Tag Archives: rerates

Podcast- Mastering Advanced Vibration Techniques: From Modal Analysis to Motion Amplification

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Hydro’s Glen Powell joined Plant Services’ chief editor Tom Wilk to talk about the evolving challenges of workforce development in the maintenance and reliability space. The conversation also touches on the role of emerging technologies like AI in reliability workflows and dives deep into vibration analysis, including its limitations and advanced applications for diagnosing issues like resonance.

Key Takeaways

  • Formal training alone isn’t enough—intentional, hands-on experience accelerates workforce readiness.
  • Bridging generational gaps requires clear career paths and trust in leadership follow-through.
  • AI tools should support, not replace, critical thinking and field expertise on the plant floor.
  • Modal analysis and motion amplification are powerful tools to diagnose and fix elusive resonance issues in aging equipment.

You can listen to the podcast below or browse all of Plant Services’ Great Question podcasts here.

Want to expand your knowledge? Explore Plant Services magazine or read our case studies focused on Hydro’s work in troubleshooting and vibration analysis.

Engineering a Long-Term Solution

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Figure 1. The pump as received

Many pumps in operation today were designed and manufactured decades ago. As plants require increased capacity, pump systems are expected to meet these higher process flow demands. Without an impeller rerate or change in speed, this increased capacity can be achieved in one of two ways. The individual pumps can supply more flow to the system, resulting in operation out on the pump curve. Alternatively, capacity can be increased by operating more pumps in parallel; in this case operation is pushed back on the curve, as operating another pump in parallel requires less flow from each individual pump to meet total system demand.

Either operational change results in a move away from the pump best efficiency point (BEP). As a result, the original designs and hydraulic characteristics no longer effectively meet plant requirements and detrimental effects from hydraulic instability can occur.

By way of example, this article will discuss a fertilizer plant in the Gulf of Mexico that had a boiler feedwater pump unit that was experiencing performance problems after a significant plant expansion project. Unfortunately, it was not the first time this particular unit had experienced a loss of capacity; the pump had been in operation only 18 months prior to the current issue.

 

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