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[Truncated abstract] Centrifugal pumps are the most prevalent, electrically powered rotating machines used today. Each pump is designed to deliver fluid of a given flow rate at a certain pressure. The point at which electrical energy is converted most efficiently into increased pressure is known as the Best Efficiency Point. For a variety of reasons, pumps often operate away from this point (intentionally or otherwise), which not only reduces efficiency, but also increases the likelihood of premature component failure. Acoustic emissions (AE) are high frequency elastic waves, in the range of 20-2000kHz, released when a material undergoes localised plastic deformation. Acoustic emission testing is the process of measuring and analysing these stress waves in an attempt to diagnose the nature and severity of the underlying fault. AE sensors mounted on the surface of a machine or structure also detect any stress waves generated within the fluid being transmitted through to the structure. Unfortunately, attempts to detect incipient component faults in centrifugal pumps using acoustic emission analysis have been complicated by the sensitivity of AE to a pump?s operating state. Therefore, the aim of this thesis was to determine how acoustic emission monitoring could be used to identify the hydraulic conditions within a pump. Data was collected during performance tests from a variety of small end-suction pumps and from one much larger double-suction pump. A system was developed to collect, process and analyse any number of AE features (be they related to discrete AE events, or due to the continuous background AE level) from continuously operating equipment. ... Unfortunately, results from smaller pumps were less conclusive, particularly at low flows, probably due to the relatively small changes in hydraulic energy across the range of flows, and consequent sensitivity to the testing process. However, even in these pumps consistent patterns in hit energies were observed resulting in the conclusion that low to medium flows in centrifugal pumps are typified by a very large number of very low energy (VLE) events. These decrease in number and increase in energy as flow approaches BEP and/or is reduced to very low flows. High flows above BEP are marked by an absence of these VLE events, with bursts having significantly higher energies and spread over a much greater range. Unfortunately, these VLE events are too small to affect averaged trends, indicating that further work on a suitable filter is required. vi

Elaborated project gives a complex design of backup hydro-mechanical unit for fuel supply of turboshaft engine TS 100. Required function of backup unit is to secure basic function of engine TS 100 over failure of primary electro-mechanical fuel system. Backup hydro-mechanical unit consists of hydrostatic fuel pump, centrifugal regulator, valve of maximum and minimum pressure, switch valve and signalization of activation hydro-mechanical unit. Parameters of hydro-mechanical unit are designed considering requested rotations speed of output shaft of engine and its allowed fluctuation. Calculation of basic parameters and dynamical calculation of behavior of the system regulator with engine is made in program DYNAST Shell. Additional calculations were made in program Microsoft Excel. Own design of hydro-mechanical unit is made in 3D design software Pro/Engineer.

Orientador: Janito Vaqueiro Ferreira / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-26T00:41:26Z (GMT). No. of bitstreams: 1 Foresti_BernardoPereira_M.pdf: 7267999 bytes, checksum: 1a200bffc0e39d2a529a64080b7ddad0 (MD5) Previous issue date: 2014 / Resumo: Neste trabalho buscou-se desenvolver uma metodologia que se valendo de dados de vibração estrutural de carcaça e da operação de uma bomba do bombeio centrífugo submerso (BCS) fosse capaz de identificar parâmetros da operação deste tipo de máquina, tais como: vazão mássica de líquido e gás, diferença de pressão, eficiência e potência mecânica. Para isso foram adaptados os seguintes métodos de diagnóstico de falhas: Método Baseado na Densidade Espectral de Potência, Método Baseado na Função Resposta em Frequência, Método Baseado na Medida de Coerência, Métodos Baseados nos Parâmetros do Modelo (Geométrico e Não-geométrico), Métodos Baseados nos Resíduos do Modelo (Baseado na Variância e Auto-covariância dos Resíduos) e Método Baseado em Modelos Funcionais. Tais métodos requerem a organização de um banco de dados, na fase de levantamento de referências utilizado para comparação com dados obtidos na fase de inspeção, visando à detecção, identificação e estimação da magnitude das falhas e defeitos, conceitos adaptados para o problema apresentado neste trabalho. A metodologia foi aplicada a dois casos: o primeiro, numérico, baseado em dados obtidos da simulação de um sistema de três graus de liberdade foi utilizado para operacionalização da metodologia e antecipação de problemas e dificuldades em sua aplicação. O segundo, experimental, principal foco deste trabalho, baseado em uma bomba utilizada no bombeio centrífugo submerso. Para aplicação da metodologia ao caso experimental, foi elaborado experimento utilizando uma bomba do BCS de quatro estágios instrumentada operando com escoamento