The Pump Condition Monitoring Engineering Essay

The warmness material body supervise Engineering EssayTo avoid unplanned down era, realize ability nest egg or other considerations, mettle users require a order or tool to see to it the set aside time for overhaul of a pump.This method or tool is utilise by rail management locomotiveers in managing assets to provide energy for riposte and energy efficiency to save ope pasture expenses or compensate to minimize greenhouse impact. This optimization method t crude oilet be use to all items w here(predicate) deterioration results in equipment breakdowns or loss of efficiency. substances analogous whatsoever rotating instrument tend to rotate in response to excitation forces break bulge out c atomic number 18 residual rotor unbalance, turbulence in liquid be given, tweet pulses, cavitations and get in of pump. If vibration frequencies and natural frequencies match, resonance occurs, amplifying the vibrations. This is a sufficient cause to suffering pump component swhy Pump check up on supervise is important (Source http//www.pumpmonitor.com)Pumps argon apply at about 20% of the worlds or so electrical proponent generating companies.about 7% of the worlds green houses gas drudgerys.power and preservation unremarkably covers more than 50% of support sequence expenses.Statistics show that 20% or more of the energy devoted by pumping strategys could be saved end-to-end equipment and mesh bowdlerises.Pumps atomic number 18 frequently considered critical mechanism of a member. whole kit depend ability is best possible when they ar maintained on a regular basis or nonstop state supervise. death penalty base precaution make ups ar considerably lesser than a instrument based bells.Hence it becomes real important to Condition Monitor the pumps.Chapter -2 end ObjectivesThe object of this research study is to critically study Condition monitor of both, outward-moving and axial pumps. That allow for include almost important aspects wishCondition observe and its percent in nourishmentPump Performance and the Effect of take inPerformance abstract and Testing of Pumps for Condition observePerformance Analysis and its Application to Optimise Time for Overhaulformer(a) Methods of Performance Analysis for Pump Condition MonitoringVibration Analysis of PumpsOther Uses of Condition MonitoringOther Condition Monitoring Methods peremptory geological fault PumpsCase StudiesChapter -3 Project planAttached with this shroudChapter -4 creative activityAbout PumpsPumps atomic number 18 utilize to add energy to unruffleds. Generally it is make by using a rotating blade to force a melted in a given draw a bead onion.Classification of pumpsPUMPSCentrifugal Pumps prescribed Displacement PumpsRadial pass PumpsAxial F little PumpsReciprocating PumpsRotary PumpsGear Pumps speculator PumpsProgressive Cavity PumpsPlunger PumpsScrew PumpsDiaphragm PumpsLobe PumpsFigure-1 Different emblems of Pumpsa) Positive Displacement pumps A positive displacement pump, as the name suggests, pushes a nomadic by containing a fixed amount of it and then displacing the full(a) contained volume into the pipe. Positive displacement pumps produce a constant range at any given locomote and hence argon called ceaseless Flow Machines. These atomic number 18 used for pumping liquifieds other than water. pastime types of mechanism are used to displace the fluida1) Reciprocating Type Reciprocating pumps are plunger pumps or diaphragm pumps. Diaphragmvalves.Recently used for slurries treatment in bases, and are used to force dangerous, toxic materials.a2) Rotary Type These pumps use revolution principle. These are mostly used in, oil burners, soaps, cosmetics, sugars, syrup, and molasses, as well in dyes, ink, bleaches, vegetable and mineral oils.Gear pump Two gears rotates in a closely fitted casing. A unwashed application of the gear pump is the engine oil pump in car engines.3655-004-DFDC07E0Figure-2 Gear PumpProgressing cavity type pump These are applied for pumping sewage sludge contaminated with queen-sized particles. Helical shaped rotor is used.Figure-3 Progressive Cavity Pump, (Image Source http//www.high meltpumps.com/)Lobe Pumps smooth-spoken is passed amidst the rotors teeth and the volute chamber.lobetheFigure-4 Lobe PumpScrew Pumps Screw pump transmits fluid into the spaces between the screw gears.screw23muthsFigure-5 Screw Pumpb) Centrifugal pump They are widely used in general piping organisations. These are used for pumping water in industry and constitute 75% of pumps installedb1) Radial Flow PumpIn a Radial Flow pump, fluid is complete in a direction perpendicular to the direction of intake or suction. The fluid flowing into the pump early makes contact with a spin impeller. This deflects the fluid out-of-door from it. The fluid is pushed out through a street arab casing