FIREWATER PUMP-ODS/FEA

DATA ACQUISITION
TOOLS OF TRADE
&
METHODS OF STATEMENT
 INTRODUCTION & OBJECTIVE
 All the three Fire Water Pump/Vertical Turbine Pump were facing
and undergoing low reliability and availability due to frequent
failures and breakdown on the pump mechanism.
 In general, the causes of the vibration problem are either due to
operations i.e. the unaccounted excitation forces generated as
the results of wear and tear, improper installation, services, etc.
or due to the structural dynamic design deficiency or both.
 Enhancement on the rectification procedures with more “virtual
prototyping” methods rather than physical “trial & error”. It is
also worthy to note that ODS/FEA is not merely a tool to
determine the natural frequencies and mode shapes. In our scope
of work, ODS/FEA is used to create a virtual model of the
structure being analysed. The reliability of the model is verified
by the FRF modal analysis results. Once the ODS/FEA model is
assured, further analysis and modification is performed ‘virtually’
on a computer. This will avoid ‘trial-and-error’ solutions such as
performing structural modification.
 MACHINERY BACKGROUND
Tag No. P-8301
Tag Description Fire Duty Pump Product Code N/A
Used for Stationery
System Description Emergency Standby Fire Water System No. N/A
Pump System

Sub System Description N/A Sub System No. N/A

Location Description Fire Water Pump Systems Area/Location. ATB Terminal and Jetty
Topside Facilities

Site Description ATT Tanjung Bin Sdn. Bhd. Site/Yard No. N/A

Technical Data – Pump

(Pump) Make & Model Weir Floway Serial No 68731-1

Rated Power (kW) 522 kW Speed (RPM) 1750

Voltage (V) N/A Current (Amp) N/A – Engine Driven

Technical Data – Primer Mover

(Engine) Make & Model Caterpillar C18 Acert Engine Serial No

Rated Power (kW) 800 HP Speed (RPM) 1750

 MACHINERY BACKGROUND
Tag No. P-8302
Tag Description Fire Duty Pump Product Code N/A
Used for Stationery
System Description Emergency Standby Fire Water System No. N/A
Pump System

Sub System Description N/A Sub System No. N/A

Location Description Fire Water Pump Systems Area/Location. ATB Terminal and Jetty
Topside Facilities

Site Description ATT Tanjung Bin Sdn. Bhd. Site/Yard No. N/A

Technical Data – Pump

(Pump) Make & Model Weir Floway Serial No 68731-1

Rated Power (kW) 522 kW Speed (RPM) 1750

Voltage (V) N/A Current (Amp) N/A – Engine Driven

Technical Data – Primer Mover

(Engine) Make & Model Caterpillar C18 Acert Engine Serial No

Rated Power (kW) 800 HP Speed (RPM) 1750

 MACHINERY BACKGROUND
Tag No. P-8303
Tag Description Fire Duty Pump Product Code N/A
Used for Stationery
System Description Emergency Standby Fire Water System No. N/A
Pump System

Sub System Description N/A Sub System No. N/A

Location Description Fire Water Pump Systems Area/Location. ATB Terminal and Jetty
Topside Facilities

