Analisis de La Performance de Una Bomba Warman

Performance analysis and design improvement on a test rig for
centrifugal slurry pumps at Weir Warman Ltd, Sydney

Tom Clabbers
12th December 2006
Abstract
The medium test rig in the test bay of Weir Warman in Artarmon needs refurbishing. Although the tests can be conducted fairly quick, the changeovers, from one test to the next,
cost too much time. The base frame on which the pump and motor are mounted is based
on a frame that Warman usually supplies with a pump and motor combination. Herein lies
the problem that the current base frame has: it is not specifically designed for a test rig, but
rather adapted from a base frame that is installed once, and then kept running for a long
time. The new design that is proposed in this study is in fact designed for this test bay.
Pumps and motors are quickly changed in between tests and the piping at both the intake
and discharge side are much easier adapted to a new setup as well.
Contents
1 Introduction
2 Warman slurry pumps

2.1 Weir Warman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Slurry pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Pump testing
3.1 Test bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Performance analysis
4.1 Changeovers . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Head, power and efficiency versus flow rate . .
4.2.2 NPSH test with constant flow rate method . .
4.2.3 Sound level, vibration and bearing temperature
4.3 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . .
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5 Design of the piping configuration

5.1 Intake side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Discharge side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6 Design of the base frame

6.1 Concept . . . . . . . . . . . . .
6.2 Dimensions and sections . . . .
6.2.1 Pump plates . . . . . .
6.2.2 Columns . . . . . . . . .
6.2.3 Floor frame . . . . . . .
6.2.4 Motor plate . . . . . . .
6.2.5 Jockey pulley frame . .
6.3 Finite element analysis . . . . .
6.3.1 Static analysis . . . . .
6.3.2 Harmonic analysis . . .
6.4 Final design . . . . . . . . . . .
6.4.1 Floor frame . . . . . . .
6.4.2 Motor plate . . . . . . .
6.4.3 E-frame pump pedestal
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rise test
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6.4.4
6.4.5
D-frame pump pedestal . . . . . . . . . . . . . . . . . . . . . . . . . .

Jockey pulley frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
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7 Conclusions
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8 Recommendations
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A Piping
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B Reaction forces
B.1 Pump reaction forces . . . .
B.1.1 Gravitational forces
B.1.2 Belt tension forces .
B.1.3 Flange loads . . . .
B.1.4 Flange moments . .
B.1.5 Total reaction forces
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C Parameter values
C.1 Motor reaction forces . . . .
C.1.1 Gravitational forces
C.1.2 Belt tension forces .
C.1.3 Motor torque . . . .
C.1.4 Total reaction forces
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in detail
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D Dimensions and sections

D.1 Pump plates . . . . . .
D.2 Columns . . . . . . . .
D.2.1 Bending . . . .
D.2.2 Buckling . . . .
D.3 Floor frame . . . . . .
D.4 Motor plate . . . . . .
D.5 Jockey pulley frame .
E Matlab programme instructions
79
F References
81
Chapter 1
Introduction
Weir Warman Ltd. is located in Sydney, Australia and designs, manufactures and tests
centrifugal slurry pumps. The testing is done on several test rigs. This report describes the
performance analysis and design improvement of one of those test setups: the medium test
rig. This test rig is somewhat dated and requires design improvements in order to save time
and money preparing and conducting the tests. The scope of this study is to improve the
medium test rig, without changing the actual testing procedures.
An analysis on the test rig shows what the points of concern are in the current setup
and a new design is proposed. In this design the piping configuration is changed. The main
focus, however, is on the base frame: the frame on which pump and motor are mounted on
for testing. The new design is thoroughly checked for strength properties and a static and
harmonic analysis are done using an FEA model. The design is presented by a CAD model
and the resulting drafts and drawings.
Chapter 2
Warman slurry pumps

2.1
Weir Warman
Weir Warman Ltd. is part of the Weir Minerals group, which has been created by bringing
together the previous global operations of Envirotech and Warman International. Weir Minerals is the world leader in the design and manufacture of slurry pumps, cyclones, slurry valves
and mill lining systems. Weir Minerals has operations across North America, South America,
Africa, Europe, Australia and Asia and employs over two and a half thousand people worldwide. Weir Warman Ltd. forms the Australian and Asian arm of Weir Minerals with sister
companies located all around the world, including Venlo, The Netherlands. Weir Minerals is
a division of The Weir Group PLC, a UK-listed engineering company founded in 1871 and
listed on the London Stock exchange since 1947. Weir Mineral brands include Warman, Ash
Pump, Galigher, Hazleton, Cavex, GEHO Pumps, Schabaver, Indupaq, Envirotech, Weiresist
and IsoGate.
Headquarters for Weir Warman Ltd. are located in Artarmon, a suburb of Sydney, Australia, employing around five hundred people. Weir Warman Sydney incorporates a fully
integrated design, testing, manufacturing and distribution facility for horizontal and verticalsubmersible centrifugal slurry pumps, ranging from 1 21 inch up to 1 meter intake flange diameter. Warman pumps are used in various applications. Many industries use Warman slurry
pumps to transport, among other things, sand, gravel, coal, phosphate, ash/dust, sugar, and
various kinds of ore. Warman pumps are used when dealing with abrasive materials like in
wet scrubber installations for flue gas desulphurization. Water treatment and public utility
plants make use of a range of Warman slurry pumps. Particular Warman pumps even suit
the specific demands of various offshore applications. [1]
2.2
Slurry pumps
A slurry can be a mixture of virtually any liquid combined with some solid particles. The
flow properties and other characteristics are determined by a great number of variables. The
combination of the type, size, shape and quantity of the particles together with the nature of
the transporting liquid make up the slurry behavior. Slurries can be roughly divided in two
groups: non-settling and settling slurries. Non-settling slurries contain only very fine particles
which can form stable homogeneous mixtures exhibiting increased apparent viscosity and
density. These slurries usually have low wearing properties but are non-Newtonian. Settling
7
slurries contain coarser particles and tend to form an unstable heterogeneous mixture. Settling
slurries have high wearing properties and form the majority of slurry applications.
All Warman slurry pumps are centrifugal pumps. The principle of a centrifugal slurry
pump is the same as a clear liquid pump. However, because slurries have such different
properties the pump has to be designed to meet the special requirements. This often results
in the use of tougher materials. Slurry pumps also have to be able to process large particles.
The biggest Warman pump can handle particles up to 53 mm in spherical size. Because of
this, they need heavier and wider impellers. Generally slurry pumps operate at lower speeds
to reduce wear. This means that they have to be larger in size than comparable clear liquid
pumps. Because the pumps are only tested using water, the specific design of slurry pumps
will not be elaborated on. [2]
Chapter 3
Pump testing
Any variation in design or manufacturing, no matter how subtle, will influence the performance of the pump. Pump testing is necessary to ensure the pump delivers the performance
as specified in the design. However, not all pumps that are tested have new design features.
Costumers can opt for an acceptance test to be carried out on their pump before it is delivered. Whatever the purpose may be, the tests are basically the same. These tests are
described in section 4.2.
3.1
Test bay
The test facilities at Weir Warman in Sydney are capable of testing the entire range of Warman
pumps. The facilities consist of four test rigs: the small and medium rig, the dyna rig and
the large test rig. The frame size of the pump to be tested roughly determines which rig is
to be used for the test. Every pump is fitted with a standardized frame. Pumps with an A,
B or C frame are tested on the small rig. The medium rig handles the D and E frames and
F frame pumps use the dyna rig. Anything bigger than an F frame is tested on the large rig.
The small and medium rig can be fitted with electric motors ranging from 3.75 to 220 kW,
driving the pumps via one or more v-belts. The dyna rig is fitted with a 201 kW motor and
the large rig with a 900 kW motor. The motors on both the dyna rig and the large rig are
directly coupled via a gearbox to the pump shafts. The four test rigs are all located in the
same test bay. The large rig has its own water basin and pressure tank. The small, medium
and dyna rig share another water tank. We will now focus on the medium test rig, as this is
the subject of this study.
Figure 3.1 shows the side view of the current medium test rig. At the far left is the water
tank. When the pump is running, the water leaves the water tank and flows through the
intake valve (2), that can automatically (partially) open and close using an electric motor.
Behind the intake valve is a flow straightener (4) that is equipped with an air vent (5) used,
together with air vent (12), to vent the air from the system when filling. At the bottom
of the flow straightener, the lowest point of the system, is a drain valve (3). Pipe (9) is a
telescopic pipe. This pipe can slide in- and outward and is necessary to adjust the total pipe
length at the intake side for each different pump. The maximum reach of the telescope is
550 mm. The pipe segment indicated by (10) can be one or more pipes that connect the
telescopic pipe with the intake flange of the pump. This set of pipes has to have one or more
reducers, because the telescopic pipe has an internal diameter (ID) that is bigger (312 mm)
9
Figure 3.1: The current medium test rig

than the intake diameter of the largest pump for the test rig (200 mm). A tapping point (16)
is present at two times the ID from the intake flange of the pump. After the water passes
the pump, it flows past another tapping point, twice the ID from the discharge flange of the
pump. Piping segment (14) should again contain one or more reducers to increase the pipe
ID to 200 mm. Flange (17) has slots in stead of bolt holes, so the segment from (17) to the
pump can be somewhat rotated. Together with two telescopic pipes (11) and (13), it enables
piping segment (14) to be fitted on any pump that is to be tested. Before the water flows
back into the tank, it flows through pipe (8), which is equipped with an orifice plate and two
tapping points (6) and (7) at either side of that plate. At the far left end is the discharge
valve (1), which has the same automatic features as the intake valve.
The pump and motor are mounted on a base frame, which is shown in figure 3.2. The
base frame consists of a floor frame (2), a motor pedestal (A) and a pump pedestal (B). In
order to adjust the height for the various pumps one or more add-on frames (3) are placed on
the base plate. An electric motor powers the pump via v-belts. The pre-tensioning of these
belts is done by adjusting the height of the whole motor. The motor is mounted on the top
plate of the motor pedestal. The vertical adjustment of that top plate is done by means of
four bolts (1) by which the plate is held up.
3.2
Tests
Performance testing at the Artarmon test bay is only carried out using water. This is because
all the standards with which the pumps have to comply require water testing. Besides, it would
be impossible to obtain all the different slurries for the numerous slurry pump applications.
Standards that are used include:
10
Figure 3.2: The base frame on the current medium test rig
Australian Standard AS 2417
International Standards Organization ISO 2548 & 3555
German Standard DIN 1944
Hydraulic Institute Standards HIS
Japanese Standard JIS B8301
American Petroleum Institute API 610
Although details differ between standards, they all require the same tests to be carried out.
These tests include testing for head and flow rate for different speeds, NPSH testing, sound
pressure level, vibration and bearing temperature rise testing.
The head and flow rate for different speeds define the pump. The pumps characteristic
curve is obtained from this test. The Net Positive Suction Head or NPSH is tested to establish
the cavitation performance. Cavitation occurs when the fluid pressure is so low in the intake
of a pump that vapor bubbles (or pockets) form and effectively block off the flow into the
pump. Cavitation degrades the pump performance and can even destroy pump parts. The
last three tests straight forward and are performed at the specified duty point of the pump.
A detailed description of the tests, including the operating procedures are laid out in section
4.2. [3]
11
12
Chapter 4
Performance analysis
Analyzing the performance of the medium test rig involves all quantitative and qualitative
aspects. The test rig should be quick and easy to use, and the test results should be accurate
and reliable.
4.1
Changeovers
The changeover time is the time it takes to set up the test rig for a test. It also includes
clearing the setup as it was used for the preceding test. The operating procedure for a
changeover on the current medium test rig is listed below, starting with a clear test rig. The
numbers between the brackets refer to figure 3.1 and 3.2.
1. Adjust height of the pump pedestal by clamping one or more add-on blocks (3.2: 3) on
base plate (3.2: 2).
2. Place and fix pump on pump pedestal (3.2: B).
3. Place and fix correct motor on motor pedestal (3.2: A).
4. Determine which pulleys and belts have to be used.
5. Search for right pulleys and place pulleys on pump and motor shafts.
6. Place belts on pulleys.
7. Pre-tension the belts by adjusting motor height.
8. Search for pipe segments and reducers for intake side (3.1: 10).
9. Get matching gaskets for flanges on intake side.
10. Adjust telescopic pipe (3.1: 9).
11. Attach pipes to telescopic pipe and intake flange.
12. Search for pipe segments and reducers for discharge side (3.1: 14).
13. Adjust telescopic pipes (3.1: 11) and (3.1: 13).
13
14. Get matching gaskets for flanges on discharge side.