bifásico ar-água em diferentes proporções. Resultados indicaram bom desempenho na detecção do tipo de escoamento (monofásico/bifásico), na identificação da vazão mássica de gás escoado e na estimação da vazão de líquido transportado pelo BCS / Abstract: In this research a method using structural vibration and operational data of a pump module normally used with and electrical submersible pump (ESP) has been developed to identify operational parameters, such as: liquid and gas flow rate, differential pressure, efficiency and shaft power. To this end, the following time-series fault detection and identification (FDI) methods were adapted: Power Spectral Density-based Method, Frequency Response Function-based Method, Coherence Measure-based Method, Parameter-based Method (Geometric and Non-geometric), Residual-based Methods (Residual Variance and Residual Uncorrelatedness) and Functional Model-based Method. For FDI, the methods require the set-up of a data base, in the baseline phase used for comparison with data obtained during inspection. The methodology was applied for two cases: A numerical problem based on a three degrees of freedom system, aiming at making functional the programs used and anticipating problematic issues and experimental data from a real ESP pump module, main focus of this work. The experiment consists of measuring structural vibration, and operational data of an ESP pump while varying liquid and gas flow rates keeping shaft speed and suction pressure constant. Results have indicated successful detection of flow type (monophasic/biphasic), identification of the gas flow and estimation of the liquid flow pumped by the ESP pump / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica

Typical deep level mines use up to 27 ML water per day for mining operations. Multistage centrifugal pumps up to 2500 MW are used in an upward cascading manor to dewater the shaft. The dewatering systems at some mines are automated to enable surface control. Automation of the pumps is typically based on the best practice procedure known when implemented. Best practice procedures are used to ensure safe pumping operations. It was found that pump failures could still occur even with the best practice implemented. Unexpected failures of pumps are of major concern because they can result in the flooding of a mine. Flooding increases the risk of environmental damage and injury to the mining personnel. An additional concern is the maintenance cost of multistage centrifugal pumps. Overhaul cost of a seized multistage centrifugal pump is almost R1-million. The aim of this study was to improve established best practice procedures for pump automation. This could be achieved by investigating the general root cause of failures of automated pumps. Additional instrumentation and protection devices to prevent similar incidents were examined. Revised system control parameters were developed to ensure that the pumps operated within the design specifications. The improved best practices proved to prevent failures as a result of overheating and cavitation. Increasing the pump reliability and availability enabled surface control. The control of the automated dewatering system realised an electricity cost saving of R6-million. The automated system also made it possible to calculate the real-time pump efficiency within 5%. Previous best practice procedure was found to be inadequate to prevent all possibilities of failure. Additional precaution measurements were added to prevent pump failure. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Compressed air makes up an important part of South African precious metal mining processes. Rising operational costs in the struggling mining sector increased the interest of the power utility, Eskom, and mine management in achievable electrical energy savings. Demand side management initiatives, funded by Eskom, realised a significant improvement in electrical energy efficiency of compressed air networks. Supply side interventions further aided optimisation by lowering operational costs. Previous research identified the need for integrating compressed air supply and demand side initiatives. Automated compressor control systems were needed in industry to realise missed opportunities due to human error on manual control systems. Automatic systems were found to be implemented in the industry, but missed savings opportunities were still encountered. This was due to the static nature of these control systems, requiring human intervention from skilled artisans. A comprehensive system is required that can adjust dynamically to the ever-changing demand and other system changes. Commercially available simulation software packages have been used by various mine groups to determine an optimal control philosophy. Satisfactory results were obtained, but the simulations were still based on static control inputs. No simulation system was found that could solve and optimise a system based on real-time instrumentation feedback. By combining simulation capabilities with dynamic control in real time, advanced optimisation could be achieved. Development was done on the theoretical design of the system, where mathematical calculations and the accuracy of the system were evaluated. This study proved that the new controller was viable