Site Description ATT Tanjung Bin Sdn. Bhd. Site/Yard No. N/A

Technical Data – Pump

(Pump) Make & Model Weir Floway Serial No 68731-1

Rated Power (kW) 522 kW Speed (RPM) 1750

Voltage (V) N/A Current (Amp) N/A – Engine Driven

Technical Data – Primer Mover

(Engine) Make & Model Caterpillar C18 Acert Engine Serial No

Rated Power (kW) 800 HP Speed (RPM) 1750

TOPOMAPPING ON P8301-
P8303 FOR ODS APPROACH
GBX-ST1 GBX-ST2

ENG-ST1
GI/P

GBX-ST3
ENG-ST2 GBX-ST6
GBX-ST4

GO/P P-PIPE1
ENDE ENG-ST3 EDE
GBX-ST5

EPLINTH1 EPLINTH4 EPLINTH7

P-PIPE2

PSTOOL1 PDE P-PIPE3

PSTOOL4

EPLINTH2 EPLINTH5 EPLINTH8

PSTOOL2
PSTOOL5

PSTOOL3
EPLINTH3 EPLINTH6 EPLINTH9 PSTOOL6
TEST PLAN FOR ODS DATA ACQUISITION
TEST PLAN FOR ODS DATA ACQUISITION
TEST PLAN FOR ODS DATA ACQUISITION
METHODOLOGY FOR ODS APPROACH
 Numbers of points to be obtained during data
acquisition:- 32
 Type of data: Transient,Coast-up,Spectogram,Bode
plot & FRF.
 Duration Given: less than 40 minutes per FWP
 Type Analyzer: NI DAQ/ OROS 36 c/w 32 channels
 ADASH V4PRO-4 channels
 Type of accelerometers: Low frequency-
 Triaxial, x12
 Software:Embedded NI
 ODS tools:
VibShape/MEScope,RBTS/ARMD,ALS/Vibtor.
OROS 25/36 CAPABILITIES
 Dynamic analyzer:
8 channel dynamic analyzer – OROS
make in France is used to perform
following operations.
➢ Filtering: Filtering of signals for over
load protection
➢ Digitization of signals: conversion of
analog signals into Digital signals
➢ Windowing: Force window for
removing noise in the input signal and
exponential window for preventing
leakage in the output signal
➢ Conversion of Signals: the signals are
transformed from time domain to
frequency domain using fast Fourier
transformation for obtaining
Frequency response Function (FRF).
ADASH V4PRO CAPABILITIES
DETAILS EXPLANATORY ODS DATA
ACQUISITION
 Transient analysis is the study of how various signals change during a
machine's process or load change. This analysis is particularly important
during a machine's startup or shutdown when critical speeds or natural
resonances are encountered.
 Observing the overall amplitudes or individual spectra will not be sufficient to
document how the entire machine behaves during transient conditions. Data
collection modes fall into two general categories: observing transducer output
signals with respect to machine speed and observing transducer output
signals with respect to time.
 Sometimes, a combination of the two modes may be required. Cross
correlation is a measure of the similarity in two time domain signals. If the
signals are identical, the cross correlation will be one, and if they are
completely dissimilar, the cross correlation will be zero. Certain dual-channel
FFT analyzers are able to measure cross correlation. Damped Natural
Frequency is the frequency at which a damped system will oscillate in a free
vibration situation.
DETAILS EXPLANATORY ODS DATA
ACQUISITION-continue…
• Low frequency accelerometers were installed on the measurement
point as shown on the following drawings. Sensors were installed
using epoxy. Or/and magnetic base.
• Cables were laid out to connect each sensor to the measurement
channels of OROS 36/NIDAQ (see table below for the relationship
between measurement points and OROS36/NIDAQ channels).
• Data acquisition parameters were setup for each individual channel.
Raw data in acceleration unit and Fmax up to 500 Hz were selected.
Data for each channel was recorded for 300 seconds
• Based on the GA drawing/PID given,a model was reconstructed on
the ME Scope software and the measured vibration data was
allocated to the measurement points on the model . This was used to
create and Operation Deflection Shape Analysis of the model. Also
the data was post processed to generate velocity spectrums for
assessment of the severity levels of the vibration. The table and
figures show the location of measurement points.
 DETAILS EXPLANATORY ODS
DATA ACQUISITION-continue…
 P8301 & P8302 shall be acquiring at difference mode/condition due to
both gearbox used were reducer,however,P8303 was the same as per
our discreet abovementioned.
 All the measurements shall be acquired at two significant
mode/conditions such as:
1. ”Full load at Recycle mode”
2. “Full load at Discharge overboard/ throw”
 FRF Modal Analysis Flowchart
1. Create wire mesh of the structure
MODEL STRUCTURE
2. Select optimum grid

