Pumps are essential components in power transmission and liquid processing systems. When a pump fails, it can trigger a chain reaction, leading to the failure of other equipment and even complete system shutdown. The higher the manufacturing cost and operational complexity of a pump, the more critical it becomes to continuously monitor its condition. In many cases, failures may not immediately result in downtime, making real-time monitoring and early detection crucial. Pumps are highly sensitive to equipment conditions, often serving as an early indicator of potential issues—such as damaged seals or dry bearings—which can lead to serious damage to impellers and housing.
To enhance equipment usability, it is important to understand how the pump's performance reflects the overall condition of the system. This understanding forms the foundation for developing intelligent diagnostic and monitoring systems for circulating pumps. The goal is to translate this relationship into a minimal set of sensing elements. According to fault analysis from service organizations and users, using 2 to 3 sensors is typically sufficient to assess pump status and detect early signs of failure. These sensors are used to:
- Detect if the pump is running without lubrication
- Monitor bearing temperature
- Measure vibration amplitude
For users, it’s vital to have a clear and concise representation of the pump’s condition. Simply measuring individual values and interpreting them separately is inefficient and requires users to perform their own logical analysis. Setting threshold-based alarms based on actual operating conditions is also essential. However, this approach has limitations unless users have a solid understanding of pump behavior. If the only purpose is to prevent failure, it doesn’t fully reflect the pump’s condition. When a pump is malfunctioning, users often want to know which specific component is at fault. Therefore, evaluations should go beyond simple limit checks.
By intelligently analyzing data from multiple sensors, it’s possible to gain deeper insights into the pump’s condition, surpassing the limitations of single-point measurements. Systems like Pump Expert enable accurate diagnosis with just a few sensors installed on the pump. The system integrates signals, compares them against expert knowledge, and uses methods like fault tree analysis. It identifies reliable measurements, applies thresholds, and logically connects them. Error reports are displayed, helping users make informed decisions. Even before reaching critical thresholds, the system can alert users that the pump is in a potentially dangerous state.
With the help of microprocessors and electronic devices, all these signals and data can be processed efficiently. This allows for quick identification of faulty components and, in some cases, even the root cause of the issue. Users can receive alerts such as "sliding bearing damage," "excessive viscosity in the fluid," or "air in the liquid."
The system provides automated, comprehensive evaluation and offers actionable recommendations to operators. It supports various communication methods, including local displays, infrared interfaces, bus connections, and remote data transmission. This ensures that users can monitor both individual pumps and overall equipment performance. Pump Expert features an intuitive interface, leveraging modern human-machine interaction technology for ease of use.
The system is flexible, adaptable to different pump types, and can integrate with higher-level management systems. The explosion-proof version is suitable for hazardous environments. Combining data analysis with real-time information marks a significant advancement in improving pump performance, reducing maintenance efforts, and paving the way for predictive maintenance.
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