CHAPTER III

RESEARCH METHODOLOGY
3.1 RESEARCH FLOW CHART
Herewith below (Fig. 3.1) describes the conceptual flow of
approaching method in deducing what vibrational root-cause in Pump Station
- Karang Pilang 3.

Fig. 3.1 : Flow Chart diagram

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 This vibration phenomena create an engineering intuitive
prediction for the root-cause, it is widely known that every rotating equipment
shall create sinusoidal wave. And particularly those rotating equipment is
transferring massive fluids with certain range of pressure value (Fluid
Interaction).

For the Soil Interaction, it is intuitively concluded (and refer to

existing drawing) that the building sub-structure system does not use piling
material. Hence it is permissible to conclude that the structure is stand on
foundation with non-linear rigidity.

3.2 PARAMETERS AND MODEL

Modelling technique in this paper uses exact dimension and
material properties from the origin of structure, soil, fluid and parts in it.

3.2.1 Soil
Looking back into the origin of this concept the modulus Eq.(2.1)
and Eq.(2.2), Bowles (Bowles, 1997) suggested providing higher ks at the
edges of the raft and smaller ks at the center position. The interpretation of an
existing soil layer data is presented in table 3.1 in refers to origin data (IPAM
Kr. Pilang 3, 2018)

Table 3.1 Initial properties of the soil used in Solidworks modelling.

Depth (m) N Soil Type kV (kN/m) kH (kN/m)

0 0 silty 0.0 0.0
-1 2 silty 16587.6 11880.0
-2 4 silty 20734.5 13200.0
-3 4 silty 20734.5 13200.0
-4 4 silty 20734.5 14520.0
-5 6 silty 24881.4 16500.0
-6 7 silty 26954.9 17160.0
-7 7 silty 26954.9 17820.0
-8 8 silty 29028.3 19800.0
-9 10 silty 33175.2 22440.0
-10 12 silty 37322.1 17820.0

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3.2.2 Structural
To model the pump station concrete building, an extensive
communication has been conducted (IPAM Kr.Pilang 3, 2018) as well as on
a site survey, in order to get the furthest approach to as-built drawings.
Consecutive re-drafting the existing drawing has been done with Solidworks
2017 to get 3D images and to have simulation using solids model. Solidworks
is based on finite element (FE) method and also able to perform dynamic
analysis for both linear and non-linear behaviour of structures. Fig. 3.2 shows
the isometric 3D view of the pump station building.

Fig. 3.2 : Isometric view of the pump station building

The model contains all elements that are considered to affect the
structural behaviour, reinforced concrete walls, roof, beams and slabs. The
non-concrete roof structure is considered to have no contribution to the overall
stiffness of the building and is therefore omitted, except as mass.

In the modelling process, boundary conditions at the building supports use

elastic support which allows rotation and translation in certain value

Table 3.2 Initial properties of the elements used in Solidworks modelling.

Mass Density 2400 kg/m3

Poisson’s Ratio 0.205

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 Concrete Strength 40 Mpa.

Elastic Modulus 2.3e10 Mpa

The initial material properties of the elements, used in the

modelling are shown in table 3.2. The maximum size of the shell elements
was 293 mm. The model contains 796968 points (nodes) and 444624 area
elements. In a 3-dimensional model, every node has six degrees-of-freedom.
Therefore the total number of degrees-of-freedom for this MDOF system is
over 450.000 which for further processing require extensive computational
capabilities. The experiment instrument to approach the building’s behaviour
is explained herewith below in table 3.3:

Table 3.3 Initial properties of the spring value used in Solidworks modelling.
Experiment Model Static Analysis Modal Analysis Spring Value
Fixed-base concrete building Yes Yes Kspring = ~
Spring-based concrete building Yes Yes Kspring = K1
Spring-based concrete building Yes Yes Kspring = 0.5K1
Spring-based concrete building Yes Yes Kspring = 0.75K1
Spring-based concrete building Yes Yes Kspring = 1.25K1
Spring-based concrete building Yes Yes Kspring = 2.5K1
Spring-based concrete building Yes Yes Kspring = 5K1
Spring-based concrete building Yes Yes Kspring = 15K1
Spring-based concrete building Yes Yes Kspring = 20K1

