sensors
Article
Monitoring and Predictive Maintenance of Centrifugal Pumps
Based on Smart Sensors
Lei Chen * , Lijun Wei, Yu Wang, Junshuo Wang and Wenlong Li






Citation: Chen, L.; Wei, L.; Wang, Y.;
Wang, J.; Li, W. Monitoring and
Predictive Maintenance of
Centrifugal Pumps Based on Smart
Sensors. Sensors 2022, 22, 2106.
https://doi.org/10.3390/s22062106
Academic Editors: Aiguo Song,
Hongwei Liu, Xinming Li, Xue Wang,
He Tian, Jikui (Jack) Luo, Xinyu Li,
Liang Ren, Qi Zhou and Lei Zhang
Received: 27 December 2021
Accepted: 7 March 2022
Published: 9 March 2022
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iations.
Copyright: © 2022 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
Sensors 2022, 22, 2106. https://doi.org/10.3390/s22062106
School of Mechanical and Power Engineering, Zhengzhou University, No. 100 Science Street,
Zhengzhou 450001, China; 202022202013978@gs.zzu.edu.cn (L.W.); wy1475899830@gs.zzu.edu.cn (Y.W.);
wangyiwww123@163.com (J.W.); liwenlong2660@163.com (W.L.)
* Correspondence: chenlei@zzu.edu.cn
Abstract: Centrifugal pumps have a wide range of applications in industrial and municipal water
affairs. During the use of centrifugal pumps, failures such as bearing wear, blade damage, impeller
imbalance, shaft misalignment, cavitation, water hammer, etc., often occur. It is of great importance
to use smart sensors and digital Internet of Things (IoT) systems to monitor the real-time operating
status of pumps and predict potential failures for achieving predictive maintenance of pumps and
improving the intelligence level of machine health management. Firstly, the common fault forms of
centrifugal pumps and the characteristics of vibration signals when a fault occurs are introduced.
Secondly, the centrifugal pump monitoring IoT system is designed. The system is mainly composed of
wireless sensors, wired sensors, data collectors, and cloud servers. Then, the microelectromechanical
system (MEMS) chip is used to design a wireless vibration temperature integrated sensor, a wired
vibration temperature integrated sensor, and a data collector to monitor the running state of the pump.
The designed wireless sensor communicates with the server through Narrow Band Internet of Things
(NB-IoT). The output of the wired sensor is connected to the data collector, and the designed collector
can communicate with the server through 4G communication. Through cloud-side collaboration, real-
time monitoring of the running status of centrifugal pumps and intelligent diagnosis of centrifugal
pump faults are realized. Finally, on-site testing and application verification of the system was
conducted. The test results show that the designed sensors and sensor application system can make
good use of the centrifugal pump failure mechanism to automatically diagnose equipment failures.
Moreover, the diagnostic accuracy rate is above 85% by using the method of wired sensor and collector.
As a low-cost and easy-to-implement solution, wireless sensors can also monitor gradual failures well.
The research on the sensors and pump monitoring system provides feasible methods and an effective
means for the application of centrifugal pump health management and predictive maintenance.
Keywords: centrifugal pump; smart sensor; edge computing; intelligent diagnosis; predictive maintenance
1. Introduction
In the fields of industrial production and municipal water affairs, centrifugal pumps
have a wide range of applications [1,2]. During the operation of centrifugal pumps, failures
such as bearing wear and impeller imbalance often occur due to various factors such as
equipment deterioration and environmental influences. These failures often occur with
the increase in local temperature and the vibration of the pump [3]. By monitoring the
physical quantities such as the vibration and temperature of the equipment, it is possible to
perceive the operating status of the equipment, analyze and evaluate the health status of
the centrifugal pump, and perform fault diagnosis and prediction for abnormal equipment
to carry out predictive maintenance [4,5] work to ensure the safety of equipment and
personnel [6].
Azadeh et al. [7] proposed a flexible algorithm to classify the condition of pumps
based on support vector machine hyper-parameters optimization and artificial neural
https://www.mdpi.com/journal/sensors
 based on support vector machine hyper-parameters optimization and artificial neura
works. Additionally, the result showed that the support vector classifier improves w
it hybridizes with a genetic algorithm and particle swarm optimization. Orrù et a
introduced a simple and easy machine learning model for early fault prediction of a
Sensors 2022, 22, 2106 trifugal pump in the oil and gas industry. They validated the learning ability 2 of 14 of mac
learning models on the KNIME platform and potential faults are successfully recogn
and classified ensuring good prediction accuracy. KNIME is an open-source softwar
networks.
creating dataAdditionally, the result showed
science. Gonçalves et al. that the support vector
[9] presented a novel classifier improvesmethod
output-only when base
it hybridizes with a genetic algorithm and particle swarm optimization. Orrù et al. [8]
theintroduced
Markov parameters to diagnose faults. Additionally, the method was applied to
a simple and easy machine learning model for early fault prediction of a
nose incipient cavitation
centrifugal pump in the oil and failures in a water
gas industry. They supply
validatednetwork
the learning centrifugal pump. Ahm
ability of machine
al. learning
[10] proposed
models onathe fault
KNIMEdiagnosis
platformmethod for multistage
and potential centrifugal
faults are successfully pumps usin
recognized
formative ratio principal component analysis. These studies mainly focus for
and classified ensuring good prediction accuracy. KNIME is an open-source software on the fe
creating data science. Gonçalves et al. [9] presented a novel output-only method based
extraction of the collected state data, to achieve the purpose of classifying equipmen
on the Markov parameters to diagnose faults. Additionally, the method was applied
ures. The quality
to diagnose of the
incipient state data
cavitation often
failures in determines
a water supply thenetwork
effect of the post-classificatio
centrifugal pump.
gorithm,
Ahmad which
et al. [10]cannot
proposed be aignored. In addition,
fault diagnosis methodthe collectioncentrifugal
for multistage quality ofpumps equipment o
ating
usingstatus information
informative directlycomponent
ratio principal affects whether
analysis.the actual
These project
studies canfocus
mainly be successfull
on
the feature
plemented. extraction of the collected state data, to achieve the purpose of classifying
equipment failures. The quality of the state data often determines the effect of the post-
Given the above situation, this paper focuses on the research and design of intell
classification algorithm, which cannot be ignored. In addition, the collection quality of
collection
equipment equipment for centrifugal
operating status information pump
directlyoperating
affects whetherstatusthe information,
actual project can andbe further
poses an IoT implemented.
successfully system architecture for centrifugal pump status monitoring and fault
nosis, to realizeabove
Given the situation,
real-time this paper focuses
monitoring, health on the researchfault
evaluation, and design of intelli-
diagnosis, and oper
gent collection equipment for centrifugal pump operating status information, and further
trend prediction of pump equipment.
proposes an IoT system architecture for centrifugal pump status monitoring and fault
The following
diagnosis, sectionsmonitoring,
to realize real-time are structured as follows:
health evaluation, Section
fault 2 analyzes
diagnosis, and operationthe applic
scenarios of this of
trend prediction design; Section 3 presents the details of this design. Section 4 furthe
pump equipment.
troduces Thethe
following
proposed sections are structured
general framework. as follows:
SectionSection 2 analyzes
5 presents thethe application and a
experiments
sis of the results. Finally, in Section 6, conclusions and future research4are
scenarios of this design; Section 3 presents the details of this design. Section further
described
introduces the proposed general framework. Section 5 presents the experiments and
analysis of the results. Finally, in Section 6, conclusions and future research are described.
2. Centrifugal Pump Operation Failure and Its Features
2. Centrifugal Pump Operation Failure and Its Features
The structure of a common single-stage horizontal centrifugal pump is shown i
Figure The
1. Itstructure
is mainly of a common single-stage horizontal centrifugal pump is shown in
composed of the base, bearing, pump body, pump cover, pump s
Figure 1. It is mainly composed of the base, bearing, pump body, pump cover, pump shaft,
impeller,
impeller,sealing ring,water
sealing ring, water retaining
retaining ring,ring, and stuffing
and stuffing box [11–13].
box [11–13].

