VIbration Monitoring of Pumps

7/28/2019 VIbration Monitoring of Pumps

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Vibration monitoring of pumps, 2008

Proprietary Information

Vibration monitoring of pumps

Monitor pump health to minimize damage,

reduce downtime, and increase productivity

The information contained in this document is the property of Wilcoxon Research and is confidential and/or copyrightmaterial. This information and this document may not be used without the express authorization of Wilcoxon Research.Any unauthorized use or disclosure may be unlawful.

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Contents

Slide

Pumping systems and failures 3

Monitoring specifics 6Monitoring techniques 11

Wilcoxons products 17


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Typical pumping system and itscomponents


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Greatly improve productivity

Early detection of failure modes

Impeller erosion

Seal leaks

Pump imbalance

Shaft looseness

Coupling problems

Cavitation

Integral part of an effectivepreventative maintenance program

Can be tied into your existingmonitoring and control system


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Four common reasons pumps failThese four most common causes of pump failure can be detected

using vibration monitoring

Insufficient lubrication 36%Bearings deprived of proper lubrication will cause pumps to fail long beforethe normal service life

Fatigue 34%Overloaded, unbalanced, or misaligned pumps cause unintended bearingloads

Improper installation 16%Improper installation techniques can lead to failures from load imbalance,misalignment, or bearings cocked on the shaft

Contamination 14%Failure can result from improper seal application resulting in debris or liquidcontamination of the bearing or impeller cavity

Source: Associated Products Inc.


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Monitoring specifics

The multitude of pump varieties can make

monitoring techniques unclear. Here is a quickguide to cut through some of the complexity.


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Centrifugal pumps horizontally mounted

On horizontally mounted centrifugal pumps:

Accelerometers are mountedperpendicular to the shaft rotation on the

pump bearing housing, as close to onebearing as possible

An axial measurement can be madenear the pump casing

Wherever possible, the accelerometersshould be mounted in the horizontaldirection, not vertically mounted


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Centrifugal pumps vertically mounted

On vertical mounted centrifugal pumps:

Two accelerometers should bemounted near the bearing housing,

90 degrees from one another,perpendicular to the shaft rotation

An axial measurement in the

vertical direction can be made nearthe pump casing


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Between bearing pumps

Same

configurationon outboardsideOn between bearing pumps:

Accelerometers should bemounted perpendicular to the

shaft, in the horizontal andvertical direction, on both theinboard and outboard side


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Vertical turbine pumpsOn vertical turbine pumps, also called bowl pumps:

Accelerometers should bemounted on or near the stuffingbox in the horizontal direction,coincident with the suction ordischarge piping; a secondmeasurement should be made at90 degrees to that

Special precaution should betaken to ensure that the electricalconnection is protected againstwater spray

In extreme cases it issometimes necessary to makevibration measurements on thepump bowl; additional influences

that must be considered include: Galvanic corrosionTurbulence

Protection against the ingressof moisture into the connection

If you are involved in such aproject, contact a Wilcoxonapplications engineer forassistance


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Monitoring techniques

Sensor output options for critical assets and

balance-of-plant equipment


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Dynamic vibration monitoring

Detailed vibration data canbe used to detect anddiagnose potential

problems as early as 18months before abreakdown

Continuous monitoring orwalk-around data collection


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4-20 mA vibration monitoring

Output signals fed to a

process control computer(PLC/DCS/SCADA) ordirectly to an alarm module

No trained analysts needed

ISO 10816 offers guidanceon vibration limits

Many facilities want to monitor pump vibration, but do not want an

expensive vibration program. 4-20 mA sensors output overall

vibration levels so that maintenance professionals can take action onpumps that indicate abnormal or increasing vibration.


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Short term and long term trends can bedetected with 4-20 mA monitoring


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Short term detection


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Detect cavitation with frequency-bandedsensors

Cavitation is a destructive conditionthat can destroy the inside of a pumpbefore you even realize it is occurring

Early detection of pump cavitationcan eliminate or reduce equipmentdamage

The high frequencies at which

cavitation can be detected areoutside the normal range of pumpoperating frequencies so Wilcoxondeveloped a sensor tuned to thesehigher frequencies


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Wilcoxons products

Accelerometers

4-20mA vibration sensors

Transmitters, alarms andcommunication

Intrinsically Safe (IS) sensors

Cables

J unction boxes


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Dual output accelerometer - 786T

A single sensor monitors bothtemperature and vibration at thepump bearing

Full dynamic spectrum

Hermetic seal and stainless steelconstruction for use in the harshestenvironments

Intrinsically Safe (IS) versionavailable


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Underwater accelerometers 757 and 746

Perfect for lower bowl bearingvibration readings

Usable on submerged pumps at

depths up to 1500 feet (457 meters)

757 corrosion resistant case andarmor braid cable ensures longevity

757 biaxial sensor measures vibrationin two directions

746 titanium case is excellent forcorrosive environments such as seawater


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Integral cable accelerometer 786F

Ideal for submerged (30 feet or 10meters typical), high temperature, or

corrosive environments

Integral cable eliminates possibility ofcontamination

Use in awkward locations whereconnector failure is a concern

Intrinsically Safe (IS) version available


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4-20 mA vibration sensors

Monitor your pump on your existingPLC/DCS/SCADA network

Standard frequencies measure between

4 Hz and 2000 Hz

Optional banded frequencies measurebetween 3 Hz to 40 Hz or 300 Hz to2000 Hz

Focus on your equipment's fundamentalrunning speed or monitor specificproblems

Intrinsically Safe (IS) version available


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Complement a standard accelerometers dynamic output with the iT

Series of 4-20 mA transmitters, alarms, and communication modules

The Intelligent Transmitter (iT) Series

The iT Transmitter convertsdynamic vibration data to 4-20 mA data

The iT Alarm notifiesmaintenance professionalswhen vibration levels get too

high

The iT CommunicationModule transmits vibration

data to any PC


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Sensor networks: cables, mountingaccessories and hardware

Wilcoxon manufactures a fullline of cables, mountingaccessories, power supplies,

junction boxes, switch boxes,and enclosures to provideyou with a complete sensornetwork


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Precisely what you need

Thank you

For more information, please contact Wilcoxons

customer sales and service team

+1 301 330 8811

[email protected]


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Confidentiality agreement

The information contained in this document is the property of Wilcoxon Research and is

confidential and/or copyright material. This information and this document may not be used or

disclosed without the express authorization of Wilcoxon Research. Any unauthorized use or

disclosure may be unlawful. The information contained in this document may be subject to the

provisions of the Export Administration Act of 1979 (50 USC 2401-2420), the ExportAdministration Regulations promulgated thereunder (15 CFR 730-744], and the International

Traffic in Arms Regulations (22 CFR 120-130). The recipient acknowledges that these statutes

and regulations impose restrictions on import, export, re-export and transfer to third countries of

certain categories of data, technical services and information, and that licenses from the US

Department of State and/or the US Department of Commerce may be required before suchdata, technical services and information can be disclosed. By accepting this document, the

recipient agrees to comply with all applicable governmental regulations as they relate to the

import, export and re-export of information.


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VIbration Monitoring of Pumps