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Vibration monitoring of pumps, 2008
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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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Vibration monitoring of pumps, 2008
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Contents
Slide
Pumping systems and failures 3
Monitoring specifics 6Monitoring techniques 11
Wilcoxons products 17
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Vibration monitoring of pumps, 2008
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Typical pumping system and itscomponents
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Vibration monitoring of pumps, 2008
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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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Vibration monitoring of pumps, 2008
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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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Vibration monitoring of pumps, 2008
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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
wilcoxon@meggitt.com
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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, 2008
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