Background
Customer
Customer is a facility management entity which operates Singapore Food Agency owned tropical marine aquaculture centre. It conducts R&D on large-scale hatchery production technology and fish feed nutrition.
Challenges
- The Sea Water Pump plays a crucial role in the water treatment system. Currently, a monthly preventive maintenance routine is conducted, which involves greasing, coolant level checks, and requires a two-hour shutdown with the assistance of two technicians.
- Annual services entail the removal of the impeller, through cleaning, coolant topping, greasing, and checking for the need for bearing replacement after specific intervals. However, the absence of effective condition monitoring has resulted in frequent pump faults.
- Given that the facility operates with limited on-site personnel, there is an urgent need for remote pump monitoring.
Solution
- Honeywell along with Mins Control (Local partner) proposed the implementation of its on-premise LoRaWAN-based Honeywell Versatilis Equipment Health Monitoring solution to monitor the sea water pumps.
- This innovative approach will enable the facility team to remotely monitor the health status of the sea water pumps. Moreover, it will provide real-time alerts, allowing for timely maintenance planning and enhancing operational efficiency.
Machine and transmitter details
Asset Type: Pump (8 Nos)
Rating: 160 KW, 2900 rpm, Variable Frequency Driven
Function: There are four pumps designated for sea water intake and an additional four pumps responsible for distributing treated water to aquaculture livestock. Each system incorporates redundancy to ensure reliability. To safeguard aquatic life, it is essential that at least one pump always remains operational.
Measurement Parameters: It includes 3-axis acceleration and velocity, surface temperature, noise levels, ambient temperature, ambient pressure, and humidity, providing comprehensive insights into pump conditions.
Transmitter location: Motor Drive End on 8 pumps.
Remote monitoring
Experion EHM
Measurement parameters
- Customer accessed the pump health through the on-premise remote monitoring platform from Honeywell known as Experion EHM.
- ISO 10816-3 standard was used to monitor the pump. User can set this ISO standard in the transmitter during the configuration stage.
- Multiple pumps generated alarm based on the ISO standard set. Trends of Velocity RMS and Frequency spectrum were analysed to understand the high vibration levels.
Vibration analysis:
Pump 01
Observation
- Alert generated in dashboard based on ISO 10816-3 Damage level (4.5 mm/s).
- Y axis reading is 255% higher than ISO damage limit.
Expert Driven Analysis
FFT- X AXIS
FFT- Y AXIS
FFT- Z AXIS
Fault detection
- Mechanical Looseness.
- (Presence of multiple harmonics related to rotating speed in the
frequency spectrum).
Recommendations
With these insights, Honeywell was able to put forward the following recommendations:
- Check the mountings and bearings in the bearing pedestal.
- Verify for internal clearance in the bearings.
- Examine for Loose bearing bushes in the bearing seat and Loose rotor.
Benefits to customer
- Simple Solution to Remove Manual Data Collection.
- Alert helped customer to gain insight with reduced operational staff.
- Early warning helps plan the maintenance work.
Text taken over from the original – Honeywell
