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Centrifugal Pumps are one of the most commonly used fluid circulating pumps due to their Smooth flow rate, Range of capacity, Design simplicity and Ease of maintenance and operations.
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Introduction • Centrifugal Pumps are the most popularly used due to their Smooth flow rate, Range of capacity, Design simplicity and Ease of maintenance and operations. • These pumps are expensive, and their repair or replacement is a cost burden for the business. • Since they are an integral part of operations in most industries, their down time leads to huge revenue losses.
Usage of Centrifugal Pumps in various Industries: • Water desalination plants: Centrifugal Pumps are most efficient at transporting solid containing sea water for the purpose of desalination. • Mining industry: In mineral processing precious minerals are separated from gangue and bitumen by centrifugal pumps. These pumps also help to process the minerals and are also used to transport the slurries and solid-containing fluids that accumulate during the mining process. • Petrochemical plants: As centrifugal pumps are robust they help to transfer flammable and valuable petrochemical products. The production of plastics, rubbers, and dyes is also done through well-designed centrifugal pumps.
Common causes for the damage of Centrifugal Pumps: • Seal damage resulting in Leakage. • Bearing failure due to incorrect lubrication, misalignment, improper maintenance or high temperature of the pumped liquid. • Impeller failure due to improper heat treatment, poor surface finish or insufficient radial clearance between impeller and volute casing. • Fracture of shaft and cracks due to Corrosive environment.
Solution • To avoid these damages that result in downtime which will eventually lead to loss of revenue for these large-scale industries, it is best to continuously monitor operational parameters of the Centrifugal Pumps. • However manual monitoring and inspection is: • Expensive • Not Accurate • Non-Comprehensive
Technology Solution • For Centrifugal Pump stakeholders such as manufacturers, rentals, users or Support teams; pump monitoring can be done easily and remotely through IIoT based application. Such an IoT platform for these IIoT integrated smart pumping solutions comprise of three significant parts: • Sensors, including cables and junction boxes • Data collection device • Monitoring/analysis software • The sensors work to pick data from different hardwarewhich is then relayed using GPRS/Internet/ Ethernetetc to a web-based application which stakeholders can access on their smart devices such as phones, laptops, and computers.
Benefits of the IIoT Solution The IIoT Platform will allow close yet remote monitoring of following types of data: • Vibrations/ Noise: Main reasons for excessive noise are impeller damage, misalignment, worn-out bearing, bent shaft or lack of prime. The IIoT platform helps to monitor noise levels and associated data. • Temperature: A centrifugal pump gets overheated due to faulty packing or bearing, misalignment, and obstruction in delivery line. When the IIoT platform picks data on temperatures crossing the ideal threshold, corrective measures can be taken. • Gap between the impeller and Pump Housing: This gap is an indication of Wear and tear of impeller blades leading to reduced pump efficiency and eventual plant downtime. As the impeller wears, the gap between the impeller and the pump housing increases. Data regarding this gap can be collected easily through appropriate sensors used in the IIoT Platform.
