M

M..P.
P. NNAACCHHIIM
MUUTTH HUU
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GAANNATATHHAANN EENNGGIINNEEEERRIINNG
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CCO
OLLLLEEGGEE

8th SEM- MECHANICAL ENGINEERING

SHAFT FAILURE ANALYSIS IN

CENTRIFUGAL PUMP
Presented by :
VEERAKUMAR.P 731716114106
BALAJI.K.S 731716114301
KAVIN.E 731716114304
SARAVANAN.K 731716114306

Guided by :
Dr. K.P.VETRIVEL, Professor and
Dr. K.P.VETRIVEL, Professor and
Hod/Mech
Hod/Mech
 ABSTRACT
 Shaft failures do not occur every day, but when they do it can be challenge to
determine the cause of failure. Here is a technical explanation of what happens
when the shaft bends to breaks. To understand the shafts and when they fails, you
need to understand the relationship between stress and strain for steel. Stress the
force carried by a material per unit area , measured in PSI OR MPA.
Have information about the various factors that needs to be considered in material
selection , design and the service environment. Once , such a problem has been
identified from the evaporator plant of SESHASAYEE PAPER AND BOARD
LTD, pallipalayam, where there is the continuous failure occurred in the shaft of
the centrifugal pump. This is the major problem for the company, which affects
the production of the plant and the cost for the maintenance of the plant needs is
also high. There are nearly 24 pumps in the plant of similar.
 LITERATURE REVIEW
Khin Cho Thin (2008) (10)
 This paper deals with the design and performance analysis of
centrifugal pump. In this paper centrifugal pump is analyzed by using
a single-stage end suction centrifugal pump.
 They explained why the vibration characteristics of shaft have been
studied detail. Knowledge of vibration behavior of impeller will use
for optimizing there fatigue life and efficiency, possibly resulting in
increased performance and applicability.
 Khincho thin in this paper discussed the various method of model
analysis testing of rotating structure and also did the frequency
analysis of centrifugal pump shaft by finite element analysis, and
compared the analytical result with the experimental result.
.
 D.R.Adkins (2003) (2)
 This study investigates the forces that result from hydrodynamic between impeller
and the volute in a centrifugal pump.
 A centrifugal pump is a kinetic device. The centrifugal action of the impeller
accelerates the liquid to a high velocity, transferring mechanical energy to the liquid.
 The result is that the available energy in the liquid decreases as the distance from the
pump increases.
 The actual energy available for the work at any point in the system is a combination
of available velocity and pressure energy at that point.
Walli Muhammad (2010) (3)
 we get the data regarding shear force, torsional load of the centrifugal pump and
impeller. Centrifugal pump are widely used in industrial and municipal applications,
and they are in importance end use application of electrical energy.
 Here discusses the usage of frequency converter in the condition and operation
monitoring of a pumping system compressing a centrifugal pump an electrical
motor and a converter.
 The main objective of this is to present methods that allows the use of a frequency
converter as a monitoring and an analysis device for a pumping system.
 V. I Kucheryavyi and S. N. Milkov (2014) (4)
 This doctoral discusses the statistical modeling of shaft, the method
studied in this can also be applied to other centrifugal pump types such
as mixed and axial flow pumps.
 Typical reason for this is the incurrent dimensioning of pump system
component and insufficiency of the applied pump control method.
 Besides the increase in energy cost an insufficient operation may
increase the risk of pump failure and their by maintenance cost. In the
worst case a pump failure may lead to a process shutdown occurring
additional cost.
Noah D.Manring (1999, 2004) (5)
 The mechanical performance of a pump would imply only the rotating
masses with no consideration given to hydraulic processes.
 The rotating masses (impellers, sleeves, nuts, couplings, bearings,
seals...). Can be examined as a pure mechanics. Outside of serious
unbalance and pump components there is no single contributor of poor
mechanical performance more significant then poor alignment. In
current alignment between a pumps and drivers can cause
 Griridharsabnavis, R.Gordon kirk, Marry kasardass (1999, 2014) (6)
 Shafts are amongst component subjected to perhaps the most arduous working
conditions in high performance rotating equipments used in process and utility
plants such as high speed compressor, steam and gas turbines, generators, pumps,
etc.
 Although usually quite robust and well designed, shafts in operation are sometime
susceptible to serious defects that develop without much appearing warning. They
are prime candidates for fatigue cracks because of the rapidly fluctuating nature of
bending stresses.
A.N.Shina (1998) (7)
 A shaft is a metal bar usually cylindrical in shaft used to support rotating
components (or) to transmit power (or) axial moment.
 Shaft operate under a board range of service condition including various
corrosive Environment and a wide temperature range.
 Shaft may be subjected to a variety of loads such as tension and compression,
bending of this.
 Kashif mairaj Deen (2010) (8)
 A number of the shaft failures were encountered in water recirculation
pumps of an industrial setup. The shaft were made of martenstic stainless
steel
 A detailed study was carried out the determine the cause of the pump
shaft failures. In this connections, the analysis performed included
chemical analysis, micro-structural characterisation fractography tensile,
shear and hardness measurement.
Mohd nasir tamin (2010) (9)
 The procedure demonstrated in performing failure analysis of a
centrifugal pump shaft. The chemical, micro structural information
provided on the material science aspects of the failure.
 The mechanical design analysis establish the cause of failure based on
the stress calculation using strength of materials approach.
Deeptesh singh (2013) (10)
 The reliability and maintainability of centrifugal pump systems have in
the overall plant availability plays a very important of a suitable
maintenance strategy.
 The key issues of this strategy are not only the reduction of unplanned
shutdowns and component repair times but also failures of critical
components elimination once and for all.
 S.Srinivasa Rao (2015) (11)
 Identifies the remedial actions are to be taken to ensure safer operation of total power of
motor and pump unit and diagnosed faults occurring in a centrifugal pump by normal
running, bearing fault, impeller fault seal fault and cavitation.
 Mainly due to incorrect operating conditions, liquid containmination and misalignment.
Sebastian Muntean (2013) (12)
 The shaft is an important in hydraulic pump used to transmit power from electrical
motor to the pump impeller .
 The paper presents failure analysis of a shaft, from a double suction hydraulic pump in
operation of approximately 30 years, in a storage station.
 The shaft material is a Romanian steel equivalent after this chemical composition and
mechanical characteristics.
Adam Henke (2016) (13)
 The main goals of research was to explain the reason of occurring fractures in pump
shaft.
 The investigation has shown that the fractures were caused mainly by the resonance
between pump shaft torsional natural vibrations and these following from the pressure
fluctuations related to the frequency of the shaft rotational speed and the number of
impeller blades.
 Devaraja k (2016) (14)
 Centrifugal pumps are sub-class of dynamic axis symetric work absorbing turbo
machining used to induce flow or raise pressure of a liquid.
 Centrifugal pump consists of a rotating five stage impeller inside a stationary volute.
The shaft passes through the stuffing box. The pump is working in the area of hot
rolling mill for de-scaling of the strip.