15. Turn discharge section using slots in flange (3.1: 17).
16. Tighten all flange bolts.
17. Attach manometer tubes to (3.1: 6) and (3.1: 7).
18. Attach pressure gauge tubes to (3.1: 15) and (3.1: 16).
19. Place optical tachometer to measure motor speed.
20. Open intake and discharge valves (3.1: 1) and (3.1: 2).
21. Open air vents (3.1: 5) and (3.1: 12).
22. Fill system with water.
23. Close all air vents once the system is full.
4.2
Testing
Before the pump can be tested, one must ensure that the pump and motor are installed
correctly and the pump is well assembled. First the operator turns on the motor for a brief
moment and lets the pump come to stop. If no irregularities occur, he turns on the motor
again and checks if the pump is running smoothly. The testing can begin, but not before the
air is bled from the instrument lines by throttling the manometer and gauge valves.
4.2.1
Head, power and efficiency versus flow rate
During this part of the test the intake valve is opened completely and the flow rate is varied by partially opening the discharge valve. For a short moment, the discharge valve is
closed entirely. Then, seven other readings are done, the flow rate increasing more or less
evenly spaced including the duty point and the maximum flow. Each time the intake and
discharge pressures, flow rate, pump speed and power are recorded. The pressures are measured with mechanical dial gauges and the flow rate is determined by measuring the pressure
difference over the orifice plate (figure 3.1: 8). The pressure difference is measured with an
air-mercury-air manometer connected at both sides of the orifice plate. The power of the
pump is determined by multiplying the flow rate and pressure difference over the pump. The
efficiency is the power the pump delivers divided by the power of the motor. That motor
power is determined with the measured current the motor draws at a known voltage.
4.2.2
NPSH test with constant flow rate method
This test starts by measuring the water temperature and the atmospheric pressure. When
the pump is set to the duty speed, the intake valve is fully opened. The discharge valve is
then adjusted to comply with the required flow rate. By entering the data into a spreadsheet,
the total discharge head (TDH) and NPSH are calculated and plotted (TDH vs NPSH). The
intake and discharge pressures, pump speed and power are now recorded. Next, the suction
head is reduced by approximately two meters by closing the intake valve, while maintaining
14
a constant flow rate by opening the discharge valve. If necessary, the drive speed can be
adjusted. The operator records the intake and discharge pressures and repeats the last step
until the the TDH drops below 10% of the stable non-cavitating TDH.
4.2.3
Sound level, vibration and bearing temperature rise test
These tests can vary between different standards to which the pump has to comply, but
most standards request the following procedure. When the pump is running at duty speed,
the sound pressure level has to be below a maximum allowable value at a certain distance
from the pump casing. A minimum number of microphone positions may also be required.
Background noise readings are taken and the measured values are corrected. The sound level
meter is calibrated before and after each test using an acoustic calibrator.
With the pump running at duty speed, vibration measurements are taken at several positions on the pump bearing assembly to cover vibration in three mutually perpendicular
planes. The measurements are done with a portable vibration meter that is to be held onto
the vibrating part.
With the pump again running at duty speed, temperature readings are taken on the
outside of the pump bearing housing, at both the drive and pump ends. Readings should
be taken over time at thirty minutes intervals, with the pump operating at fixed conditions,
until stabilized. The readings are taken with a hand held, digital read-out thermometer, with
a thermocouple type probe. Readings of temperatures rise can be high at start up due to
excessive grease churning or bearing run-in. If temperatures rise in excess of 90 C, the pump
should be stopped and allowed to cool before re-starting the test. It may be necessary to stop
and start several times before the final bearing temperature rise can be ascertained. [4]
4.3
Evaluation
The test rig should make testing as quick and easy as possible. Because changes to the testing
procedures are not within the scope of this study, the changeovers on the test rig are to be
improved.
The changeover procedure as described in section 4.1 leaves plenty of room for improvements. Starting with point 1 and 2. Because there are only two different pump frame sizes
for testing on the medium test rig, there are only two pump pedestal heights necessary, each
with four bolt holes. That the current medium test rig has several add-on blocks with many
holes and slots in the top plate makes choosing the right set-up needlessly difficult.
Pretensioning of the of the belts takes up much time currently. The operator places a
belt around the two pulleys and then jacks up the whole motor. This is done by adjusting
eight nuts on four threads, one at each corner of the motor pedestal. In order to overcome all
friction forces, the operator can only adjust one corner a little bit at a time. Meanwhile he
checks the tension of the belts by pressing against it and checking the deflection. The motor
pedestal is also the least stiff part of the base frame. Vibrational problems are therefore most
likely to occur at that side.
Finding the right reducers and pipes for the intake and discharge side can take quite some
time. Every pump has its own intake and discharge diameters, bolt hole diameters in the
flanges (PCD) and distance from the fixed pipes. Although an experienced operator probably
is rather fast in finding the right combination, time spent on a test should not depend on the
person conducting the test.
15
16
Chapter 5
Design of the piping configuration

5.1
Intake side
Figure 5.1: Situation sketch of the intake side

The piping at the intake side of the pump has to connect the intake flange of the pump to
the flow straightener, (4) in figure 3.1. Because the axial distance varies between pumps, a
telescopic pipe is needed to prevent having to use too many different pipes. Another function
this set of piping has is reducing the diameter of the pipes from the diameter of the flow
straightener to the intake flange. These diameters also vary from pump to pump. Besides the
diameter, connecting flanges also have to match the pitch circle diameter, or P.C.D. This is
the diameter of the circle described by the bolt holes in the flange. Having to keep an eye on
costs, as many pipes as possible have to be used that are already in stock. Although there is a
list of pipes present at the test bay, modifications made to these pipes are often not recorded
and a complete stock taking can be recommended. For this design however, we will assume
the list is accurate.
For the sake of simplicity, all pumps with the same frame will be bolted down at the same
position. For that reason only four holes have to be drilled in the top plates and that the
shaft ends are virtually in the same spot. In order tot achieve this goal, we have to make sure
that all these pumps can be connected to the telescopic pipe at the intake side. This telescope
17
can be extended up to 55 cm (maximum distance D in figure 5.1). For some pumps however,
this buffer is not entirely free to use. Sometimes when a pump is tested, the impeller has to
be changed in between tests. This means that a number of pumps has a minimum clearance
specified (distance C in figure 5.1). This clearance is necessary to dismantle the cover plate
and change the impellers. In such a case it is most convenient and time efficient to disconnect
the pipe from the intake flange and slide back the telescope, without having to dismantle the
whole setup.
The fixed parameter is the distance from the flow straightener to the first anchor bolt of
the current base frame (F in figure 5.1), which is 3.78 meter. There are six bolts anchored
in the concrete floor to fix the current base frame. They will also be used to fix the new
frame. The parameter that is of importance for the design of a new base frame is the distance
from the anchor bolt to a fixed position of the respective D and E frame pumps (parameter
E in 5.1). In this case the first bolt hole of the pump frame is chosen for this position.
Parameters A, B and C as shown in figure 5.1 vary for the different pumps. Parameter E can
be determined using:
Emin = A + B + P + C F
Emax = A + B + P + D F
with P being the total length of the pipe segments connecting the telescopic pipe to the intake
flange of the pump. Emin and Emax define a range in which the first bolt hole of the pump
frame can be. The pipe segments that make up P for each different pump have to be selected
so that all the ranges overlap. In this overlapping region we can pick a point to position the
bolt holes on the pump plates. As a result, not only does the operator have the simple case
of only the one position for any pump, but it is also known which pipes have to be used for
a specific pump. This saves the time and trouble of solving the puzzle every time. The pipe
combinations are listed in tables 5.1 and 5.2. Now that distance E is determined for both
frame sizes the first concept of the base frame can be designed. The values of parameters A,
B, C, E and P are listed in appendix A.
Pump
4/3 D-SH
4/3 D-AHU
4/3 D-AH
4/3 D-AHW
6/4 D-S
6/4 D-SW
6/4 D-SC
6/4 D-SCW
6/4 D-AH
6/4 D-AHW
150 D-GP
8/6 D-S
8/6 D-SW
pipe 1
C10
C10
C10
C10
D16
D16
D22
D22
D22
D22
E4
E4
E4
pipe 2
C3
C3
C6
C6
D18
D18
G6
G6
G6
G6
E12
E12
E12
pipe 3
C18
C18
C8
C8
D14
D14
pipe 4
G6
G6
Table 5.1: Necessary pipes for D-frame pumps
18
Pump
4/3 E-HH
6/4 E-SH
6/4 E-AH
150 E-L
8/6 E-SC
8/6 E-SCW
8/6 E-AH
8/6 E-AHW
pipe 1
C10
E4
E4
E4
E4
E4
E4*
E4*
pipe 2
G10
E6
E6
G10
G10
G10
G10
G10
pipe 3
D12
D12
Table 5.2: Necessary pipes for E-frame pumps. Pipes marked with * have to be slotted at the
flange to match PCDs
5.2
Discharge side
The position of the discharge flange is different for every pump. The only fixed parameter is
that the discharge flange is always in a horizontal plane. By making use of several rotation
flanges in different orientations, all degrees of freedom can be covered. This concept is
adopted from the WEIR Netherlands test facilities in Venlo, The Netherlands. Figure 5.2
shows the discharge side of the test rig in Venlo, similar to the medium test rig at Warman.
The green flanges in the picture are the rotation flanges, which can freely rotate along the axis.
Because of the geometry of the pipes, the free pipe end can move in the horizontal plane as
well as up and down. The counterweight at the right balances the pipes. The whole system
can be easily moved by one operator. The only pipe that has to be changed for different
pumps is the reducer. The reducer is clamped onto the pumps discharge flange rather than
bolted. This has three advantages: it is faster, the PCDs doesnt have to match and is saves
one rotation flange on the vertical axis to line up the bolt holes. A full, detailed design of the
piping configuration is not done due to a lack of time.
19
Figure 5.2: Discharge side of a similar test rig in Venlo
20
Chapter 6
Design of the base frame

