A22.SOW_REFERENCE_7_Rice_Lake_Reassembly_Report_Phase_II_revised_9.29.16.pdf

FLOW-TECHNICS, INC.

Reassembly Report

For

U.S. Army Corps of Engineers

Rice Lake Habitat

Banner, IL

Submitted by:

FLOW – TECHNICS, INC.

Frankfort, IL.

PHONE: 815-277-2600

FAX: 815-534-5311

Revised 9/29/2016

Introduction

Three VUPX 1001 Submersible Pumps were completed on September 19, 2016 by Flow-

Technics, Inc. The reassembly and testing of all three pumps were completed on the following dates.

Pump #1, serial number 58884, completed Thursday, September 1, 2016

Pump #2, serial number 58885, completed Wednesday, August 31, 2016

Pump #3, serial number 58886, completed Tuesday, August 30, 2016

All 3 pumps were tested Wednesday, September 7, 2016

Reassembly

The lower bearing was installed.

Next, the rotor assembly was installed into the bearing housing.

The new lower probes and bearing sensor were then installed.

The stator was installed next.

Then the motor upper bearing sensors, terminal block and inner cable seals were installed.

Followed by the installation of the upper mechanical seal.

The oil chamber was installed next.

Next the lower seal was installed.

Pressure Tests were completed on all three pumps.

Pump #1 s/n 58884

Start of ½ hour test. End of test holding 7 psi.

Pump #2 s/n 58885

Pump #3 s/n 58886

The propeller o-ring and key were installed.

Next the discharge flow ring and propeller were installed.

Followed by the installation of the wear ring, propeller nut, and the propeller cap.

Next installed was the suction bell.

The cable assembly was attached to the lid and then installed onto the pump.

The power and control cable terminations were completed next.

Pump assembly completed.

All three units were reassembled in the same manner.

On Monday, September 19, 2016 the pumps were skidded and ready for pickup for the following day.

The following pages are the test data for all three pumps.

Sulzer VUPX 1001 Submersible Pumps

U.S. Army Corps. Of Engineers

Location: Rice Lake

Pump #1 S/N 58884 Date: 9/1/2016

MEG Windings: T1 - > 550 @ 1,000V T2 - > 550 @ 1,000V T3 - > 550 @ 1,000V

Motor Resistance: T1-T2 0.1 ohms T1-T3 0.1 ohms T2-T3 0.1 ohms

Motor Thermals: 0.2 ohms at motor 0.7 ohms at cable end

Upper Bearing: 0.1 ohms at motor 0.7 ohms at cable end

Lower Bearing: 0.1 ohms at motor 0.7 ohms at cable end

Connection Chamber Probe: >550m @ 1,000V

Motor Housing Probe: >550m @ 1,000V

Oil Chamber Probe: >550m @ 1,000V

Pump #2 S/N 58885 Date: 8/31/2016

MEG Windings: T1 - > 550 @ 1,000V T2 - > 550 @ 1,000V T3 - > 550 @ 1,000V

Motor Resistance: T1-T2 0.1 ohms T1-T3 0.1 ohms T2-T3 0.1 ohms

Motor Thermals: 0.2 ohms at motor 0.7 ohms at cable end

Upper Bearing: 0.1 ohms at motor 0.7 ohms at cable end

Lower Bearing: 0.2 ohms at motor 0.9 ohms at cable end

Connection Chamber Probe: >550m @ 1,000V

Motor Housing Probe: >550m @ 1,000V

Oil Chamber Probe: >550m @ 1,000V

Pump #3 S/N 58886 Date: 8/30/2016

MEG Windings: T1 - > 550 @ 1,000V T2 - > 550 @ 1,000V T3 - > 550 @ 1,000V

Motor Resistance: T1-T2 0.1 ohms T1-T3 0.1 ohms T2-T3 0.1 ohms

Motor Thermals: 0.1 ohms at motor 0.7 ohms at cable end

Upper Bearing: 0.1 ohms at motor 0.7 ohms at cable end

Lower Bearing: 0.2 ohms at motor 0.8 ohms at cable end

Connection Chamber Probe: >550m @ 1,000V

Motor Housing Probe: >550m @ 1,000V

Oil Chamber Probe: >550m @ 1,000V

0.0

0.0

0.0

.se 0.0

0.02

0.Q1 o 10,000

Pump 1 - Motor Top - Horizontal- Vel SpecIWfm 60000 CPM

9/7/201610:14:28 AM

20,000 30,000 CfM

40,000

I ...... ~ ..... I ..... ' , O/AII 0,0685 in/s O-pk

50,000 60,000 kristen Highlight

0.0

0.0

-'" c.