1. Input sensors sensitivities

2. Display necessary frames
SETUP INSTRUMENTS
3. Select windows for input and response
4. Setup trigger conditions – test knocks

1. Select the number of averages

2. Select fixing and roving channels
ACQUIRE FRF SPECTRUM 3. Select fixing point
4. Knock at each roving point
5. Ensure good coherence

CURVE FITTING & MODAL 1. Select bands

EXTRACTION 2. Select curve-fitting polynomial

3. Extract modes of interest
1. Animate modes & display modal values
STORE & DISPLAY
2. Store modal values

1. Structural Dynamic Modification

FURTHER ANALYSIS 2. Frequency Response Simulation
3. Reference for Finite Element Analysis
 CURVE FITTING METHODS
All curve fitting methods fall into one of the following
categories,
 SDOF
SDOF is short for a Single Degree Of Freedom, or single
mode method. SDOF methods estimate modal
parameters one mode at a time.

 MDOF
Similarly, MDOF is short for a Multiple Degree Of
Freedom, or multiple mode method. MDOF can
simultaneously estimate modal parameters for two or
more modes at a time.
Figure . Curve Fitting FRF Measurements.
MODAL FREQUENCY AS PEAK FREQUENCY
➢ The frequency of a resonance peak in the FRF is
used as the modal frequency.

➢ The resonance peak should appear at the same

frequency in almost every FRF measurement.

➢ It won’t appear in those measurements

corresponding to nodal lines (zero magnitude) of the
mode shape.
 MODAL DAMPING
 The classical method of determining the damping at a resonance,
using a frequency analyzer, is to identify the half power points of
the magnitude of the frequency response function.
 r =
( a− b )
2r

 Where ( −  is
a b) the frequency bandwidth
between the two half power points.

 is the resonance frequency.
r
 MODE SHAPE
 A vibrating structure by nature deforms into
certain patterns at the natural frequencies of
the structure.

 The deformation patterns and their natural

frequencies depend only on the
characteristics of the structure, and not on
the input forces.

 These deformation patterns are the mode

shapes of the structure.
CASE STUDY ON VERTICAL PUMPS
CASE STUDY :
AMINE CIRCULATION PUMP
PROBLEM
INTRODUCTION

 The frequent failures, low reliability of Amine

circulation pumps for both the Electric motor-
driven and Steam turbine-driven since
commissioning of the pump had initiated this
investigation work

 The objective of investigation is to identify the

root cause of the frequent failures and to
provide recommendation to the above
problem
 Electric Motor -
Driven

Steam Turbine -
Driven
Amine Pump Operating Data

Handled Fluid Amine

Input Power (kW) 2768
Operating Speed (RPM) 4515 (75Hz)
Suction Pressure (bar) 6.88
Discharge Pressure (bar) 69.01
Pumping/Design Temp. (C) 75 / 110
Bearing Type
i) Radial type / make Sleeve - tilt pad / Kingsbury
ii) Thrust type / make Sleeve – tilt pad / Kingsbury

Weights
Pump + Base Plate 201 A-D/E + Gear (kg) 2200 + 8000 / 2700 + 7500
Driver - Steam Turbine / Electric Motor (kg) 1900 / 11500
 ANALYSIS TECHNIQUES

IN-SITU MEASUREMENT
COMPUTATIONAL MECHANICS
◼ OPERATING DEFLECTION
◼ FINITE ELEMENT ANALYSIS
SHAPE ANALYSIS
◼ MODAL ANALYSIS
 ANALYSIS RESULTS AND
DISCUSSIONS
-Electric Motor Driven pump-
OPERATING DEFLECTION SHAPE ANALYSIS
- Spectrum shows harmonics → indication of play or looseness -