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Fig. 3.3 (a) Plan View for Beam and Column at Elevation ± 0.00

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Fig. 3.3 (b) Plan View at Elevation – 7.50

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Fig. 3.4 Longitudinal Section A-A

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Fig. 3.5 Longitudinal Section B-B with zoom at Pump position

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Fig. 3.6 Cross Section C-C

Fig. 3.7 Beam Detail

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3.2.3 Fluids
In fluids modelling, it is necessary to provide which parts of the
pump station with the highest interfacing with fluids. Herewith below (in table
3.4) experiment instruments to support the purpose of understanding the fluid
effects on the structure

Fluids Definition:
- Fluids Type : Normal Water
- Temperature: 30○ C
Water characteristic :

Table 3.4 Karakteristik Untuk Fluida Air Pada Suhu 300 C

Density 995,77 kg/m3

Visc. Dynamic 7,91 x 10-4 kg/sec-m

Bulk Modulus 215013,5

Centrifugal Pump Specification:

The centrifugal pump’s (type: positive double suction pump)
position is below the elevation of the water reservoir. There are 7 pumps
operated and each has a flow rate of 400 litres / second (detailed at table 3.5)

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 Fig. 3.8. Centrifugal Pump

Fig. 3.9. Impeller

Table 3.5 Specification of a centrifugal pump

Brand TORISHIMA PUMP MFG.CO.LTD

Type & Size CDMV 450x350 HN
Product No T0970087
Total Head 40 m
Capacity 1440 m³/h
Speed 980 minˉ¹
Bearing No. 6318 C3-1
Product Delivery Date 12-2009

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Electric Motor Specification:
The motor used in the pump station unit of IPAM Karang Pilang
3 is an electromotor (detailed dimension on appendix 1) that is connected
vertically with each production pump. The following specifications as in table
3.6 :

Table 3.6 Specification of Electric Motor

Brand CMG Australia
Type PPA 355L110-6
Kw 200
Volts 380/660
Ampere 364.6/210.5
RPM 990
Ambient Temp. 40 °C
Serial No 964C040T
CAT No M36200001PPA/385
Specification IEC 60034/AS1359
Efficiency (%) 95.8
Cos φ 0.87
Hertz 50
Max. RMS vibration velocity 2.8 mm/s
DE BRG 6324/C3
NDE BRG QT324
Connection Delta/Star
Weight 1900 Kg

Electric Motor’s Support Specification:

In the existing configuration, the electric motor is attached to a
steel supporting system (at table 3.7). Which redraw in 3D at Fig. 3.10 and
Fig. 3.11 below :

Table 3.7 Electric Motor’s support specification

Material Steel structural

Class. A360
Strength Fy 240 Mpa
Configuration WF shape and Round Plate

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 Fig. 3.10. Round cover, Electric motor support

Fig. 3.11. Steel Beam support, below round cover

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Shafts joints and other parts :
Between centrifugal pump and electric motor, there is space with
the length of 6m. Electric motor's torque needs to be transferred into the
pump's impeller's blade. Herewith below are the parts that consider included
in the whole analysis.

Fig. 3.12. Joint Cover

Fig. 3.13. Shaft Bearing and Hub

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 Fig. 3.14. Shaft – Disc Pack

3.3 RESEARCH DESIGN

3.3.1 Modal Analysis Setup
The first thing to analyze is the modal properties of the structure,
this analysis will stand for "undisturbed" condition. It is the threshold value
of origin of vibration caused by soil and fluids. Table 3.8 and table 3.9 shown
the basic summary of modelling setup for further analysis. While the Fig. 3.15
are the meshing enhancing result pre-analysis phase

