are not
readily available, axial thrust in single-stage pumps remains a problem only in larger units.
Theoretically, a double-suction impeller is in hydraulic axial balance with the pressures on
one side equal to, and counter-balancing the pressures on, the other Fig 6. In practice, this
balance may not be achieved for the following reasons:
The suction passages to the two suction eyes may not provide equal or uniform flows to the
two sides.
1. External conditions such as an elbow being too close to the pump suction nozzle may
cause unequal flows to the suction eyes.
DISCHARGE PRESSURE
DISCHARGE
DISCHARGE
PRESSURE
PRESSURE
DISCHARGE PRESSURE
SUCTION PRESSURE
PRESSURE
PRESSURE
SUCTION
SUCTION
2. The two sides of the discharge casing may not be symmetrical, or the impeller may be
located off-centre. These conditions will alter the flow characteristics between the impeller
shrouds and casing, causing unequal pressures on the shrouds.
3. Unequal leakage through the two leakage joints will tend to upset the balance.
Combined, these factors create definite axial unbalance. To compensate for this, all
centrifugal pumps, even those with double-suction impellers, incorporate thrust bearings.
The ordinary single-suction radial-flow impeller with the shaft passing through the impeller
eye Fig 3 is subject to axial thrust because a portion of the front wall is exposed to suction
pressure, thus exposing relatively more back wall surface to discharge pressure. If the
discharge chamber pressure were uniform over the entire impeller surface, the axial force
acting towards the suction would be equal to the product of the net pressure generated by the
impeller and the unbalanced annular area.
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15th International Conference on Experimental Mechanics
IMPELLER
REDUCTION IN
BALANCE HOLE AXIAL
THRUST DUE TO
BALANCE HOLES
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cheaper and more effective than the first method. In this method the power consumed is much
less than the power loss due to leakage through balancing holes under normal conditions.
BACK VANES
IMPELLER
REDUCTION IN
AXIAL
THRUST DUE TO
BACK VANES
There are some other thrust balancing methods like Balancing Disc and ring, Balancing Drum
used specifically to reduce the axial thrust in multistage centrifugal pumps.
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15th International Conference on Experimental Mechanics
to analyze the effect of each influencing parameters on the response value. For this project
following four parameters are chosen –
1. The number of back vanes,
2. The back vane radius,
3. The back vane height,
4. Clearance between casing cover and back vanes.
All the above factors have three variations each as given in Table-1.
No of back Back vane Back vane Clearance between back
Experiment vanes diameter thickness vane and casing
no (Z) (D) mm (T) mm (S-T) mm
1 8 107.00 6.00 5.00
2 8 87.00 3.50 3.00
3 8 67.00 1.00 1.00
4 6 107.00 3.50 1.00
5 6 87.00 1.00 5.00
6 6 67.00 6.00 3.00
7 4 107.00 1.00 3.00
8 4 87.00 6.00 1.00
9 4 67.00 3.50 5.00
Table-1- Orthogonal array experiment design
5.2 Experimental setup (Measurement technique) [14].
These tests are been carried out on an end suction pump of 66 specific speed (metric) with 214
mm diameter. The test rig (fig6) used consisted mostly of the test end suction pump long
coupled to electric motor running 2960 rpm, a modified side bearing arrangement consisting
of three strain gauge type load cells located at 1200 apart over the circumference and on the
both side of cartridge. The transfer mechanism for transmittal of axial thrust from rotating
members to the stationary load cells consists of two thrust ball bearings, which are mounted
on the impeller shaft. The shaft is supported by two radial bearings, with their outer races free
to slide inside the bearing housing. The load cells are pressed slightly against the modified
bearing bracket which comes in contact with the rotating assembly through the thrust ball
bearings. The load cells were used on either side of thrust bearings so as to respond to change
in the axial thrust direction.
The total axial thrust will be the algebraic sum of the forces experienced by all the three load
cells. To avoid any error, all the load cells were preloaded slightly and at the preloaded
condition, the null reading was set.
5.3 Calibration[14]
The test rig was statically calibrated before the start of experiment by pulling and pushing the
impeller shaft against known calibrated load values from UTM (Universal Testing Machine).
The load cell response (Eb mV) to the calibration null load was set based on the known static
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load application, the graph-1 shows the response of the load cells output voltage with respect
to the known load applied.
LOAD CELL
(Back)
LOAD CELL
(front)
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15th International Conference on Experimental Mechanics
T = (Force on back shroud considering back vanes –pressure force on front shroud –
momentum thrust)
T = FB - FR - Tm (kg)
Where,
• W =Angular velocity of impeller (Rad/s)
• B = Angular velocity of fluid (Rad/s)
• ρ = Density (Kg/m3)
• H = Pump head (meters)
• Ho = Static head at the impeller outlet (meters)
• R = Impeller radius (meter)
• r1 = Impeller wear ring radius (meter)
• b = Radius of back vanes (meter)
• h = Hydraulic efficiency of pump
• Cd = Coefficient of contraction of jet flow at the impeller back vane
• u2 = Peripheral velocity at the impeller outlet (Rad/s)
• S = Axial gap between casing and impeller back shroud (mm)
• T = Vane width (mm)
• (s-t) =Vane clearance (mm)
• Z = Number of back vanes
• Re =Reynold’s number
• γ = Kinematic viscosity (m2/sec)
• S1 =Radius of shaft (meter)
• Q = Discharge (m3/hr)
• ηh = Hydraulic efficiency of pump.
