Pump Condition Monitoring Methods
From Imrtwiki
Hunter Water uses their SCADA system to monitor the performance of their pumps. Most of their pumping application reacts to a low and high level alarm to switch pumps on and off. The time it takes the pump to go from low to high level (eg fill a tank) give a good indication of its flow rate. Each application has two pumps which work alternately and the time taken by each pump gives a quick indication of their relative performance/condition. Sydney Water uses the same approach. Hunter water does not do any advanced vibration monitoring of their pumps and does not suffer significantly due to installed redundancy. Their greatest number of pumps is submersibles, mostly on sewer applications. As discussed in the seals section the standard design of pumps used have on-line monitoring of seal leakage and motor temperature.
Delta Electricity Western use extensive Condition Monitoring. Vibration monitoring is carried out manually monthly by a CM contractor based locally (CCI Pope). The scope is “if it turns it gets vibration monitored”. Large critical machines such as the feed pumps also have on-line vibration measurement. They have a Performance Analysis group that do a wide range of performance tests including Head & Flow efficiency testing of pumps. There is also extensive water and oil analysis carried out. Delta relies heavily on condition monitoring and has had good experience in predicting failure. Overhauls are not generally done on time basis but only on condition.
Shell uses a 5 week cycle for its manual vibration monitoring system for its main process equipment. This system predicts most vibration related problems with few misses. They have been using RCM processes to upgrade routine PM/Inspection systems. Shell has some strong corporate standards and they have a rule that PM’s can only be deferred once. They have extensive process monitoring with 80% of pumping systems having both suction and discharge pressured monitored. Many other parameters such as fluid flow and density are monitored. There is some monitoring of pump mechanical seal barrier fluid pressure for monitoring seal condition.