Figure
Figure Typicalstructure
1. 1.Typical structure diagram
diagramofof
thethe
centrifugal pump
centrifugal unit. unit.
pump 1. Base. 2. Waterproof
1. Base. port. port.
2. Waterproof
3. Pump body. 4. Pressure tap. 5. Impeller. 6. Bearing. 7. Support frame. 8. Water retaining ring.
Pump body. 4. Pressure tap. 5. Impeller. 6. Bearing. 7. Support frame. 8. Water retaining ring.
9. Pump shaft. 10. Motor.
Pump shaft. 10. Motor.
After the centrifugal pump is switched on, the pump shaft will drive the impeller to
After
rotate at athe
highcentrifugal
speed, forcingpump is switched
the pre-filled on, the the
liquid between pump shaft
blades will drive
to rotate. the impel
Under the
action of inertial centrifugal force, the liquid moves radially from the center of
rotate at a high speed, forcing the pre-filled liquid between the blades to rotate. Undethe impeller
to the outer periphery [14]. At the same time as the outer circumference, a low-pressure
action of inertial centrifugal force, the liquid moves radially from the center of the imp
to the outer periphery [14]. At the same time as the outer circumference, a low-pre
Sensors 2022, 22, 2106 3 of 14

area will be formed in the center of the impeller, causing the liquid to be sucked into the
center of the impeller. Relying on the continuous operation of the impeller, the liquid
is continuously sucked and discharged. Due to the structure and working principle of
the centrifugal pump, as the equipment ages or the fluid is abnormal, some mechanical
and fluid failures will occur. These failure forms are shown in Table 1, mainly including
loose fault, imbalance fault, misalignment fault, bearing fault, cavitation, water hammer,
abnormal flow passage, etc. [1,2,12,15]. These failure forms will cause changes in the pump
vibration. Therefore, a sensor and IoT system [16–20] can be designed to form a digital
unit and an industrial internet platform for smart pumps, which can effectively perform
signal acquisition, analysis, feature extraction, and fault diagnosis, and realize the digital
upgrading of pump equipment and the intelligent operation and maintenance of pump
units [21,22].

Table 1. The types of faults that often occur when centrifugal pumps are running.

Imbalance fault
Misalignment fault
Mechanical failure
Loose fault
Common faults in the running Bearing fault
state of centrifugal pumps
Cavitation
Fluid failure Water hammer
Abnormal flow passage

2.1. Mechanical Failure

2.1.1. Bearing Fault and Feature
The bearing is an important part of the centrifugal pump that supports the rotor. Due
to poor lubrication, overload, and other reasons, bearing failures will occur. Pitting, peeling,
wear, and other features appear on the rolling bearing components, causing bearing wear,
vibration, and impact [1,2,23]. As the wear continues and intensifies, it is often accompanied
by a rise in temperature. It can be monitored and judged by the total vibration value, the
vibration value under the narrow band frequency, and the kurtosis index reflecting the
impact characteristics [24].

2.1.2. Misalignment Fault and Feature

If there is a displacement or angular deviation of the shaft centerline at both ends
of the centrifugal pump coupling, it will cause misalignment and increase vibration. In
terms of frequency spectrum characteristics, it often causes changes in vibration amplitude
at two times the operating frequency [25]. Depending on the cause of the misalignment,
angular deviation, or displacement deviation, which causes vibration changes in the axial,
radial, or two directions at the same time, it can be monitored and judged by the data of
the two axial directions of the three-axis sensor.

2.1.3. Imbalance Fault and Feature

Due to processing or assembly errors, uneven material quality distribution, or impeller
defects, fouling or blockages during operation, the rotating parts of the centrifugal pump
have eccentric or unbalanced masses, causing unbalanced forces. Under the excitation
of unbalanced force, the vibration response of the system changes [26]. The vibration
change caused by imbalance is mainly manifested at the power frequency and the vibration
amplitude changes with the change in the speed.

2.1.4. Loose Fault and Feature

Centrifugal pump loosening failure generally manifests as two types of loose founda-
tion or looseness caused by the poor fit between components [27,28]. Among them, loose
Sensors 2022, 22, 2106 4 of 14

foundation, such as loosening of foundation screws, has the characteristics of prominent

working frequency components and fixed vibration direction in vibration characteristics;
looseness caused by poor assembly often has spectral characteristics of superimposed
working frequency and high-order harmonics.

