Domain Expertise
Structural Analysis
 Linear Analysis
 Non Linear Analysis
Structural Dynamics
 Modal Analysis
 Harmonic Analysis
 Spectrum Analysis
Rotor Dynamics
 Lateral critical speed analysis
• Stability Analysis
• Forced response analysis
• Transient response analysis
 Torsional critical speed analysis
• Torsional frequency analysis
• Torsional steady state analysis
• Torsional transient analysis
Thermal Analysis
 Steady state thermal analysis
 Transient thermal analysis
Fatigue and Fracture Mechanics
 Fatigue Analysis
• Low cycle fatigue using Stress based(S-N curve)
• Low cycle fatigue analysis using strain based
 Fracture Mechanics
• Linear elastic fracture mechanics (LEFM)
• Linear elastic plastic fracture mechanics (EPFM)
Computational Fluid Dynamics (CFD)
Coupled Field Analysis
 Thermal –structural Analysis
 Fluid –Structural Analysis
Design and shape optimization
 Tool Expertise
Analysis Tools:
Centrifugal pumps and
 Ansys APDL and Ansys Workbench compressors:
Modeling Tools: API 610, HIS,ASME, ISO and
 Solid Works and UniGraphics DNV
Drafting Tools:
 AutoCAD Oil and Gas subsea and surface
codes:
Rotor Dynamics Tools:
ISO 13628-7, ASME Sec-8 Div-
 RBTS
2&3, API 17D, API 17 TR8, API
Fracture Mechanics: 16R, API 6A, SAE J1099, DNV
 Franc3D and Signal FFS RP C-203, ISO 13679: 2011
Computational Fluid dynamics CAL IE, NACE MR175.
 Ansys CFX
Meshing Tools:
 Hypermesh
Design Optimization:
 DesignXplorer and iSight
Shape optimization:
 Optistruct
Ramana Podugu et al. “FINITE ELEMENT ANALYSIS (FEA) TO PREDICT CRITICAL FAILURES IN A CENTRIFUGAL PUMP”, Engineering Failure
Analysis, Elsevier, manuscript submitted and it is under review.
Centrifugal
pump casing

Background: The objective of

this analysis to structural
integrity of the casing under
hydrotest pressure load.
2D Model 3D Model

Hydrotest Pressure load

Mesh Model
FEA Analysis: 3D models are created using solidworks
software. Hydrotest pressure is applied inside the surface and
boundary conditions are imposed as per field conditions. The
analysis is done using Ansys Workbench.

vonMises stress distribution at the tongue

vonMises stress distribution Crack at the tongue region
Output: From the
FEA results , it is
observed that the
stress magnitude is
high at the tongue
region. The stress
is higher than the
Test Results Results
yield stress of the
casing material. Fig. 3.6 Crack formation at the tongue region
Based on FEA results, the casing wall From the filed From the FEA results , the high stress is shown at the
thickness is increased locally from 21 condition , it is also tongue region. The crack is also observed at the tongue
mm to 25 mm to decrease the stress observed that the
magnitude at the tongue region. region from the test results. Hence, there is a good
crack is formed at
Hence, the stress is lower than the the tongue region. agreement between FEA and test results.
yield stress of the material.
Ramana Podugu et al. “A Modal Approach for Vibration Analysis and Condition Monitoring of a Centrifugal Pump”,
International Journal of Engineering Science and Technology (IJEST), ISSN : 0975-5462 Vol. 3 No. 8 August 2011 .
3D Model and Mesh
Model Background: The objective of
this analysis to find the system
natural frequencies and
compare to the excitation
sources to ensure the structure
is dynamically adequate.