6.1
Concept
Figure 6.1: Base frame concept

The current base frame in the test rig is of a similar design to the frames that Warman
supplies with a pump and motor combination to costumers. The majority of these setups are
installed once, the motor height adjusted in order to get the right belt tension, and then kept
running. Occasionally, the motor pedestal can be readjusted to compensate for slacking of
the belts. The way to tension the belts is robust and durable rather than quick and easy. In
the test bay however, pump and motor changes are conducted regularly and getting the right
tension in the belts takes up much time. For that reason the new design will have a jockey
pulley rather than a adjustable motor height. As a result of the new tensioning system, the
motor no longer has to be mounted on a high pedestal. By moving the motor shaft from
above to underneath the pump shaft, the base frame becomes much more compact, which has
a good result on the vibrational properties.
Figure 6.1 shows the first base frame concept. The whole structure rests on the floor
frame. It has a U shaped cross section and is attached to the concrete floor with six anchor
21
Figure 6.2: Jockey pulley system: side, top and iso view
bolts. On the left-hand side is the motor plate. This is the plate that supports the motor.
Because the motor plate is placed directly on the floor frame, there is too little space to
place and tighten any nuts underneath. For this reason, a thread will be tapped in all the
holes in the motor plate. This will also save time when mounting the motors, for it makes
nuts obsolete. To ensure that the motor plate can be easily removed for maintenance and
modification in case of new motors, it will be bolted on the floor frame rather than welded.
Underneath the motor plate a stiffener is added. This stiffener is a plate perpendicular to the
motor plate and parallel to the long side of the floor frame. In order to keep the holes in the
motor plate clear, the stiffener is placed on the middle line of the plate. As figure 6.1 shows,
there are two pump plates. The lower one is for E frame pumps and is welded onto four square
hollow tubes which will be referred to as the columns. Underneath the columns supports are
added in the floor frame to decrease the bending moment in the floor frame. The upper plate
is for the D frame pumps and is welded on four columns of the same sort, though shorter.
This plate and columns structure is only used when a D frame pump is tested, and can be
bolted on the fixed lower pump plate when necessary. Both pump plates are strengthened by
stiffeners: similar to the stiffeners underneath the motor plate, although in this case there are
two crossed stiffeners per plate. The pulley frame in the back consists of two flange channels
with a beam between them. This beam is attached with two bolts, one through each channel.
A jockey pulley should be as close to the smallest pulley as possible at the slack side of the
belt. Because any combination of pulleys is possible for use on the test rig, the position of the
jockey pulley has to be adjustable in three directions. The beam can be adjusted in height
by choosing another set of holes in the channels. The beam carries a jockey pulley with its
adjusting mechanism. This is not depicted in figure 6.1, but the complete jockey pulley part
of the base frame is shown in figure 6.2. The jockey mechanism consist of the main frame,
two arms a push rod and an aluminium block on top to connect the rod with the main frame.
The main frame is bolted through a slot in the beam between the flange channels. This gives
the jockey pulley the second degree of freedom. Now only the last degree of freedom has to
be taken into account. This is done by means of the previously mentioned pulley mechanism.
The side view in figure 6.2 clearly shows four pin joints connecting the arms and the rod both
to the mainframe and the rod and the pulley both to the arms. Because the aluminium block
22
has a hole through which the rod can slide freely, the pulley can be positioned in forward
direction. To secure the position, the rod is threaded and two nuts, one at both sides of the
block. Because two different belt types can be used, SPB and SPC belts, there have to be
two interchangeable jockey pulleys. There will be two complete mechanisms which can be
bolted on the slotted beam in between the flange channels.
6.2
Dimensions and sections
In order to determine the sections and dimensions of the base frame, we have to know the
forces that are acting on the base frame. Because many pump, motor, pulley and belt
combinations are possible for testing, a worst case scenario is considered in all calculations.
Some assumptions have been made for the calculation of the sections and dimensions in order
to keep the calculations transparant. The main assumption is that all loads on the pump act
on the base frame only at the points at which the pump is fixed to its pedestal and likewise
for the motor side. These reaction forces are calculated in appendix B.
Knowing the forces acting on the base frame, the plate and profile thicknesses can be
determined. In order to do so, the structure is split up in smaller parts. These parts are all
evaluated separately using approximations and fundamental structural mechanics. Detailed
calculations can be found in appendix D.
6.2.1
Pump plates
Although the two pump plates differ slightly, they can be checked in the same manner. They
consist of the plate, two stiffeners underneath and four bolt holes on which the assumed point
forces act. Due to the load, the structure will bend. The stiffeners will contribute the most
to the stiffness of the structure and because they are placed in such a way that they are very
close to the holes, the assumption is made that the forces act directly on those members.
For the sake of simplicity, the stiffeners will be checked separately. To account for the plate
stiffness somehow, the members will be considered as T sections. Due to the forces acting
on the bolt holes, there will be reaction forces at the ends of the stiffeners, where they are
attached to the columns. With these reaction forces, a maximum bending moment can be
determined for each stiffener. According to the Australian standards handbook [5], the design
bending moment is restricted as:
Mx fy Ze .
(6.1)
Where the design bending moment (Mx ) is the maximum bending moment as determined
before and fy the ultimate shear strength. Is the capacity factor according to Australian
standards [5] and Ze the effective section modulus, which depends on the thicknesses of the
plate and stiffeners.
The pump plates have the following dimensions.
D-frame pump plate: 16 mm
Stiffener for D-frame pump plate: 70 16 mm
E-frame pump plate: 16 mm
Stiffener for E-frame pump plate: 60 12 mm
23
6.2.2
Columns
The columns of the pump pedestal are subject to compression, tension and a bending moment.
They will be checked for buckling and bending, as these will be far more likely to occur than
pure compression or tension failure.
According to Australian Standards handbook [5], the elastic buckling load Nom of a member can be calculated as given below. This value should be higher than the maximum force
exerted on the columns.
2 EI
(6.2)
Nom =
(ke l)2
Where E is the modulus of elasticity and l the length of the column. ke Is the member effective
length factor that accounts for the way the column is fixed. The loads on the columns are
the reaction forces at the ends of the stiffeners, due to the point loads on the bolt holes, as
determined in the previous subsection.
The bending should be calculated as in section 6.2.1. In this case Mx is the maximum
lateral force determined in section B multiplied by the length of the column.
Fl l fy Ze
(6.3)
The BHP catalogue [7] contains standard square hollow tubes. For each tube size the effective
section modulus Ze is given. This way the right tube can be selected.
The dimensions of the selected tubes for the columns are 75 75 3 mm.
6.2.3
Floor frame
The forces that act on the columns also act on the floor frame. The floor frame is made of
a U-profile channel on its side, resulting in a C-profile. Directly underneath the columns,
stiffeners are added. A stiffener and a side of the C-profile form a T-section that is subject
to compression, tension and buckling. Checking for buckling is done as in section 6.2.2, with
Nom being the reaction forces R as determined in section 6.2.1. The maximum compression
a member with cross section area A and ultimate shear strength fy can withstand is
Fc = fy A.
(6.4)
The thickness of the floor frame is 5 mm.
6.2.4
Motor plate
As explained in section 6.1, threads will be tapped in the motor plate to bolt the motor
directly onto the plate. The motor plate has to be thick enough to have an adequate thread
for even the biggest bolts. Because the plate basically substitutes the nuts, it will be as thick
as the biggest nut it replaces (20 mm, see Ajax Fasteners, [8]). The plate has one stiffener
underneath in longitudinal direction, which is placed in the center. Because of symmetry, half
the structure is considered for the strength calculations. The considered member consists of
half the motor plate, half the stiffener and the adjacent part of the floor frame. This part of
the structure is checked for bending due to the motor reaction forces found in section C.1.
After that, it will be checked for compression under the maximum compression force and its
24
own weight. Bending is checked in the same manner as before, using equation (6.1). In this
equation, only the effective section modulus Ze is unknown, which depends on the section of
the structure. The geometry and the thicknesses of the motor plate and the floor frame are
known. Using those numbers, the minimum thickness of the stiffener is calculated. Compression is checked by again using equation (6.4), in which Fc has to be larger than the maximum
compression force acting on the motor plate.
The thickness of the motor plate is 20 mm and the thickness of the stiffener is 5 mm.
6.2.5
Jockey pulley frame
The jockey pulley frame is made up by four parts that will be checked separately to determine the sections and dimensions. The main force acting on the whole frame is the force that
the belts exert on the jockey pulley. First this force has to be calculated using the earlier
determined belt tension. The force acting on the jockey pulley is then directed through the
arms and the push rod onto the main frame and the flange channels. The arms and the push
rod have one specific orientation in which the buckling or bending load has a maximum value.
These worst case scenarios are considered when calculating the sections and dimensions of
these parts. The main frame is subject to bending. This bending moment also depends on
the orientation of the mechanism. The flange channels finally are the last link in the chain
and bear the whole load at a certain height, which make up the bending moment they are
subject to.
The resulting sections and dimensions can be found in appendix D.5.
6.3
Finite element analysis
In order to check the design of the base frame, both a static and harmonic analysis are
conducted. The finite element analysis (FEA) software Strand7 was used to create a model
of the base frame. Figure 6.3 shows that model. Because the base frame consists mainly
of plates, the model is built up by plate elements, of the quad8 kind. An exception is the
beam in the jockey pulley system, for which brick elements were chosen. Each element was
assigned the right structural properties and thicknesses. In figure 6.3, sections with the same
properties have the same color. The baseplate is fixed to the ground at the positions of the six
anchor bolts, which attach the base frame to the floor. To prevent any numerical problems,
an area around the bolt holes was fixed, rather than one node. The masses of the pump,
motor and pulleys are represented by point masses at the respective centers of mass. The
point masses, forces and moments acting on the pump and motor are all directly connected to
the bolt holes on which the motor or pump is fixed using rigid links. Rigid links only transfer
the forces and moments from one point to the other, without having any further physical
representation. The forces are visualized in figure 6.3 as light blue arrows, the moments as
green double pointed arrows. The rigid links have the same color as the forces and the gold
colored spheres depict the point masses.
25
Figure 6.3: Strand7 FEA model
6.3.1
Static analysis
For the calculations done for designing the base frame, many assumptions and approximations
were used. Wrong choices in these assumptions and miscalculations can not be tolerated. This
analysis is primarily done to check whether the calculations are indeed well conducted. The
static analysis calculates the stresses in the material and the displacement of every node in
which the base frame is subdivided.
Figure 6.4 is the output of the stress calculations on the base frame. Von Mises Stresses
were chosen for the output, because that is a combination of the three main stress components.
The figure shows that there are very high stress peaks, up to 1421 MPa. Comparing that
to the ultimate shear strength of steel, around 240 MPa, there is obviously a problem. In
this case however it is a numerical problem. Because the each rigid links is connected to only
eight nodes at the edge of a bolt hole, the loads are distributed over a very small area. This
makes the stresses unrealistically high and these FEA results therefore unreliable. Refining
26
Figure 6.4: Stresses on the base frame as calculated with Strand7
the mesh around these bolt holes and linking the loads to more nodes would reduce this error.
This is however time consuming, both to model and to run the simulation. Moreover, the
outcome would remain unreliable, as the magnitude of the error would still be uncertain.
Rather than that, we look into the displacement of the nodal points of the model. Figure
6.5 shows the displacements of the base frame. First of all we see that the displacements have
no large peaks and are evenly distributed. This indicates that there are no singularities like
in the stress calculations. The maximum displacements of the plates occur in the Y-direction
(see figure for coordinates), with a maximum absolute displacement of about 1.2 mm. The
bricks in the beam of the jockey pulley system have their maximum displacements in the Zdirection and are at most 2.8 mm. Both values are perfectly acceptable and we can therefore
confirm that the structural design of the base frame is satisfactory so far.
6.3.2
Harmonic analysis
It is very important to make sure that the base frame has good vibrational properties. Like
the base frame, every structure has several natural frequencies. To prevent violent vibrations
of the base frame during tests, it is preferred that these frequencies are not in the range of
frequencies acting on the frame. The problem is that there are many different vibrations
acting on different parts of the base frame. To get an understanding of how the natural
frequencies of the base frame behave, a harmonic analysis is done on the Strand7 model of
the base frame as described above. The simulation resulted in the first four natural frequency
27
Figure 6.5: Displacement of the base frame as calculated with Strand7

modes:
1. 10.8 Hz, 649 rpm
2. 13.1 Hz, 785 rpm
3. 28.0 Hz, 1682 rpm
4. 55.1 Hz, 3303 rpm
Figures 6.6 to 6.9 show how the base frame behaves at the natural frequencies. The first mode
(figure 6.6) is a rotating motion of the pump pedestal about an axis in the Y-direction, located
at the center of the concentric lines of displacement. The rest of the modes are translating
motions. The second mode (figure 6.7) is a motion in Y-direction, with a maximum deflection
at the right hand side columns. Mode three (6.8) is the pump plate vibrating in X-direction
and the fourth mode concerns the entire motor plate. As can be seen in figure 6.9, the motor
plate vibrates in Y-direction, having a maximum displacement at the right hand side motor
bolt holes. The maximum displacements which occur at the natural frequencies are 1 to 2
mm, which is most satisfying. Nonetheless, it is not desirable for any of the drive running
speeds; motor speed, pump speed, impeller tip speed and belt speed, to interfere with a
natural frequency of the base frame and set off a response. The fact that so many pump,
motor, impeller, pulley and belt combinations are possible for use on the test rig makes it
28
Figure 6.6: First mode of natural frequency. Note: depicted displacements are scaled up for
visual purposes
29
Figure 6.7: Second mode of natural frequency. Note: depicted displacements are scaled up for
visual purposes
30
Figure 6.8: Third mode of natural frequency. Note: depicted displacements are scaled up for
visual purposes
31
Figure 6.9: Fourth mode of natural frequency. Note: depicted displacements are scaled up for
visual purposes
32
Pump
6/4 S
4/3 SH
8/6 S
6/4 SC, 8 vanes
6/4 SC, 3 vanes
4/3 AH
150 GP
6/4 AH
6/4 SH
150 L, 5 vanes
150 L, 4 vanes
4/3 HH, 5 vanes
4/3 HH, 4 vanes
8/6 AH, 4, 560 vanes
8/6 AH, 6, 545 vanes
8/6 AH, 4, 510 vanes
Max. speed
1800 rpm
1900 rpm
1650 rpm
1800 rpm
1800 rpm
2750 rpm
1400 rpm
1800 rpm
1450 rpm
1300 rpm
1500 rpm
1400 rpm
1400 rpm
1300 rpm
1300 rpm
940 rpm
test speed
1440 rpm
1520 rpm
1320 rpm
1440 rpm
1440 rpm
2200 rpm
1120 rpm
1440 rpm
1160 rpm
1040 rpm
1200 rpm
1120 rpm
1120 rpm
1040 rpm
1040 rpm
752 rpm
10%
1296
1368
1188
1296
1296
1980
1008
1296
1044
936
1080
1008
1008
936
936
677
of
test speed
1584 rpm
1672 rpm
1452 rpm
1584 rpm
1584 rpm
2420 rpm
1232 rpm
1584 rpm
1276 rpm
1144 rpm
1320 rpm
1232 rpm
1232 rpm
1144 rpm
1144 rpm
827 rpm
Table 6.1: Maximum, test and critical speeds of various pumps