Abdul Hamid (2017) (15)

 Pump shafts are generally exposed to the liquid being pumped after on a continual
basis or at certain locations along the length of the shaft.
 The shaft material is austentic stainless steel, description ASTM AU79 TYB16 the
purpose of this study is to determine the failure of the water pump shaft used in the
power plant.
 Metallurgy is the study and structure metal shaft can used as a means for CWP
metal pelting for the purpose of damaged or deeply degraded areas.
 FEASIBILITY OF STUDY
 The major causes for the failure of the shaft are due to the impluse force,
radial force and impeller weight. This load are been acting over the shaft
during the process performed, and which tends to the shaft failure.
 The failure of the shaft can be avoided by redesigning the shaft. The
redesigning of the shaft can be obtained by increasing the diameter of the
shaft or by changing the material properties of the shaft.
 So after analyzing the cause of shaft failure, here we suggest that the
shaft material to be changed from MS C45 TO SS316L.
 The change in shaft material also gives advantage in four times more
than the material life, reduce in labour cost of dismantling and
overhauling also downtime of the machine.
CENTRIFUGAL PUMP
 PROBLEM IDENTIFICATION

Note: The rounded part indicates the shaft failure due

to the vibration, over load , imbalance of impeller.
 WORKING PRINCIPLE
 One of the most common and popular type of pumps used for
transfer of fluids.
 The centrifugal pump have wide range of models depending on the
application needs, industry requirements and viscosity.
 To applying a centrifugal force, water or other fluid are pushed
using impeller.
 Undoubtedly, these are the perfect choice in delivering liquids
from one location to another in numerous industries
 PROBLEM DEFINITION
 Inability to deliver the desired flow and heat is just one of the
most common conditions for taking a pump out of service.
 There are other many condition in which a pump, despite
suffering no loss in flow or head, is considered to have failed
and has to be pulled out of service as soon as possible.
 These includes pump shaft related problem ( breakage), pump
and motor bearings related problems ( loss of lubrication,
cooling, contamination of oil, abnormal noise, etc.), leakage
from pump casing, very high noise and vibration levels, or
driver ( motor or turbine) related problems.
 SOLUTION

The load are been acting over the shaft during the process

performed, and which tends to the shaft failure.

 The failure of the shaft can be avoided by redesigning the shaft.

