Pump Condition Monitoring - Lab Report Example

CONDITION MONITORING AND FAULT DIAGNOSIS Name: Instructor: Course: Institution: Date: Condition monitoring and fault diagnosis Task 1 Part 1: Equipment’s operation and construction materials Centrifugal pump operational characteristics A centrifugal pump in normal circumstances provides a low-pressure increase in the coolant. When the centrifugal pump is operating at a constant speed, the increase in the pressure on the flowing coolant, results in a reduction in the level and magnitude of the volumetric rate of flow that can be maintained by the centrifugal pump. The centrifugal pump contains encompasses blocks and heads, a drive belt impeller which helps in the circulation of the coolant and a thermostat mechanical that controls the temperature levels to avid leakages and corrosions, radiator to help cool the coolant and a radiator cap transmitter that helps to control the air pressure of the coolant and data loggers which helps indicate the temperature and vibration values and the condition of the system parts. Additionally, the centrifugal pump contains bearings that help in the circulation and movement of the condition monitoring parts either backward or forward. The analysis of the co-relationship that exists between the volumes that the centrifugal pump can maintain, and the volumetric flow rate as well as the pressure differential across the centrifugal pump revolves around some physical characteristic of the system fluid and the pump. The variables used in conditioning and monitoring of a centrifugal pump are based on power supplied to the pump, the efficiency of the pump, diameter of the impeller, blading and the rotational speed. See Fig 01 below: shows the interior of a centrifuge pump. Centrifuge image interior Fig: 01 Working of induction motors It is well known that Induction motors are some of the most commonly employed electrical machines1. Additionally, as compared to the other electrical alternatives, they are more rugged, easier to maintain and cheaper. The induction motor that is employed in this cooling machine is a three-phase induction motor. An induction motor is basically made up of two parts namely the Rotor and the Stator. By definition, the Stator is the induction motor’s stationary part while the Stator is primarily the rotating part as shown below in Figure 1 Figure 1: Stator and rotor of an indicator It is acknowledged that, whenever a three phase AC current goes through the motor winding, it produces what is commonly known as RMF (a rotating magnetic field)2. The magnetic field produced is rotating in nature and is a very crucial concept when it comes to electrical machines as shown below3. In the induction motor used in the cooling machine, a more similar scenario is witnesses. However, instead of a simplified loop, a squirrel cage is employed which is made up of bars that are made short by end rings. Figure 5: A squirrel cage motor When a three phase current passes through the induction motor’s stator, it produces a magnetic field that is rotating in nature. In this case, the current will be directly induced in the motors squirrel cage making the motor start rotating4. Moreover, the variation of the current can be easily noted in the motor’s squirrel cage bars5. In simple terms, the variation in the induced current in the squirrel cage bars is due to the magnetic influx change in one squirrel bar which is primarily different in orientation to the next squirrel cage bar. But the variation speed will change over time. By way of explanation, the name induction motor emanates from the fact that no direct current is used but rather an induced current. To help such a vast electromagnetic induction in the motor, inside the rotor, insulated lamina basically of an iron core nature is packed as shown below. Figure 6: Insulated iron core lamina . Part 2: Potential problems and faults that would occur with this equipment in the marine environment Potential failure Probable cause Method of detection Worn bearings Failure to lubricate Age Stress Increased vibration Increased noise Increased heat Worn mechanical seal Age Stress Misaligned shaft Worn bearings Leaking seal Damaged impeller Age Stress Cavitation Suspended solids in liquid Increased vibration Increased noise Reduced pump output The level and extent of the failure of the cooling system depend on the cooling system’s principle as well as its operational technique. Additionally, to curb these environmental consequences caused by the failure of the cooling system, proper design, and appropriate selection technique is employed6. However, a water pump impeller may fail and cause the engine motor to start overheating. This may be caused by lack of enough water flow in the impeller system, or maybe the water cooling system is operating in a marine environment that is filled with weeds and grasses, the condition and monitoring device helps detect this problem through increased vibration, increased noise and the overall reduction in the output of the pump. In simple terms, system failure and breakdown, normal winterization of the cooling system is needed to inspect all coolers for blockage. Worn out bearings is another potential failure that may occur in a water pump cooling machine. Additionally, this may be caused by failure to lubricate, stress, or age, this may be detected though increased vibration and temperature a mechanical seal failure is another potential failure that may be caused by broken or misaligned shaft. To help monitor this situation, the motor of the cooling system is designed in such a way that the tubes in which the coolant circulates are cooled which in turn cools the object they contain. In this case, the coolants are designed such that they allow both dry and wet operation to curb visible plume formation. Other common failures of the water pump cooling system include the noise, vibration, the erosion, corrosion, pressure variation, speed change, flow reduction and the oil debris. Task 2 Part 1: Condition monitoring system equipment’s design The conditioning and monitoring system of the cooling system are made up of some sensors, transmitters, data loggers and indicators coupled with a fluid that cooperate to detect in failures and ensure that the engine of the cooling system