Technical Solution for The Vibration Monitoring System of Key Pumps And Fans

1. Project Overview

1.1 Project Background

Rotating machinery such as key pumps and fans operate in continuous running conditions for long‑term service. Issues including unbalance, misalignment, mechanical looseness, bearing faults, gear failures and other defects may occur in components such as bearings, rotors, couplings, gears and foundations during operation.

Conventional manual inspection is subject to long monitoring cycles, insufficient data continuity and delayed detection of anomalies. Therefore, this solution adopts the technical architecture consisting of vibration sensors, edge‑computing acquisition units and data analysis platforms to implement continuous condition‑based vibration monitoring for critical pumps, fans and other equipment.

The system acquires operating‑condition signals of equipment via vibration, displacement and temperature sensors installed at key measuring points of equipment. Signals are wired to edge‑computing acquisition units, which complete data acquisition, signal processing, feature‑value calculation and edge‑side analysis. Processed data is uploaded to upper‑level monitoring platforms or third‑party systems via industrial networks.

2. System Construction Objectives

The system is designed to achieve the following objectives:

1. Realize online vibration monitoring for rotating equipment including key pumps and fans;

2. Realize tri‑axial / single‑axis vibration monitoring of equipment housings;

3. Realize shaft displacement and shaft vibration monitoring for critical rotating equipment;

4. Realize equipment temperature monitoring;

5. Realize calculation and analysis of parameters including vibration acceleration, velocity and displacement;

6. Realize trend analysis of equipment vibration;

7. Realize FFT spectrum analysis and characteristic‑frequency analysis;

8. Realize automatic alarming for equipment anomalies;

9. Realize storage of abnormal data and historical data;

10. Implement on‑site data pre‑processing through edge‑computing acquisition units;

11. Support data uploading to upper‑level monitoring platforms;

12. Enable third‑party systems to obtain data via standard communication protocols.

3. Overall System Architecture

The system adopts a layered‑architecture design:

4.Monitored Objects

The system targets the following equipment:

5. Vibration Sensor Configuration Scheme

5.1 Equipment‑housing Vibration Sensors

Piezoelectric IEPE acceleration sensors are deployed to measure housing vibration of equipment such as pumps and fans.

According to on‑site installation and monitoring requirements, the following configurations are available:

• Single‑axis IEPE acceleration sensor

• Tri‑axial IEPE acceleration sensor

• Magnetic‑mount sensor

• Thread‑mount fixed sensor

Thread‑mount Fixed Sensor

Primarily applied for long‑term online monitoring. Advantages:

• High mounting rigidity

• Stable mechanical coupling

• Good high‑frequency response

• Suitable for long‑term continuous monitoring

Magnetic‑mount Sensor

Main use‑cases:

• Equipment inspection

• Temporary measurement

• Rapid measuring‑point switching

• Locations where permanent drilling installation is impractica

6. Vibration Measuring‑point Layout for Pumps

For typical pumps, measuring points shall be arranged according to equipment structure as shown below:

In practical projects, final measuring‑point layout shall be determined considering:

• Motor structure

• Pump structure

• Bearing positions

• Coupling position

• Equipment running direction

• On‑site installation conditions

7. Tri‑axial Vibration Measurement

Tri‑axial sensors simultaneously measure:

• X direction

• Y direction

• Z direction

Vibration status of equipment in three orthogonal directions can be obtained.

For pumps, fans and similar equipment, it is recommended to define directions in accordance with on‑site mounting orientation:

• X: Axial direction

• Y: Horizontal direction

• Z: Vertical direction

Actual directions shall conform to the on‑site mounting coordinate system and be uniformly calibrated in equipment configuration.

8. Shaft Displacement Monitoring

Eddy‑current displacement sensors are adopted for shaft‑displacement monitoring of critical rotating machinery.

8.1 Axial Displacement

Non‑contact measurement is performed on rotating‑shaft end faces by eddy‑current sensors. It is used to monitor:

• Axial shaft float

• Axial‑displacement trend

• Thrust bearing anomalies

• Rotor operating conditions

8.2 Radial Shaft Vibration

Two mutually perpendicular eddy‑current displacement sensors are deployed.

Dynamic displacement signals in X and Y directions support further calculation of:

• X‑direction shaft vibration

• Y‑direction shaft vibration

• Shaft orbit

• Shaft eccentricity

• 1X vibration

• 2X and harmonic components

9. Edge‑computing Acquisition Unit

The edge‑computing acquisition unit serves as the core for on‑site data acquisition and processing in this solution. Positioned between sensors and upper‑level software platforms, it realizes real‑time on‑site data acquisition, processing, analysis, buffering and uploading.

