ANSI HI HYDRAUL HI 9.6.5-2016 Rotodynamic Pumps Guideline for Condition Monitoring (B122).pdf

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1、ANSI/HI9.6.5-2016ANSI/HI 9.6.5-2016American National Standard forRotodynamicPumpsGuideline for Condition Monitoring6 Campus DriveFirst Floor NorthParsippany, New Jersey07054-4406www.Pumps.orgHydraulic Institute Standards, Copyright 1997-2016, All Rights Reserved ANSI/HI 9.6.5-2016American National S

2、tandard forRotodynamic Pumps Guideline for Condition MonitoringSponsorHydraulic Institutewww.Pumps.orgApproved July 21, 2016American National Standards Institute, Inc.Hydraulic Institute Standards, Copyright 1997-2016, All Rights ReservedApproval of an American National Standard requires verificatio

3、n by ANSI that the requirements for due process, consensus and other criteria for approval have been met by the standards developer.Consensus is established when, in the judgment of the ANSI Board of Standards Review, substantial agreement has been reached by directly and materially affected interes

4、ts. Substantial agreement means much more than a simple majority, but not nec-essarily unanimity. Consensus requires that all views and objections be considered, and that a concerted effort be made toward their resolution.The use of American National Standards is completely voluntary; their existenc

5、e does not in any respect preclude anyone, whether he has approved the standards or not, from manufacturing, marketing, purchasing, or using products, processes, or proce-dures not conforming to the standards.The American National Standards Institute does not develop standards and will in no circums

6、tances give an interpretation of any American National Standard. Moreover, no person shall have the right or authority to issue an interpretation of an American National Standard in the name of the American National Standards Institute. Requests for interpretations should be addressed to the secreta

7、riat or sponsor whose name appears on the title page of this standard.CAUTION NOTICE: This American National Standard may be revised or withdrawn at any time. The procedures of the American National Standards Institute require that action be taken periodically to reaffirm, revise, or withdraw this s

8、tandard. Purchasers of American National Standards may receive current information on all standards by call-ing or writing the American National Standards Institute.Published ByHydraulic Institute6 Campus Drive, First Floor NorthParsippany, NJ 07054-4406www.Pumps.orgCopyright 2016 Hydraulic Institut

9、eAll rights reserved.No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher.Printed in the United States of AmericaISBN 978-1-935762-51-5 American National StandardRecycledpaperHydraulic Institute S

10、tandards, Copyright 1997-2016, All Rights Reserved iiiContentsPageForeword . ix9.6.5 Rotodynamic Pumps for Condition Monitoring .19.6.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19.6.5.1.1 Sco

11、pe 19.6.5.1.2 Purpose 19.6.5.1.3 Use of this document 19.6.5.2 Monitoring Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39.6.5.2.1 Monitoring frequency 39.6.5.2.2 Control limits .39.6.5.2.2.1 Alert limit settings .39

12、.6.5.2.2.2 Alarm limit settings 49.6.5.2.2.3 Shutdown limit settings .49.6.5.2.2.4 Definition of baseline used in alarm set point limits .49.6.5.2.2.5 Definition of field acceptance level or industry standard level .49.6.5.3 Power monitoring .49.6.5.3.1 Introduction 49.6.5.3.2 Means of power monitor

13、ing .59.6.5.3.3 Power monitoring frequency .69.6.5.3.4 Power control limits .69.6.5.4 Temperature monitoring 69.6.5.4.1 Introduction 69.6.5.4.2 Means of monitoring temperature 69.6.5.4.3 Specific applications of temperature monitoring 69.6.5.4.3.1 Motor-winding temperature .69.6.5.4.3.2 Temperature-

14、sensitive liquids 69.6.5.4.3.3 Rolling element bearing temperatures .79.6.5.4.3.4 Liquid-film bearing and seal faces temperatures .79.6.5.4.3.5 Pumped liquid temperature rise 79.6.5.4.4 Sealless pump liquid temperature 79.6.5.4.4.1 Sealless pump temperature damage 79.6.5.4.5 Temperature monitoring f

15、requency 89.6.5.4.6 Temperature control limits 89.6.5.5 Corrosion monitoring 89.6.5.5.1 Introduction 89.6.5.5.2 Means of corrosion monitoring .89.6.5.5.2.1 Corrosion monitoring by visual/dimensional inspection 8iv Hydraulic Institute Standards, Copyright 1997-2016, All Rights Reserved9.6.5.5.2.2 Cor

