Failure Prediction of Centrifugal Pumps with Wireless Monitoring System

Predicting centrifugal pump failures as part of predictive maintenance minimises the risks of leaks, fires, costly repairs, process problems and downtime, as well as any unnecessary repairs, so doing so in a timely manner in real time is a significant cost and time gain for the industry.

The years leading up to the new millennium saw a rapid evolution of industrial communication networks from analogue to digital. By the year 2000, information technology tools in fluid handling systems marked the beginning of the convergence of pump technology and automation.

Currently, wired communication systems in field devices are being replaced by wireless communication as the new standard, for the failure prediction for centrifugal pumpsThis is helping to improve lifecycle cost decisions and perform true predictive maintenance in real time, without the need for manual data collection.

The main objective of this document is to analyse how the failure prediction of centrifugal pumps with a wireless monitoring systemThe benefits of implementing it using a combination of process and machine data as part of a predictive maintenance programme.

Early warnings that can be easily understood by operators and maintenance managers as alerts to the presence of "caution" without the need for machinery experts to interpret the data are as follows:

• Discharge and suction pressure differential.
• Filter pressure differential.
• Oil level and seal pressure.
• General vibration data.
• Pump vane impact data.
• Temperature increase in the pump bearing.
• Increase and/or decrease of pump speed.
• Start/stop indication.

These alerts are predictable with wired transmitter monitoring that requires a supporting wired infrastructure, including a power supply, cabling, conduit and cable trays, carrying the signal to a field junction box or marshalling cabinet, making installation a very costly and difficult task.

However, wireless transmitters perform the same function but have power modules and do not require wired infrastructure or local power supply, so they can be installed in places where power and wiring are too costly or dangerous. and make an early prediction of failures in centrifugal pumps and other machinery.

Installation is simple, a typical wireless transmitter is installed, configured and operational in a matter of hours, unlike wired transmitters which can take days or even weeks. Detecting centrifugal pump failures with the wireless monitoring system avoids unnecessary maintenance on pumps that are healthy.

Wireless technology has changed the landscape of remote pump monitoring and has brought great benefits to industries, as it is a tool that provides real-time information from the pump system, which helps plant managers make decisions based on long-term operating costs to keep plant uptime available and sustainable over time.

Benefits of failure prediction in Centrifugal Pumps with Wireless Monitoring System

• There is automatic or manual control of the pumps using wirelessly transmitted pond level readings.
• It generates process and asset reliability, as there is full motor, pump and fan control, as well as valve control and filter monitoring.
• There is a constant measurement of the efficiency and performance of the centrifugal pump, due to the monitoring of the tank level and the heat exchanger.
• There is permanent monitoring of the steam trap and oil and gas/steam injection, which facilitates the prediction of Centrifugal Pump failures in real time, allowing immediate action to be taken on a "heads up" basis.
• It contributes to the protection of Health, Safety and Environment, as there is monitoring of discharge emissions, pressure level at the relief valve, and secondary level measurements on other machinery.
• Generates staff productivity through manual meter replacement, reduced operator rounds and availability of mobile workers.
• Reduction of maintenance activitiessaving man-hours that can be spent on centrifugal pumps and other assets that need attention.

Serious and costly centrifugal pump problems can be prevented with wireless monitoring systems. The challenge starts with getting the right maintenance done at the right time, which is why these predictive maintenance technology solutions are available for any pump in an industrial plant or refinery.

A critical factor in a highly effective pump monitoring programme can depend on the choice of software application used to analyse pump health from measuring variables and providing real-time actionable data to significantly reducing unplanned production losses and maintenance costs, while improving safety and mitigating recordable incidents.

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