FEA Analysis: 3D models are created using solid works

software. Ansys workbench tool is used for finite element
analysis. Boundary conditions are imposed as per field
conditions. Modal analysis and harmonic analysis are
performed to find the resonance and maximum amplitude at
the resonance point.
Mode shape: Bending
FEA Results mode
Modified Design
Output: From the
FEA results , it is
observed that the
first frequency is
very nearer to the
1x pump speed. Additional stiffener plates are added to the
The amplitude at pump pedestals to increases the stiffness of
Test Results Results
the first mode is the structure. Thus , the first natural
showing frequency is increased.
maximum. The FEA
With the modified design, the first
results are in good
agreement with natural frequency is away from the
experimental 1xpump operating speed. This, the
results. design is adequate.
Ramana Podugu et al. “A novel approach of assessing the lateral critical speed analysis for multistage centrifugal pump
casing as per API guide lines”, International Journal of Mathematics and Computational Methods in Science & Technology,
Vol.3, No.2, 2013, October ,pp75 of 93, ISSN 2249 8915 .
3D Model of the multistage centrifugal Natural frequencies at dry,1xAPI and 2xAPI
pump casing Background: A novel approach of assessing the
Dry run critical speeds
lateral critical speed analysis for multistage
centrifugal pump casing as per API guide lines.
The objective of this analysis is to; Finding
lateral critical speeds in dry run, 1xAPI, 2xAPI
load cases, identity the critical speeds,
assessing the dynamic performance through
First bending mode in RBTS
damping diagram, and performing forced
response analysis to check the maximum
displacement at each wear ring location,
evaluating the displacement to ensure that the
Rotor model with masses and
maximum displacements at each wear ring
stiffness and damping
should be is less than the radial clearance of
coefficients.
the wear rings as per API criteria.
FEA model in RBTS
First bending mode in ANSYS
FEA Analysis: Rotor model is
created using beam element.
Impeller weights and stiffness and
damping coefficients are imposed
at their respective locations of
impellers, seals, couplings and
wear rings. Computed lateral
critical speeds in dry run, 1xAPI,
2xAPI.Campbell diagram is
generated to identify the critical
speeds. Rotor damping stability is Campbell diagram
FEA model in ANSYS
assessed using damping diagram
chart (damping factor Vs natural
frequency). Imbalance force is
computed as per API guidelines.
Forced response analysis is
performed to measure the
maximum displacement at each
wear ring location.
Damping diagram for 1xPI and 2xAPI Theoretical calculations

From the damping

diagram, it is noted that
one point of 2xAPI fall in
unacceptable region. It
indicates the damping
system provided to the
rotor is not sufficient. In
this case, there are two
possibilities to improve
the design of rotor. One is
damping system has to
be improved. another
way is to check maximum
displacement at the wear
ring location to ensure
there is sufficient
clearance.
Forced response diagram
From the forced
response analysis ,it is
observed that the
maximum
displacement at all
wear ring locations are
35% of the diameteral
running clearance at all
wear ring locations.
Hence, the design
requirements are
satisfactory as per API
criteria.
Theoretical calculations for finding first natural frequency
Ramana Podugu et al. “A novel approach of assessing the torsional critical speed analysis for multistage centrifugal pump
casing as per API guide lines International Journal of Research and Reviews in Applicable Mathematics & Computer Science,
Vol. 2, No 5, 2012 , August ,Page 52 -79, ISSN 2249 8931

FEA Analysis: Torsional vibration analysis is performed for

complex system of pump shaft, motor shaft, VFD and gear
box combination. Campbell diagram was drawn to compare
all torsional frequencies with excitations; pump speed, motor
speed, vane passing frequency, and gear mesh frequency.
Resonance is observed at 2x pump speed, and vane passing
frequency. Design is changed to avoid the resonance at
2xpump speed. Resonance is still present at vane passing
frequency with modified design.
Torsional steady state analysis: Torsional steady state analysis
is performed at the vane passing frequency to compute the
dynamic stresses at each location of the entire gear train. The
dynamic stresses are compared with fatigue strength through
Goodman’s diagram to ensure the design is adequate or not.
Torsional frequencies (RBTS/ANSYS/Hand Calculations

Rotor model with pump shaft, motor shaft, VFD and Gear
box (RBTS)

Rotor model with pump shaft, motor shaft, VFD and Gear
box(ANSYS)

Mode Shape at TCF 1(RBTS)

Ramana Podugu et al. “A novel approach of assessing the torsional critical speed analysis for multistage centrifugal pump
casing as per API guide lines International Journal of Research and Reviews in Applicable Mathematics & Computer Science,
Vol. 2, No 5, 2012 , August ,Page 52 -79, ISSN 2249 8931