around the impeller. In this case fluid air pressure increase non the speed.Fluid i s sucked into the pump on the axis of rotation of the impeller. It is quicken in a perpendicular direction into a diffuser chamber. From here it is throwd into the outlet pipe. Centrifugal pumps are applied where there is lessened head and abundant dismission is required. These have high hydraulic efficiency.These are used in waste treatment plants. Screw type centrifugal pumps are real effective in sludge handling , comprising of ropy elements and for handling sludge with up to 10% dry matter .centrifugalpumps11Figure-6 Centrifugal Pump (Image source http//www.thomasnet.com/articles/ regard/centrifugal-pump.jpg)b2) Axial flow pumps In an axial pump, the discharge and suction are both in the equal direction. Flow is along the axis of the blade. Axial pumps are used to increase of speed of fluid flow without increase of pressure. They have high flow rates and nooky operate at very low pressure.QZ-Axial-Flow-PumpFigure-7Axial Flow Pumphttp//www.made-in-china.com/image/2f0 j00vBjTwGKSSIbeM/QZ-Axial-Flow-Pump.jpgChapter -5 livelihood and Condition MonitoringAbout MaintenanceThe intention of do caution is to provide optimum capacity of production at the begin comprise. Maintenance should be preferred for dependableness and not as repair. at that place are 4 Types of Maintenance, which are given below(a) Preventive Maintenance This type of sustainment prevents failure from occurring. It comprises of plan periodic guardianship checks. much(prenominal) maintenance prevents breakdowns and ensures delay free functioning.The advantages of preventive maintenance include deepen systems dependability. come downs salute of substitute.cuts system downtime.Better standby account management.(b) Corrective Maintenance Maintenance fulfiled to correct an mistake after a failure has occurred is disciplinal maintenance. The failed component whitethorn require restoration , repair or replacement.(c) equipment failure Maintenance If a mold breaks down or ma lfunctions , breakdown maintenance is performed to return it to normal functioning. This is done by replacing or repairing parts.(d) prophetic Maintenance This type of maintenance consists of methods of observing the develop of in supporter utensils and thus predicting when maintenance is required to be performed. This method reduces cost as compared to preventive maintenance as tasks are only performed when necessary.Condition observe is a type of predictive maintenance. It involves prediction of civilize of a machine by on observe its military operation, statistical process control or equipment behaviour to detect defects at an early stage and rectify them, which could otherwise result in delays leading to unnecessary expenditure.Maintenance is performed dapple the machine/ equipment is in operating regularly , with little or no severance in its functioning. The methods for detection of errors include infrared thermographs, circuit analysis, analysis of vibrations an d so ontera Predictive Maintenance or Condition monitor a wound way to reduce downtime and reduce cost.The fundamental purpose of maintenance is to head for profit objectives, by maximizing the production and safety of people and plant.This report will explore how maintenance should be used as a tool to keep pumps working to its optimum level.Condition based maintenanceDefinition of Condition MonitoringCondition supervise is part of maintenance, not something done by experts from outside (Beebe, 2001)Signs of degradation are detected in operational equipment by monitor the equipment through continuous direction. Data self-contained is analysed , and a prediction is made for the duration in which a machine elicit run safely without failure.Condition Monitoring is the art of observe of the equipments health by takingsimple measurements of the machine performance. It works the same as aDoctor checks (measure) the health by checking pulse, temperature,blood pressure and so onof a person.If we measure the current draw and the outlet flow of a pump and find out that that the current draw was increasing while the outlet flow was decreasing, as compared to the previous months measurements, there are very good chances that the delineate is deteriorating and that some maintenance was due for the pump,The scheduling of the monitoring is decided by the size of plan, ease of info collection etc. This may be done bothday, once a month or on an annual basis.Advanced technology may be used for delimit monitoring. It may not be limited toVibration sensors unseeable ThermographsOil sensorsUltrasonic equipmentMotor Current AnalysisPump carriage cycle bePump life cycle cost is delimit as the sum of the commissioning cost, maintenance cost, running cost and decommissioning cost for the period of a pumps service