seemingly impossible to rule out interference with every excitation. Therefore we use and
crystallize the information that we do have at our disposal. First, most of the motors in the
test bay are four pole motors and run at around 1400 rpm. Preferably, there is no natural
frequency at at least 10% of an excited frequency. This means that the base frame should
not have a natural frequency in the range 1260 1540 rpm. Because the first three modes are
all vibrations of the pump pedestal, we would like to know at which speeds the pumps are
likely to run when tested. In every Warman pump performance curve, there is a maximum
running speed specified. Because most of these pumps (and impellers) are relatively small, so
to put enough energy into the flow to maintain a decent flow rate (and achieve an acceptable
level of efficiency) the test speeds are in the higher range of the pump operating speeds.
Roughly, the running speeds can be supposed to be at 80% of the maximum running speeds.
Table 6.1 shows all the pumps that have a known maximum running speed and could be
tested on the medium test rig.
Comparing the 10% test speed ranges, one can see that there are two odd ones in the
list, namely the 4/3 AH pump and the last listed 8/6 AH pump. The rest of the pumps
have a supposed test speed from 1040 to 1520 rpm. Therefore it should be wise to design
the base frame in such a way that there are no natural frequencies between 936 and 1672
rpm. Although this condition is already satisfied, we will see wether the design can be further
optimized, i.e. wether the safe margin can be enlarged. We define a margin relative to the
natural frequencies of the base frame and we now have the following lower and upper margins
(l and u ):
l =
1040 785
1682 1520
100% = 32.5% and u =
100% = 9.6%.
785
1682
To obtain better margins, we first look at the third natural frequency of the base frame and
notice that its 1682 rpm is very close to the 1672 rpm we would like to evade. Preferably,
33
the third natural frequency mode must be increased, without raising the second mode too
much, as we want to stay well clear from the 936 rpm lower limit. Examining the second
and third mode, we see that the second mode is mainly due to bending of the floor frame,
while the third mode involves stretching and twisting of the pump pedestal columns. So by
stiffening the pump pedestal and leaving the floor frame as it is, a more satisfying result
should be achieved. First we increase the thickness of the pump pedestal columns from 3 to
5 mm. After adapting the FEA model the simulation is ran again. These are the new first
four natural frequency modes:
1. 12.1 Hz, 730 rpm
2. 13.7 Hz, 819 rpm
3. 32.0 Hz, 1921 rpm
4. 55.2 Hz, 3310 rpm
The third mode has indeed gone up more than the second and the new margins are:
l =
1040 819
100% = 27.0%
819
and u =
1921 1520
100% = 20.9%.
1921
The lower margin is still well acceptable whereas the upper margin has doubled. Even the
earlier discarded running speeds of the 4/3 AH and 8/6 AH pumps fit in better now.
Adding even more stiffness to the pump pedestal by adding diagonal 5 mm stiffener plates
at the sides between the columns does raise the third mode of natural frequency, but raises the
second one dramatically as well. This one now interferes with the pump and motor speeds,
as the natural frequencies show:
1. 13.7 Hz, 822 rpm
2. 20.5 Hz, 1230 rpm
3. 54.6 Hz, 3276 rpm
4. 56.6 Hz, 3396 rpm
Considering all, base frame will be adapted only by increasing the thickness of the pump
pedestal columns from 3 to 5 mm.
34
6.4
Final design
Figure 6.10: Base frame: front view

In this section the final design of the base frame is presented. The design is an outcome of
the results obtained in the entire chapter. The base frame is modeled accordingly in the CAD
package Unigraphics NX3 and the drawings that are presented are drafted using this model.
These drawings might not be ideal to use for manufacturing, because not every part that has
to be manufactured is drafted separately and any additional fabrication information lacks.
Rather than that, it is an overview of the base frame showing the essential geometries and
dimensions. Using this information, the final manufacturing drawings should be easily made.
The base frame should be made entirely out of steel, unless otherwise indicated. Figure 6.10
shows the assembled base frame. For visualization purposes a motor and a pump are plotted
over the base frame. The total height of the bare base frame is reduced to only 800 mm. As
predicted, the horizontal position of the centerline of the (arbitrarily chosen) D-frame pump
is 900 mm and the pump and motor shafts are perfectly aligned.
6.4.1
Floor frame
Figure 6.12 shows a draft of the floor frame. A few notes are in place. To indicate the position
of the pump pedestal, the columns are added in the top view. At the left side, where the
motor plate is situated, the stiffeners of the motor plate are shown as well. Because the motor
plate has te bolted on, there has to be room to tighten the nuts at the assembly. Therefore,
the left side-plate of the floor frame is 150 mm shorter than the one at the right side. This
35
Figure 6.11: Base frame
gives assembly 75 mm space to fit his spanner at each side. A similar upright plate is located
underneath the right end of the motor plate. This plate is not taken into account for the
strength calculations in appendix D.4, so if it would cause practical problems, it can be left
out. The holes for the anchor bolts are measured on site and although the four outer holes
are in a perfect rectangle, the two inner ones have a 5 mm offset, as shown in firgure 6.12.
6.4.2
Motor plate
The motor plate is shown in 6.13. As explained, every motor can be bolted directly onto
the threaded holes. The four outer holes are used to bolt the motor plate to the floor frame
with M24 bolts and are not threaded. There are many motors available at Warman for
testing on the medium test rig and the motor plate has to be able to fit all these motors.
Like pumps, motors have standardized frames with standard dimensions. A stock taking was
done and every motor makes use of one of eight different frames. For practical reasons the
dimensions of the holes necessary for each motor are not shown in the figure but are listed
below. Parameters A, B, C and D as depicted in figure 6.13 can be found in the Toshiba
catalogue [9]. Note that hole diameter D is the hole diameter in the motor frame. The thread
in the plate should be that of the nearest standard metric thread. Parameter C is chosen in
such a way that the entire motor shaft is aligned directly underneath the pump shaft.
36
Figure 6.12: Floor frame: top and front view
Frame
D280M
D250M
D250S
D200L
D180L
D160L
D160M
D132M
6.4.3
A
419
349
311
305
279
254
210
178
B
457
406
406
318
279
254
254
216
C
191
169
169
191
112
99
99
75
D
24
24
24
19
15
15
15
12
E-frame pump pedestal
The dimensions of the pump pedestal for E-frame pumps are shown in figure 6.14. Columns
are welded on the floor frame at the position shown in figure 6.12. The 30 mm diameter holes
are used for bolting on the E-frame pumps and are positioned in such a way that the set of
pipes listed in table 5.2 can connect the intake flange to the fixed pipes of the test rig. Also,
the pump is positioned in such a way that the pump shaft is aligned directly above the motor
shaft. The 20 mm diameter holes are used to bolt on the pedestal for D-frame pumps.
37
Figure 6.13: Motor plate: top view
6.4.4
D-frame pump pedestal
The pedestal for D-frame pumps is only used when a D-frame pump is tested. Figure 6.16
shows the top and side view of the D-frame pump pedestal with its dimensions. The pedestal
is bolted on the fixed pump pedestal with four bolts. The parts that are used for this connection are shown in figure 6.16. The reason that there are two different fasteners is simple:
the stiffeners leave little room for the operator to fit the bolts.
6.4.5
Jockey pulley frame
As mentioned before, it is most recommended that the pulley and belt supplier is consulted
about the use and design of the jockey pulley and its frame. There has been some contact, in
which the supplier indicated that it should be possible to use such a belt tensioning system,
but no more information was present at that time. The actual pulley is not modeled, but it is
represented by a simple cilinder. Obviously, the design can change depending on the jockey
pulley and any additional information from the supplier. When altering the frame, one should
38
Figure 6.14: E-frame pump pedestal: top and front view
39
Figure 6.15: D-pedestal fasteners
always recalculate the structural properties as done in section 6.2.5 and appendix D.5. The
dimensions of the jockey pulley frame are given in figures 6.17 and 6.18. There should be two
different mechanisms. Each one consists of the mechanism shown in 6.18 without the slotted
beam and supports either an SPB or an SPC size pulley. Depending on the belt that is used,
the right mechanism is simply bolted on the slotted beam. This beam could be quite heavy
and less manageable when made of steel, so making it of aluminium is more practical. The
same applies to the member through which the push rod can slide and is connected to the
main frame.
40
Figure 6.16: D-frame pump pedestal: top and side view
41
Figure 6.17: Complete jockey pulley frame: top, side and front view
42
Figure 6.18: Jockey pulley mechanism: side, front and top view
43
44
Chapter 7
Conclusions
The medium test rig in its current state leaves much room for improvement. The operator
conducting a test faces the same challenges every time a new pump is set up for testing. The
base frame is not standardized for the standard pump and motor frames. To get the right
tension in the v-belts the operator has to lift the whole motor by adjusting eight nuts on
four threads, small steps at a time to overcome friction. To find the piping that is necessary
to connect the fixed piping to the intake flange of the pump requires experience because the
pipes in stock are not properly documented. To fit the discharge pipes the operator has to
use a scissor lift to adjust several telescopic pipes, which takes time and some safety risks.
Solutions to all these problems are presented. A new design for a base frame proposed
that makes use of a jockey pulley to pre-tension the v-belts quick and easy, adjusting only
one thread. It also also makes use of the standardized frames of the motors and pumps.
Thanks to this standardization, every combination of pipes at the intake side of the pump
is known. These combinations are documented and enable any Warman employee to quickly
find the right pipes. A whole new drag n drop piping configuration at the discharge side is
proposed using rotation flanges. Fitting these flanges in the correct orientation and adding a
counterweight makes it very easy to fit the piping to the discharge flange of the pump.
The base frame is thoroughly checked for its structural and vibrational properties. The
approximations for finding the reaction forces on a pumps bolt holes presented in appendix
B are described in great detail and can be used for similar problems.
45
46
Chapter 8
Recommendations
In this chapter there will be some comments on the study presented in the report. First of
all, although much effort has gone in to this research, it is no guarantee that everything is
without errors. Moreover, there is no substitute for experience, so please make sure the report
gets read carefully by an experienced Warman engineer.
For a smoothly operating test bay, it is recommended that all pipes and reducers are labeled
and stored orderly. A well arranged stock combined with tables 5.1 and 5.2 make changing
the piping at the intake side of the setup light work. An idea for the piping at the discharge
side is proposed in chapter 5.2. Although it is not completely designed in this report, it is
worthwhile to look into. It is recommended that the supplier is contacted about the rotation
flanges. If desired, Weir Netherlands in Venlo, where this system is already implemented, can
also be contacted.
The spreadsheet that is currently used for calculating the reaction forces on Warman base
fram contains some crude calculations and approximations. This is the reason why appendix
B proposes a new calculation of these forces. Because some of the problems are statically
indeterminate, approximations had to be used, resulting in errors as well. These errors, however, are minimized. The calculations are documented very detailed and can easily be fed
into a spreadsheet.
As mentioned before, the jockey pulley frame and especially the adjusting mechanism is
designed around the actual jockey pulley. The supplier of belts and pulleys will know more
concerning the materials that are best to be used. The frame can than be carefully adjusted
to the pulley, respecting the strength calculations in section 6.2.5 and appendix D.5.
In designing the base frame, standard material dimensions were not always reckoned with.
The flange channels of the jockey pulley frame and the square hollow sections used for the
columns are in fact found in supplier catalogues, but the rest of the plate material was not.
If it turns out to be more practical or economical to change some dimensions of the base
frame, please make sure the essential dimensions, e.g. the pump height, remain unchanged.
Obviously, the altered parts should be checked again for there structural properties.
47
48
Appendix A
Piping
Listed below are the values of parameters A, B, C, E and P as shown in figure 5.1 for each
pump suitable for the medium test rig. All values are in mm.
Pump
4/3 D-SH
4/3 D-AHU
4/3 D-AH
4/3 D-AHW
6/4 D-S
6/4 D-SW
6/4 D-SC
6/4 D-SCW
6/4 D-AH
6/4 D-AHW
150 D-GP
8/6 D-S
8/6 D-SW
A
280
279
280
408
248
375
281
409
317
446
330
265
393
B
165
192
187
187
152
152
186
186
220
219
185
184
184
Pump
4/3 E-HH
6/4 E-SH
6/4 E-AH
150 E-L
8/6 E-SC
8/6 E-SCW
8/6 E-AH
8/6 E-AHW
A
381
356
351
376
376
531
402
554
B
248
216
219
237
233
233
292
292
C
180
149
230
180
254
C
279
250
275
350
Emin
-725
-751
-837
-520
-870
-552
-657
-785
-727
-855
-600
-534
-662
Emax
-175
-381
-436
-200
-500
-2
-107
-235
-431
-305
-50
16
-112
E
550
370
401
320
370
550
550
550
296
550
550
550
550
P
3510
3510
3600
3155
3700
3255
3420
3420
3420
3420
3315
3315
3315
Emin
-574
-687
-685
-473
-469
-624
-554
-706
Emax
-303
-137
-385
-198
81
-74
-354
-156
E
271
550
300
275
550
550
200
550
P
3175
3345
3345
3090
3090
3090
3090
3090
49
50
Appendix B
Reaction forces
The reaction forces on the base frame are important parameters in the new design. These
forces are made up by several forces acting at the pump and motor. Equation (B.1) shows
the reaction forces on the pump pedestal and equation (B.2) shows the reaction forces on the
motor pedestal.
pump:
motor:
F~f rame = F~g + F~belt + F~f lange