Table 3.8 Modal Analysis Setup

Analysis type Modal

Mesh type Solid Mesh
Number of frequencies 40
Solver type FFE Plus
Zero strain temperature 298 Kelvin
Unit system SI (MKS)
Pressure/Stress N/m^2

Table 3.9 Mesh setup for Modal Analysis

Mesher Used: Curvature-based mesh

Jacobian points 4 Points
Max and Min element size 879.159 mm
Minimum element size 879.159 mm
Fixed Geometry and
Fixture Detail
Spring value (table3.3)
Total Nodes 235003

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 Total Elements 135659
Maximum Aspect Ratio 45.536
% of elements with Aspect Ratio < 3 65.6
% of elements with Aspect Ratio > 10 17.6

Fig. 3.15 : Mesh view of Pump Station building

3.3.2 Static Analysis Setup

This analysis holds significant purpose to determine the alternating of the
geometry of the building. Static analysis (table 3.10 and table 3.11) in this
section will be calculated in different foundation base condition, hence it will
producing a graph relationship between soil spring value with the rotation of
the vertical pump's geometry.

Table 3.10 Static Analysis Setup

Analysis type Static

Mesh type Solid Mesh
Incompatible bonding options Automatic

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 Solver type FFE Plus
Soft Spring: Off
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Unit system SI (MKS)
Pressure/Stress N/m^2

Table 3.11 Mesh Setup for Static Analysis

Mesh Used: Curvature-based mesh

Jacobian points 4 Points
Maximum element size 293.053 mm
Minimum element size 293.053 mm
Fixed Geometry and
Fixture Detail
Spring value (table3.3)
Total Nodes 796968
Total Elements 444624
Maximum Aspect Ratio 41.068
% of elements with Aspect Ratio < 3 90.7
% of elements with Aspect Ratio > 10 4.82
% of distorted elements(Jacobian) 0

3.3.3 Computational Fluid Dynamics (CFD) Analysis Setup

Computational Fluid Dynamics (CFD) is a branch of fluid
mechanics that uses numerical analysis and data structures to solve and
analyze problems that involve fluid flows are used to perform the calculations
required to simulate the interaction of liquids and gases with surfaces defined
by boundary conditions,

Herewith below (table 3.12) some definition as applied on the Solidworks

2017 Flow Simulation feature

Table 3.12 Mesh for CFD Analysis

X min 0.209 m

X max 1.011 m

Y min -0.615 m

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 Y max 0.413 m

Z min -0.756 m

Z max 0.641 m

Total Cell count: 2128

Fluid Cells: 2128

Solid Cells: 1988

Partial Cells: 1332

Flow Type: Laminar and turbulent

Time-Dependent Analysis: On

Thermodynamic parameters (at Static Pressure: 101325 Pa

Initial Conditions) Temperature: 293.20 K

Velocity parameters (at Initial

0 m/s
Conditions)

Coordinate system Global

Reference axis X

Total Pressure: 400000 Pa

Thermodynamic parameters (at
Environment pressure: 101325.00 Pa
Boundary Conditions)
Temperature: 293.20 K

3.3.4 Electric Motor vibration analysis

The analysis is to check how large is the electric motor will
vibrate, is performed shortly in this section. According to [8] from the factory
data test, it is declared that the electric motor will vibrate at the maximum 2.8
mm/s of vibration velocity. Using the simple harmonic calculation to find the
value of displacement, it will be usefull to know wether the modelling of
electric motor is needed as a whole parts or is enough only as the weight force.

= 0.5 sin(2 ) and = cos(2 )

If the value v = 2.8 mm/s subtituted in the equation, it resulted that

the displacement caused by the electric motor vibrations is max 0.0233 mm.

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Hence for the effect of the vibration will be neglected for the simplification
of the whole analysis.