life.Complete understanding of the pumps lifecycle cost helps us to radically reduce the energy consumed , thus greatly reducing the pumps environmental i mpactPLCC = Cin + Cins + Cpo + Cop + Cm + Cd + Cen + CdcPLCC = life cycle costCin = initial cost, purchase price (pump, system, pipe, other services)Cins = installation and commissioning cost (including training)Cpo = power consumed costsCop = operation costsCm = maintenance and repair costs (routine and predicted repairs)Cd = delay costs (loss of production).Cen = environmental costs (contamination from pumped liquid )Cdc = decommissioning (counting renovation of the home Environment)Maintenance equal of a Pump in its Life CycleFigure-8 Maintenance Cost (Image Source http//www.waterworld.com)The costs for maintenance are dependent on the actual equipment involved , records stinkpot be consulted to make cost estimates. The annual cost has to include the side by side(p)Value of spare parts used.Charge for any third ships company work.plant employment.workplace charges.Normally Maintenance cost of a Pump within its life cycle is estimated 20%.Pump selection dependableness factor sReliability of machines, has been increasingly debated in recent years . Low reliability of commonly used centrifugal pumps has been a focal point of this debate.Pump selection is very important its reliability. But it is not the only factor for reliable pump operation.Other critical installation parameters are similarly important. The main factor for enhanced reliability is selecting the right pump.Pump selectionThe first step in pump selection is deciding the pump parameters. The head and capacity required have to be channelised. There are three major conditions related to reliability which affect selection operating speed (FR), impeller diameter (FD) and flow rate (FQ).Operating Speed rpm (FR) Wear based on operating speed caused due to corrasion in rubbing contact surfaces like mechanical seals and jockey seals affects the reliability. Life of bearings and heat generated in bearings is another cause for lack of reliability. For all the preceding(prenominal) mentioned con ditions wear has a linear relationship with the operating speed of the pump.Impeller diam (FD) The impeller exerts a signifi send packingt load on the shaft and bearings . This directly affects the reliability of the pump. Two types of loads are produced one is due to the non uniform pressure distribution in the casing, the due south is due to the interaction between the blades of the impeller and the discharge.This second effect is extremely hazardous as it forces the seal faces to move away from each other repeatedly during each revolution. The intensity of this movement may be greater than steady deflection. There is a cubic equipoise between these loads and the impeller diameter.Flow Rate (FQ) The flow rate of a centrifugal pump is the best efficiency point or BEP. Pumps are designed in such a way that they are most reliable only at a given flow rate for a specific operating speed and impeller diameter. The loads exerted on impeller at this flow rate are minimised. If the flo w rate is more or less than the BEP than the load intensity increases and there is turbulence in the rotation of the impeller. Such unpredictable loads share the same effects on reliability as the impeller/discharge loads discussed above. Pumps are examined to check the ability to withstand the effects of these impacts. The main parameters of the tests areR.P.M.Impeller dimensions.Flow velocity.Pump shaft to motor alignment.N.P.S.H. Margin.Reliability Index (RI) The Reliability directory is shaped as a product of three factorsRI = FR x FD x FQValues depart from zero to one the higher the value the better the dependability is.proficiencys of Condition MonitoringVibration Monitoring Analysis is commonly used as a Monitoring analysis. It helps to determine the structural stability in a system. It is best suitable for rotating machines like pumps. Vibration step instruments are used for measurement.The relative frequency of the vibrations are mapped. If a defect is present a concomi tant frequency will be detected. Analysis made previously on existing equipment can be compared to analysis on new equipment. This selective information will give the condition of the equipment.vibrationFigure-9Vibration Chart(Source http//www.pemms.co.uk/Condition_Monitoring.html)Visual surveillance Devices like mirrors, TV Camers are used for Visual inspection.Visual inspection in its most basic form may besides be done by experienced inspectors and maintenance technicians. Causes of failure like cracks, leaks and eroding can be detected and prevented. This is the cheapest form of condition monitoring. It also adds a sense of attachment between the equipment and the people who work on it. moreover opthalmic inspection