16、rosion by electrical resistance (ER) 99.6.5.5.2.3 Corrosion by linear polarization resistance (LPR) 99.6.5.5.2.4 Corrosion by ultrasonic thickness measurement (UTM) 99.6.5.5.3 Corrosion monitoring frequency 99.6.5.5.4 Corrosion parameter control limits 99.6.5.6 Leakage monitoring 109.6.5.6.1 Introdu

17、ction .109.6.5.6.2 Means of monitoring leakage .109.6.5.6.2.1 Leakage by visual inspection .109.6.5.6.2.2 Leakage by organic vapor analyzer (OVA) inspection 109.6.5.6.2.3 Seal leakage in submersible pumps 109.6.5.6.2.4 Leakage in an inner seal of dual unpressurized seal arrangements .119.6.5.6.2.5 L

18、eakage in an inner seal of dual pressurized seal arrangements .119.6.5.6.2.6 Double-walled system 119.6.5.6.3 Leakage monitoring frequency 129.6.5.6.4 Leakage control limits .129.6.5.7 Pressure monitoring 139.6.5.7.1 Introduction .139.6.5.7.2 Means of pressure monitoring 139.6.5.7.3 Pressure monitor

19、ing frequency .139.6.5.7.4 Pressure control limits 149.6.5.8 Vibration monitoring 149.6.5.8.1 Introduction .149.6.5.8.2 Means of vibration monitoring 159.6.5.8.3 Vibration monitoring frequency 159.6.5.8.4 Vibration control limits 159.6.5.9 Lubricant analysis. . . . . . . . . . . . . . . . . . . . .

20、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169.6.5.9.1 Introduction .169.6.5.9.2 Measuring metal particles from wear .169.6.5.9.2.1 Evaluating wear rates .179.6.5.9.3 Measuring contamination of lubricant 179.6.5.9.3.1 Organic contamination of lubricant .179.6.5.

21、9.3.2 Inorganic contamination of lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179.6.5.9.4 Measuring lubricant degradation 189.6.5.9.5 Lubricant sampling techniques 189.6.5.9.6 Lubricant monitoring frequency .189.6.5.9.7 Lubricant control lim

22、its 18Hydraulic Institute Standards, Copyright 1997-2016, All Rights Reserved v9.6.5.10 Shaft position monitoring 189.6.5.10.1 Introduction .189.6.5.10.2 How to monitor shaft position .199.6.5.10.3 Shaft monitoring frequency 199.6.5.10.4 Shaft control limits .199.6.5.11 Rate-of-flow monitoring .199.

23、6.5.11.1 Introduction .199.6.5.11.2 Measuring rate of flow 199.6.5.11.3 Rate-of-flow monitoring frequency .199.6.5.11.4 Rate-of-flow control limits 199.6.5.12 Rotational speed (rpm) monitoring .209.6.5.12.1 Introduction .209.6.5.12.2 Speed measurement methods 209.6.5.12.3 Speed monitoring frequency

24、.209.6.5.12.4 Speed control limits 209.6.5.13 Bearing wear monitoring of plain bearings in sealless pumps 209.6.5.13.1 Introduction .209.6.5.13.2 Means of detecting bearing wear 209.6.5.13.2.1 Bearing materials 209.6.5.13.2.2 Bearing wear detection methods 219.6.5.13.3 Bearing wear monitoring freque

25、ncy 229.6.5.13.4 Bearing wear control limits .229.6.5.14 System and pump design review 229.6.5.14.1 Introduction .229.6.5.14.2 Design review practice 229.6.5.14.2.1 Mechanical application review 229.6.5.14.2.2 Hydraulic application review 229.6.5.14.2.3 Installation review 239.6.5.14.2.4 Operating p

26、rocedures review .249.6.5.14.3 Design review frequency 249.6.5.15 Maintenance inspection .249.6.5.15.1 Introduction .249.6.5.15.2 Maintenance inspection practice 259.6.5.15.2.1 Maintenance inspection of keys and keyways 259.6.5.15.2.2 Maintenance inspection of coupling flexible elements 259.6.5.15.2