2.2. Fluid Fault

2.2.1. Abnormal Flow Passage and Feature
During the operation of the centrifugal pump, due to blockages in the volute, improper
assembly of the impeller, etc., the overall vibration of the centrifugal pump will increase
and the pump efficiency will be reduced [13]. The characteristics of the vibration signal are
mainly manifested as the blade passing frequency in the vibration signal is outstanding
and the vibration intensity increases significantly with the increase in the rotation speed of
the centrifugal pump.

2.2.2. Water Hammer Fault and Feature

Due to the sudden opening and shutdown of the centrifugal pump or the sudden
change in the valve, the phenomenon of shock caused by the sudden change in the flow in
the pump body and the surrounding pipeline is called a water hammer [29]. A slight water
hammer is often accompanied by a short and weak vibration and noise. A severe water
hammer can make the pressure in the pump body or pipeline hundreds of times higher than
normal, causing damage to the centrifugal pump components or pipeline bursts, etc. [30].
When a centrifugal pump water hammer failure occurs, it is manifested as the amplitude of
the time-domain waveform of the vibration signal increasing sharply and then decreasing
rapidly. It is a typical shock signal, and the amplitude of the high-frequency part is more
prominent in the frequency domain.

2.2.3. Cavitation Fault and Feature

Cavitation is a common problem of centrifugal pumps, which can cause an increase in
pump vibration and noise, decrease in performance, and cause serious damage to pump
parts [31,32]. There are many reasons for cavitation, but from the perspective of vibration
response, whether it is caused by turbulence, internal reflux, or other reasons, it will
show a shock vibration response [33]. The vibration feature of such a cavitation fault is a
continuous wide-band signal. At the bottom of the spectrogram, there will be an overall
uplift relative to the normal signal. Generally, there is a response from 300 Hz (or even
lower) to the upper limit of the frequency band. A band-pass filter can be added to the
signal, and for a signal in the passband, such as 500–2000 Hz, features are extracted to
determine whether cavitation occurs or not.

3. Smart Collection Equipment

To realize the purpose of intelligent diagnosis of the centrifugal pump, the data
acquisition equipment installed on the centrifugal pump is designed and developed to
provide a data basis for the realization of the system functions, mainly including wireless
sensors, wired sensors, and intelligent collectors. The wireless sensor is connected with the
cloud platform data layer interface through NB-IoT [34,35] to form a wireless application
scheme; the wired sensor result is connected to the data collector, and the data collector
uploads the collected result to the cloud server through 4G communication to form a wired
application. Solution: according to the different application scenarios of the monitored
pump, wireless or wired sensors can be used to complete data collection. The system
topology diagram of the smart collection equipment is shown in Figure 2.

3.1. Wireless Sensor

The wireless sensor transmits data to the server through the NB-IoT communication
method. However, because of the battery power supply, the collection and transmission
need to consume electrical power, which affects its battery life. From the perspective of
 Sensors 2022, 22, 2106 5 of 14

Figure 2. System topology diagram of the smart collection equipment.

industrial equipment maintenance, the sensor needs to have a service life of 2 years or more,
and then the battery is replaced during the maintenance process. Data transmission adopts
3.1. Wireless Sensor
an interval collection and transmission method, and a group of data is transmitted every
half ansensor
The wireless hour under rated conditions
transmits data tototheensure the service
server throughlife of theNB-IoT
the battery. The sensor
communicatio
adopts MEMS chip design and integrates three-axis vibration and 1-channel temperature
method. However, because of the battery power supply, the collection and transmissio
measurement to obtain a more comprehensive source of information. It supports MQTT
need to consume
(Messageelectrical power, Transport)
Queuing Telemetry which affects its batteryprotocol,
data communication life. From the
and the edgeperspective
calcu- o
lation function
industrial equipment supports digitalthe
maintenance, integration,
sensorvibration
needs characteristic
to have a value,servicestatistical
life of value
2 years o
calculation functions, and can determine whether to transmit the complete original signal
more, and then the battery is replaced during the maintenance process. Data transmissio
transmission schedule according to whether the set feature value threshold exceeds the
Sensors 2022, 22, x FORadopts an interval
PEER REVIEW standard.collection and transmission
The parameters used to configuremethod, andcana be
the collector group
issuedoffrom
data theisserver,
transmitte
5 of 14
every half an hour under rated conditions to ensure the service life of the battery. Th
and OTA (Over The Air) remote upgrade is supported. The circuit block diagram of the
wireless sensor is shown in Figure 3.
sensor adopts MEMS chip design and integrates three-axis vibration and 1-channel tem
perature measurement to obtain a more comprehensive source of information. It support
MQTT (Message Queuing Telemetry Transport) data communication protocol, and th
edge calculation function supports digital integration, vibration characteristic value, sta
tistical value calculation functions, and can determine whether to transmit the complet
original signal transmission schedule according to whether the set feature value threshol
exceeds the standard. The parameters used to configure the collector can be issued from
the server, and OTA (Over The Air) remote upgrade is supported. The circuit block dia
gram of the wireless
Figure sensor
Figure 2. System
2. System is shown
topology
topology diagram in
diagram of Figure
of the
the 3.
smart collection
smart collection equipment.
equipment.

