461

Modification of BB1 pump vibration characteristics

to meet ISO 13709 2nd edition (API 610 11th) limits
Simon Bradshaw, Global API Product Development Manager
Eugene Sabini, Director of Research
462

Summary of the pump in question #1

API 610 designation BB1

Pump Service Cooling water circulation (through cooling towers)

Ruling Specification API 610 8th edition

Impeller diameter D2 1073mm (42.25”) rated, 1219mm (48”) maximum

Running speed 514 RPM
Flow 8400 m3/hr (36985 USGPM) rated
Design Head 40m (131.2 ft)
Specific Speed 50 Metric (2600 US)
Suction Specific Speed 166 Metric (8550 US)

Casing Arrangement Double volute, 180°opposed volute lips

Impeller Arrangement 6 vane double entry impeller, non staggered vanes

Bearing arrangement Sleeve radial with dual oil rings, flooded tilting pad
thrust bearing with shaft drive circulation system

2
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Summary of the pump in question #2

Supplied by a different division of ITT

Factory tested September 2007

Commissioned ≈ 2008

Vibration problems seen at low flow (50 to 75% of rated) that were not seen
during factory testing

Site vibration values exceeded API 610 allowable levels

Pump was shipped to our R&D facility for further evaluation

3
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Test loop setup #1

Shop Air 100 psig Vacuum pump
(valve normally closed) (valve normally closed)

Tower

Drain valve Backpressure

(normally closed)
valve

Suction
valve Discharge valve
(pressure breakdown)

Pump under Pump drive via

test VFD & gearbox
4
465

Test loop setup #2

Gearbox

Motor

Pump

5
466

Initial testing results #1

Tested with “expected” site NPSHa of 13.4m (44ft), the pump met IS0 13709
(API 610) vibration criteria of 3.0 mm/s (0.12 in/s) in the preferred region (70 to
120% of rated) and 3.9 mm/s (0.156 in/s) elsewhere

The customer requested testing to ISO 13709 2nd edition (API 610 11th) section
8.3.3.6, which requires testing at no more than 110% of rated NPSHa.

The pump was retested at the rated NPSHa of 10m (33 ft) and vibration levels
significantly exceeded the allowable vibration criteria
0.3
7 Vibration @
6 13.4m (44ft)

Vibration (mm/s)
Vibration (in/s)

NPSHa
0.2 5
4
Vibration @
3 10m (33ft)
0.1 NPSHa
2
1
ISO 13709
0 0 Limit
0% 25% 50% 75% 100%
% BEP Flow 6
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Initial testing results #2

Vane pass noise

Broadband
hydraulic noise
7
468

Analysis of contributors
1. Pump design circa 1970 intended for municipal water service (although
successful used in ISO 13709 service on prior occasions)

•6 vane design, less than ideal with a 180°volute

•Unstaggered vane design
•Impeller eye larger than optimum by modern design rules
•Suction casing area progression not optimum by modern design rules

2. Never previously required to meet ISO 13709 section 8.3.3.6 test

Recirculation
3. Large impeller trim onset Shockless
1219mm (48”) Flowrate

1073mm (42.25”)

Reduced
flow range
before
recirculation

8
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Analysis of fixes
Fix Positives Negatives Vane Suct. Disch. Used
pass side side
vibration recirc. recirc
Bull ring in the impeller ring Will suppress suction Increases NPSHr at high
eye side recirculation flows 0 ++ 0 Yes
Profile ring with artificial “A” Will suppress suction Long lead time
gap and bull ring side and discharge side 0 ++ +++
incorporated recirculation

Cutback top half casing Will reduce vane pass Will increase radial thrust.
volute lip to 168° vibration ++ 0 0 Yes
V cut both casing volute lips Will reduce vane pass Reduction effect will not be
vibration as much as the 168° + 0 0 Yes
cutback
Alter the position of the Can improve the Requires a CFD analysis
suction casing stop piece uniformity of flow into for correct location. Only a
impeller and suppress small improvement 0 + 0
instability expected

Cast and machine and Will suppress discharge Long lead time
impeller with full diameter side recirculation Cost 0 0 ++
shrouds and trimmed vanes
Design and manufacture a Improves all symptoms Long lead time
new 5/7 vane impeller with Cost +++ ++ ++
closer to full diameter

9
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Application of chosen Fixes #1

A suction side restriction ring (commonly known as a “Bull Ring”), was added
to the casing.

The purpose of this ring is to limit suction side impeller recirculation

Original inlet Revised inlet

design Recirculation
design

Bull Ring

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Application of chosen Fixes #2

The top half casing volute lip was cutback to create an angle of 168°relative to
the lower half volute lip.

The cutback was angled 30°to smear the pressure pul se in the time domain

White marks
indicate material
removed

11
472

Application of chosen Fixes #3

The bottom half casing volute lip was angled 30°to smear the pressure pulse
in the time domain

White marks
indicate material
removed

12
473

Testing results after modifications #1

Testing confirmed the effectiveness of the modifications at suppressing low
flow vibration behavior, but created a problem at higher flows.

So what went wrong ?

0.3
7 Vibration
before mods

Vibration (mm/s)
6 @ 10m (33ft)
Vibration (in/s)

0.2 NPSHa
5

4 Vibration after
3 mods @ 10m
0.1 (33ft) NPSHa
2

1
ISO 13709
0 0 Limit
0% 25% 50% 75% 100%
% BEP Flow
13
474

Testing results after modifications #2

A review of the NPSHr results gave a clue

The bull ring was causing significant head loss at higher flows:

•Head loss = Broadband hydraulic noise = Extra vibration

25
7
NPSHr before
20 6 mods
5

NPSHr (m)
NPSHr (ft)

15
4
10 NPSHr after
3
mods
2
5
1
0 0
0% 25% 50% 75% 100%
% BEP Flow
14
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How to fix a Bull Ring #1

We applied a little used variant of the bull ring, which we call the Sabini Ring

Existing bull ring

slotted to achieve
approximately
47% open area

Leading edge
chamfered to
reduce losses

15
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Testing results after bull ring changes #1

Testing confirmed the effectiveness of the changes to the bull ring

Vibration was now well controlled over the whole flow range

0.3
Vibration before
7 mods @ 10m
(33ft) NPSHa

Vibration (mm/s)
6
Vibration (in/s)

0.2 5 Vibration after

4 mods @ 10m
(33ft) NPSHa
3
0.1
2 Vibration after bull
ring mods @ 10m
1 (33ft) NPSHa

0 0
ISO 13709 Limit
0% 25% 50% 75% 100%
% BEP Flow
16
477

Testing results after modifications #2

The NPSHr results also indicate the success of the final bull ring design

25
7 NPSHr before
mods
20 6
5

NPSHr (m)
NPSHr after bull
NPSHr (ft)

15 ring mods
4
10 3 NPSHr after
mods
2
5
1
0 0
0% 25% 50% 75% 100%
% BEP Flow
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478

Conclusions
1. ISO 13709 section 8.3.3.6 testing can cause problems in older pump designs

2. Modern designs with the following are preferred:

• 5 or 7 vane impellers with 180°volutes
• 6 vane impellers with 168°volutes
• Impeller eye diameter minimized in relation the target Nss value

3. Avoid large impeller trims as these promote recirculation and give a false
indication of the true BEP (shockless) flow

4. Slotted bull rings offer a superior balance of recirculation suppression vs.

NPSHr increase compared to plain rings.

Thanks for your attention

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