technique is not enough. It should be augmented by other techniques.Performance Monitoring and Analysis Analysis is done on usage of energy, as more energy usage means deteriorating condition of the machine. Performace can bne measured with parameters like Press ure, flow rate or temperature etc.Analysis of wear particles in lubricants or contamination of process fluid This process gives advance warning than many other predictive maintenance methods.oilanalysisFigure-10 Contamination of Process Fluid(Source http//www.pemms.co.uk/Condition_Monitoring.html)Spectrographic oil analysis may be used to test the chemical composition of the oil. Chemical analysis of oil is carried out for appearance, density, viscosity, moisturecontent, mechanical impurities. High silicon content points to a presence of contamination of grit.. etc, and high iron levels depute to tiring components. Independently, elements give reasonable indications, but when used together they can accurately determine the failure modes, e.g. for internal combustion engines, the presence of iron/alloy, and carbon would indicate damaged piston rings. (Source http//en.wikipedia.org/wiki/Condition_monitoring)Ferrous and non ferrous particles in the lubricant may be detected by wear de bris detection sensors which can give a warning if the condition of the equipment deteriorates. This system prevents failure in machines like gearboxes , turbines, pumps etc.Ultrasonic Analysis Time and frequency selective information from ultrasonic tests can reveal a lot on the health of a machine.Portable ultrasonic interrogation equipment is now a common tool for noticing leaks, testing steam traps, finding cavitations, bearing condition testing and toughness testing.What are sonography Signals?Ultrasound refers to noise of frequency beyond the range of the human ear. For detecting airborne leaks, the frequency at which the most sound is produced by an unstable leak is 38.4 kHz. There are instruments, which listens to this frequency to detect leaks.Electronics processing is required to make ultrasound audible. This is done filtering of frequencies.Why Record Ultrasound Signals?Judgment, Trending, verification of analysis.Guidance of Maintenance observers.Examination of low spe ed bearings.Investigation of electrical defects.Inspecting of steam traps.Analysis of reciprocating compressors.How to Record Ultrasound Signals?Regulates rise of detector.Corrects level of recording device.Spins Auto Gain Control .Records the foreshadow and transfer to PC.Opens predicts in computer for laboratory analysis.The classic time signal for a bearing defect gives a goldfish envelope like this. (Thomas J. Murphy)ultrasound_analysis_07Figure-11Ultra sound signalsInfrared ThermographyTemperature is the best indicator of the state of a machine. One can check the temperature of any surface and determine the condition of a machine..Infrared Thermography is an inspection technique which gives accurate, reliable and correct temperature adumbrate of any material exterior without getting in touch with the surface.The essential perceptive of thermography is that every object produces certain amount of Infrared energy and the intensity of this radiation is a task of temperature, h ence by measuring infrared radiation, temperature of surface can be calculated. (Garnaik)Infrared thermography is a dissolute and secure way of detecting imperfections in different conditions. Infrared cameras can be used to detect increases in temperature that indicate latent problems. These may increase the temperature of electrical contacts or insulators. IR thermography can soft be carried out during normal operation of equipment as it is non contact. This reduces downtime.Advantages Disadvantages of IR ThermographyFollowing are advantages and disadvantages of this technique.Advantages It is a non-contact type technique, and modern Infrared camera can be used . It is Fast, reliable accurate output. Time required to measure large surface area is very less. The output can be presented in visual digital form. Since the output can be presented in visual form, there is little skill required for monitoring.Disadvantages Instrument cost is very high. This technique is used to wor k out the temperature of surface. It is unable to detect the at bottom temperatureNoise monitoringNoise level are taken every month at designated locations.Steps for implementation of Condition Monitoring Technique for PumpsSelection of equipmentSelection of parameters / probeSelection of monitoring frequency supplying of schedulePreparation of database.Actual monitoring and analysisSelection of monitoring frequencyDaily (for critical equipments)Fortnightly (for sub critical equipments).)Figure-12 Condition Monitoring StepsBenefits of Condition monitoringCondition monitoring has become a proved method and has