3.1. Wireless Sensor

The wireless sensor transmits data to the server through the NB-IoT communication
method. However, because of the battery power supply, the collection and transmission
need to consume electrical power, which affects its battery life. From the perspective of
Block diagrammaintenance,
Figure 3.equipment
industrial of a wireless sensorthe circuit.
sensor needs to have a service life of 2 years or
Figure 3. Block diagram of a wireless sensor circuit.
more, and then
Since thethe battery
wireless is replaced
sensor during theand
is battery-powered maintenance process.
needs to collect Data transmission
and transmit data at
adopts an interval
intervals, this collection
working and
mechanism transmission
makes the method,
diagnostic
Since the wireless sensor is battery-powered and needs to collect and transmit and a group
function of of
the data
wirelessis transmitted
sensor dat
every half an
solution hour Some
limited. underoccasional
rated conditions
equipment to failures
ensure cannot
the service life of the
be effectively battery. The
monitored
at intervals, this
sensor
working
and adopts
judged, such
MEMS
mechanism
aschip
water hammer
design
makes the diagnostic
andfailures of centrifugal
integrates
function
three-axispumps, butof
vibration
the
for
and the wireless senso
gradual tem-
1-channel
solution limited.
perature Some
deterioration occasional
of equipment
measurement equipment
to obtainfailures,
a more such failures
as imbalance,
comprehensive cannot be wear,
bearing
source effectively
of monitored
etc., it can
information. still be
It supports an
judged, such
MQTTeffectively
as water
(Messagemonitored
hammer
Queuingand diagnosed.
failures
Telemetry of centrifugal
Transport) data pumps, but for the
communication gradual
protocol, anddeterio
the
edge3.2.calculation
ration of equipment function
Wired failures,
Sensors andsuch supports digital integration,
as imbalance,
Collectors bearing wear, vibration
etc.,characteristic
it can still be value, sta-
effectivel
tistical value
monitored and diagnosed. calculation functions, and can determine whether to transmit
The wired sensor is connected to the collector through the IEPE (Integrated Electronics
the complete
original signal transmission
Piezo-Electric) interface, the schedule according
analog quantity to whether
is converted into athe set quantity
digital feature value
through threshold
the
exceeds
collector to complete the digitization and carry out the edge calculation to realize the signalfrom
the standard. The parameters used to configure the collector can be issued
3.2. Wired the
Sensors and Collectors
server,extraction.
and OTA Due (Over
feature to The Air) remote
the external powerupgrade is supported.
supply operating mode, The
datacircuit block dia-
acquisition
The wired sensor is connected to the collector through the IEPE (Integrated of
gramand of the wireless
processing can sensor
be is shown
performed in Figure
continuously 3.
and in real time. The block diagram Electron
the wired sensor and collector circuit principle is shown in Figure 4. The wired sensor
ics Piezo-Electric) interface, the analog quantity is converted into a digital quantit
uses the same triaxial MEMS sensor chip as the wireless sensor to ensure the consistency
through the of collector
bandwidth toandcomplete
measurementthe accuracy
digitization and
when the carryand
wireless out thesolutions
wired edge calculation
collect t
realize the signal feature
vibration signals.extraction. Due of
The analog output tothe
thewireless
external power
sensor supply
is connected operating
to the collector mode
through a standard interface. The collector uses 220 V AC power supply, has 4G, WIFI,
data acquisition and processing can be performed continuously and in real time. The bloc
RJ45, RS485,diagram
and otherof adata interfaces, and has rich data communication functions. A
diagram ofFigure
the 3. Block
wired
24-bit sensor and
AD converter
wireless
collector
is adopted
sensor circuit.
circuit
to ensure principle isaccuracy
the measurement shownrequirements.
in Figure 4.The The wire
sensor uses the same
collector
Since thetriaxial
wirelessMEMSsensor issensor
processor is designed chip as the
with a high-performance
battery-powered andwireless
needs to sensor
ARM (Advanced
collect and to ensure
RISC
transmitthe
Machine)
datacon
processor
sistency ofatbandwidth and is equipped with an embedded LINUX operating system to ensure rich edge
intervals, thisand
data preprocessing
measurement
working mechanism
capabilities.
accuracy when
makes theprogram
The embedded
thefunction
diagnostic wireless
supports OTAof
and wired sensor
the wireless
remote upgrades.
solution
collect vibration
solutionsignals. The analog
limited. Some occasional output
equipmentof the wireless
failures sensor
cannot is connected
be effectively monitored to the
and co
judged,
lector through a such as water
standard hammer failures
interface. of centrifugal
The collector uses pumps,
220 V AC but for
powerthe gradual
supply, deterio-
has 4G
ration of equipment failures, such as imbalance, bearing wear,
WIFI, RJ45, RS485, and other data interfaces, and has rich data communication function etc., it can still be effectively
monitored and diagnosed.
 A 24-bit AD converter is adopted to ensure the measurement accuracy requirements. The
collector processor is designed with a high-performance ARM (Advanced RISC Machine)
Sensors 2022, 22, 2106
processor and is equipped with an embedded LINUX operating system to 6ensure of 14
rich
edge data preprocessing capabilities. The embedded program supports OTA remote up-
grades. In addition to retaining the vibration measurement interface, the collector can also
In addition to retaining the vibration measurement interface, the collector can also be
be connected to process quantity sensor signals such as pressure and flow.
connected to process quantity sensor signals such as pressure and flow.

Figure 4. Block diagram of wired sensor and collector circuit principle.