is operating at optimal temperatures and air pressure as well . The conditioning and monitoring system encompasses blocks and heads, a drive belt which helps in the circulation of the coolant and thermostat temperature sensors that control that can be employed in detecting any increase in bearings temperature, motor bearings, impellor housing and windings using its infrared sensors.. Additionally, Vibration sensors are employed in detecting the acceleration of the shaft incase the bearing breaks down. In simple terms, these vibration sensors should be fitted just next to the bearings at 90 degree rotation so as to capture and horizontal and vertical acceleration. The coolant that goes through the cooling system withstands extreme cold and hot temperatures and possesses rust lubricants and rust inhibitors that ensure that the water pump cooling system is running smoothly7. The coolant in the system goes through a circulating path that starts with the cooling system’s water pump. In the Water pump, there is a transmitter known as the impeller which employs centrifugal force to attract the coolant from the radiator to the engine block. Additionally, the presence of a sound analyzer is used to analyze any increase in noise or sound in case the impeller breaks down. The water pumps are in the most cases serpentine timing belt, fan or timing chain driven by a three phase AC induced current. In the case of a leakage, the conditioning, and a monitoring device contains an Impeller breakage sensor that is used to detect in failure in the systems impellers which may be causing any potential leakages8. As the coolant passes through the system, it gains heat before arriving at the thermostat sensor that is used to detect the level of the coolant temperatures and in the process allows it to move to the radiator. In this case, the conditioning and monitoring system will work to ensure that the thermostats remain in a good working condition since if it fails to function, the entire water pump cooling system will be affected. Once the coolant is released by the thermostat, it is then the work of the conditioning and monitoring system to ensure that it goes through the hose pipe until it reaches the radiator where it is cooled. The sound analyzer indicator is used to detect the condition of the bearings since a new bearing produces less noise as compared to a worn-out bearing9. In this case, the conditioning and monitoring system ensures that the correct pressure is needed for better lubrication of the water pump seal. Increasing the pressure of the cooling system, in the end, raises the boiling point of the antifreeze. The conditioning, therefore, will ensure that the pressure gauges and the digital data loggers record the level of air pressure that goes through the coolant so as to allow the spring loaded valve to allow effectively the pressure to go out10. Part 2: Merits and Demerits of condition monitoring system parts The water pump conditioning and monitoring system contain some devices that enable it to perform its function clearly. Some of these devices include sensors, thermostat, transmitters, and data loggers. Additionally, the vibration sensors are mechanical, electromagnetic devices using piezorsistive or piezoelectric technology that are devised to determine the tractive effort of the water pumps11. The vibration sensors are useful in detecting increased vibration of the bearings, volute, and impellers which signal a potential failure in vibration condition. The Sound analyzers sensors installed in the water pump have no constant moving parts which make them offer long-term reliability and stability as far as detecting a potential failure in bearings. The data loggers have very dynamic ranges and wide frequency which ensures that they can be effectively be integrated to produce effective displacement and velocity values in case of temperature increase Traditionally, machine maintenance is done whenever there is a machine breakdown or failure. However, the transmitters and sensors have made things easier when it comes to conditioning and monitoring of machines as far as the cost of replacement and repair is concerned12. One striking disadvantage of these features is that most of them are very expensive to acquire and not easy to replace. Some people have gone ahead to argue that, the effect and cost of protecting the conditioning parts are well worth the effort than dealing with unexpected and random damage that occurs without protection. Task 3 Part 1: Data Analysis through vibration and temperature analysis criteria in conditioning and monitoring Vibration data analysis Temperature data analysis Predicative maintenance by using vibration monitoring is a scientific approach that tends to establish itself as the new route to conditioning and monitoring. It is known that machines including the new ones produce some mechanical vibrations13. In this case, small levels of machine vibrations can be taken as normal, but higher vibration levels, as well as increasing trends, are a clear sign of abnormal machine condition. Therefore, machine vibration as an important technique for machine faults analysis and identification is made up of frequency scale analysis and the time domain. In this case, the most preferred form of analysis is the frequency based analysis since it can provide more detailed information about the machine status while the time domain offers qualitative information regarding the machine condition. Using the vibration data as shown in the graphs above, the back bearing does not vibrate vibrates since the average rate of vibration increases and decreases at intervals. The motor bearing is vibrating at increasing levels from week 1 to week 5 and reduces to 5 in week six which can be classified as abnormal vibration. It then continues to increase its vibration as from week 7 to 12 again. Additionally, the pump bearing shows some increasing levels of vibration as from week 5 to week 9 and decreases drastically in week ten where it starts witnessing increasing vibrations. From this data, it can be noted that the front motor bearing and the pump bearing have recorded increasing vibrations levels on some occasions which are a worrying trend when it comes to the condition of the machine. By so saying, it means that, higher