become essential part of industries as companies has proven its cost benefits.Condition monitoring gives early detection of wear out/damage.Condition Monitoring people tour the plant and picks up create faultsDeterioration is detected in time and repairs are scheduled.It minimises unnecessary cloture and opening up of plantCost of labour, material and loss of production is savedMore satisfying work of maintenance, less effect of errors because of direct feedback of quality work.Judicious use of Condition monitoring can yield 10 to 20 times the initial outlay within first year (IK Dept trade Industry report, maintenance to late 1990s)Condition monitoring reassurance of safe continued operation(and vary effective when nursing on plant to a suitable maintenance opportunity)Condition Monitoring saves cost reduce spare usage and lower insurance.Cost Savings from Condition MonitoringA Quick cost saving estimate is made to calculate the cost saving easily. Quick cost saving estimate at each inspection saves delays. For example, a coupling is found broken and rocky to cause about 2 hours of delay leads to an unplanned maintenance job.The countingCost A If the coupling broke down without warning handle * Cost of Delay/hr + Direct maintenance cost (unplanned Unscheduled) + potence damagesCost B Maintenance during scheduled shutdown.Actual cost of maintena nce Delay (if any should be fixed in scheduled shutdown) * Cost of Delay/hr + direct maintenance cost (planned scheduled) + Damages(= 0) .A- B = Cost saving, which may be as high as thousands of DollarsFollowing is a Case study of Qatar oil color, which shows a huge saving of costs because of Condition MonitoringCase Study141. K0302 FLUE GAS strike outCurrent Drawn before balancing the Fan 83 type ACurrent drawn post balancing the fan 76 type ANet Current reduction 7 Amps(Hourly Average)Power Saving = 3 x V x I x Cos 3 x 11 x 7 x 0.85KWhAnnual Cost Savings = 113.3X0.081X24X365(Power Cost = 0.081QR/Kwh) = 80393 QR/YearLast Six Months Predicted Failures at Qatar PetroleumStandards used for condition monitoring (Source http//www.iso.org)ISO 13381-12004 provides guidance. The basic purpose is toLet the clients, manufacturers of condition monitoring and symptomatics systems to share general thoughts in the fields of machinery error analysis.Allow users to determine the essential cultivation, characteristics and behaviour necessary for accurate estimate.Outlines an appropriate approach to predict development.Introduces predictions concepts in order to ease the development of emerging systems and training.ISO 18436-62008 Condition monitoring and diagnostics of machines Prognostics Part 1 General guidelinesISO 18436-62008 states the call for for reserve and evaluation of personnel who perform machinery condition monitoring and diagnostics using acoustic production. A certificate or declaration of abidance to ISO 18436-62008 will provide credit of the qualifications and ability of individuals to perform acoustic production measurements and analysis machinery condition monitoring using acoustic emission equipment. This turn may not apply to peculiar(a) equipment or other definite situations. ISO 18436-62008 specifies a three class assortment programme.ISO 18434-12008 provides an introduction to the application of infrared thermography (IRT) to machinery condition monitoring and diagnostics, where machinery includes machine auxiliaries such as valves, fluid and electrically powered machines, and machinery-related heat ex falsifyr equipment. In addition, IR applications pertaining to machinery performance appraisal are addressed.ISO 18434-12008 introduces the terminology of IRT as it pertains to state checking and diagnostics of machines explains the types of IRT procedures and their qualities provides leadership on establishing cruelty appraisal criteria for anomalies identified by IRT outlines methods and requirements for carrying out IRT of machines, including safety suggestions provides information on data understanding, and appraisal criteria and reporting requests provides measures for determining and compensating for reflected obvious temperature, emissivity, and attenuating media.ISO 18434-12008 also includes testing procedures for determining and recompense a reflected obvious temperature, emissivity, and attenuating media when measuring the exterior temperature of an aim with a quantitative IRT camera.ISO 18436-32008 Condition monitoring and diagnostics of machines Requirements for qualification and sound judgement of personnel Part 3 Requirements for training bodies and the training processISO 18436-32008 defines the requirements for operating training programmes for personnel who carry out machinery condition monitoring, have it off machine faults, and propose corrective action. Procedures for training of condition monitoring