A major offshore oil and gas operator faced a pressing issue: excessive vibration in Mud Pump 2 which plays a crucial role in drilling operations. Mud pumps are high-stress, high-maintenance components, and when they’re not running smoothly, operations can suffer. The pump, powered by twin drives and V belts, was experiencing alarming vibration levels that threatened its performance and reliability.
Our Approach
To address these concerns, Sensoteq initiated a comprehensive investigation with a twofold approach:
Vibration Pattern Analysis: We deployed Sensoteq's Kappa wireless sensors to monitor Mud Pump 2 across various load conditions, ensuring we captured a full spectrum of operational states. Eight strategically placed sensors continuously recorded vibration data in real time, providing a detailed view of vibration behaviour throughout the pump’s range of operations.
Physical Observations: Alongside the sensor data, our team conducted physical inspections of Mud Pump 2. By directly observing the pump’s mechanical behaviour at different loads, we could identify potential irregularities or mechanical weaknesses that might be contributing to the excessive vibration.
This dual approach allowed us to gather robust data, combining technical measurements with on-the-ground observations. The goal was clear: uncover the root cause of the vibration and implement a corrective plan to restore optimal performance.
By strategically placing these sensors on the drive end, non-drive end, blower, foot, and base of both motors, we collected comprehensive data on vibration patterns, focusing on critical load conditions.
Key Findings
Machine Operation Analysis
During operational tests, we observed significant changes in vibration as the pump cycled between speeds of 30 and 110 strokes per minute (SPM). High-speed operations (over 90 SPM) produced elevated vibrations in the blower and motors, with Motor B particularly affected even at speeds above 50 SPM.
Motor B Analysis: Foot vs. Base
We detected an average vibration of 3 mm/s between the motor foot and base, an indication that the base may lack sufficient rigidity to support the motor during high-speed operation. This instability likely excited resonant frequencies within the base, amplifying vibrations in the components mounted above.
Physical Observations
During our physical inspection, we discovered a significant issue: an excessive gap between the main motor foot and the base for both Motor A and Motor B, with only 15–20% of the motor foot actually contacting the base. This weak contact likely contributed to instability, leading to increased vibrations and resonant conditions.
Solution & Recommendations
To effectively reduce vibration in both motors and their blowers, it was essential for the client to address the “soft foot” condition of the main motors. This corrective action involved adjusting and securing the motor foot to ensure firm, even contact with the base, eliminating gaps that compromise stability. Reinforcing this foundation minimised vibrations and radically improved performance and structural integrity, leading to smoother operation of the machinery even under high-load conditions.
Through Sensoteq’s precise wireless monitoring and data-driven analysis, the client swiftly identified the root causes of excessive vibration in Mud Pump 2. By uncovering structural issues and pinpointing critical vibration thresholds, Sensoteq enabled them to take targeted corrective actions.
Our findings underscore the importance of robust vibration monitoring in high-demand environments like offshore oil rigs. Sensoteq’s wireless monitoring solutions provided critical insights that enabled precise, data-driven corrective actions, helping ensure that the mud pump operates at peak performance with minimal downtime.
Book a demo today and gain critical insight into how Sensoteq sensors can minimise vibration and increase overall site reliability and efficiency.