Acoustic Detection of Leaks in Pumps

Sitrans DA400 (Diagnosis Acoustic) continuously monitors the pump status and detects even the smallest leaks on pump valves.

The new system comprises an acoustic sensor mounted on the pump, and the diagnostics device connected to the sensor by up to twenty meters of cable. With continuous online monitoring of leaks, leakage losses of as low as two percent can be detected, indicating a drop in efficiency of the pump, and unscheduled plant standstills can thus be avoided. The measurement results are displayed online on the diagnostics device, or transferred to the control room over Profibus, and analyzed there in the Simatic PCS 7 process control system, for example.

Sitrans DA400 is suitable for all oscillating positive-displacement pumps as used, for example, in mining, the chemicals industry, petrochemicals, and sewage treatment to pump, say, fluids containing impure solids such as sludge. The diagnostics device in degree of protection IP65 can be operated between minus 20 and plus 60 degrees Celsius, and the sensor in IP66/68 between minus 40 and plus 110 degrees.

The ultrasonic acoustic sensor detects cavitation generated by the structure-borne sound at the leakage point. Previous processes were costly and not sufficiently reliable. In the case of critical pumps, for example, and depending on the load, personnel regularly had to inspect the plant on foot and use their experience to listen for any faults.