ODS FRF spectrum for Pump ODS FRF spectrum for Gearbox

ODS FRF spectrum for Electric Motor

OPERATING DEFLECTION
SHAPE ANALYSIS

ODS animation for Electric Motor-driven pump

- Showing movements of the base plate -
OPERATING DEFLECTION
SHAPE ANALYSIS

ODS animation for Electric Motor-driven pump

- Showing movements of the base plate -
MODAL ANALYSIS AND FEA

Modal FRF indicates modes

close to operating frequencies

Modal FRF of Pump Modal FRF of Gearbox

Mode Pump Gearbox FEA

1 45 47 48
2 67 - 71
3 83 85 78
MODAL ANALYSIS AND FEA

Mode Shape at around

47Hz
MODAL ANALYSIS AND FEA

Mode shape at around 70Hz

MODAL ANALYSIS AND FEA

Mode shape at around 83Hz

FEA STUDY ON BASE PLATE

Original model Base plate fixed

TOTAL CLAMPING OF BASE PLATE

INDICATES PLAY IN ORIGINAL MODEL
- Natural frequency increase to 104Hz -
FEA STUDY ON BASE PLATE

Original model Base plate fixed

TOTAL CLAMPING OF BASE PLATE

INDICATES PLAY IN ORIGINAL MODEL
- Natural frequency increase to 107Hz -
FEA STUDY ON BASE PLATE

Original model Base plate fixed

TOTAL CLAMPING OF BASE PLATE

INDICATES PLAY IN ORIGINAL MODEL
- Natural frequency increase to 134Hz -
SUMMARY OF RESULTS

From the combined analyses, the root cause

of the frequent failures of amine pump were
due to the base plate may not be rigidly
attached to its foundation. This has resulted
an unexpected lower modes generated by
the flexible base plate near the operating
region of the amine pump
STRUCTURAL DYNAMIC MODIFICATION

BOLTING THE BASE PLATE TO ITS

FOUNDATION
STRUCTURAL DYNAMIC MODIFICATION

BOLTING THE BASE PLATE TO ITS

FOUNDATION
STRUCTURAL DYNAMIC MODIFICATION

BOLTING THE BASE PLATE TO ITS FOUNDATION

HAVE SHIFTED THE NATURAL FREQUENCIES
ABOVE ITS OPERATING REGION

Mode Pump Gearbox FEA FEA FEA

Total fixed Bolted
1 45 47 48 104 97
2 67 - 71 107 101
3 83 85 78 134 126
RECOMMENDATIONS

 IN SUMMARY, THE BASE PLATE HAVE TO BE

STRENGTHEN BY BOLTING IT TO THE FOUNDATIONS

 CONCURRENTLY, THE AMINE PUMP HAS TO BE

OVERHAULED; AND

 WE ALSO RECOMMEND THAT THE SUB-STRUCTURES OF

THE AMINE PUMP TO BE INSPECTED FOR WEAR AND
LOOSENESS CAUSED BY THE LONG OPERATION IN
UNDESIRABLE CONDITION
ODS ANALYSIS FOR STEAM TURBINE
DRIVEN UNIT
- Spectrum shows harmonics → indication of play or looseness -

ODS FRF spectrum for HPRT ODS FRF spectrum for Pump

ODS FRF spectrum for Steam Turbine ODS FRF spectrum for Base Plate
ODS ANALYSIS FOR STEAM TURBINE
DRIVEN UNIT

ODS animation for Steam Turbine-driven pump

- Showing movements of the base plate -
STRUCTURAL DYNAMIC MODIFICATION
- STEAM TURBINE DRIVEN UNIT -

FIXING THE BASE PLATE TO ITS FOUNDATION

HAVE SHIFTED THE NATURAL FREQUENCIES
ABOVE ITS OPERATING REGION

Mode Pump HPRT Steam FEA FEA

Turbine Total fixed
1 65 64 - 62 88
2 77 72 70 74 95
3 - 82 82 75 119
OHAIYO KUDARAMAS!
GRACIAS!