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<p>This study presents a three-year industrial field investigation on detecting flow-induced corrosion in a centrifugal pump volute using vibration analysis. Continuous monitoring revealed the sudden onset of a 366.5&#xa0;Hz resonance, corresponding to the pump impeller’s natural frequency. This frequency showed no correlation with known bearing or mechanical faults and was attributed to turbulence-induced pressure pulsations combined with localized corrosion at the volute inlet and outlet. Periodic inspections confirmed severe material loss, supporting the vibration-based diagnosis. The transition from stable harmonic responses to high-amplitude resonance provided a clear indicator of corrosion initiation and progression. To the best of our knowledge, this is the first documented correlation between impeller natural frequency excitation and volute corrosion under real operating conditions. These findings establish the 366.5&#xa0;Hz resonance as a robust diagnostic parameter for predictive maintenance, enabling early intervention and preventing catastrophic pump failure.</p>

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Failure and Root Cause Analysis of Volute Corrosion in a Centrifugal Pump Using Vibration Signal Processing: Excitation of the Impeller Natural Frequency (366.5 Hz) in a Three-Year Case Study

  • 期刊论文

  • 发表日期：

    2025年10月13日

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  • Ali Hemati

摘要

This study presents a three-year industrial field investigation on detecting flow-induced corrosion in a centrifugal pump volute using vibration analysis. Continuous monitoring revealed the sudden onset of a 366.5 Hz resonance, corresponding to the pump impeller’s natural frequency. This frequency showed no correlation with known bearing or mechanical faults and was attributed to turbulence-induced pressure pulsations combined with localized corrosion at the volute inlet and outlet. Periodic inspections confirmed severe material loss, supporting the vibration-based diagnosis. The transition from stable harmonic responses to high-amplitude resonance provided a clear indicator of corrosion initiation and progression. To the best of our knowledge, this is the first documented correlation between impeller natural frequency excitation and volute corrosion under real operating conditions. These findings establish the 366.5 Hz resonance as a robust diagnostic parameter for predictive maintenance, enabling early intervention and preventing catastrophic pump failure.