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MRE5006: Machine Condition Monitoring And Fault Diagnosis
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MRE5006: Machine Condition Monitoring And Fault Diagnosis
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Course Code: MRE5006
University: Monash University
MyAssignmentHelp.com is not sponsored or endorsed by this college or university
Country: Australia
Question:
First, what is a “system”?
Read in conjunction with notes in Study Guide 3.
Pump supplies nozzle into pit to keep ash slurry in suspension
“Ash nozzle was checked last year”
Pump trips on “high current”
Pump sent away and overhauled
But, problem still occurs!
Investigation: Head, Flow tests
This was used, but what better device could be used today for repeatable for site Flow measurement?
Structural Analysis and New Drug Development against Multidrug Efflux Pumps.
Heavy Metal Pumps in Plants: Structure, Function and Origin.
How to apply pump CM by performance analysis Sketch along with Ray
Condition monitoring of steam turbines by performance analysis Journal of Quality in Maintenance Engineering,
Answer:
Introduction
The main goal of any pump test experiment is to establish the pump viability and consistency in performing its task. This helps to deter any unexpected breakups that could be fatal to the industry, and also prevents unnecessary opening of the pump. Pump tests gives a basis to how and when should the pump be serviced. The paper has used different techniques, which have been illustrated by the Ajax typical model. This same technique could be used to test other models of pumps. The main reason why we examine the pumps is to find out the performance characteristics which could lead to identifying why the pump is not functioning as required.
There are different categories of which the pump tests have been performed. This two can be classified as either manual approach or using tools. Test done by observation, visual sight or even hearing could be classified as manual. Other methods, which include using tools to perform the tests such as temperature, vibration or even pressure. (Brennen, 2011).
Pump tests and calculations
While testing the pump, the following conditions were used.
5kW powered motor, maximum load full speed 1445 r/min.
Maximum current at full load 35.1A @415V. 258mm with impeller fitted. The current readings when there is load were not provided.
Utilities used in power measuring were disoriented
Pipework, valve settings, instrument calibrations are unchanged from before the overhaul.
Most field testing is to find the extent of internal wear in a pump, and the Head-Flow test is sufficient
Annubar® primary element installed on outlet pipe.
Testing the pumps flow
This was achieved by following the guidelines below
The pump was run for approximately 5 minutes
The pumps sanction and discharge were recorded.
Checking was done to ensure there was no leakage.
Use visual aids to check in case of any unnecessary vibration
Check for any unnecessary pump behavior, such as overheating.
Interpret result
Figure 1 Flow readings
Calculations.
Meter readings = 96 %
To get flow.
Use flow= 0.6 × percentage of flow
= 0.6 × 96%
Which gives 0.576L/s
These calculations were performed for other flow rates. Data table below.
tests
1
2
3
4
5
6
Power kw
10
12
14
16
18
18.5
flowrate
0.32
0.39
0.45
0.52
0.576
0.6
The comparison curve between the power supplied and the flowrate was drawn as follows
The Power- Flow chart will be different depending on the density of the liquid of which the pump is pumping
suction calculations take flow as70 litres per second.
The diameter of the pump was 200m
= π 0.2²/22 = 0.03 m².
The velocity will be given as
={ 70 ÷ 1000}/0.03 = 2.33 m/s).
Readings from suction metre= 133kpa
Corrected pressure will be (133kpa – 0.2) = 132.8kPa;
Static layer is zero
Static Suction Head = 132.8 ÷ 9.81 = 13.55m
Total pressure plus flow = V²/2g [g = 9.8]
= 2.33²/(2 ×9.8) = 0.277m,
Total height of suction head = 13.55 + 0.277 = 13.828m
Head at suction
Suction pressure
Calibration
Suction pressure corrected
Static Suction Head
Static leg
Corrected
Velocity at Suction
Velocity Head at Suction Vs²/2g
Total
reading
(test sheet)
(calc’d)
(measured)
Static
Vs
(calc’d)
Suction Head
Suction
(Calc’d)
(includes velocity head)
Head
Test gauge
-0.2
kPa ÷ 9.8
0
Q/As
A
kPa
kPa
kPa
m
m
m
m/s
m
m
133
-0.2
132.8
13.55
13.55
13.55
2.33
0.277
13.828
Suction pressure reading =133kpa
Pressure tests.
