Multi-Domain Modeling Platform for Electrical-Signature-Based Condition Monitoring of Motor-Driven Pumps

Document Type : Research Article


School of Mechanical Engineering, University of Tehran, Tehran, Iran


Due to the vital role of motor-driven pumps in various industries such as oil and gas, manufacturing, chemical, etc., their continuous monitoring and implementing effective maintenance methods is of crucial importance. Periodic inspections and intermittent vibration data collection using accelerometers is among the most common methods. Electrical signature analysis is an alternative approach that only uses electrical measurements for the purpose of fault detection. Despite the unique advantages of this method, such as its non-intrusiveness and possibility of continuous monitoring of the equipment, there have been limited studies on its underlying theory with majority of the proposed ESA-based methods taking data-driven approach towards condition monitoring problem. Data-driven methods rely on the experimental data collected from the equipment to train the statistical models. This imposes a serious limitation on the application of electrical signature analysis and makes the generalization harder. In this paper the electromechanical coupling in a motor-driven centrifugal pump is studied in order to demonstrate the effects of different operating conditions of pump on motor electrical signals. Lumped parameter approach is employed to derive governing equations of the induction motor and computational fluid dynamics is utilized to analyze the interaction of the centrifugal pump blades and fluid. Such a modeling platform presents a physics-based approach towards electrical signature analysis based condition monitoring. A closed-loop hydraulic test rig is built to compare and verify the simulation results.


Main Subjects

[1]   G. Mousmoulis, N. Karlsen-Davies, G. Aggidis, I. Anagnostopoulos, D. Papantonis, Experimental analysis of cavitation in a centrifugal pump using acoustic emission, vibration measurements and flow visualization, European Journal of Mechanics-B/Fluids, 75 (2019) 300-311.
[2]  A.R. Al-Obaidi, Investigation of effect of pump rotational speed on performance and detection of cavitation within a centrifugal pump using vibration analysis, Heliyon, 5(6) (2019) e01910.
[3]  A. Choudhary, D. Goyal, S.L. Shimi, A. Akula, Condition monitoring and fault diagnosis of induction motors: A review, Archives of Computational Methods in Engineering, 26 (2019) 1221-1238.
[4] R. Greene, D. Casada, C. Ayers, Detection of pump degradation, Nuclear Regulatory Commission, 1995.
[5] R. Kryter, H. Haynes, Condition monitoring of machinery using motor current signature analysis, Oak Ridge National Lab., 1989.
[6] C.S. Kallesoe, V. Cocquempot, R. Izadi-Zamanabadi, Model based fault detection in a centrifugal pump application, IEEE transactions on control systems technology, 14(2) (2006) 204-215.
[7] T. Dalton, R. Patton, Model-based fault diagnosis of a two-pump system, Transactions of the Institute of Measurement and Control, 20(3) (1998) 115-124.
[8] K. Kim, A.G. Parlos, R.M. Bharadwaj, Sensorless fault diagnosis of induction motors, IEEE Transactions on Industrial Electronics, 50(5) (2003) 1038-1051.
[9] C. Kallesøe, Fault detection and isolation in centrifugal pumps, Department of Control Engineering, Aalborg University, 2005.
[10]  M.L. Nilugal, K.V. Karanth, N. Madhwesh, A critical review on the application of computational fluid dynamics in centrifugal turbomachines, in:  Journal of Physics: Conference Series, IOP Publishing, 2020, pp. 012012.
[11] S. Shah, S. Jain, R. Patel, V. Lakhera, CFD for centrifugal pumps: a review of the state-of-the-art, Procedia Engineering, 51 (2013) 715-720.
[12] E. Bacharoudis, A. Filios, M. Mentzos, D. Margaris, Parametric study of a centrifugal pump impeller by varying the outlet blade angle, The Open Mechanical Engineering Journal, 2(1) (2008).
[13]  S. Shah, S. Jain, V. Lakhera, CFD based flow analysis of centrifugal pump, Proceedings ofInternational Conferenceon Fluid Mechanics and Fluid Power. Chennai, India, paper# TM08,  (2010).
[14] A. Zabihi, Fault Detection of Centrifugal Pump: a Comparison of Fluid Pressure Fluctuation Sim- ulation with Mesuearment of Casing Vibration, University of Tehran, 2017.
[15] J. Lu, S. Yuan, Y. Luo, J. Yuan, B. Zhou, H. Sun, Numerical and experimental investigation on the development of cavitation in a centrifugal pump, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 230(3) (2016) 171-182.
[16] T. Lei, Z.B. Shan, C.S. Liang, W.Y. Chuan, W.B. Bin, Numerical simulation of unsteady cavitation flow in a centrifugal pump at off-design conditions, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of mechanical engineering science, 228(11) (2014) 1994-2006.
[17] E. Blanco-Marigorta, J. Fernández-Francos, J.L. Parrondo-Gayo, C. Santolaria-Morros, Numerical simulation of centrifugal pumps, in:  Proc. ASME Fluids Engineering Summer Conference (FEDSM’00), 2000.
[18]  R. Spence, J. Amaral-Teixeira, Investigation into pressure pulsations in a centrifugal pump using numerical methods supported by industrial tests, Computers & fluids, 37(6) (2008) 690-704.
[19] J. Gonza´ lez, C. Santolaria, F. Castro, M.T. Parra, Numerical model for the unsteady flow behaviour inside a double suction pump, in:  Fluids Engineering Division Summer Meeting, 2003, pp. 1149-1155.
[20] C. ANSYS, ANSYS CFX Solver Modeling Guide, Release 15.0, Volume, 455 (2013) 162-168.
[21] A.E. Fitzgerald, C. Kingsley, S.D. Umans, Electric machinery,  (2003).
[22]S.D. Umans, Steady-state, lumped-parameter model for capacitor-run, single-phase induction motors, IEEE Transactions on Industry Applications, 32(1) (1996) 169-179.