Expert system for the diagnosis of the condition and pumping efficiency of centrifugal pumps

The reliable and economical performance of centrifugal pumps is essential to Finnish industry. About 10% of the total electrical energy produced in Finland is consumed by pumps and in some cases the cost of pumping can be as high as 50% of total electrical energy. With the economical and reliable performance of pumps, it is possible to achieve significant savings because wear and even partial failures result in downtime, slower production and poor efficiency. A small laboratory arrangement has been used for testing the effectiveness of various condition monitoring methods. This information has been used in the development and definition of a diagnosis expert system CEPDIA which can be used for diagnosing the condition of a pump and its components. The diagnosis is based on measuring results from the sensors and information about maintenance actions carried out on the pump and its components. CEPDIA can also be used for the calculation of the efficiency of the electrical motor and the pump. The diagnosis system has been tested in the plant environment and it can be configured according to the requirements of the pumps in question. Training and adjustment of the diagnosis database ensure correct fault definition and consequently appropriate maintenance actions.