3.3.5 Operational Deflected Shape (OSD) Analysis Setup

This OSD analysis is the continuity from the static analysis. Every
geometric rotational value results from the static analysis shall be
correspondent to this analysis, applied as the vertical pump's misalignment.
The output of this analysis will be considered as the vibrational force wave-
like. Which will be our main external force at for the harmonic loading at
dynamic analysis. Table 3.13 and table 3.14 describe the initial setup for the
motion analysis in Solidwork 2017, and the 2D view at Fig. 3.16 revealed how
the parts of vertical pump deflected each to one another.

Table 3.13 ODS Analysis Method Setup

Analysis type Static

Mesh type Solid Mesh
Incompatible bonding options Automatic
Solver type Large Problem Direct Sparse
Soft Spring: Off
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Unit system SI (MKS)
Pressure/Stress N/m^2

Table 3.14 ODS Analysis Mesh and Loading Setup

Mesher Used: Curvature-based mesh

Jacobian points 4 Points
Max. and Min. element size 63.24 mm and 12.6 mm
Fixture Detail Fixed Geometry
Values: 9.81
Gravity Load
Units: m/s^2
Angular Velocity: 120 rad/s to 88
Centrifugal Load
rad/s
Values: -2432, 1993,
Fluid Force
1538 N
Electric Motor Weight Values: 19219.5 N

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 Fig. 3.16 Analyzing with Deflected Shape

3.3.6 Non-Linear Time History (NLTH) Analysis and Summary

This NLTH analysis will take the ODS analysis output as string
data force within specific windowing time. This analysis will conducted using
FEM software SAP2000 (compacted in table 3.15), particularly focused on
the performance of NLTH Analysis at the pump station building. The desired
outcome from ODS analysis will be take on both conditions fixed and spring
base, each conditions shall be represented by force-time wave graph relations.

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 Table 3.15 : NLTH analysis setup

Analysis type Non-Linear TH

Integration Direct – Hilber Hughes
Loading Time History Function
Initial Cond. Cont. from NL static
TH Motion type Transient
Damping Prop. Proportional
Time Step 0.1 s
Unit system SI (MKS)
Fixture Fixed and Spring
Rotation Freq 19, 17, 16, 14 Hz

Table 3.16 shall summarize the 5 basic steps within this thesis,
and it is predicted to have an intuitive and evaluative output which lead to
conclusion drawing.

Table 3.16 : Summary of Experimental Step

Spring Base
Analysis
Aim Fixed Base (various
Type
value)
Step 1 Modal Resonate Frequencies √ √

Step 2 Static Displacement √ √

Flow Force by Fluid
Step 3 - -
Simulation And impeller angular speed
Step 4 ODS Force Reaction’s Graph - √

Step 5 NLTH Structural Behavior √ √

3.4 STRUCTURE RESPONSE ANALYSIS

Dynamic analysis can be performed on a mechanism or a
structure,these analyzed objects can be an aeroplane wing, a car, a building
subjected to an earthquake, an engine or a doorbell making the sound.
Dynamic analysis can deal with rigid and/or elastic bodies, however vibration
analysis would be more specific, it deals only with elastic bodies vibrating
about the position of equilibrium. The scenario for the loading conditions
follow the combinations as below (table 3.18 and table 3.17), as decribed by
the site surveying and communication with (IPAM Kr. Pilang 3, 2018):

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 Table 3.17 : Combination Load at Full service condition
Pump Pump Pump Pump Pump Pump Pump
1 2 3 4 5 6 7
Comb 1 4 bar 4 bar 4 bar - 4 bar 4 bar 4 bar

Table 3.18 : Combination Load at Start-up condition

Pump Pump Pump Pump Pump Pump Pump
1 2 3 4 5 6 7
Comb 2 1 bar 1 bar 1 bar - 1 bar 1 bar 1 bar

It is informed to author that the availability of those 6 pumps are

essential and running 24 hours, and for the backup plan (in case of emergency,
or maintenance) it shall use the 7th pump. For the purpose of this thesis, these
combinations will conducted on both ‘start’ and ‘full-service’ conditions, in
order represent 1 bar to 4 bar fluid pressure.

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