and diagnostic personnel are specified.ISO 18436-72008 Condition monitoring and diagnostics of machines Requirements for qualification and assessment of personnel Part 7 ThermographyISO 18436-72008 specifies the requirements for qualification and assessment of personnel who perform machinery condition monitoring and diagnostics using infrared thermography. An official schedule or declaration of conventionality to ISO 18436-72008 will provide recognition of the qualifica tions and competence of individuals to do thermal measurements and investigate machinery condition monitoring using transportable thermal imaging equipment. This procedure may not apply to particular equipment or other precise situations. ISO 18436-72008 specifies a three category classification programme.ISO 13373-12002 Condition monitoring and diagnostics of machines Vibration condition monitoring Part 1 General proceduresISO 13373-22005 Condition monitoring and diagnostics of machines Vibration condition monitoring Part 2 Processing, analysis and presentation of vibration dataISO 13373-22005 recommends actions for dealing out and presenting vibration data and analysing vibration signatures for the reason of monitoring the vibration state of rotating machinery, and performing diagnostics as suitable. Different methods are described for different applications. Signal improvement techniques and analysis methods used for the investigation of exacting machine dynamic phenomena a re included. Many of these techniques can be applied to other machine types, as well as reciprocating machines. typesetters case formats for the parameters that are commonly plotted for valuation and diagnostic purposes are as well given.ISO 13373-22005 is divided basically into two essential approaches when analysing vibration signals the time domain and the frequency domain. Some approaches to the modification of diagnostic results, by ever- changing the operational circumstances, are also covered.Pump Performance and the Effect of WearPumps wear as they are used but their efficiency can be maintained byCondition monitoring and accordingly returnFigure-13 Effect of wear on pump characteristicsSource http//re.jrc.ec.europa.eu/solarec/index.htm (European commission formulate Research Center)Figure-14 Average wear trends for maintained and unmaintained pumpsSource http//re.jrc.ec.europa.eu/solarec/index.htm (European commission joint Research Center)Effect of internal wear on pum p performanceThe effect of Internal wear on pump is dependent on type of Pump . Slurry pumps are Designed to cope with erosive liquids. good operating cost can be reduced by up(p) wear life. Wear is increased by High Velocity, large unscathed size and high concentration.Chapter -6 Performance Analysis and Testing of Pumps for Condition MonitoringThe aims of testing a systems pump performance are toRecord system pumps performance.Verifying the impeller size at present installed in the pump.Launch the system reduce for the pumping system.Establish the operating point of the pump i.e. the point where the pumps impeller curve intersects the system curve with the discharge valve throttled and with the discharge valve fully open.Measures the match between full flow flow delivered by the pump with the discharge valve fully open and the real plan flow requirement.Considers the implications of throttled discharge valves and opportunities to open discharge valves and adjust pump performa nce by means of trimming the impeller, changing the motor to get an incremental motor/pump speed change or installing a VFD to change the motor/pump speed to a non-incremental value. The objective of all of these modification techniques is to provide design flow without the head forced by the throttled valve. As a consequence, the system will advantage from reduced pump energy use and operating costs.Considers the flow variations produced in the system as different active elements are repositioned by their control processes.becomes aware of and make a diagnosis of other control or performance problems.Performance analysis needs performing dataTemperaturePressureFlowSpeedPowerEfficiency CalculationFigure-15 Pumps in System and relationship to Condition MonitoringChapter -7 Performance Analysis and its Application to perfect Time for OverhaulThe head test at Duty full pointLike it is known that condition monitoring is used as a tool for Predicting maintenance requirements of pumps. The idea Flow examination is the essential way can be used to inspect assumed poor performance. (http//www.engineeringnet.be)Head flow measurement is a useful type of condition monitoring because it checks pump deterioration and also shows flaws in system resistance.. (Heinz P. Bloch)It is easier to determine the head. alter in volume according to the time can be easily measured if an appropriate vessel i