Figure 4. Block diagram of wired sensor and collector circuit principle.
Wired sensors can realize continuous data collection and embedded software can
Wired
easily realizesensors can realize
the functions continuous
of signal data filtering,
preprocessing, collectionintegration,
and embedded
feature software
value can
easily realize
calculation, thereal-time
and functions of judgment
fault signal preprocessing, filtering,
according to the integration,
configuration of the feature value cal-
server and
the threshold
culation, setting. Combined
and real-time with feature
fault judgment judgment,
according to theitconfiguration
can also effectively
of themonitor
server and the
occasional setting.
threshold faults. Combined with feature judgment, it can also effectively monitor occa-
sional faults. and Diagnosis
3.3. Monitoring
The embedded programs of wireless sensors and collectors integrate the basic al-
3.3. Monitoring and Diagnosis
gorithm library, which can perform calculations such as filtering, integration, Fourier
The embedded
transform, etc., extractprograms of wireless
the main vibration sensors index,
characteristic and collectors integrate whether
and then determine the basic algo-
to upload
rithm complete
library, whichrawcandata according
perform to the magnitude
calculations of the feature
such as filtering, indicators,
integration, re- trans-
Fourier
duce the requirements of network transmission bandwidth, and increase the real-time
form, etc., extract the main vibration characteristic index, and then determine whether to
monitoring
upload and diagnosis
complete raw dataof equipment
accordingfailures.
to the magnitude of the feature indicators, reduce
Digital devices such as wireless sensors and collectors upload the characteristic pa-
the requirements of network transmission bandwidth, and increase the real-time moni-
rameters of vibration and part of the raw data to the server. The server software conducts
toring and diagnosis of equipment failures.
data modeling and analysis and divides into a variety of working conditions according to
Digital devices
the different operatingsuch
loadsasand
wireless
speedssensors and collectors
of centrifugal upload
pumps, and finallythe characteristic
completes the pa-
rameters of vibration and part of the raw data to the server. The server software
automatic identification and diagnosis of common faults to realize the intelligent operation conducts
data modeling and
and maintenance analysis and divides into a variety of working conditions according to
of equipment.
the different operating loads and speeds of centrifugal pumps, and finally completes the
4. Overall System Architecture
automatic identification and diagnosis of common faults to realize the intelligent opera-
For better
tion and application
maintenance in reality, we further propose an IoT system architecture for
of equipment.
centrifugal pump status monitoring and fault diagnosis in this paper. The system topology
diagram is shown in Figure 5. It is mainly composed of four main parts: the monitored
4. Overall System Architecture
object, the edge device layer, the platform layer, and application layer.
For
The better application
first layer in reality,
is the monitored wethat
object, further
is, thepropose
equipmentanwe
IoTneed
system architecture
to monitor. In for
centrifugal
this article, itpump
is the status monitoring
centrifugal pump unit. and fault diagnosis in this paper. The system topol-
The second
ogy diagram layer isin
is shown the edge device
Figure layer, which
5. It is mainly mainlyof
composed includes sensors
four main andthe
parts: collec-
monitored
tors. Through these sensors and collectors, the digitization of
object, the edge device layer, the platform layer, and application layer.pump equipment operation
information is realized. The digitized equipment is an important part of the pump and
completes the intelligent upgrade of the pump. In the edge collection equipment, complete
signal collection, and preprocessing, the edge calculation and judgment of main features
are realized and cooperate with the data model of the cloud platform to realize edge–cloud
collaboration and improve the real-time and reliability of monitoring and diagnosis.
Sensors 2022, 22, x FOR PEER REVIEW 7 of 1
Sensors 2022, 22, 2106 7 of 14

Platform layer Application layer

Equipment
Cloud Server Manager

Terminals

The edge device

layer

Collector

Wireless Sensor Wired Sensor Wireless Sensor

The monitored object

Figure5.5.System
Figure System topology
topology diagram.
diagram.

The
Thethird
first layer
layer isis the
the platform
monitoredlayer, which
object, thatmainly
is, theprovides
equipment an Internet
we needservice
to monitor. In
platform, consisting of a cloud server
this article, it is the centrifugal pump unit.and software running on it. Data modeling and
algorithm improvement can be performed on the server. The operation status evaluation
The second layer is the edge device layer, which mainly includes sensors and collec
and fault diagnosis of the equipment are realized according to the data collected by the edge
tors. Through these sensors and collectors, the digitization of pump equipment operation
device layer. With the continuous accumulation of data, the platform layer can realize the
information
big data learningis realized. The digitized
of alarm thresholds equipment
and send is anresults
the learning important part of criteria
and judgment the pump and
completes the intelligent upgrade of the pump. In the edge collection
to the edge hardware devices. Finally, the analysis results of the cloud server are providedequipment, com
plete
to signalthrough
end-users collection, and preprocessing,
the application layer. the edge calculation and judgment of main fea
turesThe
arelast
realized
layer and
is thecooperate with
application the data
layer. modelserver
The cloud of theprovides
cloud platform to realize
algorithms and edge–
computing power for the monitoring, evaluation, diagnosis, and prediction of
cloud collaboration and improve the real-time and reliability of monitoring and diagnosis centrifugal
pumps,Theand connects
third layer isthethe
diagnosis
platformresults
layer,with
whichenterprise
mainlybusiness
providessystems to form
an Internet a
service plat
centrifugal pump health management and predictive maintenance system. Equipment
form, consisting of a cloud server and software running on it. Data modeling and algo
managers can check the running status of monitored objects on various devices such as web
rithm improvement can be performed on the server. The operation status evaluation and
pages and mobile terminals and arrange maintenance and production plans in a targeted
fault diagnosis
manner accordingoftothethe equipment are realized
results of monitoring and according
diagnosis. to the data collected by the edge
device layer. With the continuous accumulation of data, the platform layer can realize the
big data learning of alarm thresholds and send the learning results and judgment criteria
to the edge hardware devices. Finally, the analysis results of the cloud server are provided
to end-users through the application layer.
The last layer is the application layer. The cloud server provides algorithms and com
puting power for the monitoring, evaluation, diagnosis, and prediction of centrifuga
pumps, and connects the diagnosis results with enterprise business systems to form a cen
 trifugal pump health management and predictive maintenance system. Equipment man-
agers can check the running status of monitored objects on various devices such as web
Sensors 2022, 22, 2106 8 of 14
pages and mobile terminals and arrange maintenance and production plans in a targeted
manner according to the results of monitoring and diagnosis.

5.5.Experimental
ExperimentalTesting
Testingand
andApplication
ApplicationVerification
Verification
5.1. Test Environment
5.1. Test Environment
To
Toverify
verifythe
theavailability
availabilityof
ofthe
thedesigned
designedsensors
sensorsin inthe
thepump
pumpintelligent
intelligentdiagnostic
diagnostic
system,
system, the centrifugal pump produced by Grundfos was selected, which
the centrifugal pump produced by Grundfos was selected, which has
hasaatypical
typical
pump
pumpstructure.
structure.AAtest
testbench
benchwas
wasbuilt
builton
onthis
thisbasis,
basis,as
asshown
shownininFigure
Figure6.6.

Figure6.6.Experimental
Figure Experimentalsetup
setupfor
forfault
faultdiagnosis
diagnosisof
ofthe
thecentrifugal
centrifugalpump.
pump.

