Monitoring machine vibration is crucial, particularly for equipment handling harsh materials or chemicals. Kappa X has transformed various sectors, including manufacturing and pharmaceuticals, by providing exceptional vibration and temperature data for clear and concise analysis. The client required a robust solution to monitor circulation pumps with known limited lifespans. Without rigorous vibration monitoring, minor issues could rapidly escalate into major failures, resulting in costly downtime and extensive repairs.
Machinery and Operations
The client possessed a 250 kW Centrifugal pump running at 2771 RPM in an ATEX-zoned area. This pump was involved in a harsh application, mixing sulphuric and nitric acid, and required a special alloy impellor and bowl. Due to the aggressive environment, these components had a known limited lifespan.
Implementation
Kappa X wireless sensors were installed on the pump to monitor vibration and detect any unwanted faults or failures. These sensors transmit short-term tri-axial vibration and temperature readings every 3 minutes. Additionally, spectrum and waveform data are sent every 24 hours, up to a range of 10kHz. This comprehensive data collection provides extensive vibration information to identify and address machinery issues effectively.
The Problem
The image below shows two graphs, one depicting short-term data and the other long-term, each spanning 9 months. This dual approach enables a thorough analysis of both immediate and gradual changes in the machinery's condition, facilitating timely and informed maintenance decisions.
The Short-Term Data indicates a slight increase in G levels, initially reaching 9 G’s PK-PK between December and April. The levels continued to rise between April and August, peaking at 13 G’s. Although these short-term readings were not sufficient to trigger either the warning or critical alarms, the Long-Term Data revealed a concerning trend. G levels increased to 119 PK-PK, raising the critical alarm on several occasions between April and August.
Cavitation occurred in the machine, as the rapid movement of the impellor created partial vacuums in the liquid. This resulted in a spike in the frequency spectrum and an increase in broadband noise from 3-7kHz.
Seeing as the spike in broadband noise is only perceptible between 3-7kHz, Kappa X demonstrates its unique and vital ability to capture extensive machine data and provide additional detail. The Time Waveform data shows consistently high G’s of around 40-80 PK-PK with a spike of 119 G’s PK-PK, related to the pump’s cavitation.
An analysis revealed that the machine’s inefficiency was due to wear on the rotating impellor and pump casing due to the aggressive application. Over time, the impellor's material deteriorated, leading to potential fragmentation. These broken fragments could scatter within the pump, causing significant internal damage and further reducing the machine's efficiency.
The Solution and Result
The graph below illustrates the significant decrease in cavitation and the reduction in broadband noise following the pump replacement. The new pump effectively mitigated the issues caused by the worn impellor and pump casing, resulting in smoother operation. This improvement not only enhances the machine's efficiency but also prolongs its operational lifespan by preventing further damage and wear.
On 4th August, a small spike occurred at 3kHz and the broadband noise increased drastically when observing the frequency at 6kHz. After the new pump installation, the reading on 17th August shows a decrease in broadband noise and an increase in efficiency.
With Sensoteq solutions, high-frequency wireless vibration monitoring offers an effective method to assess internal pump wear in this application and ensures early detection of possible issues. This advanced technology enables proactive maintenance, resulting in significant cost savings and improved operational efficiency for our clients. The Kappa X sensor’s vibration analysis allowed users to identify these issues promptly. For more information on how our solutions can benefit your business, contact us to book a demo.
Case study supplied by our partner https://rms-reliability.com/