• N = speed in (rpm)
• A1 = Eye opening area (m2)
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2) From graph it is observed that as number of back vanes increases the back vane force
developed also increases since the increase in number of back vanes increases the
angular velocity of the fluid between the back shroud of impeller and pump casing.
But after some limit, if no. of back vanes increased that will not be served. In these
experiments the optimum number of back vanes was found to be 8 [graph 2].
(Kg)
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15th International Conference on Experimental Mechanics
(Kg)
Graph 5 – Axial thrust Vs Clearance between casing cover and Back vane face
6) The axial thrust variation with respect to flow for all 9 tests is as given below in graph
6-
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800
700
600 Expt 4
Expt 1
Expt 3
500
Expt 8
Axial Thrust (kg)
Expt 2
Expt 7
400
Expt 9
Expt 6
300 Expt 5
200
100
0
0 20 40 60 80 100
Flow (lps)
7.0 Conclusion
1. Maximum influencing parameter
From the experimental data, it is observed that the back vane radius contributes to the
maximum extent to the variation of axial thrust.
2. The order of importance of other back vane parameters is as follows:
Back vane height
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15th International Conference on Experimental Mechanics
Number of vanes
Clearance between back vanes and casing cover
3. Close control of back vane parameters is essential to maintain optimum thrust values
for mass produced pumps. The variation in thrust values due to change in the
dimensions of back vane height and clearance has been tabulated[14]
Axial Thrust at BEP Axial Thrust at 20% Left Pump efficiency at BEP
condition (kg) of BEP condition (kg) condition
Experiment Without With back Without With back Without With back
no. (Refer back vane vane back vane vane back vane vane
table 1)
Test Test Test Test Test Test Test Test Test Test Test Test
1 2 1 2 1 2 1 2 1 2 1 2
1 640 642.5 100 101.5 815 812 295 298 82.3 82 78 78.5
2 630 628.5 378 377 795 794 594 592 82.3 82 78 78.5
3 590 588 553 552 673 674 707 580 82.3 82 78 78.5
4 590 588 282 283.5 673 674 497 501 82.3 82 78 78.5
5 640 642.5 556 551 815 812 749 748 82.3 82 78 78.5
6 630 628.5 510 513 795 794 690 691.5 82.3 82 78 78.5
7 630 628.5 545 547.5 795 794 730 733 82.3 82 78 78.5
8 590 588 388.5 385 673 674 547 546 82.3 82 78 78.5
9 640 642.5 482.5 480 815 812 688 688 82.3 82 78 78.5
References
1) K J Zanker, “Experiments with back vanes used for balancing axial thrust on centrifugal
pump impellers”, British Hydromechanics Research Association, Vol. 3, 5th Annual meet.
(Apr. 1962), pp.7-14.
2) George Schaefer and Eric Olson, ”Experimental Evaluation of Axial Thrust”, Journal of
World Pumps, Issue 393, June 1999, pp. 34-37.
3) Majan Gantar, Dr. Dussn Florjancic, Dr. Brane Sirok, “Hydraulic Axial Thrust in
Multistage Pumps - Origins and Solutions”, proceedings of ASME FEDSM’01, May 29 -
June1.2001, pp. 1-8.
4) Marc P. Mignolet Byeong-Keun Choi, “Robust Optimal Positioning of Strain Gages on
Blades”, journal of turbo machinery- transactions of ASME Vol. 125, October 2002. pp.
155-164.
5) J. Szwedowicz, S. M. Senn and R. S. Abhari, “Optimum Strain Gage Application to
Bladed Assemblies”, journal of turbo machinery- transactions of ASME Vol. 125, January
2003. pp. 606-613.
6) Igor J Karassik & Ray Cartor, “Centrifugal pumps”, Tata McGraw Hill Book company-
2nd Edition, 1960. pp. 3.129-3.339.
7) A.J. Stepanoff, “Centrifugal and Axial flow pumps - Theory, Design & Application” ,
John Wiley and Sons – 2nd edition – 1953. pp. 182-223.
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8) Stephen Lazarkiewicz & Adam T. Troskolanski, “Impeller pumps”, Pergramon Press- 1st
edition 1965. pp. 346-365.
9) Val S. Lobanoff & Robert R. Ross, “Centrifugal Pumps design and application”, Jaico
publishing house – 2nd edition 1995. pp. 333-353.
10) “Centrifugal pumps for petroleum, heavy duty chemical and gas industry services”,
American Petroleum institute – 610 10th edition-October 2004
11) “General catalogue” SKF bearings.
12) “Bearings in Centrifugal Pumps – Application handbook – Part I &II”, SKF100955_1,
SKF bearings.
13) “ISO 281: Rolling Bearings - Dynamic Load Ratings and Rating Life.”, Second edition
1990-03-25.
14) “Experimentation on suction pump for axial thrust evaluation”, R&D, Kirloskar Brothers
limited, Kirloskarvadi.
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