Enhanced Centrifugal Pump Casing Design to Prevent Failure in Burst Pressure Testing

Abstract

This study presents the design optimization of a centrifugal pump casing to prevent failures observed during burst pressure testing. For high-pressure centrifugal pumps, both the material selection and geometric design of the casing play a critical role in ensuring mechanical integrity. As part of prototype validation, burst pressure testing was conducted, during which premature failure of the casing was observed—an issue taken seriously within the organization.

A detailed failure investigation revealed that the rib geometry was inadequate to sustain the required pressure. To further analyse the failure mechanism, stress simulations were performed. The results showed a strong correlation between the high-stress regions predicted by simulation and the actual failure locations on the casing. Subsequent design optimization iterations were undertaken, focusing on reducing stress concentrations and improving the structural integrity of the casing. These iterations included modifications to the rib geometry to ensure the design could withstand the target burst pressure. Stress distribution in the critical rib area was analysed, and the factor of safety was calculated for each design iteration. The final optimized design met the desired stress limits and safety factor requirements. CAD models were accordingly updated to reflect the improved design. This optimization effort resulted in significant benefits, including enhanced reliability, improved product quality, structural feasibility, and a better strength-to-weight ratio. Furthermore, the redesigned casing contributed to increased customer satisfaction and alignment with sustainability goals by improving long-term durability.