Mode Shape at TCF 1(ANSYS)

Torsional steady state analysis Campbell diagram

Goodman diagram
Ramana Podugu et al. “A novel approach of assessing the torsional critical speed analysis for multistage centrifugal pump
casing as per API guide lines”, International Journal of Research and Reviews in Applicable Mathematics & Computer
Science, Vol. 2, No 5, 2012 , August ,Page 52 -79, ISSN 2249 8931

Theoretical calculations through Holzer method

No of iterations performed to plot the graph (torque- frequency)

Moment of inertia and torsional stiffness are calculated
at each location of complete rotor
Ramana Podugu et al. “A novel approach of assessing the torsional critical speed analysis for multistage centrifugal pump
casing as per API guide lines International Journal of Research and Reviews in Applicable Mathematics & Computer Science,
Vol. 2, No 5, 2012 , August ,Page 52 -79, ISSN 2249 8931

Theoretical calculations

From the graphs, torsional frequencies are calculated at the point

where torque is equal to zero. The theoretical calculations are
compared with the FEA procedure through ANSYS ad RBTS. Good
agreement is fund between FEA and theoretical calculations.
Ramana Podugu et al. “A novel approach of assessing the torsional critical speed analysis for multistage centrifugal pump
casing as per API guide lines International Journal of Research and Reviews in Applicable Mathematics & Computer Science,
Vol. 2, No 5, 2012 , August ,Page 52 -79, ISSN 2249 8931
Torsional steady state analysis calculations

Dynamic stresses are calculated using dynamic torque from

FEA calculations . Goodman diagram is plotted to check the
fatigue life of the component. From the calculations it is
observed that the design of rotor is safe,
Ramana Podugu et al. “Three-Dimensional Finite Element Simulation of Fatigue Crack Growth in a Centrifugal Pump Casing”,
International Journal of Engineering Fracture Mechanics, Elsevier, manuscript submitted

Objective: This work summarizes new results for predicting crack Stress intensity factor plot
shape and fatigue life for a centrifugal pump casing using
computational fracture mechanics principles. The predictions are based
on linear elastic fracture mechanics theories combined with the finite
element method. In order to compute fatigue crack propagation, the
ANSYS APDL and Franc3D were used.

Crack initiation in Franc3D tool

Crack propagation till interface of casing and volute

and crack has been split in two and propagated
with respective to branches

Stress plot at the crack tip in Ansys

Ramana Podugu et al. “Three-Dimensional Finite Element Simulation of Fatigue Crack Growth in a Centrifugal Pump Casing”,
International Journal of Engineering Fracture Mechanics, Elsevier, manuscript submitted

Crack propagation inside the casing

Crack propagation simulation: 3D crack propagation simulation is
performed using FRANC3D and ANSYS. The simulation was carried out
till crack reached to critical crack length. The simulation results are in
good agreement with failed casings in real world. Casing design is
further modified to improve the crack life.

Mode Shape

Fig. 3.6
Crack Crack formation
propagation at the
outside tongue
of the region
casing
FEA results from Franc3D-Ansys

FEA results from Franc3D-Ansys

Campbell Diagram
 Base skid stress analysis for main channels ( Side channels)

The objective of this analysis is to find the strength of main channel

(side channel) under lifting condition.

FEA Approach:
• 3D model of base skid is considered for FEA analysis. All weights are
applied at the respective positions as point loads ( mass element).
• Loading factors for transportation conditions are considered as per
guide lines.
• Lifting lug locations are constrained as simple supports boundary
conditions.

Von Mises stress plot form FEA results.

3D Model of the base skid with all The maximum stress is observed as
mountings 132 MPa
 Base skid stress analysis for main channels ( Side channels)
Theoretical calculations:
• For problem simplification, main beam(side channel) is taken for
hand calculations. All weights (half of the load) are applied on main
beam. Self weight of the base skid is applied as UDL.
• Reaction forces at lifting lug location are calculated. Shear force
and bending moment at various positions are calculated. The
maximum bending moment is observed at the center of the beam.
Bending stress is calculated at that location. The bending stress that
is calculated from hand calculations is in good agreement with FEA
results.