Centrifugal pumps are essential in many industrial processes. An accurate operation diagnosis of centrifugal pumps is crucial to ensure their reliable operation and extend their useful life. In real industry applications, many centrifugal pumps lack flowmeters and accurate pressure sensors, and therefore, it is not possible to determine whether the pump is operating near its best efficiency point (BEP). This paper investigates the detection of off-design operation and cavitation for centrifugal pumps with accelerometers and current sensors. To this end, a centrifugal pump was tested under off-design conditions and various levels of cavitation. A three-axis accelerometer and three Hall-effect current sensors were used to collect vibration and stator current signals simultaneously under each state. Both kinds of signals were evaluated for their effectiveness in operation diagnosis. Signal processing methods, including wavelet threshold function, variational mode decomposition (VMD), Park vector modulus transformation, and a marginal spectrum were introduced for feature extraction. Seven families of machine learning-based classification algorithms were evaluated for their performance when used for off-design and cavitation identification. The obtained results, using both types of signals, prove the effectiveness of both approaches and the advantages of combining them in achieving the most reliable operation diagnosis results for centrifugal pumps.

Motor current signature analysis (MCSA) used in the diagnosis of centrifugal pumps has become a hot topic due to its non-intrusive and cost-effective nature. Yet, traditional current-based diagnosis methods show limitations as massive computation and power frequency interference. Moreover, most of them focus on the fault detection, fewer discuss the applications in operation evaluation. Therefore in this article, the hydro-mechanical-electric coupling effect that exists in the induction motor-centrifugal pump system is analyzed systematically. On this foundation, novel indicators that can reflect the harmonic distortion and noise proportion of stator current signals, and further indicate the hydraulic stability and operation status are proposed. Theoretical and experimental analysis support this paper, and results have demonstrated that our proposed indicators can indicate the operation change, identify the optimal operation region, and reflect the development of cavitation for centrifugal pumps. These indicators have the advantages of easy calculation and identification, therefore can be conveniently compared with accepted standards and enable immediate remedial actions to be implemented to ensure the stable operation.

In order to explore the dynamic characteristics of the mechanical seal under different fault degrees, this paper selected the upstream pumping mechanical seal as the object of study. The research established the rotating ring-fluid film-stationary ring 3D model, which was built to analyze the fault mechanism. To study extrusion fault mechanism and characteristics, different dynamic parameters were used in the analysis process. Theoretical analysis, numerical simulation, and comparison were conducted to study the relationship between the fault degree and dynamic characteristics. It is the first time to research the dynamic characteristics of mechanical seals in the specific extrusion fault. This paper proved feasibility and effectiveness of the new analysis method. The fluid film thickness and dynamic characteristics could reflect the degree of the extrusion fault. Results show that the fluid film pressure fluctuation tends to be more intensive under the serious extrusion fault condition. The extrusion fault is more likely to occur when the fluid film thickness is too large or too small. Results illustrate the opening force is affected with the fluid film lubrication status and seal extrusion fault degrees. The fluid film stiffness would not always increase with the rotating speed growth. The seal fault would occur with the increasing of rotating speeds, and the leakage growth fluctuations could reflect the fault degree.

During operation, failures in a centrifugal pump’s rotary shaft seal—such as wear, deformation, or thermal cracking—can adversely affect system performance. This study utilizes both theoretical and experimental methods to investigate the vibration characteristics of centrifugal pumps under different rotary-shaft-seal conditions. Vibration signals are collected and processed using empirical mode decomposition (EMD) and autoregressive (AR) modeling to generate an EMD-AR spectrum. The results show that rotary-shaft-seal failure leads to decreases in both the head and efficiency of the centrifugal pump. For improved operation stability, centrifugal pumps should operate at or slightly above their design flow rates (Q_d), while avoiding low-flow conditions. Furthermore, the amplitude of the EMD-AR spectrum increases progressively as rotary-shaft-seal degradation worsens. Therefore, the EMD-AR spectrum provides a reliable diagnostic indicator for detecting rotary-shaft-seal damage.

This paper presents an energy-saving strategy that was applied to a parallel variable frequency pump system of a water circulation pumping station. Firstly, the mathematical model of shaft power consumption for the parallel pump system was established using quadratic polynomial fitting, with some constraints configured according to the system’s water supply demands. Then, the algorithm program was designed with the goal of minimizing the energy consumption through the application of an improved differential evolution algorithm. Additionally, the energy consumption model and constraints were integrated and simplified in order to adapt to the algorithm calculation. In the end, the algorithm was implemented according to the pump design parameters and supply targets of the pumping station. Meanwhile, a comparison was done between the differential evolution (DE) algorithm and the genetic algorithm (GA). Furthermore, an experimental test was conducted in an aluminum company in order to verify the applicability of the energy-saving algorithm in practice. The results demonstrated the feasibility of using the improved differential evolution algorithm in order to achieve a minimum energy consumption operation strategy; the results consequently manifested the superiority of the differential evolution algorithm in both computing time and optimal solution aspects.

Off-design operation conditions might not only seriously affect the internal flow status of a centrifugal pump, but also result in additional energy loss and potential mechanical damage. Therefore, early-stage monitoring and predication on off-design operation conditions for centrifugal pumps have become essential. Single-value indicators have favorable factors such as a smaller amount of calculation and easier identification. As a result, industries prefer the more straightforward approach: obtaining single-value indicators directly from the signals which could be easier compared with accepted standards. The possibility of applying the single-value indicators of vibration into operation condition monitoring for a centrifugal pump is studied theoretically and experimentally, which shows that the statistical features of vibration might be suitable for hydraulic instability detection for a centrifugal pump.