9.1 Core Functions

Edge‑computing acquisition units implement the workflow: Signal Acquisition → Digital Filtering → Data Processing → Feature‑value Calculation → Edge‑side Analysis → Alarm Judgment → Local Buffering → Data Uploading

10. Edge‑computing Functions

Algorithms supported by acquisition units are listed below:

Time‑domain Analysis

• RMS

• Peak

• Peak‑to‑Peak

• Crest factor

• Kurtosis

• Standard deviation

Frequency‑domain Analysis

• FFT

• Spectrum

• PSD (Power Spectral Density)

• Frequency‑band energy

• Rotational‑frequency analysis

• Harmonic analysis

Signal Processing

• High‑pass filtering

• Low‑pass filtering

• Band‑pass filtering

• Detrending

• Integration

• Signal normalization

11. Calculation of Acceleration, Velocity and Displacement

For IEPE acceleration sensors, after acceleration signals are sampled by acquisition units, velocity and displacement parameters can be obtained via digital signal processing.

Typical processing workflow:

In practical calculation, appropriate high‑pass filtering, band‑pass filtering and detrending shall be applied to prevent DC drift and low‑frequency drift generated during integration.

12. Alarm Functions

Edge‑computing acquisition units support on‑site alarm judgment.

Alarm parameters cover:

• Acceleration

• Velocity

• Displacement

• Temperature

• RMS

• Peak

• Peak‑to‑Peak

• Characteristic frequency band

• Characteristic frequency

Suggested status classification:

Alarm capabilities include:

• Threshold configuration

• Alarm delay

• Alarm recovery

• Alarm hysteresis

• Alarm event logging

• Upload of alarm status

13. Data Upload and Open Interfaces

Edge‑computing acquisition units feature open communication capability. They can upload data to the matching platform as well as provide data for third‑party platforms. Supported protocols & interfaces:

• Ethernet

• TCP/IP

• Modbus TCP

• Modbus RTU

• MQTT

• OPC UA

• HTTP RESTful

• Websocket

• MYSQL

• FTP

14. Cloud‑platform Data Functions

14.1 Real‑time Monitoring

• Equipment status

• Real‑time vibration values

• Real‑time temperature

• Real‑time alarm status

14.2 Graphical Analysis

• Time‑domain waveform

• FFT spectrum

• Trend curve

14.3 Historical Data

• Historical trend

• Historical waveform

• Historical spectrum

• Alarm records

• Data query

14.4 Equipment Diagnosis

Auxiliary judgment based on algorithm outputs for:

• Unbalance

• Misalignment

• Looseness

• Bearing abnormality

• Gear abnormality, etc.

15. System Data Flow

Raw data, feature data and alarm data shall be clearly differentiated.

Acquisition units are not mere data‑forwarding devices; they act as intelligent acquisition nodes with capabilities for on‑site data processing, feature extraction, alarm judgment and edge‑side analysis.

16. Main Hardware Configuration Table

17. Advantages of System Solution

17.1 Unified Access for Multi‑type Sensors

Supports piezoelectric, eddy‑current and temperature sensors simultaneously, satisfying monitoring requirements for pumps, fans and other equipment.

17.2 Online Monitoring

Supports thread‑mount fixed installation for long‑term online monitoring.

17.3 Compatibility of Single‑axis and Tri‑axial Configurations

Single‑axis or tri‑axial sensors can be flexibly configured in accordance with equipment importance and measuring‑point requirements.

17.4 Edge Computing

On‑site data pre‑processing, feature calculation and alarm judgment are completed locally, which reduces load of networks and servers.

17.5 Open Data Architecture

Apart from the proprietary matching platform, acquisition units deliver data via standard protocols to PLC, SCADA, DCS, MES, equipment‑management systems and third‑party platforms.

Yangzhou Xiyuan Electronic Technology Co.,Ltd.

#77 Yeqiao Road, Liandong U Valley slender West Lake Innovation port, building 10-2,Hanjiang District, Yangzhou,Jiangsu,China

Mobie Phone: +86 180-5105-8377

Tel: +86 514-82885589

Whatsapp:+86 182-6066-6867

Email: sale1@yzxyt.com

Fax: +86 514-82885089