Wireless Condition Monitoring Of Pump Group Based On WirelessHART

In chemical industry, to maintain the normal daily production and increase profits mustbe based on the high reliable production facilities and advanced maintenance mode. Pump, asa critical machine, plays a very critical role in chemical production chains. To define pump’srunning condition, traditionally people carry out the inspection by daily routing patrolimplementation, hands touching and ear hearing. These old inspection methods cost very highhuman resources with big risk to get different conclusions or even wrong’s due to people havedifferent knowledge and experiences to the pump. Fundamentally such traditional methodscould not eliminate the pump faults.In1980s, On-line system was becoming popular to be used in chemical industry byrouting cables, mounting sensors and surveillance devices in site to monitor the pump’srunning condition, people can define pump’s failure mode, bearing faults position and faultslevel by analysis the collected vibration data. This advanced maintenance mode has changedthe old maintenance from failure maintenance mode to the predicative maintenance mode. Inview of the needs of the explosion-proof in chemical industry in specific areas for any newsystems installation like routing cables, mounting sensors and surveillance devices need tohave long installation period、high material cost、expensive human resources and highmaintenance cost in the future.With the rapid technology evolvement in modern telecommunication and micro-chips,people can setup the wireless condition monitoring network to make the same functions asOn-line condition monitoring more quickly with the low cost of installation, commissioningand maintenance in the future. This WirelessHART (Wireless Highway Addressable RemoteTransducer) network use sensor polls and gateway polls to get data and upload them into themain computer.The WirelessHART system can collect velocity values(mm/s)、acceleration enveloping(mm/s^2)、temperature values(oC) and battery level. It is the first WirelessHART systemapplication implemented in monitoring pumps vibration condition in China withoutinstallation experiences to take reference. Based on the experiences accumulated from theproject, the paper will study:1) How to select the installation position for gateway andadapter to setup the reliable and wide coverage WirelessHART network;2) How to selectinstallation position for WirelessHART sensor and antenna direction to ensure good vibrationsignal collection without effect the WirelessHART signal transmission;3) How to setup datacollection mode, data collection period and cyclic period, sensor mode to ensure the robust of the WirelessHART network and longer running life of the sensor battery;4) How to analysisthe reliability of the WirelessHART network and nodes by reading the network log file;5)How to interpreter the collect vibration data to verify the data validity by analyzing the earlybearing outer-race defects6) Provide future system improvements based the applicationneeds.