and, as a result, the development of a fully dynamic control Automation of compressor networks through a dynamic control system iii system incorporating the verified mathematical models followed. All of this was done following a theoretical approach. Intricate control requirements on the supply side were evaluated to determine the impact of new intelligent compressor control strategies. It was found that improved compressor control realised an additional 6.2% electrical energy saving on top of existing savings initiatives. Practical limitations and human perception issues were also addressed. Financial cost-benefit analyses were used to evaluate the viability of using automated compressor control. Ample maintenance data obtained from two leading mining companies was used to evaluate the impact of increased stopping and starting of compressors. Financial cost savings from electrical energy efficiency control strategies were found to considerably outweigh the minimal increase in compressor maintenance. Savings potential on deep-level mines proved to be in the order of 5% of the baseline consumption. When these results are extrapolated to the remaining 22 South African deep-level gold and platinum mines already subjected to demand side management initiatives, potential savings of 12.67 MW can be realised. Based on the Eskom 2014/2015 Megaflex tariff structure, the financial cost saving from 12.67 MW is R61 million. / PhD (Electrical Engineering), North-West University, Potchefstroom Campus, 2015

Typical deep level mines use up to 27 ML water per day for mining operations. Multistage centrifugal pumps up to 2500 MW are used in an upward cascading manor to dewater the shaft. The dewatering systems at some mines are automated to enable surface control. Automation of the pumps is typically based on the best practice procedure known when implemented. Best practice procedures are used to ensure safe pumping operations. It was found that pump failures could still occur even with the best practice implemented. Unexpected failures of pumps are of major concern because they can result in the flooding of a mine. Flooding increases the risk of environmental damage and injury to the mining personnel. An additional concern is the maintenance cost of multistage centrifugal pumps. Overhaul cost of a seized multistage centrifugal pump is almost R1-million. The aim of this study was to improve established best practice procedures for pump automation. This could be achieved by investigating the general root cause of failures of automated pumps. Additional instrumentation and protection devices to prevent similar incidents were examined. Revised system control parameters were developed to ensure that the pumps operated within the design specifications. The improved best practices proved to prevent failures as a result of overheating and cavitation. Increasing the pump reliability and availability enabled surface control. The control of the automated dewatering system realised an electricity cost saving of R6-million. The automated system also made it possible to calculate the real-time pump efficiency within 5%. Previous best practice procedure was found to be inadequate to prevent all possibilities of failure. Additional precaution measurements were added to prevent pump failure. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Compressed air makes up an important part of South African precious metal mining processes. Rising operational costs in the struggling mining sector increased the interest of the power utility, Eskom, and mine management in achievable electrical energy savings. Demand side management initiatives, funded by Eskom, realised a significant improvement in electrical energy efficiency of compressed air networks. Supply side interventions further aided optimisation by lowering operational costs. Previous research identified the need for integrating compressed air supply and demand side initiatives. Automated compressor control systems were needed in industry to realise missed opportunities due to human error on manual control systems. Automatic systems were found to be implemented in the industry, but missed savings opportunities were still encountered. This was due to the static nature of these control systems, requiring human intervention from skilled artisans. A comprehensive system is required that can adjust dynamically to the ever-changing demand and other system changes. Commercially available simulation software packages have been used by various mine groups to determine an optimal control philosophy. Satisfactory results were obtained, but the simulations were still based on static control inputs. No simulation system was found that could solve and optimise a system based on real-time instrumentation feedback. By combining simulation capabilities with dynamic control in real time, advanced optimisation could be achieved. Development was done on the theoretical design of the system, where mathematical calculations and the accuracy of the system were evaluated. This study proved that the new controller was viable and, as a result, the development of a fully dynamic control Automation of compressor networks through a dynamic control system iii system incorporating the verified mathematical models followed. All of this was done