F~f rame = F~g + F~belt + F~torque
(B.1)
(B.2)
We assume that the total force on the frames only act at the four points at which the pump
or motor frame is fixed to its pedestal. This gives a good insight in the load distribution and
is not to laborious to calculate. Because this base frame will be designed for a wide range
of pumps rather than one, assumptions have to be made based on worst case scenarios. In
calculating the reaction forces of the various forces and moments acting at different points of
the pump and motor, we will first use parameters in stead of values to be able to check the
results more easily.
Because the pump and motor are fixed to their pedestals at four points, some of the
problems are statically indeterminate. In order to make a good estimate for the reaction
forces in these cases, we use two dimensional views from both the side and the front. The
side view is used in the left drawing of figure B.2, the front view is the view onto the intake
flange. Combining the results from both views gives an approximation for the reaction forces
in the bolts. Because many of the problems in this section are of similar nature: reactions of
a force at an offset, a general 2D model is introduced. This model is presented in figure B.1.
Specific values and parameters will be assigned to the model for each situation.
First, the reaction forces will be determined for a force in the vertical direction, Fy . One
can see straight away that there are no horizontal reaction forces: Pz = Qz = 0. The vertical
reaction forces are determined by the balance of moments about points p and q.
Mp = 0 :
(l1 + l2 )Fy + l1 Qy = 0
Mq = 0 :
l2 Fy l1 Py = 0
This gives:
l2
Fy and
l1
l1 + l2
=
Fy .
l1
Py =
(B.3)
Qy
(B.4)
51
Fz
Fy
p
l3
q
Pz
Qz
Qy
Py
l2
l1
Figure B.1: 2D force model
A quick check shows that all forces add up to zero: Py + Qy + Fy = 0. Now we consider a
horizontal force, Fz . This time the horizontal reaction forces are not equal to zero. Again,
this problem is indeterminate, because both points p and q are fixed in horizontal direction.
To avoid elaborate calculations of minimal value, we assume that the horizontal force Fz is
equally distributed over points p and q:
1
Pz = Qz = Fz .
2
(B.5)
The vertical reaction forces Py and Qy can also be determined by using the moments about
p and q.
Mp = 0 :
l3 Fz + l1 Qy = 0
Mq = 0 :
l3 Fz l1 Py = 0
This gives:
B.1
l3
Fz and
l1
l3
= Fz .
l1
Py =
(B.6)
Qy
(B.7)
Pump reaction forces
Figure B.2 shows the 8/6 AH slurry pump. This is the biggest and heaviest pump that can be
tested on the medium test rig and which has a known mass. The most important dimensions
as well as the assigned numbers to the four bolt holes are depicted. As mentioned before the
dimensions that are used will be parametrical for the time being.
B.1.1
Gravitational forces
The pump mass is represented by a single point load acting at the center of mass. When a
pump is designed at Weir Warman, the center of mass is not entirely determined. Only the
horizontal distance from the intake flange is calculated, but it is reasonable to assume that
the center of mass is on the centerline of the pump. We can now use the model presented in
52
Figure B.2: pump dimensions

figure B.1 and plug in the right parameters for the problem. In this case, l1 = C, l2 = D and
Fy = mp g, where mp is the mass of the pump and g is the gravitational acceleration. Point p
represents the line through points 1 and 4, and q the line through 2 and 3. Due to symmetry
Py and Qy are equally distributed over the points on lines p and q. This results in:
D
mp g and
2C
C +D
= Ld
mp g.
2C
F1y,1 = F4y,1 = Ld
(B.8)
F2y,1 = F3y,1
(B.9)
With F1y to F4y the reaction forces in vertical direction at points 1 to 4. Ld is a safety factor
according to Australian standards [12]. The standard specifies safety factors for two types of
loads: dead loads (Ld ) and live loads (Ll ). Live loads are loads that are applied externally
and/or involve moving parts, the dead load is none of that and thus basically the gravitational
force. The mass of the pulley also has to be taken into account. This is represented by a point
load at the end of the pump shaft. Similar to the method used above, now l1 = C, l2 = K
and Fy = mpl g, where mpl is the mass of the pulley. Parameter p represents the line through
points 2 and 3, and q the line through 1 and 4. Py and Qy are again equally distributed over
the points on lines p and q. We find:
C +K
mpl g
2C
K
= Ld
mpl g.
2C
F1y,2 = F4y,2 = Ld
F2y,2 = F3y,2
B.1.2
and
(B.10)
(B.11)
Belt tension forces
Warman protocol states that the belt tension is to be calculated according to the Fenner belt
drive manual. To calculate the static tension, TS , we need to estimate the force, P , required
to depress a belt 16 mm per meter of span. An indication of P and the formulae (B.12) to
(B.14) can be found in the catalogue. With nb being the number of belts used:
TS = 32P nb
53
(B.12)
To determine the approximate total, dynamic tension, TD , imposed by a drive when running,
the centrifugal tension per side, TC , must be subtracted from the static tension.
TD = 2(16P TC )nb
(B.13)
The centrifugal tension developed in a belt is a function of its weight and the square of its
velocity.
dn
TC = M S 2 , with S =
(B.14)
60
In (B.14), M is the mass per meter length of the belt, d the diameter of one pulley and n the
rotational speed of that pulley in revs/min. As well as P , M can be found in Fenner [10].
Similar to the gravitational force of the pulley, the belt tension force acts at the end of the
pump shaft.
dn 2 i
C +Kh
16P M
nb
C
60
i
K
dn 2
= Ll
16P M
nb .
C
60
F1y,3 = F4y,3 = Ll
F2y,3 = F3y,3
and
(B.15)
(B.16)
Again, safety factors are applied.
B.1.3
Flange loads
For every Warman pump there is a list of maximum allowable flange loads and moments [11].
Because these are the maximum loads the pump can bare before breaking, these loads include
nearly every external load on the pump. This is the reason why the shaft torque from the
belt drive and the impuls due to the fluid flow are not separately considered. A base frame
for a pump has to be designed to withstand the reaction forces of those loads. In those loads
a safety factor is already included. The maximum allowable flange loads and moments are
shown in figure (B.3). The forces and moments are specified as listed below.
Intake flange:
Fz = Axial load along the z axis, into or out of the pump through A
Fxy = Force in the xy plane in any direction through A
Mz = Torsional moment about the z axis through A
Mxy = Torsional moment about any axis in the xy plane through A
Discharge flange:
Fy = Axial load along the y axis, into or out of the pump through B
Fxz = Force in the xz plane in any direction through B
My = Torsional moment about the y axis through B
Mxz = Torsional moment about any axis in the xz plane through B
54
My
Mxz
B
Fxz
z
Fy
x
y
Mz
Fz
Mxy
Fxy
Figure B.3: maximum allowable f lange loads and moments

Point A is located at the center of the outside face of the intake flange and point B at
the center of the outside face of the discharge flange. Although axial and radial forces are
actually acting at the bolt pitch circle diameter (PCD), they are assumed to act as point
loads at points A and B. The directions in which the forces and moments act are based on a
worst case scenario adding as much as possible to the already calculated reaction forces. The
directions are depicted in figure B.3.
First, we determine the reaction forces due to the loads acting at the intake flange. Once
again, the model in figure B.1 and the symmetry is used. This time, l1 = C, l2 = F and
l3 = G. Point p represents the line through 1 and 4, q the line through 2 and 3. Filling in
these values in equations (B.3) and (B.4) gives the reaction forces due to Fxy .
F
Fxy
2C
C +F
=
Fxy .
2C
F1y,4 = F4y,4 =
(B.17)
F2y,4 = F3y,4
(B.18)
The reaction forces due to Fz are determined by using equations (B.5) to (B.7). Again using
the symmetry to find the correct formulae.
1
F1z,1 = F2z,1 = F3z,1 = F4z,1 = Fz
4
G
F1y,5 = F4y,5 =
Fz
2C
G
F2y,5 = F3y,5 =
Fz
2C
(B.19)
(B.20)
(B.21)
Determining the reaction forces due to the loads on the discharge flange is not as straight forward as the previous cases. Because the discharge flange is not on the center plane (involving
55
the centerline and the y axis), we can no longer appeal to symmetry and simply divide the
forces found from the side view by 2. To overcome this problem, we use the views from both
the side and the front and average the reaction forces found in these views for each point.
This will give a good estimate for the actual answer to the indeterminate problem. Beginning
with the side view, we find that l1 = C, l2 = E and l3 = H. Point p represents the line
through 1 and 4, q the line through 2 and 3. For the front view, l1 = A, l2 = B and l3 = H.
Point p represents the line through 3 and 4, q the line through 1 and 2. With superscript s
for the side view reactions and f for the front view we find the reactions due to Fy :
E
Fy
2C
C +E
=
Fy
2C
A+B
=
Fy
2A
B
=
Fy .
2A
s
s
F1y
= F4y
=
s
s
F2y
= F3y
f
f
F1y
= F2y
f
f
F3y
= F4y
Averaging the forces found for both views gives the approximation of the reaction forces due
to Fy .
E
1A + B
Fy
2
2A
2C
1A + B C + E
+
=
Fy
2
2A
2C
C + E
1 B
=
Fy
2 2A
2C
E
1 B
+
Fy
=
2 2A 2C
F1y,6 =
(B.22)
F2y,6
(B.23)
F3y,6
F4y,6
(B.24)
(B.25)
The reaction forces due to the horizontal force on the discharge flange, Fxz , are approximated
in the same manner as the reactions due to Fy . Using equations B.5 to B.7 we find:
1
F1z,2 = F2z,2 = F3z,2 = F4z,2 = Fxz
4
1 H
H
F1y,7 =
Fxz
2 2A 2C
1 H
H
F2y,7 =
+
Fxz
2 2A 2C
1 H
H
F3y,7 =
Fxz
2 2A 2C
1 H
H
F4y,7 =
+
Fxz .
2 2A 2C
B.1.4
(B.26)
(B.27)
(B.28)
(B.29)
(B.30)
Flange moments
In order to calculate the reaction forces as a result of the maximum allowable flange moments
in the xz plane, the model in figure B.1 is slightly modified, as presented in figure B.4.
Starting with the left model, where there is a moment M acting at two offsets, the balance of
forces in the horizontal direction shows that Pz = Qz . This means that there is no resulting
56
r
l3
l3
p
q
Pz
p
Qz
Pz
Qy
Py
l1
Qz
Qy
Py
l2
l1
Figure B.4: 2D moments model

force acting on the holding bolts or the base frame. We now consider the sum of forces in the
vertical direction and the sum of moments about point r to find reaction forces Py and Qy .
Mr = 0 :
(l1 + l2 )Py + l2 Qy M = 0
Fy = 0 :
Py + Qy = 0
This results in the reaction forces:

M
and
l1
M
= .
l1
Py =
(B.31)
Qy
(B.32)
We find that the reaction forces are independent of l2 and l3 , so calculating the reaction forces
for the situation on the right hand side of figure B.4 should give the same results.
1
1
IPy IQy M = 0
2
2
Py + Qy = 0
Mr = 0 :
Fy = 0 :
As expected, the resulting reaction forces are the same as found in equations (B.31) and
(B.32):
M
and
l1
M
= .
l1
Py =
(B.33)
Qy
(B.34)
The reaction forces as a result of Mxz , Mz and Mxy are now easily found, considering the
reactions Py and Qy are equally distributed over the two point on lines p and q, because the
moments act on an axis rather than at a point.
Mxz
2A
Mxz
2A
F1y,8 = F2y,8 =
(B.35)
F3y,8 = F4y,8 =
(B.36)
57
Mz
2A
Mz
2A
F1y,9 = F2y,9 =
(B.37)
F3y,9 = F4y,9 =
(B.38)
Mxy
(B.39)
2A
Mxy
F2y,10 = F3y,10 =
(B.40)
2A
The last moment we have to find the reaction forces for is My , a torque acting on the discharge
F1y,10 = F4y,10 =
My
1
Fz
Fx
FM
Figure B.5: model for My approximation

flange. Once again, this is an indeterminate problem. It is clear that the moment doesnt
inflict any vertical forces. However, there are reaction forces in the horizontal plane, that
have to be approximated. For this approximation, we replace the moment at the discharge
flange with a force, FM , acting at the center of the rectangle made up by points 1, 2, 3 and
4, producing moment My . A sketch is shown in figure B.5. FM is made up by its components
in x and z direction: Fx and Fz :
Fx = My
Fz = My
B + 12 A
(B + 12 A)2 + (E + 21 C)2
(B +
E + 12 C
+ (E + 21 C)2
1
2
2 A)
These forces have reaction forces at points 1, 2, 3 and 4. Because Fx and Fz act at the center,
the reaction forces are evenly distributed over the four points:
F1x = F2x = F3x = F4x =
58
B + 12 A
My
4 (B + 21 A)2 + (E + 12 C)2
(B.41)
F1z,3 = F2z,3 = F3z,3 = F4z,3 =
B.1.5
E + 21 C
My
4 (B + 21 A)2 + (E + 12 C)2
(B.42)
Total reaction forces
The total reaction forces on the pump frame are the sum of all the forces acting at one point
in one direction. In the x direction there are only the reaction forces due to moment My .
F1x =
B + 12 A
My
4 (B + 12 A)2 + (E + 21 C)2
(B.43)
F2x =
B + 12 A
My
4 (B + 12 A)2 + (E + 21 C)2
(B.44)
F3x =
B + 12 A
My
4 (B + 12 A)2 + (E + 21 C)2
(B.45)
F4x =
B + 12 A
My
4 (B + 12 A)2 + (E + 21 C)2
(B.46)
The total reaction force in the y direction for each point is the sum of the 10 separate
calculated reaction forces.
F1y =
10
X
D
C+K
F1y,i = Ld 2C
mp g Ld C+K
16P M
2C mpl g Ll C
i=1
G
2C Fz
1
2
A+B
2A
E
2C
Fy
1
2
H
2A
H
2C
dn
60
2 i
Mxz
2A
Fxz
F
2C Fxy
nb +
Mz
2A
+ ...
Mxy
2A
(B.47)
F2y =
10
X
K
K
F2y,i = Ld C+D
2C mp g + Ld 2C mpl g + Ll C 16P M
i=1
G
2C Fz
1
2
A+B
2A
C+E
2C
Fy
1
2
H
2A
H
2C
dn
60
Fxz
2 i
Mxz
2A
nb
C+F
2C Fxy
Mz
2A
...
Mxy
2A
(B.48)
F3y =
10
X
K
K
F3y,i = Ld C+D
2C mp g + Ld 2C mpl g + Ll C 16P M
i=1
G
2C Fz
1
2
B
2A
C+E
2C
Fy +
1
2
H
2A
H
2C
dn
60
Fxz +
2 i
C+F
2C Fxy
nb
Mxz
2A
Mz
2A
...
Mxy
2A
(B.49)
F4y =
10
X
D
C+K
F4y,i = Ld 2C
mp g Ld C+K
16P M
2C mpl g Ll C
i=1
G
2C Fz
1
2
B
2A
E
2C
Fy +
1
2
H
2A
H
2C
Fxz +
dn
60
Mxz
2A
2 i
nb +
Mz
2A
F
2C Fxy
+ ...
Mxy
2A
(B.50)
The total reaction forces in the z direction are:
F1z =
F2z =
3
X
E + 21 C
1
My
1
;
F1z,i = Fz Fxz
4
4
4 (B + 21 A)2 + (E + 21 C)2
i=1
3
X
E + 21 C
1
1
My
F2z,i = Fz Fxz
;
4
4
4 (B + 21 A)2 + (E + 21 C)2
i=1
59
(B.51)
(B.52)
F3z =
F4z =
3
X
E + 21 C
1
1
My
F3z,i = Fz Fxz
;
1
2 + (E + 1 C)2
4
4
4
(B
+
A)
2
2
i=1
3
X
E + 21 C
1
1
My
F4z,i = Fz Fxz
.
1
2 + (E + 1 C)2
4
4
4
(B
+
A)
2
2
i=1
(B.53)
(B.54)
The parameter values are listed in appendix C. Filling these values in the equations above,
we find the values of the pump reaction forces.
F
1
2
3
4
x
-0.145
-0.145
-0.145
-0.145
kN
kN
kN
kN
y
-45.5 kN
63.3 kN
81.1 kN
-38.6 kN
60
z
-9.79
-9.79
-9.79
-9.79
kN
kN
kN
kN
61
Appendix C
Parameter values
D-frame pumps
Parameter
pump dimension
pump dimension
pump dimension
pump dimension
pulley diameter
pump dimension
pump dimension
flange load
flange load
flange load
flange load
pump dimension
gravitational acceleration
pump dimension
pump dimension
safety factor
safety factor
belt mass
motor mass
pump mass
pulley mass
flange load
flange load
flange load
flange load
motor running speed
number of belts
pre-tension force
motor power
motor dimension
motor dimension
motor dimension
Symbol
A
B
C
D
d
E
F
Fxy
Fxz
Fy
Fz
G
g
H
K
Ld
Ll
M
mm
mp
mpl
Mxy
Mxz
My
Mz
n
nb
P
Pm
U
V
W
Value
0.432
0.013
0.213
0.249
0.400
0.317
0.537
9550
2050
4100
19100
0.330
9.81
0.668
0.271
1.25
1.5
0.315
800
615
44.0
2800
485
243
1400
1480
5
150
220
0.419
0.360
0.457
62
Unit
m
m
m
m
m
m
m
N
N
N
N
m
m/s2
m
m
kg/m
kg
kg
kg
Nm
Nm
Nm
Nm
rpm
N
kW
m
m
m
Source
6/4D-AH drawings
6/4D-AH drawings
6/4D-AH drawings
6/4D-AH drawings
Fenner belt drives design manual [10]
6/4D-AH drawings
6/4D-AH drawings
Warman data sheet [11]
6/4D-AH drawings
6/4D-AH drawings
6/4D-AH drawings
Australian Standard 1170-1 1989 [12]
Toshiba motor catalogue [9]
E-frame pumps
Parameter
pump dimension
pump dimension
pump dimension
pump dimension
pulley diameter
pump dimension
pump dimension
flange load
flange load
flange load
flange load
pump dimension
gravitational acceleration
pump dimension
pump dimension
safety factor
safety factor
belt mass
motor mass
pump mass
pulley mass
flange load
flange load
flange load
flange load
motor running speed
number of belts
pre-tension force
motor power
motor dimension
motor dimension
motor dimension
C.1
Symbol
A
B
C
D
d
E
F
Fxy
Fxz
Fy
Fz
G
g
H
K
Ld
Ll
M
mm
mp
mpl
Mxy
Mxz
My
Mz
n
nb
P
Pm
U
V
W
Value
0.546
0.045
0.257
0.290
0.400
0.402
0.694
16900
4400
8800
33800
0.457
9.81
0.917
0.351
1.25
1.5
0.315
800
1464
44.0
6000
1400
700
3000
1480
5
150
220
0.419
0.360
0.457
Unit
m
m
m
m
m
m
m
N
N
N
N
m
m/s2
m
m
kg/m
kg
kg
kg
Nm
Nm
Nm
Nm
rpm
N
kW
m
m
m
Source
8/6E-AH drawings
8/6E-AH drawings
8/6E-AH drawings
8/6E-AH drawings
8/6E-AH drawings
8/6E-AH drawings
8/6E-AH drawings
8/6E-AH drawings
8/6E-AH drawings
Motor reaction forces
Remembering equation (B.2), the reaction forces on the motor frame consist of the reactions
due to the gravitational forces, the belt tension forces and reactions due to the motor torque.
Figure C.1 shows an electric motor and it dimensions. The bolt holes have the same numbering
as the bolt holes in the pump frame. The side view in figure C.1 shows points 1 and 4 at the
left and 2 and 3 at the right side. In the front view its 3 and 4 at the left side and 1 and 2
at the right.
63
Figure C.1: motor dimensions
C.1.1
Gravitational forces
Similar to the calculations in section B.1, both the gravitational forces of the motor and the
pulley inflict reaction forces at the holding bolts. The center of mass of the motor is unknown,
but it is reasonable to assume that it is on the shaft centerline of the motor in the middle of
the bolt holes in the motor frame. This means that the reaction forces due to the weight of
the motor are equal on every point.
1
F1y,1 = F4y,1 = F2y,1 = F3y,1 = Ld mm g,
4
(C.1)
with mm the mass of the motor. Modifying equations (B.10) and (B.11) for the motor
dimensions gives the reaction forces on the motor frame as a result of the weight of the
pulley.
C.1.2
V
mpl g
2U
U +V
= Ld
mpl g
2U
F1y,2 = F4y,2 = Ld
(C.2)
F2y,2 = F3y,2
(C.3)
Belt tension forces
The tension in the belts is also calculated in section B.1. Using the motor dimensions and
equations (B.15) and (B.16) while keeping in mind that the tension forces now act in the
opposite direction we find:
dn 2 i
U +V h
16P M
nb
U
60
h
i
V
dn 2
= Ll
16P M
nb .
U
60
F1y,3 = F4y,3 = Ll
F2y,3 = F3y,3
C.1.3
and
(C.4)
(C.5)
Motor torque
The motor torque Tm acts on the motor as a moment on the shaft line. The 2D moment model,
figure B.4, is used again. Parameter I represents the width of the motor base, dimension W
64
in figure C.1. Converting formulas (B.33) and (B.34), we find for the reaction forces:
F1y,4 = F2y,4 = Ll
F3y,4 = F4y,4 = Ll
Tm
2W
Tm
2W
(C.6)
(C.7)
A live load factor is applied. The motor torque is not directly measured, but calculated using
the power Pm and running speed n of the motor.
Tm =
Pm
,
with =
2
n
60
(C.8)
The motor torque reaction forces are now available:

