Equipment Type
Pump
Equipment Name
Cooling Sludge Circulation Pump
Faults
Component Rubbing
Early Detection of Cooling Sludge Circulation Pump Part Rubbing
How AI Ensured Continuous Operation at a Wastewater Treatment Facility
Water Utility
Introduction
This case study demonstrates the diagnosis of a component rubbing fault in a cooling sludge circulation pump at a wastewater treatment facility. For such an environment, ensuring the continuous and stable transport of fluids is critical for operational safety and overall process stability.
Equipment Overview
The cooling sludge circulation pump features a horizontal structure, which is both compact and energy-efficient. This horizontal, single-suction centrifugal pump is designed for the continuous and stable conveyance of various media, including corrosive and clean liquids. Its simple structure, stable operation, and ease of maintenance enable it to lower energy consumption and enhance operational efficiency.
The Challenge
Diagnosing potential issues in a wastewater environment presents unique challenges:
Wear and Contamination Risk: The need to handle corrosive liquids and sludge increases the risk of damage, particularly to components like mechanical seals.
Complexity of Component Rubbing: The underlying causes of part rubbing are varied and complex, including issues like incorrect bearing installation, foundation deformation, and rotor imbalance.
Operational Continuity: Maintaining the consistent operation of the cooling sludge pump is essential for the entire wastewater treatment process.
Wisper Solution
Wisper CMS is deployed and continuously monitors the health status of the pump. On August 6, 2024, the AI monitoring detected abnormal characteristics at the pump's input end and automatically generated a diagnostic report, prompting on-site personnel to check the equipment's running status. On August 14, 2024, after the equipment was briefly shut down and restarted, the pump's input end indicator significantly worsened and surpassed the alert threshold. The system re-triggered a diagnosis report, identifying the fault as Part Rubbing.
Wisper CMS diagnostic report (Aug 6, 2024)
Wisper CMS diagnostic report (Aug 14, 2024)
The outcome
Ensured Continuous Operation:
By detecting the early-stage fault, the maintenance was planned and executed before catastrophic failure, guaranteeing the pump's continuous and stable function for the facility.
Accurate Fault Diagnosis:
The diagnosis report was fully verified by the on-site inspection, which found that the mechanical seal was damaged, allowing sludge to enter the shaft system and cause the observed wear.
understanding the root cause
The fault, Component Rubbing, can be caused by various factors, including:
Improper clearance between the rotor and surrounding components (e.g., seals, baffles, or the stator).
Poor fit between the bearing's inner ring and the shaft, or the outer ring and the bearing housing bore.
Rotor issues such as imbalance, misalignment, or large dynamic deflection.
Deformation of the foundation or the pump casing.
Material accumulation, such as ash or dirt, on components like the rotor and shaft seals.
Uneven thermal expansion during machine operation, or issues with rotor displacement and misalignment.
