Predictive Maintenance of Pumps Using Condition Monitoring (eBook)

Front Cover 1
Predictive Maintenance of Pumps using Condition Monitoring 2
Copyright Page 3
Contents 4
Preface 8
Chapter 1. Condition monitoring and its part in maintenance 12
1.1 The purpose of maintenance 12
1.2 The basic types of maintenance 13
1.3 The machine life cycle 15
1.4 Condition monitoring 16
1.5 The techniques of condition monitoring 18
1.6 The benefits of condition monitoring 22
1.7 Organising for performing condition monitoring 24
1.8 Leading edge maintenance management 24
References 27
Bibliography and other resources 28
Chapter 2. Pump performance and the effect of wear 32
2.1 Pump performance characteristics 32
2.2 Effects of internal wear on pump performance 35
2.3 Relationship between internal wear and efficiency 39
2.4 Rate of wear 40
2.5 Pump selection reliability factors 42
2.6 Case studies in detected performance shortfall 43
References 44
Chapter 3. Performance analysis and testing of pumps for condition monitoring 46
3.1 Performance analysis needs performance data 46
3.2 Temperature 47
3.3 Pressure 48
3.4 Flow 52
3.5 Speed 57
3.6 Power 58
3.7 Efficiency calculation 58
3.8 Pumps in systems and relationship to CM 59
References 65
Chapter 4. Performance analysis and its application to optimise time for overhaul 67
4.1 The Head-Flow test at duty point 67
4.2 The Shut-off Head method for monitoring of pumps 71
4.3 How to calculate the optimum time for overhaul 72
4.4 Optimisation using shut-off head test results 77
4.5 Example to try 78
References 79
Appendix 80
Chapter 5. Other methods of performance analysis for pump condition monitoring 83
5.1 Introduction: simple parameters 83
5.2 Measurement of the balance device leakoff flow 84
5.3 Case Study: Balance leakoff flow method 85
5.4 Some other experience with the balance-flow method 87
5.5 Thermometric testing 88
5.6 Head-Power Characteristics 91
References 92
Chapter 6. Vibration analysis of pumps–basic 94
6.1 The scope of vibration analysis 94
6.2 How vibration is measured and used 95
6.3 Assessing the severity of vibration: general severity assessment 99
6.4 Specific vibration severity standards for pumps 103
6.5 Use of overall vibration levels 107
References 110
Chapter 7. Vibration analysis of pumps – advanced methods 112
7.1 Finding the vibration frequency 112
7.2 Using the vibration spectrum 117
7.3 Vibration phase angle 118
7.4 Resonance 119
7.5 Rolling element bearings 120
7.6 Diagnosis of machine condition and faults 121
7.7 Vertical pumps 135
7.8 Effect of internal wear on vibration 135
7.9 Control of vibration 136
7.10 Setting band levels for monitoring 138
7.11 Permanent monitoring of pumps 138
References 142
Bibliography 145
Chapter 8. Other uses of condition monitoring information 146
8.1 Tuning a pump system 146
8.2 Impeller trimming: Medium size pump – 132kW 147
8.3 Impeller trimming: Large size pump – 1320kW 151
8.4 Condition monitoring of shaft seals 153
8.5 Monitoring of seal-less pumps 154
References 155
Chapter 9. Other condition monitoring methods 157
9.1 Visual inspection 157
9.2 Non-destructive testing 158
9.3 Analysis of wear debris in lubricants 159
9.4 Other methods of condition monitoring associated with pumps 163
References 164
Chapter 10. Positive displacement pumps 166
10.1 Introduction 166
10.2 Performance characteristics 167
10.3 Condition monitoring by vibration analysis 168
10.4 Condition monitoring by performance analysis 169
10.5 Condition monitoring by analysis of wear particles in liquid pumped 171
References 171
Chapter 11. Case studies in condition monitoring of pumps 173
Index 186