Thewireless
The wirelesssensor
sensorand
andthethewired
wiredsensor
sensorwere
wereinstalled
installedvertically
verticallyside
sidebybyside
sideon
onthe
the
bearingbox
bearing boxofofthe
thepump.
pump. TheThe
datadata collection
collection waswas carried
carried out out by wireless
by wireless sensor,
sensor, wiredwired
sen-
sensor,
sor, and collectors,
and collectors, respectively,
respectively, and
and the the intelligent
intelligent diagnostic
diagnostic test verification
test verification of cen-
of centrifugal
trifugal
pump pump imbalance,
imbalance, misalignment,
misalignment, looseness,looseness,
cavitation,cavitation, bearing
bearing wear, wear,faults
and other and other
was
faults was completed.
completed. The vibration The vibrationexperiment
diagnostic diagnostic is experiment
carried outisoncarried out onpumps,
centrifugal centrifugal
and
the experimental
pumps, centrifugal pump
and the experimental includespump
centrifugal NK, NKE, CR,NK,
includes etc. Grundfos
NKE, CR, series centrifugal
etc. Grundfos se-
pump. In this article,
ries centrifugal pump.theIndiagnosis of centrifugal
this article, the diagnosis pump fault analysis
of centrifugal pumpis described as anis
fault analysis
example
describedofasexperiments
an exampleon of the NKE pump.
experiments on theThe
NKEmain parameters
pump. The main of the experimental
parameters of the
pump are shown
experimental pump in Table 2. Experiments
are shown are carried out
in Table 2. Experiments arewith independently
carried developed
out with independently
wireless
developed andwireless
wired three-axis
and wired acceleration sensors. These
three-axis acceleration sensors
sensors. Thesehave a sensitivity
sensors of
have a sensi-
200 mV/g. These sensors are fastened in the radial direction of the bearing housing
tivity of 200 mV/g. These sensors are fastened in the radial direction of the bearing housing using
strong glue bonding.
using strong glue bonding.

Table2.2.Main
Table Mainparameters
parametersofofthe
theexperimental
experimentalpump.
pump.

Parameter
Parameter Numeric
NumericValue
Value
Type of of
Type pump
pump NKE 40-250/255
NKE 40-250/255
Rated power
Rated power (kW) (kW) 22 22
Rated speed
Rated speed (rpm) (rpm) 2940
2940
Center height (mm) 185
Center
Numberheight (mm)
of impeller blades 185 5
Number of impeller
Mains frequencyblades
(Hz) 5 50
MainsType
frequency (Hz)
of bearing 50 roller bearing
Cylindrical
Type of bearing Cylindrical roller bearing
5.2. The Process of Testing
To more realistically simulate the various failures of centrifugal pumps in reality,
we conducted different experiments. Detailed test steps for different kinds of faults are
shown below:
(1) Imbalance fault:
 5.2. The Process of Testing
5.2. The Process of Testing
To more realistically simulate the various failures of centrifugal pumps in reality, we
To more realistically
conducted simulate theDetailed
different experiments. various test
failures
stepsoffor
centrifugal pumps
different kinds ofin reality,
faults are we
shown
conducted
below: different experiments. Detailed test steps for different kinds of faults are shown
Sensors 2022, 22, 2106 below: 9 of 14
(1) Imbalance fault:
(1) Imbalance fault:
Make 3 impellers with different unbalance levels in the factory, the unbalance levels
Make
are 3 impellers
11, 15, and 20 g.with different unbalance levels in the factory, the unbalance levels
are 11, 15,Make
and 3 impellers
20 with different unbalance levels in the factory, the unbalance levels
g. the unbalance
are Step
11, 15,1:and
Install
20 g. impeller on the pump.
StepStep
1: Install
2: Setthe
the unbalance
pump impeller
speed to on the
1800, pump.
2400, orpump.
3000 r/min (almost 60%, 80%, 100% of
Step Step
2: Set1: the
Install
pumpthe unbalance
speed to impeller
1800, 2400, on
or the
3000 r/min (almost 60%, 80%, 100% of
the rated
Step speed).
2: Set the pump speed to 1800, 2400, or 3000 r/min (almost 60%, 80%, 100% of
the ratedStep
speed).
3: Power on the pump, and keep the pump working for 5–10 min.
the rated speed).
StepStep
3: Power on the thepump, and keep the pump working for 5–10 min.
Step 3: Record
4: Power on result.
the pump, and keep the pump working for 5–10 min.
StepStep
4: Record the result.
Step 5:4: Power
Recordoff thethe pump.
result.
StepStep
5: Power
6: off the
Repeat the pump.
2–5 steps 3 times for each speed.
Step 5: Power off the pump.
StepStep
6: Repeat
7: the 2–5
Replace steps impeller
another 3 times for
to each
test speed.
again.
Step 6: Repeat the 2–5 steps 3 times for each speed.
Step 7: Replace another impeller to test again.
(2) Misalignment
Step 7: Replace fault:
another impeller to test again.
(2) Misalignment fault:
(2) The misalignment
Misalignment includes parallel misalignment and angle misalignment, Figures 7
fault:
The8misalignment
and show the actual includes parallel misalignment and angle misalignment, Figures 7
condition.
and 8 show Thethe
misalignment includes parallel misalignment and angle misalignment, Figures 7 and 8
actual condition.
show the actual condition.

Figure 7. Parallel misalignment.

Figure
Figure 7. Parallel
7. Parallel misalignment.
misalignment.

Figure 8. Angle misalignment.

