Centrifugal Pump Test Rig

Figure 1 the centrifugal pump test-rig

Test rig description

The test rig was constructed to evaluate the performance of a pump system using a different measurement. The test rig consists of a centrifugal pump, pipes, two water tank, discharge valve, two pressure sensors were located in both the suction and the discharge lines.

Instrumentation

For the measurements, an accelerometer is mounted vertically on the pump casing to measure the vibration. The hydrophone is fixed on the discharge line. A microphone is located 50 mm away from the pump body to measure the airborne sound of pump components. Furthermore, a flow sensor is fixed on the discharge line to measure the amount of flow rate of the liquid. An encoder is installed on the motor shaft to measure the rotational speed of the centrifugal pump. All the sensors are linked to a data acquisition (DAQ) system with sampling rate of 96kHz.

Typical fault simulation

The test rig can simulate various faults, including bearing fault, impeller fault, mechanical seal fault, and cavitation faults, as shown in Table 5. The performance of the pump carried out under nine different flow rates by manipulating the discharge valve of (0, 50,100,150,200, up to 450) l/min.

No.Fault positionFault type
1BearingInner race, Outer race
2impellerWear Fault in Inlet Vane of Impeller Impeller Inlet faults (small l, large Blockages) Impeller Outlet Vans Fault (by Cutting Vans)  Impeller Inlet Vans Fault (by Cutting Vans)
3Mechanical sealThe sealing gap on part of the seal faces
4cavitationDetection incipient cavitation in centrifugal pump
Table 1 Typical fault simulation

Key publications

  • [1] Albraik, A., Althobiani, F., Gu, F. and Ball, A., 2012, May. Diagnosis of centrifugal pump faults using vibration methods. In Journal of Physics: Conference Series (Vol. 364, No. 1, p. 012139). IOP.
  • [2] Osama Hamomd, Samir Alabied, Yuandong Xu, Alsadak Daraz, Fengshou Gu and Andrew Ball, vibration based centrifugal pump fault diagnosis based on modulation signal bispectrum analysi, University of Huddersfield, UK, accepted for publication on ICAC17 Proceedings of the 23rd International Conference on Automation & Computing, Huddersfield, UK.
  • [3] Samir Alabied, Osama Hamomd, Alsadak Daraz, Fengshou Gu, and Andrew D Ball, Fault Diagnosis of Centrifugal Pumps based on the Intrinsic Time-scale Decomposition of Motor Current Signals, University of Huddersfield, UK, accepted for publication on ICAC17 Proceedings of the 23rd International Conference on Automation & Computing, Huddersfield, UK.
  • [4] Alsadak Daraz, Samir Alabied, Ann Smith, Fengshou Gu and Andrew D Ball, Detection and Diagnosis of Centrifugal Pump Bearing Faults Based on the Envelope Analysis of Airborne Sound Signals, Newcastle University, UK, accepted for publication on ICAC18 Proceedings of the 24rd International Conference on Automation & Computing, University Newcastle upon Tyne, UK.
  • [5] Samir Alabied, Usama Haba, Alsadak Daraz, Fengshou Gu and Andrew D Ball, Empirical Mode Decomposition of Motor Current Signatures for Centrifugal Pump Diagnostics, Newcastle University, UK, accepted for publication on ICAC18 Proceedings of the 24rd International Conference on Automation & Computing, University Newcastle upon Tyne, UK.
  • [6] Alsadak Daraz, Samir Alabied, Fengshou Gu and Andrew D.Ball, Modulation Signal Bispectrum Analysis of Acoustic Signals for the Impeller Wear Detection of Centrifugal Pumps, Lancaster University, UK, accepted for publication on ICAC19 Proceedings of the 25rd International Conference on Automation & Computing, Lancaster, UK.
  • [7] Alsadak Daraz, Samir Alabied, Dong Zhen, Fengshou Gu and Andrew D.Ball, Detection and Diagnosis of Mechanical Seal Faults in Centrifugal Pumps Based on Acoustic Measurement, University of Huddersfield, UK, accepted for publication on COMADEM2019 Proceedings of the 25rd International Conference on Automation & Computing, Lancaster, UK.
  • [8] Weili Tang, Fengshou Gu, Hanling Mao, Andrew D. Ball, Alsadak Daraz, Rotor Dynamics in a Pump System with Magnetoelectrical, Fluid and Mechanical Effects using ANSYS. InSixteenth International Conference on Condition Monitoring and Asset Management 2019 Aug 1 (p. 136). British Institute of Non-Destructive Testing.
  • [9] Samir Alabied, Alsadak Daraz, Khalid Rabeyee, Ibrahim Alqatawneh, Fengshou Gu and Andrew D.Ball, Motor Current Signal Analysis Based on Machine Learning for Centrifugal Pump Fault Diagnosis, Lancaster University, UK, accepted for publication on ICAC19 Proceedings of the 25rd International Conference on Automation & Computing, Lancaster, UK.
  • [10] Alsadak Daraz, Samir Alabied, Fengshou Gu and Andrew D.Ball,  A comparative study of acoustic and vibration signals for bearing fault detection and diagnosis based on MSB analysis, Beijing Institute of Technology, China, accepted for publication on IncoME-V 2020 Proceedings of the 5th International Conference on Maintenance Engineering, Zhuhai, China.
  • [11] Al Thobiani, F., Gu, F., and Ball, A. (2010) The monitoring of cavitation in centrifugal pumps using spectral entropy of vibro-acoustic measurements, 7 th Int. Conf. on Condition Monitoring and Machinery Failure Prevention Technologies, 22-24 June 2010, Stratford-upon-Avon, UK
  • [12] Al Thobiani, F., Gu, F., and Ball, A. (2011) Monitoring of cavitation in centrifugal pumps using a non-invasive capacitance sensor. Proc. 24th Int. Congress on Condition Monitoring and Diagnostics Engineering Management, Stavanger, Norway
  • [13] Abdulrahman Albraik, Faisal Al Thobiani, Fengshou Gu and Andrew Ball. (2011) The Diagnosis of Centrifugal Pump Impeller Faults based on Vibration Analysis, In Proceedings of the 25th International Congress on Condition Monitoring and Diagnostics Engineering Management. COMADEM 2011, Huddersfield, UK
  • [14] A. Al-braik, F. Al Thobiani, Fengshou GU and Andrew Ball. (2012) The Diagnosis of Centrifugal Pump Faults Using Vibration Method, Proceedings of the 25th International Congress on Condition Monitoring and Diagnostics Engineering Management. COMADEM 2012, Huddersfield, UK.
  • [15] A. Al-braik, Osama Hamomd, F. Gu and A. D. Ball (2014). Diagnosis of Impeller Faults in a Centrifugal Pump Based on Spectrum Analysis of Vibration Signals. Proceeding of the CM2014- MFPT2014, University of Manchester, June 2014, Manchester, UK.
  • [16] Osama Hamomd, Xiange Tian, Zhi Chen, Abdulrahman Al-braik, Fengshou GU, Andrew Ball (2014). A New Method of Vibration Analysis for the Diagnosis of Impeller Faults in a Centrifugal Pump. Proceeding of the 21st International Congress on Sound and Vibration 13-17 July 2014, Beijing/China.
  • [17] Xiange Tian, Guojin Feng, Zhi Chen, Abdulrahman Al-braik, Fengshou Gu and Andrew D. Ball (2014). The investigation of motor current signals from a centrifugal pump for fault diagnosis. Proceeding of the 27th International Congress of Condition Monitoring and Diagnostic Engineering, 16-18 September 2014. Brisbane Convention and Exhibition Centre, Australia.

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