27、.3 Maintenance inspection for shaft bending fatigue .269.6.5.15.2.4 Maintenance inspection for shaft torsional fatigue .269.6.5.15.2.5 Maintenance inspection for torsional overload 26vi Hydraulic Institute Standards, Copyright 1997-2016, All Rights Reserved9.6.5.15.2.6 Maintenance inspection for imp

28、eller fatigue/breakage 269.6.5.15.2.7 Maintenance inspection for erosion wear from the action of flow, abrasion, and/or corrosion 269.6.5.15.2.8 Maintenance inspection for cavitation erosion 279.6.5.15.2.9 Maintenance inspection for hydraulic performance 279.6.5.15.3 Maintenance inspection frequency

29、 .279.6.5.16 Wireless data transmission technology .279.6.5.16.1 CBM: transmission schemes for wireless systems .279.6.5.16.2 Wireless communication for CBM sensor systems 289.6.5.16.3 Wireless communication standards 29References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Appendix A Condition monitoring, failure modes 30Appendix B Condition monitoring indicators .36Appendix C Vibration analysis 41Appendix D Condition-based maintenance 51Appendix E Preinstallation hydrostatic tes

31、t 54Appendix F Definitions 55Appendix G Condition Monitoring as a Tool for Asset Reliability Management .57Appendix H Index 59Figures9.6.5.1.3 Typical P-F interval curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19.6.5.16.1

32、Example of a Vibration Diagnostic System Network (star topology) . . . . . . . . . . . . . . . . . . . . . . . . .28C.1 Typical vibration waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42C.2 Typical waveform over ti

33、me . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42C.3 Example of ski slope spectral signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43C.4 High-frequency spec

34、tral signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43C.5 1 running speed spike due to imbalance dynamic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43C.6 1 running speed spike due to imba

35、lance overhung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44C.7 1 running speed spike due to imbalance vertical pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44C.8 Vibration spike due to eccentric sheaves . . . . . . . . . . . . .

36、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45C.9 Misaligned sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45C.10 Belt resonance . . . . . . . . . . . . . . . . . . . . . .

37、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45C.11 Bent shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46C.12 Parallel misalignment . . . . . .

38、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Hydraulic Institute Standards, Copyright 1997-2016, All Rights Reserved viiC.13 Angular misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39、 . . . . . . . . . . . . . . . . . . . . . . . . .47C.14 Severe misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47C.15 Cocked bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47C.16 Rotating looseness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48C.17 Structural looseness . . . . . . . . . . . . . . . . . . . . . . . .

41、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48C.18 Bearing wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49C.19 Natural frequencies of bearing system . . . . . .

42、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49C.20 Bearing race flaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49C.21 Bearing ball or roller damage . . . . . .

43、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50C.22 Bearings severely damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50D.1 Summary of condition-based monitoring (CBM)

44、strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Tables9.6.5.1.3 Asset reliability management strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29.6.5.6.2.6 Application guidelines for leakage monitoring syst

45、ems mechanical seals 129.6.5.8.4 Recommended vibration control limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16A.1 Condition monitoring failure modes .30A.2 Additional failure modes for sealless pumps and pumps with journal bearings 35B.1 Con

46、dition monitoring indicators 36Hydraulic Institute Standards, Copyright 1997-2016, All Rights ReservedThis page intentionally blank.Hydraulic Institute Standards, Copyright 1997-2016, All Rights Reserved ixHI Rotodynamic Pumps Guideline for Condition Monitoring 2016Foreword (Not part of Standard)Pur

47、pose and aims of the Hydraulic InstituteThe purpose and aims of the Institute are to promote the continued growth and well-being of pump manufacturers and further the interests of the public in such matters as are involved in manufacturing, engineering, distribution, safety, transportation, and othe

48、r problems of the industry, and to this end, among other things:a) To develop and publish standards and guidelines for pumps;b) To collect and disseminate information of value to its members and to the public;c) To appear for its members before governmental departments and agencies and other bodies

49、in regard to mat-ters affecting the industry;d) To increase the amount and to improve the quality of pump service to the public;e) To support educational and research activities;f) To promote the business interests of its members but not to engage in business of the kind ordinarily carried on for profit or to perform particular services for its members or individual persons as distinguished from activities to improve the business conditions and lawful interests of all of its members.Purpose of