Figure 8. Angle misalignment.
Figure 8. Angle misalignment.
Step 1: Adjust the pump to work in the best condition.
Step 1: Adjust the pump to work in the best condition.
Step
StepStep 2: Adjust
1: Adjust the parallel
the pump misalignment
to work as the following level shown in Table 3.
in the best condition.
2: Adjust the parallel misalignment as the following level shown in Table 3.
Step 2: Adjust the parallel misalignment as the following level shown in Table 3.
Table 3. Parameter setting of misalignment fault.
Table 3. Parameter setting of misalignment fault.
Table 3. Parameter setting of misalignment fault.
Serial Number Misaligned (Parallel) Level (µm) Misaligned (Angle) Level (µm)
Serial Number Misaligned (Parallel) Level (μm) Misaligned (Angle) Level (μm)
Serial Number
1 1 Misaligned (Parallel) Level
Initial (μm) Misaligned (Angle)
Initial Level (μm)
Initial
Initial
1 2 2 Initial − 500 −
Initial 3000
−500 −3000
2 3 3 −500−200 −200 −3000 −1500
−1500
4 +200 +3000
3 4 5 −200+200 +500 −1500+3000
+1500
4 5 +200+500 +3000+1500
5 +500 +1500
Under the same parameters of parallel misalignment or angle misalignment, three dif-
Under
ferent the
speeds ofsame
1800, parameters of parallel
2400, and 3000 r/min weremisalignment or min.
run for 5–10 angle misalignment, three
Under the same parameters of parallel misalignment or angle
different speeds of 1800, 2400, and 3000 r/min were run for 5–10 min.misalignment, three
(3) speeds
different Loose fault:
of 1800, 2400, and 3000 r/min were run for 5–10 min.
As shown in Figure 9, the four corner screws were defined as 1, 2, 3, and 4. They were
tightened before the test. During the test, the screws were loosened one by one, and the
screw status and cloud results were recorded (every change should be kept for 5–10 min to
make sure the loosening changed the pump state).
 (3) Loose fault:
As shown in Figure 9, the four corner screws were defined as 1, 2, 3, and 4. They were
tightened before the test. During the test, the screws were loosened one by one, and the
Sensors 2022, 22, 2106 screw status and cloud results were recorded (every change should be kept for 5–1010min of 14
to make sure the loosening changed the pump state).

Figure
Figure9.9.Four
Fourcorner
cornerscrews
screwsininthe pump.
the 1, 1,
pump. 2, 2,
3 and 4 represent
3 and thethe
4 represent screws onon
screws thethe
four corners
four of of
corners
the
thepump
pumpfoundation.
foundation.

Thepump
The pumpspeed
speedwas
wasset
settoto1800,
1800,2400,
2400,oror3000
3000r/min.
r/min.
(4)
(4) Bearing fault:
Bearing fault:
Housings
Housingsfor
forbearings in in
bearings thethe
centrifugal pump
centrifugal were
pump artificially
were wornworn
artificially to different de-
to different
grees, and the worn parameters of the experiments were set as shown in Table
degrees, and the worn parameters of the experiments were set as shown in Table 4. 4.

Table
Table4.4.Parameter
Parametersetting
settingofofbearing
bearingouter
outerring
ringwear
wearamounts.
amounts.
Serial Number
Serial Number X (Length)
X (Length)(mm)
(mm) Y Y(Width)
(Width) (mm)
(mm) ZZ
(Depth)
(Depth)(mm)
(mm)
1 0 0 0
1 0 0 0
22 33 15
15 11
33 66 15
15 11
44 1515 15
15 11

To
Totest
testit,it,follow
followthese
thesesteps:
steps:
Step
Step 1: Install oneworn
1: Install one wornbearing
bearingon onthe
thepump.
pump.
Step
Step 2: Set the pump speed to 1800, 2400,oror3000
2: Set the pump speed to 1800, 2400, 3000r/min.
r/min.
Step
Step3:3:Power
Poweron onthe
thepump,
pump,andandkeep
keepthethepump
pumpworking
workingfor
for5–10
5–10min.
min.
Step
Step4:4:Record
Recordthe theresult.
result.
Step
Step5:5:Power
Poweroff offthe
thepump.
pump.
Step
Step 6: Repeat the 3–5 steps3 3times
6: Repeat the 3–5 steps timesforforeach
eachspeed.
speed.
Step 7: Replace another bearing to test
Step 7: Replace another bearing to test again. again.

5.3.Test
5.3. TestResults
Resultsand
andAnalysis
Analysis
Statisticalcalculation
Statistical calculationmethods
methods for for misdiagnosis,
misdiagnosis, missed diagnosis,
diagnosis, andandcorrect
correctdiagno-
diag-
sis in the test: (1) Monitor the vibration amplitude of the sensor in three
nosis in the test: (1) Monitor the vibration amplitude of the sensor in three axial directions axial directions
andthe
and thefault
faultindication
indication index
index value
value simultaneously.
simultaneously.(2) (2)IfIfthe
thetotal
totalvibration
vibrationvalue
valueinin
either
ei-
direction
ther directionof the
of sensor exceeds
the sensor the set
exceeds thealarm threshold,
set alarm therethere
threshold, mustmust
be a diagnostic result.
be a diagnostic
If there
result. is noisdiagnostic
If there result
no diagnostic output,
result it belongs
output, it belongsto missed
to missed diagnosis.
diagnosis.IfIfthe
thediagnosis
diagno-
result is inconsistent with the actual fault, it is a misdiagnosis. (3) If the total
sis result is inconsistent with the actual fault, it is a misdiagnosis. (3) If the total vibration vibration
valueinineither
value eitherdirection
direction of
of the
the sensor
sensor does
does not
not exceed
exceedthethesetsetalarm
alarmvalue,
value,diagnosis
diagnosiscan
canbe
omitted. (4) The total vibration value does not exceed the alarm threshold, but a certain
characteristic index change triggers the diagnostic logic. If a diagnosis is made, when
the diagnostic output result is consistent with the actual form of failure, the diagnosis is
considered correct; if the output diagnostic results do not match the actual situation, it is
a misdiagnosis. (5) Use precision (P), recall (R), error rate (ER), and accuracy (A) [36,37]
Sensors 2022, 22, 2106 11 of 14

as performance indicators to evaluate the fault diagnosis results. P, R, ER, and A can be
obtained using the following equations:

TP
P= (1)
TP + FP

TP
R= (2)
TP + FN
FP + FN
ER = (3)
TP + TN + FN + FP
TP + TN
A= = 1 − ER (4)
TP + TN + FN + FP
In Equations (1)–(4), the terms TP, FN, FP, and TN, respectively, represent true positive,
false negative, false positive, and true negative, as shown in Table 5. In a practical test
statistic, the value of TP is the number of correct diagnoses, the value of FP is the number
of misdiagnoses, and the value of FN is the number of missed diagnosis. The sum of TP,
TN, FN, and FP is the number of test samples.

Table 5. The status table of real value and diagnosis.