following a theoretical approach. Intricate control requirements on the supply side were evaluated to determine the impact of new intelligent compressor control strategies. It was found that improved compressor control realised an additional 6.2% electrical energy saving on top of existing savings initiatives. Practical limitations and human perception issues were also addressed. Financial cost-benefit analyses were used to evaluate the viability of using automated compressor control. Ample maintenance data obtained from two leading mining companies was used to evaluate the impact of increased stopping and starting of compressors. Financial cost savings from electrical energy efficiency control strategies were found to considerably outweigh the minimal increase in compressor maintenance. Savings potential on deep-level mines proved to be in the order of 5% of the baseline consumption. When these results are extrapolated to the remaining 22 South African deep-level gold and platinum mines already subjected to demand side management initiatives, potential savings of 12.67 MW can be realised. Based on the Eskom 2014/2015 Megaflex tariff structure, the financial cost saving from 12.67 MW is R61 million. / PhD (Electrical Engineering), North-West University, Potchefstroom Campus, 2015

Thesis (MScEng)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: The use of micro gas turbines (MGTs) for the propulsion of unmanned aerial vehicles (UAVs) has become an industry standard. MGTs offer better performance vs. weight than similar sized, internal combustion engines. The front component of an MGT serves the purpose of compressing air, which is subsequently mixed with a fuel and ignited to both power the turbine which drives the compressor, and to produce thrust. Centrifugal compressors are typically used because of the high pressure ratios they deliver per stage. The purpose of this project was to design a centrifugal compressor impeller, and to devise a methodology and the tools with which to perform the aforementioned. A compressor impeller adhering to specific performance and dimensional requirements was designed. The new compressor was designed using a mean-line performance calculation code. The use of the code was vindicated through comparison with the results from a benchmark study. This comparison included mean-line, Computational Fluid Dynamic (CFD), and experimental results: the new design mean-line results were compared to the results of CFD simulations performed on the same design. The new design was optimised using an Artificial Neural Network (ANN) and Genetic Algorithm. Prior to and during optimisation, the ANN was trained using a database of sample CFD calculations. A Finite Element Analysis (FEA) was done on the optimised impeller geometry to ensure that failure would not occur during operation. According to CFD results, the final design delivered good performance at the design speed with regards to pressure ratio, efficiency, and stall margin. The mechanical stresses experienced during operation were also within limits. Experimental results showed good agreement with CFD results of the optimised impeller. Keywords: micro gas turbine, centrifugal compressor, impeller, CFD, experimental, optimisation, FEA. / AFRIKAANSE OPSOMMING: Die gebruik van mikrogasturbines vir die aandrywing van onbemande vliegtuie het ‟n standaard geword in die industrie. Mikrogasturbines bied beter werkverrigting teen gewig as binnebrandenjins van soortgelyke grote. Hierdie eienskap verseker dat mikrogasturbines as aandryfmotors vir onbemande vliegtuie uiters voordelig is. Die voorste komponent van ‟n mikrogasturbine dien om lug saam te pers, wat dan met brandstof gemeng en daarna aan die brand gesteek word om krag aan die kompressor en stukrag te voorsien. Sentrifugaalkompressors word tipies gebruik as gevolg van die hoë drukverhoudings wat hierdie komponente per stadium kan lewer. Die doel van hierdie projek was om ‟n sentrifugaalkompressor te ontwerp, en ‟n metode en die hulpmiddels te ontwikkel om laasgenoemde uit te voer. ‟n Kompressor rotor wat voldoen het aan sekere werkverrigtings en dimensionele vereistes is ontwerp. Die nuwe kompressor rotor is met behulp van 1-dimensionele werkverrigting-berekeningskode ontwerp. Die berekeningsakkuraatheid van die kode en díé van ‟n kommersiële Berekenings Vloeidinamika pakket is bevestig deur die berekende resultate te vergelyk met die van eksperimente. Die nuwe rotor is gevolglik deur middel van ‟n Kunsmatige Neurale Netwerk en Genetiese Algoritme geoptimeer. Die Kunsmatige Neurale Netwerk is voor en gedurende optimering deur Berekenings Vloeidinamika simulasies opgelei. Die meganiese sterkte van die geoptimeerde rotor is nagegaan met behulp van ‟n Eindige Element Analise. Dit is gedoen om te verseker dat die rotor nie sal faal by die bedryfspunt nie. Berekenings Vloeidinamika resultate het getoon dat die finale rotor ontwerp ‟n goeie werkverrigting lewer by die ontwerpspoed, met betrekking tot drukverhouding, bennutingsgraad, en stakingsmarge. Eksperimentele resultate het goeie ooreenstemming met die Berekenings Vloeidinamika resultate van die geoptimeerde rotor getoon. Sleutelwoorde: mikrogasturbine, sentrifigaalkompressor, rotor, Berekenings Vloeidinamika, eksperimenteel, optimering, Eindige Element Analise.