15Pm
nW
15Pm
.
= Ll
nW
F1y,4 = F2y,4 = Ll
F3y,4 = F4y,4
C.1.4
(C.9)
(C.10)
Total reaction forces
The total reaction forces on the holding bolts are the sum of the reactions calculated in this
section.
F1y =
F2y =
F3y =
F4y =
dn 2 i
1
V
U +V h
15Pm
F1y,i = Ld mm g +Ld
mpl g Ll
(C.11)
16P M
nb +Ll
4
2U
U
60
nW
i=1
4
X
dn 2 i
1
U +V
Vh
15Pm
F2y,i = Ld mm g Ld
mpl g + Ll
(C.12)
16P M
nb + Ll
4
2U
U
60
nW
i=1
4
X
dn 2 i
1
U +V
Vh
15Pm
F3y,i = Ld mm g Ld
mpl g + Ll
16P M
nb Ll
(C.13)
4
2U
U
60
nW
i=1
4
X
dn 2 i
1
V
U +V h
15Pm
F4y,i = Ld mm g +Ld
mpl g Ll
(C.14)
16P M
nb Ll
4
2U
U
60
nW
i=1
4
X
Again using the values parameter values from C we find the motor reaction forces.
1
2
3
4
Fy
29.4 kN
-14.1 kN
-18.8 kN
24.7 kN
65
66
Appendix D
Dimensions and sections in detail

D.1
Pump plates
d1
2
d2
Figure D.1: Pump plate model with parameters

Although the two pump plates differ slightly, they can be checked in the same manner. Figure
D.1 shows a pump plate. It consists of the plate, two stiffeners underneath and four bolt holes
on which the assumed point forces act. Due to the load, the structure will bend. The stiffeners
will contribute the most to the stiffness of the structure and because they are placed in such a
way that they are very close to the holes, the assumption is made that the forces act directly
on those members. For the sake of simplicity, the stiffeners will be checked separately. To
account for the plate stiffness somehow, the members will be considered as T sections. d1 , d
And d2 , as depicted in figure D.1 and D.2 are respectively the distance from the end of the
member to the first hole, the distance between both holes and the distance from the second
hole to the other end of the member. In order to calculate the maximum bending moment of
a member the reaction forces at both ends of the beam (R1 and R2 in figure D.2) have to be
determined. This is done using basic structural mechanics: the sum of all moments should
be equal to zero. For the sake of convenience we take the moments about R1 and R2 , with
l = d1 + d + d2 .
MR2 = 0 :
R1 l + F1 (d + d2 ) + F2 d2 = 0
(D.1)
MR1 = 0 :
F1 d1 + F2 (d + d1 ) + R2 l = 0
(D.2)
67
R1
wp
F1
tp
hs
yc
ts
F2
d1
R2
d
d2
Figure D.2: T-beam model
Knowing the reaction forces at the ends of the beam, the maximum moment acting on the
beam can be determined. This maximum moment is the largest absolute value of the moments
acting at the bolt holes M1 and M2 .
R1 =
F1 (d + d2 ) F2 d2
l
M1 = R1 d1
F1 d1 F2 (d + d1 )
l
M2 = R1 (d + d1 ) F1 d
and
R2 =
and
(D.3)
(D.4)
Recalling equation (6.1), the design bending moment Mx is now the maximum absolute
bending moment in equation (D.4).
Mx fy Ze .
(D.5)
Before we go any further, some values are given in the next following table, so that the
calculations can be easily checked. D13 means the D-pump plate stiffener supporting holes 1
and 3. Note that the signs of the values are relative to the force directions shown in figure
D.2.
D13
D24
E13
E24
d1 [mm]
103
103
105
105
d [mm]
462
462
589
589
d2 [mm]
188
188
10
10
F1 [kN]
40.5
36.6
45.5
38.6
F2 [kN]
-52.5
-43.6
-81.1
-63.3
R1 [kN]
-21.9
-20.7
-37.6
-31.9
R2 [kN]
33.9
27.7
73.2
56.6
Mx [kNm]
6.36
5.21
3.94
3.35
The ultimate shear strength fy of steel is 240 MN/m2 and capacity factor is 0.9 [5]. The
effective section modulus Ze has to be calculated. In order to calculate the effective section
modulus the second moment of area I and the neutral axis yc of the T-section have to be
determined: I = Ze yc . Figure D.2 shows the cross section of the T beam with its dimensions.
First the neutral axis must be found. We divide the cross section in two pieces; the plate (1)
68
and the stiffener part (2). We determine the areas and neutral axes of the separate parts to
combine those for the neutral axis of the whole section (yc ).
A1 = tp wp and A2 = ts hs
1
1
y1 = hs + tp and y2 = hs
2
2
(D.6)
(D.7)
A1 y1 + A2 y2
A1 + A2
yc =
(D.8)
The second moments of area for the separate parts can be determined again using basic
mechanics. These are then summed with respect to the neutral axis to find the second
moment of area for the entire section.
I1 =
wp t3p
12
and I2 =
ts h3s
12
(D.9)
Ic = I1 + A1 (y1 yc )2 + I2 + A2 (yc y2 )2
(D.10)
The effective section modulus is found by:

Ic
.
yc
Ze =
(D.11)
By varying the the thickness of the plate (tp ) and the height and thickness of the stiffener
(hs , ts ), the effective section modulus can be adjusted. The parameter wp is of little influence
and is set to 300 mm. Recalling equation (D.5), this value has to satisfy:
Ze
Mx
.
fy
Choosing the values is negotiating, because they all influence Ze . The thicknesses that have
been picked are standard plate thicknesses, leaving the stiffener height as final tune parameter.
The following table shows the picked dimensions and some other parameters to make checking
the calculations easier.
D13
D24
E13
E24
D.2
tp [mm]
ts [mm]
hs [mm]
yc [mm]
Ic [106 mm4 ]
Ze [103 mm3 ]
16
16
16
16
16
16
12
12
70
70
60
60
69.9
69.9
63.0
63.0
2.24
2.24
1.22
1.22
32.0
32.0
19.4
19.4
Mx
fy
[103 mm3 ]
29.5
24.1
18.3
15.5
Columns
The columns of the pump pedestal are subjected to compression, tension and a bending
moment. They will be checked for buckling and bending, as these will be far more likely to
occur than pure compression or tension failure.
69
D.2.1
Bending
Australian Standards handbook [5] restricts the design bending moment Mx of a member as:
Mx fy Ze .
(D.12)
fy Being the ultimate shear strength of steel: 240 MN/m2 , the capacity factor as prescribed
by the handbook: 0.9 and Ze the effective section modulus, which is listed in the BHP
catalogue [7] for every available product. For the design bending moment we take highest
lateral pump reaction force, Fz = 9.79 kN multiplied length of a column, l = 322 mm:
with Fz l fy Ze ,
we find Ze 14.6 103 mm3 .
(D.13)
The BHP catalogue shows that the 75 75 3 mm Tubeline square hollow section has an
effective section modulus of 22.5 103 mm3 , which satisfies (D.13).
D.2.2
Buckling
According to the Australian Standards handbook [5], the elastic buckling load Nom of a
member can be calculated as given below. This value should be higher than the maximum
compression force exerted on the columns, which is R1 = 37.6 kN found in section D.1.
Nom =
2 EI
(ke l)2
(D.14)
Where E is the modulus of elasticity of steel as specified in the Australian standards [5], 200
GN/m2 and l the length of the column, 322 mm. ke Is the member effective length factor
that accounts for the way the column is fixed. In this case ke = 1.2 [8]. Like the effective
section modulus, the second moment of area I is also given in the BHP catalogue [7].
R1
2 EI
(ke l)2
gives 37.6 kN 9.47 MN
(D.15)
The selected columns (75 75 3 mm) will therefore not buckle and are accepted.
D.3
Floor frame
The floor frame supports the columns and the motor plate. The floor frame will be designed
to withstand the forces on the pump side, and further on checked for the motor side. Figure
D.3 shows the simplified piece of the floor frame which is directly underneath on of the pump
pedestal columns. It consists of many members, of which the T section depicted with a solid
line contributes the most to the stiffness of the structure. The top and bottom plates are
therefore neglected. The floor frame is checked for buckling and compression.
Buckling is checked again according to the Australian standards [5], this time about the
Y and the X axes:
2 EIX
2 EIY
Nom,X =
and
N
=
(D.16)
om,Y
(ke l)2
(ke l)2
with Nom the maximum compression force on the frame, which should be smaller then the
maximum compression force on the columns (R1 =37.6 kN). The material parameters fy and
70
R1
wp
tp
hs
yc
ts
Figure D.3: Floor frame model
E remain the same as before. The parameter ke is now 0.7 [5] and l is the height of the floor
frame (95 mm). We use equations (D.6) to (D.10) to determine the second moments of area
IX and IY . We take wp to be 400 mm, and set all the thicknesses to be the same, starting at
5 mm, for keeping an eye on the vibrational properties.
Compression is easily checked. The material starts to fail when R1 fy A, with A the
cross section area of the member. The table below shows the results of the calculations with
a frame thickness of 5 mm.
tp , ts [mm]
5
hs [mm]
70
yc [mm]
67
R1 [kN]
37.6
Nom,X [GN]
0.253
Nom,Y [GN]
11.9
fy A [kN]
564
One can see that the critical loads Nom,X , Nom,Y and fy A are well above the compression
force R1 and thus the 5 mm frame thickness is acceptable.
D.4
Motor plate
Because of symmetry only half the plate is considered. Figure D.4 shows the motor plate
model. The base frame is bolted down to the floor approximately at the ends of the motor
plate, so the plate plus its stiffener and adjacent floor frame can be modeled as simply
supported at both ends. The member consisting of the half plate, half the stiffener and
the adjacent floor frame is considered as a simply supported beam with two forces acting on
it. This pair of forces on one half of the plate creates a bending moment. The problem is
now exactly the same as the pump, plate problem and we have to find the design bending
moment first. Using equations (D.4) to (D.5), we find the design bending moments. For the
side with holes 1 and 2 and the other side, 3-4.
1-2
3-4
d1 [mm]
242
242
d [mm]
169
169
d2 [mm]
349
349
F1 [kN]
29.4
24.7
F2 [kN]
-14.1
-18.8
R1 [kN]
-16.9
-12.7
R2 [kN]
1.60
6.75
Mx [kNm]
4.09
3.06
Using equations (D.6) to (D.11) we find the neutral axis yc , the second moment of area Ic
and the effective section modulus Ze . Only the stiffener thickness tm is variable, because tf
71
d1
d
1
2 tm
d2
tp
tf
Figure D.4: Motor plate model
is the thickness of the floor frame and tp is as thick as the biggest nut it replaces with its
thread, which is 20 mm [5]. The height of the member is 90 mm and the width is 310 mm.
1-2
3-4
tm [mm]
tp [mm]
tf [mm]
yc [mm]
Ic [106 mm4 ]
Ze [103 mm3 ]
5
5
20
20
5
5
94.6
94.6
2.50
2.50
26.5
26.5
Mx
fy
[103 mm3 ]
18.9
14.2
A stiffener of 5 mm thickness turns out to be sufficient to bear the loads at either side, because
the values satisfy
M
Ze x .
fy
D.5
Jockey pulley frame
The force exerted on the jockey pulley, Fjock , is directly related to the belt tension force as
determined in section B.1.2, Fbt . Together with the contact angle of the belt on the pulley
(), the resulting force can be calculated withe the simple formula. For clarification see figure
D.6.
Fjock = 2 sin(/2)Fbt
(D.17)
It is very unlikely that the contact angle exceeds 45 , so that value will be taken as in the
worst case. Keeping the live load safety factor and implementing the angle in the equation
for the belt tension force adopted from equation (B.15), we find:
h
Fjock = 2 sin(/2)Ll 16P M
dn 2 i
60
nb .
(D.18)
By filling in the parameters as given in C we find for the force on the jockey pulley: Fjock =
12.0 kN.
The parts of the jockey pulley frame that have to be checked and dimensioned are the
flange channels, the main frame, the arms and the push rod. Reminder: The flange channels
72
Figure D.5: jockey pulley system: side, top and iso view
are the upright members carrying the slotted beam. The main frame is attached to the beam
and connects to the push rod and the arms. The latter sandwich the jockey pulley. See also
figure D.5
Flange channels
The flange channels are subject to a bending moment
due to the force on the jockey pulley. They are assumed to be attached to the base frame only at the
very bottom. Using the criterion for a bending moment on a member (6.1) again, we have:
Fbt
1
Mx = Fjock lf fy Ze
2
Fjock
with lf being the distance from the floor to the beam

