Monitoring Centrifugal Pump Performance With Vibration

Monitoring Pump Performance
with Vibration
Mitchell Stansloski, PhD, PE
Centrifugal Pumps
Centrifugal pumps
Centrifugal Pumps (Radial Flow Pumps): A pump using radial flow
impellers that give their energy to fluid primarily by centrifugal force
Volute Centrifugal
Axial Flow
www.pioneer-engineering.com
Centrifugal pumps
Higher pressure, lower flow compared to axial flow
Impeller adds energy to fluid by increasing velocity
Volute (where fluids goes outexpansion cavity) converts
velocity into pressure
Basic Pump Operation
Operating range given by intersection of system and pump curves.
Pump Curve with Power

and Efficiency
System Curve
Pump friction and head losses.
Pump Flow Control
Various ways to control pumps.
Pump Curve vs. Impeller
Pump curve showing different impeller sizes.
Pump Curve vs. RPM
Pump curve showing different speeds.
Pump Curve and Vibration
Centrifugal pump severity

Machine
Displacement
(mils, p-p)
NA
Rigid mounted
centrifugal
Resilient mounted NA
centrifugal
Volute Centrifugal
Velocity
(ips, pk)
0.05 - 0.25
Acceleration
(g, pk)
0.5 1.5
0.10 0.50
0.5 1.5
Axial Flow Centrifugal

12
Two Types of Pump Vibes

Periodic
Vane passing frequency
Shaft/Coupling/Impeller Unbalance
Random
Cavitation
Turbulence
Pump performance directly affects both!!
Signal Processing Warning

Changing resolution directly affects random
vibration amplitude
Pump Performance and

Vibration Frequencies
Periodic Vane passing frequency
Load
Random Cavitation and Turbulence

Efficiency
Centrifugal pumps
Vibration Diagnostics:
Vane Pass Frequency: Vibration caused by movement of each blade
in a pump or fan
Each time blade passes an arbitrary point on pump, it generates a
small vibration
Load on pump directly changes amplitude of VPFcan detect
problems (like blocked suction or discharge)
16
Centrifugal pumps
Poor Installation: Application of extra force on suction and discharge
flanges to align and mate flanges
Extra force on pump housingcan distort housing
Distortion causes hydraulic unbalance
Can cause high 1X running-speed and VPF vibrations
19
Pipe Design
http://www.chemicalprocessing.com/articles/2004/218/
Centrifugal pumps
Cavitation: Implosion of air bubbles in and around impeller of pump
Occurs when net positive suction head is too low:
Net Positive Suction Head Required (NPSHR): pressure of fluid at inlet
in order satisfy the rated output and overcome frictional or shock losses
Net Positive Suction Head Actual (NPSHA): Actual positive suction
headdetermined by system feeding the pump (piping, level of inlet
reservoir, etc.)
If NPSHA insufficient:
Some fluid vaporizes upon entrance to pump housing
Vapor bubbles collapse violently near impeller
Cause excessive damage and corrosion (throw fan out of
balance)
21
Centrifugal pumps
Identifying Cavitation:
1) Random
2) Broad-band (over large frequency range)
3) High frequency (30,000 cpm to 120,000 cpm)
--Think of it like implosions act like many tiny hammers that
ring natural frequencies of pump housing
22
Centrifugal pumps
Eliminate Cavitation:
1) Reduce NPSHR
2) Increase NPSHA
Reduce NPSHR:
1) Restrict discharge
2) Over-size pump
3) Use impeller with larger eye (inlet)
--ALL affect efficiency so be careful!
Increase NPSHA:
1) Raise height of source fluid

2) Lower pump
3) Reduce pipe friction
4) Pressurize supply tank
5) Reduce pump speed
--ALL affect efficiency so be careful!
23
Pump Cavitation
v op [inch/ s]
CH W Sec o ndary Pump 1\ Pump\ OB V\ Std Vel Meas\ Sp ec trum 12/ 13 / 2011 11:3 3:55 AM
RPM : 1780 (29.67Hz)

M(x) : 120.00 cpm (0.07 Orders)
M(y) : 0.02141 inch/ s
0.034
0.032
0.030
0.028
0.026
0.024
0.022
0.020
0.018
0.016
0.014
0.012
0.010
0.008
0.006
0.004
12/ 13/ 2011
0.002
3/ 29/ 2012
4/ 30/ 2012
0.000
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
f [cpm]
Pump Cavitation
v op [inch/ s]
T ertiary CHW Pump 1\ Pump\ IB V\ Std Vel Meas\ Spec trum 4/ 30/ 2012 9:20:54 AM
0.040
RPM : 1780 (29.67Hz)
0.038
0.036
0.034
0.032
0.030
0.028
0.026
0.024
0.022
0.020
0.018
0.016
0.014
0.012
0.010
0.008
0.006
2/ 15/ 2011
0.004
3/ 29/ 2012
0.002
4/ 30/ 2012
0.000
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
f [cpm]
Cavitation Improved
v op [inch/ s]
FH X CW Pump\ Pump\ IB A\ Std Vel Meas\ Spec tru m 1/ 25/ 20 12 8:2 0:0 3 AM
RPM : 1780 (29.67Hz)

0.034
0.032
0.030
0.028
0.026
0.024
0.022
0.020
0.018
0.016
0.014
0.012
0.010
0.008
0.006
10/ 13/ 2011
0.004
12/ 13/ 2011
0.002
1/ 25/ 2012
0.000
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
f [cpm]
Centrifugal pumps
Turbulent Flow: Irregular motion of fluid particles in directions
transverse to the direction of the main flow
Occurs when poor piping or recirculation cause rough flow of
fluid through pump
Poor Piping: Should be at least 10 diameters of constant geometry pipe
before and after pump
Recirculation: Amount of discharge is too high for outlet piping, fluid
will return to volute causing turbulence in housing
Random, broad-band vibrations at low frequencies
27
Using Vibration to Set

Performance
Cascade Plot
Monitor broadband vibration FFT spectra versus
RPM
Waterfall Plot
Monitor broadband vibration FFT spectra versus
valve position
Single Channel Signal

Processing
Cascade Plot: Series of spectra as machine speed varies
Cascade Plot
Pump Performance
http://www.emeraldinsight.com/journals.htm?articleid=843213&show=html
Summary
Periodic vibration (vane passing frequency)
Indicates pump load
Random vibration (cavitation & turbulence)

Indicates pump efficiency
Cascade and Waterfall Plots

Vibration vs. RPM or valve position
Easily identifies changes in both

Monitoring Centrifugal Pump Performance With Vibration

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Monitoring Pump Performance

Mitchell Stansloski, PhD, PE

Basic Pump Operation

Operating range given by intersection of system and pump curves.

Pump Curve with Power

Pump friction and head losses.

Pump Flow Control

Various ways to control pumps.

Pump Curve vs. Impeller

Pump curve showing different impeller sizes.

Pump Curve vs. RPM

Pump curve showing different speeds.

Pump Curve and Vibration

Centrifugal pump severity

Axial Flow Centrifugal

Two Types of Pump Vibes

Pump performance directly affects both!!

Signal Processing Warning

Pump Performance and

Random Cavitation and Turbulence

1) Raise height of source fluid

RPM : 1780 (29.67Hz)

12/ 13/ 2011

RPM : 1780 (29.67Hz)

RPM : 1780 (29.67Hz)

12/ 13/ 2011

Random, broad-band vibrations at low frequencies

Using Vibration to Set

Single Channel Signal

Random vibration (cavitation & turbulence)

Cascade and Waterfall Plots

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