The redesigning of the shaft can be obtained by increasing the

diameter of the shaft or by changing the material properties of the

shaft.
 MATERIAL SELECTION
Shaft details :
 Diameter :55mm
 Length:668.4mm
 Material of the shaft: Mild steel C-45
 Density of shaft: 7800kg/m^3
 Young’s modulus: 2.1e+005 Mpa
 Poisson’s ratio: 0.34615
 Bulk modulus : 2.275e+005 Mpa
 Shear modulus : 78000 Mpa
 Tensile yield strength: 350 Mpa
 Tensile ultimate strength: 390 Mpa
Shaft details :
 Diameter : 55 mm
 Length: 668.4 mm
 Material of shaft: Stainless steel 316L
 Density of the shaft: 8027 kg/m^3
 Young’s modulus: 2.1+005 Mpa
 Poisson’s ratio: 0.21951
 Bulk modulus : 1.188e+005 Mpa
 Shear modulus : 82000 Mpa
 Tensile yield strength: 250 Mpa
 Compressive yeild strength: 250 Mpa
Shaft details:
 Diameter : 55 mm
 Length: 668.4 mm
 Material of shaft: Nickel alloy(Ni)
 Density of the shaft: 8900 kg/m^3
 Young’s modulus: 200 Gpa
 Poisson’s ratio: 0.31
 Bulk modulus : 180 Gpa
 Shear modulus : 76 Gpa
Shaft details:
 Diameter : 55 mm
 Length: 668.4 mm
 Material of shaft: Nickel Chromium (Ni-cr)
 Density of the shaft: 8400 kg/m^3
 Young’s modulus: 245 Gpa
 Poisson’s ratio: 0.325
 Bulk modulus : 205 Gpa
 Shear modulus : 100 Gpa

From this three material, we will select the material by using ANSYS
software according to Total deformation , Equivalent stress, Shear
stress . We will select the suitable material for our project .
 SPECIMEN PREPARATION
The specimen preparation are done using “CREO PARAMETRIC 3.0”
software for our project using basic dimension .
Diameter = 70mm
Length = 668.400mm
 Data collection

The data collection of the project was done with some specified data for
their evaluation object
MILD STEEL (C45)- MEDIUM CARBON STEEL
Melting point=1425-1540c
Density=7.85 g/cm^3
Specific gravity =8.00
Application:
 Axles
 Spindles
 Shafts
 Automotive parts
 Knives
Chemical composition:
 C=0.42%
 Si=0.35%
 Mn=0.50%
 P=0.040%
 S=0.044%
 Cr=0.39%
 Mo=0.9%
 Ni=0.40%
 Cr+Mo+Ni= 0.60%
Heat treatment :
 The samples were subjected to different temperature in an electric furnace
with the max temperature capacity of 1000 c.
 The heating temperature are selected by transformation- temperature –time –
diagram .
Mechanical properties :
 Tensile strength ultimate = 81900psi
 Tensile strength yeild=45000 psi
PSI= Pound Square Per Inch
1PSI = 6.89 KPA
 Elongation =30%( varies according to heat treatment process)
Stainless steel ( 316L): (Austentic steel)
Meting point = 1390 to 1440 c
Density = 8.027g/ cm^3
Specific gravity= 8.03
Application :
 Boat fittings, chemical containers, heat exchanger, spring, thread and
Fasterners
 Labortary , benches, and equipment etc..
Chemical composition:
 Alloy= 316L
DATA COLLECTION
 C= 0.3%
 Mn= 2.00%
 P=0.040%
 S=0.030%
 Si=1.00%
 Cr= 16.0 to 18.0%
 Ni= 10to 14%
 Mo= 2to3%
 Cu=0.75%
Heat treatment:
 316 alloy the solution anneal is accomplished by heating in the 1040to 1175
c
 Cooling should be sufficiently rapid through the 816 to 427 c.
Mechanical properties:
 Tensile strength minimum 70000 PSI
 Yeild strength minimum 25000 PSI
% Elongation 40%
PSI= Pound Square Per Inch
1PSI = 6.89 KPA
DATA COMPARSION:

S.NO PARAMETR MILD STAINLESS BETTER

S STEEL STEEL
1 MELTING 1425-1540 C 1390-1440 C MILDSTEEL
POINT
2 DENSITY 7.85g/cm^3 8.02g/cm^3 STAINLESS
STEEL
3 SPECIFIC 8.00 8.03 STAINLESS
GRAVITY STEEL
4 TENSILE 70000 PSI 819000 PSI STAINLESS
STRENGTH STEEL
5 YEILD 25000 PSI 45000 PSI STAINLESS
STRENGTH STEEL
 Data are compared according to their melting point, density, specific gravity , tensile
strength, yield strength etc..
 Mild steel C45 has more melting point temperature then stain less steel 316 L because
steel has high melting capacity to withstand the high temperature .
 But when compared to other parameter the stainless steel is higher then the mild steel
to withstand all the problem then C45steel .
when compared with data collection :
 According to the data collection of the two material Mild steel C45 and Stain less steel
316L .
 The mild steel C45 has low capacity then Stainless steel.
 The Mildsteel C45 can’t with stand load deformation , stress , vibration , shocks.
 But Stain less steel can withstand all the parameter because of their composition .
 At present Mild steel C45 are used in my project continues shaft failure due to light
weigth material , over load , vibration ,imbalance weigth.
 After taking data comparsion, I choose “Stainless steel 316L” is better for my project
to avoid shaft failure in centrifugal pump.
 Analysis using ansys
Using mild steel as shaft material:
Meshed model with boundary conditions and loading to
represent 4-point bending in ANSYS. After applying loads,
master degrees of freedom is also needed, and then start the
solution calculations. After building the models and
obtaining the solutions, the post processors in..
TOTAL DEFORMATION:

 
b) Equivalent stress:

c) Shear stress:
Using stainless steel as shaft material
Meshed model with boundary
conditions and loading to represent 4-point
bending in ANSYS. After applying loads,
master degrees of freedom is also needed, and
then start the solution calculations. After
building the models and obtaining the
solutions, the post processors in..
TOTAL DEFORMATION:
Equivalent stress

Shear stress
 COST ESTIMATION
 Diameter of stainless steel and mild steel= 55mm
 Density of mild steel C45= 7.8 x10 -6 kg/mm3
 Density of stainless steel 316L= 8.2 x10 -6 kg/mm3
 Rate/kg of MS=Rs54/-
 Rate/kg of SS316L= Rs250/-
 Area of mild steel and stainless shaft = (3.14/4)x55 2
= 2375.8mm2
 Volume of mild steel and stainless steel= Area x Length
= 2375.8 x 668.4
= 1587984.72mm3
Weigth of mild steel = Density x Volume
= 1587984.72 x 7.8x 106
= 12.38kg
Price of MS = Weigth x Rate / Kg of MS
= 12.38 x 54
= Rs 669/-
Weigth of stainless steel= Density x Volume
= 1587984.72 x 8.2x106
= 13Kg

Price of SS 316L = Weight x Rate/ Kg of SS 316L
= 13 x 250
= Rs 3250/-

SL.NO MATERIAL WEIGTH UOM PRICE/ GROSS MACHININ

KG PRICE G
COST

1 MILD 12.38 KG 54 670 1000

STEEL C45

2 STAINLESS 13 KG 250 3250 1000

STEEL 316L
 RESULT AND DISCUSSION

Comparison between MS C45 and SS 316L:

Stainless steel maximum revolution / Mild steel maximum

revolution

= 57.6 × 106 / 144 × 105

=4 times

Hence stainless steel shaft life is 4 times greater than

Mildsteel.
 CONCLUSION
 The major causes for the failure of the shaft due to the impulse force,
radial force and impeller weight. This load are been acting over the
shaft during the process performed and which tends to the shaft
failure. This failure of the shaft can be avoided by redesigning the
shaft. The redesigning of the shaft can be obtained by increasing the
diameter of the shaft or by changing the material properties of the
shaft.
 So after analyzing the cause of shaft failure, here we suggest that the
shaft material to be changed from MS C45 to SS316L. The change in
shaft material also gives advantage in four times more than the
material life, reduce in labor cost of dismantling and overhauling also

downtime of the machine.

 REFERENCE

 Rosanel A. Morales 2009, “Fluid shear effects of centrifugal pump on Oil-water flow”.
 Noah D. Manring vol. 124, September 2002, “Designing a Control and Containment
Device for Cradle- Mounted, Axial-Actuated Swash Plates.
 G. P. Sullivan, R. Pugh, A. P. Melendez, W. D. Hunt December 2002, “Operations &
Maintenance Best Practices.
 Eduard Egusquiza 31 January 2012, “Failure invertigation of a large pump-turbine
runner”.
 Joao alberto menin paul meuter 2005, “High-Pressure Pumps for High-Viscosity Fluids
Getting the Oil to the Shore”.
 Griidhar Sabnavis, R. Gordon Kirk, Mary Kasarda and Dane Quinn vol.36, No.4, July
2004, “Cracked Shaft detection and Diagnostics”.
 Mario A. Garcia October 23, 2004, “PUMPX: An expert System for pump Diagnosis”.
 Strength Of Materials by R.S. Khurmi.
 Fluid Mechanics and Fluid Power by R K Banson
 Pumps and Cistans by V Thamsan Fedarik.
THANK YOU SIR