vibration levels, as well as increasing vibration levels of a machine, are a clear sign that this machine is likely to breakdown. Changes in the fault parameters such as temperatures may also indicate emerging fault conditions in the machine14. In this case, the temperature values indicate some changes in the motor back bearing, front motor bearing and the pump bearing in a varying velocity and frequency trend over time. Part 2: Possible recommendations and analysis In some instances, the phase and the magnitude of the vibration vector in an unbalanced state might change with time. In such circumstances, the correct conditioning measure is not rebalancing of the machine. In this case, the vibration data shows some imbalances, but it does not go beyond the recommended limit. The temperature also shows some imbalances but it does not go beyond the recommended level by the manufacturer15. It can, therefore, be noted that a machine in such like circumstances can only be deemed to be vulnerable to fault if it displays increasing vibration levels beyond the stipulated level and varying temperatures beyond the stipulated limit. Thus, the values indicate that the bearings recorded low vibration levels in week four and week five which also were the recommended days that the temperature values could be exceeded. To prevent such kind of cases, it is important to ensure that there is no any defective bearing installation, no cases of incorrect loading, ensure that the magnetic pull is balanced, the bearings are always lubricated, and there is no major overheating case. Task 4 Part 1: Online and Offline conditioning advantages and disadvantages From the point of collecting data and periodicity analysis, conditioning and controlling systems used for protecting the cooling systems and diagnostic can be categorized as offline or online systems. Offline systems are those systems that are used on data periodicity, periodic machine maintenance and data analysis based on a periodic time scale that is determined by vibration specialist as well as responsible maintenance managers in charge of maintenance. In this case, the vibration and temperature sensors are only attached to the system when the data is being collected. Additionally, periodicity data acquisition should revolve around the current machine vibration levels. On the other hand, Online Systems are permanently installed monitoring systems with permanent sensors that used for vibration acquisition of signals and analysis16. The system used in such kind of protection must be an online system. All these systems have their advantages and disadvantages. In this case, they can be analyzed regarding investment and how best the investment return is to them. For instance, very critical water pumping cooling system will need an online system that is already installed with surveillance, protection, and diagnostic functions. However, condition monitoring of very simple cooling machines such as fans, pumps can revolve around portable vibration analyzers that are handheld, as well as periodic measurements and analyzers17,18. However, Online conditioning which ensures continuous monitoring of conditioning of the machine may help overcome this limitation by incorporating a condition or predictive based strategy to take effect19. Part 2: appropriate condition monitoring techniques and methods Leaks, corrosions and cracks of the reactor coolant are a clear indication of the poor conditions of the water pumps cooling system20. It is, therefore, important to examine and investigate the operational well-being of the system in such circumstances. Online systems may be challenging owing to the fact that the system does not clearly indicate the environmental impact of the cooling system21. One of the conditions monitoring systems that can be used is the employment of infrared and ultra sound sensors that can be used in detecting potential corrosions and cracks.. For example, avoiding the employment of hygroscopic materials will help curb the water ingress as well as swelling and in the process reducing the probability of incurring corrosions and cracks. Another condition and monitoring techniques that can be used is replacing those components made up of materials that are acknowledged to be sensitive to SCC by those made of less sensitive materials to help detect early cracks occurrences hence reducing leakages22. Part 3: RTF Run to Failure and Planned Preventive maintenance (PPM) By definition, RTF is a strategy that allows the assets to operate deliberately until they fail or breakdown and until the reactive maintenance is conducted. In simple terms, no maintenance or conditioning is allowed to be performed on the assets including preventative maintenance until the clear asset fails23. Under this type of strategy, it is of utmost importance to possess staff and spare parts at hand to maintain equipment availability and replace spare parts. Conditioning and monitoring in this kind of strategy are useful in identifying the assets that on failure does not possess minimal safety risks, and they also have little effect on production. Additionally, RTF has some advantages owing to the fact that it requires minimal planning, and it is easy to understand. However, RTF is unpredictable, inconsistent, and costly and it possesses inventory costs. PPM (Planned Preventive Maintenance) is a maintenance strategy that is regularly performed on equipment to reduce the likelihood of incurring failures or a breakdown. Additionally, Conditioning and monitoring systems may be employed in PPM to help the maintenance and monitoring of the machine while it is still operating so that it may not fail or break down unexpectedly24. Moreover, with conditioning and monitoring ensures that PPM is planned in advance to ensure that the required resources are made available. Regarding operation, PPM is more complex as compared to RTF owing to the fact that the monitoring and maintenance must be planned in advance. On the other hand, it is less complex when compared to predictive maintenance because the results do not need to be interpreted nor monitoring planned in advance. Furthermore, those instruments that are effectively monitored using the PPM strategy have failure or breakdown modes that can be prevented or possess a critical