on which the jockey pulley mechanism rests. Because
there are two channels, each is subject to 12 Fjock .
In the worst case lf is 567 mm, the ultimate shear
strength fy of steel is 240 MPa and as in the previous
cases, = 0.9. Filling in these values in D.20 gives:
Ze 15.8 103 mm3 .
Fbt
Figure D.6: Determining Fjock
(D.19)
(D.20)
From the BHP catalogue [7] the 75 PFC channel is

selected which has an effective section modulus of
Ze = 21.4 103 mm3 .
Main frame
See figure D.7. The main frame is subject to a bending moment. We consider the main frame
as a U-profile and take the worst case scenario for the position of the jockey pulley with respect
73
b
t
1
2
lm
1
2 Fjock
1
2 Fjock
Figure D.7: Main frame model: the main frame on the beam (left) and the cross section
(right)
to the main frame, the case that the arms are horizontal. The maximum beding moment Mx
equals Fjock multiplied by the distance from the point where the arms are attached to the
underside of the beam (lm ). The following equation applies.
Mx = Fjock lm fy Ze
(D.21)
All parameters in the equation are known except for the effective section modulus. Fjock =
12.0 kN, lm = 147 mm, fy = 240 MPa and = 0.9. We know now that the effective section
modulus must satisfy Ze 8.17 103 mm3 .
The effective section modulus is calculated in the same manner as before with the pump
plates, using equations (D.6) to (D.11), though slightly modified for this problem.
A1 = bt and A2 = 2th
1
1
y1 = h + t and y2 = h
2
2
(D.22)
(D.23)
A1 y1 + A2 y2
(D.24)
A1 + A2
The second moments of area for the separate parts can be determined using basic mechanics.
These are then summed with respect to the neutral axis to find the second moment of area
for the entire section.
th3
bt3
and I2 =
(D.25)
I1 =
12
12
Ic = I1 + A1 (y1 yc )2 + I2 + A2 (yc y2 )2
(D.26)
yc =
The effective section modulus is found by:

Ze =
Ic
.
yc
(D.27)
For the sake of manufacturing convenience we take all thicknesses to be the same (t), see also
figure D.7. The width of the member is fixed: b = 136 mm. The parameter h is varies over
74
the length, so a mean value is used for the calculations. Together with thickness t, h is a free
parameter. Choosing t = 5 mm and h = 57 mm results in an effective section modulus of
Ze = 8.30 103 mm3 , which satisfies the earlier posed condition that Ze 8.17 103 mm3 .
Arms
The arms will be checked for pure buckling (in case of maximum extension) and for bending
(in case of minimum extension), because the push rod connects some distance away from the
pulley where Fjock acts on.
Buckling is checked with the following formula.
Nom =
2 EI
(ke l)2
(D.28)
In which the elastic buckling load Nom should be higher than the force on each arm: 12 Fjock .
E is the modulus of elasticity of steel, 200 GN/m2 [5]. ke Is the member effective length factor
that accounts for the way the member is fixed. In this case ke = 0.85. For length l we take
the longest free part of the arms, the part between the push rod and the main frame: l = 210
mm. The only parameter unknown to us is the second moment of area I. For a rectangular
cross section it is specified as:
ht3
,
(D.29)
I=
12
h Being the height of the member and t the thickness. By choosing h = 40 mm and t = 4
mm, the second moment of area becomes 213 mm4 and Nom = 13.2 kN, which is larger than
1
2 Fjock = 6.00 kN.
Next we will check if the selected values for h
and t will also prevent bending of the arms when
1
the jockey pulley is minimally extended. As beF
2 jock
R1
fore, bending is checked with:
Mx fy Ze
l1
R2
l2
Figure D.8: Bending model for the arms
(D.30)
In this case the maximum bending moment Mx

is l1 Fjock sin . Because is close to 90 , Mx will
be approximated to be l1 Fjock . Again, fy = 240
MN/m2 and = 0.9. Ze is the last unknown and
can be determined using equation (D.11): Ze =
I/yc . I is now th3 /12 and yc , the neutral axis of
the cross section of the arm, is equal to h/2. This
makes Ze = th2 /6 and every parameter is known.
Checking the bending criterion (D.30) gives:
Mx = 480 Nm
and fy Ze = 230 Nm,

(D.31)
which does not satisfy D.30. In order to accomplish that we increase height h to 52 mm and
thickness t to 5 mm. The result is that condition D.30 is now satisfied.
Mx = 480 Nm
and fy Ze = 486 Nm
75
Mx fy Ze
(D.32)
Fn
Fjock
Rr
Rn
l1
l2
Figure D.9: Model of the jockey pulley system
Push rod
See figure D.9. This is a 2D model of the jockey pulley system. Comparing the model to
figure D.5, one can see the only approximation made is length b. In reality this length can
vary slightly due to the way the push rod is connected to the main frame. This small variation
is neglected in order to keep the calculations transparant. The push rod is only subject to
buckling, due to force Rr . The buckling criterion is similar to the ones used earlier, see e.g.
equation D.28. The length l in that equation is replaced with rod length a, Nom should be
larger than Rr and ke is 0.85. E is still 200 GN/m2 and I is yet to be determined and only
depends on the diameter of the push rod. This results in the following criterion.
Nom =
2 EI
(ke l)2
Rr
2 EI
(ke a)2
Rr (ke a)2
2E
(D.33)
We now have to find the reaction force Rr . It is a reaction force of the earlier determined
Fjock . First, we take the component of Fjock perpendicular to the arms, because only this
component causes a reaction force at the end of the rod: Fn = Fjock cos . The reaction force
2
it causes is Rn , again a force normal to the arms: Rn = l1 l+l
Fn . Buckling force Rr can now
2
be calculated using angle : Rr = Rn / sin . We combine these these results with the sine
sin
rule: a sin = b sin and the fact that cos
= tan .
a(l1 + l2 )
Fjock
b l2 tan
Rr =
(D.34)
Because the push rod is adjustable in length (consequently adjusting the whole system),
length a is a function of angle (or any other angle). Pythagoras states:
a=
b2 + c2 2bc cos
(D.35)
Note that is roughly in the range 10 < < 90 . One can see straight away that Rr
decreases with approaching 90 . On the other hand, the length of the rod (a) increases
76
0.8
0.6
0.4
Compression force
Length of rod
Required second moment of area
0.2
20
30
40
50
60
angle []
70
80
90
Figure D.10: Compression force (Rr ), rod length (a) and minimum required second moment
of area (I) as function of angle . Note that all values on the y-axis are normalized to 1.
when increases. Therefore, looking at (D.33), there must be an maximum value in the
required second moment of area. This maximum value is at the angle where the elastic
buckling load is the greatest and the push rod should be designed to withstand the loads at
that angle. To determine this critical angle, the mathematic computer package Matlab7 is
used to calculate and plot Rr , a and I as a function of . The programme instructions are
printed in appendix E. The results can be found in figure D.10. At an angle of = 62.7 , the
maximum second moment of area is required. At that angle length a is 22.6 cm and Rr = 8.63
kN. The maximum required second moment of area is 162 mm4 . From basic mechanics we
know that
D4
,
(D.36)
I=
64
which results in a minimum diameter of the push rod of 7.6 mm. Although an M8 thread
would do, in this case a more convenient M12 is chosen.
77
78
Appendix E
Matlab programme instructions

% clear workspace %
clc
clear all
close all
% parameters %
Fj=12e3;
l1=0.08;
l2=0.21;
b=0.224;
c=l2;
ke=0.85;
E=200e9;
N=10000;
alphamax=0.5*pi;
alphamin=0.1*pi;
nalpha=(alphamax-alphamin)/N;
alpha = alphamin:nalpha:alphamax;
for n=1:N+1
a(n)=sqrt(b^2+c^2-2*b*c*cos(alpha(n)));
Rr(n)=Fj*(l1+l2)/(l2*tan(alpha(n)))*a(n)/b;
I(n)=(Rr(n)*(ke*a(n))^2)/(E*pi^2);
end
alphagrad=alpha/pi*180;
% output: plots %
figure
plot(alphagrad,Rr/max(Rr),--k,linewidth,2);
hold on
plot(alphagrad,a/max(a),:k,linewidth,2);
79
plot(alphagrad,I/max(I),-k,linewidth,2);
hold off
legend(Compression force,Length of rod,Required second moment of area,...
...Location,south)
axis([min(alphagrad) max(alphagrad) 0 1.1])
xlabel(angle \alpha [\circ],fontsize,[16],fontname,Times New Roman)
% output: values at maximum I %
[Imax,b]=max(I);
Imax
alphagrad_Imax=alphagrad(b)
Rr_Imax=Rr(b)
a_Imax=a(b)
D=(64*Imax/pi)^(1/4)
80
Appendix F
References
1. Weir Warman Newsletter, September 2003, Introducing Weir Minerals p 1.
2. Slurry pump handbook, Weir Warman , Introduction pp 6-8.
3. Warman Technical Bulletin, No. 20, April 1992, Pump performance testing pp 1-4.
4. Standard operating procedure, July 2005, pp 1-28.
5. Australian Standards AS 4100-1998, Steel structures.
6. BHP Catalogue, 1998, Hot rolled and structural steel products p 31.
7. BHP Technical information, april 1999, Structural cold formed sections and profiles
pp 26-27.
8. Ajax Fasteners, Issue 99, Metric Hexagon Nuts, p 100.
9. Toshiba catalogue, Toshiba electric motors Dimensions for TEFC motors
10. Fenner Belt drives, Fenner Australia
11. Warman international LTD, September 2003, Maximum allowable loads and moments
on pump flanges.
12. Australian Standards AS 1170-1, 1989
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Performance analysis and design improvement on a test rig for

centrifugal slurry pumps at Weir Warman Ltd, Sydney

2 Warman slurry pumps

5 Design of the piping configuration

6 Design of the base frame

D-frame pump pedestal . . . . . . . . . . . . . . . . . . . . . . . . . .

D Dimensions and sections

E Matlab programme instructions

Warman slurry pumps

Figure 3.1: The current medium test rig

14. Get matching gaskets for flanges on discharge side.

Head, power and efficiency versus flow rate

NPSH test with constant flow rate method

Sound level, vibration and bearing temperature rise test

Design of the piping configuration

Figure 5.1: Situation sketch of the intake side

Table 5.1: Necessary pipes for D-frame pumps

Figure 5.2: Discharge side of a similar test rig in Venlo

Design of the base frame

Figure 6.1: Base frame concept

Dimensions and sections

The thickness of the floor frame is 5 mm.

Jockey pulley frame

Finite element analysis

Figure 6.3: Strand7 FEA model

Figure 6.4: Stresses on the base frame as calculated with Strand7

Figure 6.5: Displacement of the base frame as calculated with Strand7

Table 6.1: Maximum, test and critical speeds of various pumps

Figure 6.10: Base frame: front view

Figure 6.11: Base frame

Figure 6.12: Floor frame: top and front view

E-frame pump pedestal

Figure 6.13: Motor plate: top view

D-frame pump pedestal

Jockey pulley frame

Figure 6.14: E-frame pump pedestal: top and front view

Figure 6.15: D-pedestal fasteners

Figure 6.16: D-frame pump pedestal: top and side view

F~f rame = F~g + F~belt + F~f lange

Figure B.1: 2D force model

Pump reaction forces

Figure B.2: pump dimensions

Belt tension forces

Again, safety factors are applied.

Figure B.3: maximum allowable f lange loads and moments

Figure B.4: 2D moments model

This results in the reaction forces:

Figure B.5: model for My approximation

F1z,3 = F2z,3 = F3z,3 = F4z,3 =

Total reaction forces

Motor reaction forces

Figure C.1: motor dimensions

Belt tension forces

The motor torque reaction forces are now available:

Total reaction forces

Dimensions and sections in detail

Figure D.1: Pump plate model with parameters

The effective section modulus is found by:

we find Ze 14.6 103 mm3 .

gives 37.6 kN 9.47 MN

Figure D.3: Floor frame model

Jockey pulley frame

Fjock = 2 sin(/2)Ll 16P M