0.02

0.01 o 10,000

Pump 2 - Motor Top - Horizontal- Vel SpeclWfm 60000 CPM

9/7/20168:47:13 AM

20,000 30,000

CFM

40,000

I <;.oI~"'" I VI , D/AII 0,0576 in/s O-pk

50,000 60,000

0.09

0.07·

0.0

0.05 0.

-"! .s

0.0

0.0

0.02-

0.01 o 10,000

L- ................ /~'"' .... ..+

Pump 3 - Motor Top - Horizontal- Vel SpeclVVfm 60000 CPM

9/7/20169:23:54AM

j

2-0,000 30,000

CFM

40,000

, u:::r ....... , VI , O/AII 0.09866 in/s O-pk

50,000 60,000

FlgUI1! 2·12 Displacement/Velocity sBv6rlty chart.

VIBRATION FREQUENCY - CPM

006 0 0 0 0 00 0 00 00 0 0 0 00 0

0 0 '" '" 00 00 0000 0 0 0 00 0' '" O .. N .. '" 0

0'000 0' 0' 0" 0"

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8.00 1 '" 6.00 '" '" "' 1 I

'- "- , N "- I VAL.UES SHOWN .... RE FOR

, FILTERED RE AOINGS TAKEN

4.00 ON THE ........ CHINE STRUCTURE

~ "- '- 'l "- OR BEARING C AP.

3.00

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2-11

Information Provided by Phase

Phase measurements are essential in vibration analysis to diagnose specific machinery problems. Comparative phase measurements are used as follows:

, Balancing-Phase is used to determine the type of unbalance, stalic or dynamic, and to calculate the amount and angular location of correcting weights. It Is also used to evaluate effects of temperature, load, etc.

, Misallgnment- Comparative phase measurements reveal the type of misalignment (angular or offset) and the location.

, Looseness- Phase is used' to detect relative movement in machine components that is due to poor grouting, broken or cracked' foundations, etc.

• Modal Studies- Comparative phase readings can reveal mode shapes in all types of machine structures.

Phase information is obtained using a stroboscopic light trig gered by the vibration signal, a phase reference pickup, or in some cases, an oscilloscope. Details on phase measurement are covered in Chapter 5.

Assessina Vibration Severity (How Much \lib ration is Too Much?)

Because vibration amplitude is a measure olthe severity of the trouble in a machine, your next question should be: How much vibration is too much? To answer this question, it is important to bear in mind that the objective is to use vibration checks to detect trouble in its early stages and schedule an appropriate correction procedure. The real goal is to get a fair warning'of impending trouble, not to determine how much vibration' a machine can withstand before it fails.

There are no realistic figures forselecting a vibration limit which, if exceeded, will result in immediate machinery failure. The events surrounding the development of a mechanical failure are too complex to set any reliable limits. On the other hand, you must have some general Indication of machinery condition that can be evaluated on the basis of vibration amplitude. This is possible through the use of general guidelines that have been developed by experience over many years.

General Vibration S.everity Charts

The vibration severity chart in Figure 2-t2 is one example of a general guide to machinery condition. On this chart, the horizontal axis is scaled in terms of vibration frequency and the vertical axis in terms of displacement. The area between the diagonal lines represent. levels of vibration severity, from EXTREMELY SMOOTH to VERY ROUGH.

If you measure a displacement amplitude of 0.30 mils peak-to peak at a frequency of 3600 CPM, by cross-referencing these two values on the chart, you will find that the machine is operating in the GOOD range. The chart clearly shows that the severity of a machine's vibration depends on both the amount of displacement and Ihe frequency of vibration. As the fre quency of vibration increases, the. amount of displacement

-.£I~re~.ses for a given machine condition (e.g. GOOD).

2-10

Tne same chart is much simpler to use with vibration velocity.

Notice that each of the lines dividing the areas of severity are labeled with a figure for vibration velocity. The SLIGHTLY ROUGH areas, for example, begins at 0.157 in/sec and ends at 0.314 in/sec. Therefore, if you measure a velocity of 0.20 in!

·sec, regardless of the frequency, the chart indicates the ma chine is running SLIGHTLY ROUGH.

The severity chart in Figure 2-13 works much the same way, but uses velocity and acceleration parameters, and covers a higher CPM range. The frequency range, 18,000 to 600,OOOCPM, is plotted along the horizontal axis, and peak acceleration along the vertical axis. You must associate a given acceleration reading with a filtered frequency in order to determine the severity condition of a machine. But notice that you can refer tothe diagonal lines, those representing velocity, to determine the condition solely on the basis of vibration velocity.

_._ ... __ w._·_ .. _. __ " .. _ .. _ ... _ .... -. -.. ------------, ..... --.--.-------kristen Highlight

Rectangle