operation function and above all, they have a high chance of breaking down that increases as time goes by. Task Five Part 1: Appropriate sensor and its principle of operation To maintain the reliability of the water pumping cooling system high, some diagnostic or monitoring tools should be used. Additionally, the wear, the vibration, the pressure, the temperature and the flow are the significant condition monitoring parameters used to predict the failures in a water pump25. The most common degradation / deterioration in a water pump cooling system are the noise, vibration, the erosion, corrosion, pressure variation, speed change, flow reduction and the oil debris. In this case, the design and the success of the water pump cooling system condition and monitoring system do not only revolves around how perfect the monitoring software or hardware themselves but rather it depends on correct monitoring integration with the cooling system’s maintenance when both events can be categorized as one. The condition and monitoring system of the water pump cooling system are designed with a particular focus on the systems’ critical areas such as the impellers and the bearings to prevent frequent shut downs, safety problems, reliability issues and hazardous situations. Additionally, the philosophy of operation is also significant for the water pumps monitoring and conditioning Temperature monitoring In a water pump cooling system, the coolant that goes through a circulation path is initiated by the water pump. As the coolant passes through the cooling system, it gains up some heat from the water pump engine before reaching the thermostat. The thermostat contains a thermostat sensor which is a valve that is used to determine the temperature of the water pump’s coolant and opens up to allow the coolant’s hot fluid to move the radiator. Vibration analysis The water pump cooling system’s vibration analysis revolves around the vibrational sensor measurement as well as the comparison to a very advanced dynamic mode to establish the problem which in one way or the other may be an early indication of a potential system failure. The vibrational sensor measurement should take into account all the flexibilities and the main components of the water pump cooling system. In this case, Rotor assembly supports such as bearings, the rotor assembly, the pump casing as well as all the cooling systems’ external support should be established and modeled correctly. In many water pumps cooling systems which employ rolling element bearings, the flexibilities of the support, casing and the bearing make the cooling systems dynamic model more complex. Therefore, a more accurate vibration sensor measurement should be used in determining a more accurate value of the pump’s theoretical model in order to predict the mechanical/bearing/ structural condition of the-the water pump cooling system. Leak Detection The water pump is the main operational system of the coolant system. In the water pump, there is an impeller that is used to circulate water through the cooling system26. One of the weaknesses of the water pump is that they can sometimes be vulnerable to leakages. In this case, whenever the shaft seal breaks, the water pump starts leaking which makes the impeller for failing. The radiator sensors and impellor sensors are used to detect and inspect the engine for any possible leaks. Detecting corrosions and cracks The reason behind the oil/wear analysis can be an early indication of the water pumps cooling systems’ critical condition. In the case, the wear oil sensor alongside the vibration analysis sensor provides the cooling system with the opportunity to monitor the condition of its bearings and possible cracks. A Spectrometric Oil Analysis sensor measurement can be employed to measure and determine the metal quantity in the oil with an intention of predetermining excessive wear particular in those cooling systems that are furnished with the rolling-element bearings. Part 2: Commercially available sensors for each model and cost Temperature sensor Engine coolant sensor which is a Positive Temperature Coolant model (PTC model) Vibration analysis MAP sensor- (PTC model) Leak Detection Mass Flow Sensor (MAF sensor)-ECU model Detecting corrosion and cracks Oxygen sensor which determines the amount of oxygen in the cooling system responsible for causing corrosion (PTC model) Task 6 exercise to carry out real-time Condition monitoring data from the pump I positioned the vibration sensor and temperature sensor at a number of positions in the water pump cooling system and measured the temperature and vibration levels at each position as shown in the table below. Position of sensor Vibration Temperature 1 7.5mm/s 20c 2 6.6 mm/s 19.2c 3 8.14 mm/s 19.2c 4 8.1 mm/s 18.1c 5 6.9 mm/s 17.3c 6 5.3 mm/s 16.7c 7 7.6 mm/s 15.1c 8 7.8 mm/s 15.3c 9 13.2 mm/s 14.7c 10 11.3 mm/s 14.7c Electrical current=1.32AMP S RMP=1352 Part 2 Vibration and temperature analysis The temperature of the monitoring system decreases as we change positions in the water pump which indicates that the condition of the water pump is effective. However, vibration increases with change in positions but temperatures at these positions are not increasing which means that the machine is working effectively. Reference list Bennett, Sean. 2015. Modern diesel technology: diesel engines. Stamford, Connecticut: Cengage Learning Dixon, John. 2014. Modern diesel technology: heating, ventilation, air conditioning, & refrigeration. Clifton Park, NY: Delmar Cengage Learning Erjavec, Jack. 2005. Automotive technology: a systems approach. Australia: Thomson Delmar Learning. Huntimer, Tony E. 2004. How to build & modify GM pro-touring street machines: classic looks with modern performance! North Branch, MN: Car Tech Auto Books & Manuals. Knowles, Don. 2005. Tech one: basic automotive service and maintenance. Clifton Park: Thomson Delmar Learning. Sclar, Deanna. 2009. Auto repair for dummies. http://public.eblib.com/choice/publicfullrecord.aspx?p=380481. Shepard, Larry. 2003. How to hot rod small-block Mopar engines: high performance modifications for street and racing : covers all Mopar "A" engines, 1964-1992. New York: HPBooks. Szilagyi, Jim. 2005. How to build big-inch Mopar small blocks. North Branch, MN: CarTech. Read More