Data recorded from the pressure meter below
Figure 2. pressure test gauge meter.
Pressure data.
Test
1
2
3
4
5
Test gauge reading (kpa)
2685
2680
2675
2670
2680
Average readings =
=2678kpa
Other considerations to note are:
Zero drift calibration from sheet
+8kpa
Static water leg
-4 kpa
Atmospheric pressure
102kpa
Overall pressure = 8+102+2678-4
=2784kpa
Ajax pump performance calculations
The performance of the ajax pump would be evaluated by comparing the results of the flow and power output.
Efficiency is calculated by using the following formulae.
E=
Initials defined below
E = pump efficiency
Q = Flowrate, units in L/s
ρ = Density of liquid, units in kg/m3
g = force gravitational = 9.8 m/s2
H = Head, distance, in meters of liquid pumped 1m = 9.8kPa)
P = total power used, W
(ρg is the specific weight)
Efficiency will be calculated as follows
E=
=0.95 (Brennen, 2011)
Conclusion
This exercise establishes the main reason why we examine the pumps to find out the performance characteristics which could lead to identifying why the pump is not functioning as required. The readings and observations were compared to those of the ajax pipes manufacturers. Pumps should be efficient, efficiency of the pump should range between 90% to 99% for optimum performance.
References
Yamasaki, S., Nakashima, R., Sakurai, K., Yamaguchi, A., & Nishino, K. (2017). Structural Analysis and New Drug Development against Multidrug Efflux Pumps. Yakugaku zasshi: Journal of the Pharmaceutical Society of Japan, 137(4), 377-382.
Østerberg, J. T., & Palmgren, M. (2018). Heavy Metal Pumps in Plants: Structure, Function and Origin.
Brennen, C. E. (2011). Hydrodynamics of pumps. Cambridge University Press.
Kaya, D., Yagmur, E. A., Yigit, K. S., Kilic, F. C., Eren, A. S., & Celik, C. (2008). Energy efficiency in pumps. Energy Conversion and Management, 49(6), 1662-1673.
Federal university (2018) how to apply pump CM by performance analysis Sketch along with Ray
Federal university (2018). condition monitoring and fault diagnosis: study guides
federal university (2018). predictive maintenance by condition monitoring using performance analysis
federal university (2018). pumps: performance and condition monitoring
federal university (2018). study guide 3. performance analysis
ray beebe (2014). notes and workbook
Beebe, Ray (2003a) Condition monitoring of steam turbines by performance analysis Journal of Quality in Maintenance Engineering, Vol 9 No 2
Beebe, Ray (2003b) Use PdM to optimise overhauls on pumps 11th Process and Power Plant Reliability Conference, Houston, November (reprinted in HYDROCARBON PROCESSING, April, 2003, and in Heinz Bloch’s Pump User’s Handbook, 2003 and 2006)
Pump Testing. (2018). Tasonline.co.za. Retrieved 13 October 2018, from https://www.tasonline.co.za/pumptesting.htm
Pumping Tests :. Aquifer Testing 101. (2018). Aqtesolv.com. Retrieved 13 October 2018, from https://www.aqtesolv.com/pumping-tests/pump-tests.htm
eXe. (2018). Learning.uonbi.ac.ke. Retrieved 13 October 2018, from https://learning.uonbi.ac.ke/courses/SGL406/scormPackages/path_2/73_pumping_tests.html
odee.pl, O. (2018). Ingeo.com.pl. Retrieved 13 October 2018, from https://www.ingeo.com.pl/pumping-tests,69,en.html#kot
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