Detection of Broken Impeller in Submersible Pump by Estimation of Rotational Frequency from Motor Current Signal
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ORIGINAL PAPER
Detection of Broken Impeller in Submersible Pump by Estimation of Rotational Frequency from Motor Current Signal Prasanta Kumar Pradhan1 · S. K. Roy1 · A. R. Mohanty1 Received: 17 June 2019 / Revised: 19 July 2019 / Accepted: 30 July 2019 © Krishtel eMaging Solutions Private Limited 2019
Abstract Introduction With the growth of automation in industry, it has become necessary to monitor the condition of machines and machinery systems to avoid sudden failures which may be catastrophic. There are various condition monitoring techniques available such as wear debris analysis, thermography, vibration analysis, motor current signature analysis (MCSA), etc. for fault detection of machines. Among these, MCSA is a new and emerging technique for fault detection of a submersible pump and other machineries. Apart from proper signal selection, the proper signal processing technique is also important for machinery fault diagnosis. A number of signal processing techniques such as FFT, STFT, and CWT are used for detection of faults by various researchers. In presence of fault, the speed of rotor changes. That will be hidden in the current signal in the form of modulation. Hence, instantaneous frequency (IF) estimation technique is an important technique, which can extract the hidden information. Purpose The present work attempts to detect the broken impeller in submersible pump using MCSA. Methods Zero-crossing technique and frequency-domain-based IF estimation technique has been adopted to estimate IF from motor current signal and that has been used to detect the fault in submersible pump. Result and Conclusions Using these techniques, it is observed that the speed fluctuation increases when there is a defect or level of defect increases in impeller. Keywords Condition monitoring · Submersible pump · Motor current signature analysis (MCSA) · Instantaneous frequency · Zero-crossing technique (ZCT)
Introduction Submersible pump is an essential mechanical device in today’s industries such as nuclear power plant, mining, petroleum exploration, and chemical industries. In such industries, submersible pumps are used rather than surface centrifugal pump because of specific requirements and conveniences. Pump availability and its reliability are essential in such industries. Often a failure of non-redundant pumping system will bring an entire plant complex to a standstill. Continuous condition monitoring helps to avoid malfunction, damage, wear and promote the optimal utilization of component’s service life. Major problems in submersible pump [1] are wearing out of impeller, vibration (due to * Prasanta Kumar Pradhan [email protected] 1
Mechanical Engineering Department, Indian Institute of Technology Kharagpur, Kharagpur, India
unbalance of impeller and other causes), corrosion problem, leakage along shaft, surge, bearing failure etc. The conditions of the components such as pump shaft, impellers are monitored by means of vibration measurement. But in some cases, mounting of vibration sensor is difficu
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