Figure 6: Insulated iron core lamina . Part 2: Potential problems and faults that would occur with this equipment in the marine environment Potential failure Probable cause Method of detection Worn bearings Failure to lubricate Age Stress Increased vibration Increased noise Increased heat Worn mechanical seal Age Stress Misaligned shaft Worn bearings Leaking seal Damaged impeller Age Stress Cavitation Suspended solids in liquid Increased vibration Increased noise Reduced pump output The level and extent of the failure of the cooling system depend on the cooling system’s principle as well as its operational technique.

Additionally, to curb these environmental consequences caused by the failure of the cooling system, proper design, and appropriate selection technique is employed6. However, a water pump impeller may fail and cause the engine motor to start overheating. This may be caused by lack of enough water flow in the impeller system, or maybe the water cooling system is operating in a marine environment that is filled with weeds and grasses, the condition and monitoring device helps detect this problem through increased vibration, increased noise and the overall reduction in the output of the pump.

In simple terms, system failure and breakdown, normal winterization of the cooling system is needed to inspect all coolers for blockage. Worn out bearings is another potential failure that may occur in a water pump cooling machine. Additionally, this may be caused by failure to lubricate, stress, or age, this may be detected though increased vibration and temperature a mechanical seal failure is another potential failure that may be caused by broken or misaligned shaft. To help monitor this situation, the motor of the cooling system is designed in such a way that the tubes in which the coolant circulates are cooled which in turn cools the object they contain.

In this case, the coolants are designed such that they allow both dry and wet operation to curb visible plume formation. Other common failures of the water pump cooling system include the noise, vibration, the erosion, corrosion, pressure variation, speed change, flow reduction and the oil debris. Task 2 Part 1: Condition monitoring system equipment’s design The conditioning and monitoring system of the cooling system are made up of some sensors, transmitters, data loggers and indicators coupled with a fluid that cooperate to detect in failures and ensure that the engine of the cooling system is operating at optimal temperatures and air pressure as well .

The conditioning and monitoring system encompasses blocks and heads, a drive belt which helps in the circulation of the coolant and thermostat temperature sensors that control that can be employed in detecting any increase in bearings temperature, motor bearings, impellor housing and windings using its infrared sensors.. Additionally, Vibration sensors are employed in detecting the acceleration of the shaft incase the bearing breaks down. In simple terms, these vibration sensors should be fitted just next to the bearings at 90 degree rotation so as to capture and horizontal and vertical acceleration.

The coolant that goes through the cooling system withstands extreme cold and hot temperatures and possesses rust lubricants and rust inhibitors that ensure that the water pump cooling system is running smoothly7. The coolant in the system goes through a circulating path that starts with the cooling system’s water pump. In the Water pump, there is a transmitter known as the impeller which employs centrifugal force to attract the coolant from the radiator to the engine block. Additionally, the presence of a sound analyzer is used to analyze any increase in noise or sound in case the impeller breaks down.

The water pumps are in the most cases serpentine timing belt, fan or timing chain driven by a three phase AC induced current. In the case of a leakage, the conditioning, and a monitoring device contains an Impeller breakage sensor that is used to detect in failure in the systems impellers which may be causing any potential leakages8.

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