Diagnosis: Fault A Diagnosis: Normal or Other Faults

Real: Fault A True positive False negative
Real: Normal False positive True negative

According to the above principles, the imbalance fault and misalignment fault were
tested and recorded at three speeds of 1800, 2400, and 3000 rpm, respectively, and the
statistical results were as follows.
As shown in Table 6, for the imbalance fault, the diagnostic accuracy and precision
of the wired sensor are slightly lower than that of the wireless sensor, but the recall rate
of the diagnosis is higher than that of the wireless sensor. For misalignment faults, the
diagnostic accuracy, precision, and recall of wired sensors are higher than those of wireless
sensors. Because in practical applications, to meet the power consumption requirements of
the battery, wireless sensors often use a data collection and upload cycle of 30 min or even
longer. Compared with wired sensors, the collection and upload interval are longer, which
means that it is easy to cause misses or misdiagnoses. The wired way can continuously
sample and transmit to ensure the accuracy of data, and the feature calculation can be
placed on the edge device, which can effectively reduce the requirements for network
bandwidth and improve real-time monitoring.

Table 6. Statistical records of tests for imbalance fault and misalignment fault.

Number Number of Number of Number of Diagnostic Diagnostic Diagnostic

Type of Type of Sample Sample of
of Test Correct Missed Misdiag- Accuracy Precision Recall
Fault Sensor of Normal Failure
Samples Diagnosis Diagnosis nosis

Imbalance Wired 90 35 55 46 4 5 90.00% 90.20% 92.00%

fault Wireless 88 41 47 39 4 4 90.91% 90.70% 90.70%

Misalignment Wired 38 20 18 17 0 1 97.37% 94.44% 100%

fault Wireless 37 23 14 11 2 1 91.89% 91.67% 84.62%

We tested the faults such as loose fault, bearing fault, cavitation, etc., in the same
method, and the automatic diagnosis accuracy, precision, and recall obtained by the test are
shown in Table 7. In Table 7, for bearing fault and cavitation fault, the shutdown operation
was carried out due to the short duration after the failure occurred, and the acquisition and
transmission mechanism of the wireless sensor had the possibility of not collecting data, so
Sensors 2022, 22, 2106 12 of 14

the test results of the wireless sensor were not counted. However, tests have also shown
that if fault data is collected through wireless sensors during equipment failure, correct
fault classification can be performed.

Table 7. Experimental test results.

The Type of Fault The Type of Sensor Diagnostic Accuracy Diagnostic Precision Diagnostic Recall
Wired 90.00% 90.20% 92.00%
Imbalance fault
Wireless 90.91% 90.70% 90.70%
Wired 97.37% 94.44% 100%
Misalignment fault
Wireless 91.89% 91.67% 84.62%
Wired 95.08% 100% 91.43%
Loose fault
Wireless 80.33% 91.30% 83.13%
Wired 100% 100% 100%
Bearing fault
Wireless N.A. N.A. N.A.
Wired 85.71% 100% 85.71%
Cavitation fault
Wireless N.A. N.A. N.A.

The experimental test results show that the designed sensors and the sensor-based
centrifugal pump monitoring and diagnosis system can effectively collect the dynamic
vibration data of the equipment during operation. The fault features are extracted in the
software system and the threshold self-learning of the feature indicators is completed.
The diagnosis system can make correct judgments on faults such as loose faults, impeller
imbalance, rotor misalignment, bearing wear, and cavitation. For wired sensors overall, the
diagnostic accuracy is over 85.71%, the diagnostic precision is more than 90.20%, and the
diagnostic recall rate exceeds 85.71%. For wireless sensors overall, the diagnostic accuracy
is over 80.33%, the diagnostic precision is more than 90.70%, and the diagnostic recall
exceeds 83.13%.
In addition, except for imbalance fault, the acquisition methods of wired sensors and
collectors have higher diagnostic accuracy, precision, and recall than wireless sensors in
various faults. Due to the limitations of its battery and transmission mechanism, wireless
sensors cannot continuously collect signals in real time, resulting in an inability to effectively
monitor and judge some occasional and sudden faults, resulting in lower performance.
However, the wireless sensor method is still effective for faults that deteriorate over time.
It can be used as an effective and low-cost method for monitoring the operation status of
equipment, and at the same time, the installation is more convenient than the wired method.

6. Conclusions
Taking centrifugal pumps as the object of action, this paper studied and designed
digital devices such as wireless sensors, wired sensors, and collectors, and centrifugal
pump monitoring and a diagnosis IoT system that uses these digital devices. Targeted tests
and verifications were carried out for common failure forms. The test results show that
the designed sensors and sensor application system can make good use of the centrifugal
pump fault mechanism and automatically diagnose the equipment failure. Using the
wired sensor and collector, the diagnostic accuracy rate is more than 85%. As a low-cost,
easy-to-implement solution, wireless sensors can also monitor progressive faults very well.
The research of the paper provides a feasible IoT system and a set of practical tools for
equipment health management and digital application of industrial enterprises. We will
also further improve the condition monitoring and fault diagnosis system of centrifugal
pumps in future work.
With the deepening of the application, there will be an increasing amount of sensor
monitoring data connected to the server. These data can be used on the server for the learn-
ing and optimization of the fault diagnosis mechanism model, to improve the threshold
judgment standard of the fault characteristic data, and to improve the diagnostic accuracy
of the existing methods. On the other hand, it can also be used to design a hybrid intelligent
Sensors 2022, 22, 2106 13 of 14

diagnosis model driven by data and mechanism in the future to promote the application of
digital intelligence.

Author Contributions: Conceptualization, L.C. and L.W.; designed and performed the experiments,
L.W., J.W. and W.L.; writing—original draft, L.W. and Y.W.; writing—review and editing, L.C.,
L.W., Y.W. and J.W., supervision, L.C. All authors have read and agreed to the published version of
the manuscript.
Funding: This work is partially supported by the National Natural Science Foundation of China
(51775515), Key Scientific and Technological Projects in Henan Province (182102210016) and National
Key Research and Development Project of China (2016YFF0203104-5).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The data presented in this study are available on request from the
corresponding author. The data are not publicly available due to privacy or ethical restrictions.
Conflicts of Interest: The authors declare no conflict of interest.

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