In the realm of industrial machinery, vibration monitoring has long been heralded as a critical tool for identifying issues in pumps and rotating equipment. The market is awash with low-cost microelectromechanical systems (MEMS)-based vibration sensors, offering a budget-friendly solution for general vibration monitoring. However, while vibration sensors detect when something goes wrong, for pumps they fall short of identifying the root cause of the problem, often leaving maintenance teams with unanswered questions about system anomalies.
A common misconception in the Industrial Internet of Things (IIoT) landscape is that vibration monitoring alone is sufficient for ensuring pump reliability. This oversimplification overlooks a crucial reality: more than 70% of pump issues stem from process-related factors rather than mechanical faults. Studies reveal that nearly half of pump failures arise from operational process conditions, with sealing systems and installation flaws contributing significantly as well.
Vibration: A Second-Order Effect
Vibration is not the root cause of most pump problems but a symptom of underlying process and hydraulic optimizations. For instance, running a pump outside its Best Efficiency Point (BEP) often triggers vibration, but by the time these symptoms manifest, the damage may already require costly repairs or unplanned shutdowns. Addressing vibration without investigating the process only treats the symptom, not the cause.
Root Cause Analysis: A Case Study
Using the Five Whys methodology, consider a scenario where excessive pump vibration occurs:
- Why are we having excessive pump vibration? The seal is starting to fail.
- Why is the seal causing this vibration? The seal is not getting enough coolant and the faces are overheating, causing separation of the faces causing the pump to vibrate.
- Why is the seal not getting enough coolant? Because of inadequate flush pressure going to the seal.
- Why is the seal not getting the right flush pressure? Because no one realized the seal pressure needed to be higher than the pressure of the process, and the process often operates with different operating parameters, making the problem intermittent.
- Why did no one realize the delta pressure was intermittent? Because the process parameters where not being monitored and are difficult to capture and understand.
This example underscores the importance of process monitoring. Without accurate, real-time data on key parameters—such as suction, discharge, and sealing pressures—maintenance teams are left reacting to failures rather than preventing them.
The Process-First Solution
A.W. Chesterton’s approach emphasizes the need for proactive, process-first monitoring. The Chesterton Connect™ system integrates Bluetooth-enabled wireless sensors and a cloud-based platform to monitor critical parameters. These sensors track pressure and other key pumping parameters needed for optimal operation. A cellular gateway transmits data to the cloud, where intelligent algorithms assess pump performance against baseline conditions.
The system’s intuitive interface uses visual indicators, such as color-coded warnings, to notify users of potential issues. This enables everyone, from mechanics to engineers, to quickly assess pump health and take corrective action. Importantly, the solution is backward-compatible, so for existing users it only requires minimal additional sensors, making the upgrade accessible for most facilities.
Benefits of Process-First Monitoring
By focusing on process parameters, Chesterton Connect™ empowers maintenance teams to address issues before they escalate into mechanical failures. Monitoring process conditions can ensure pumps operate near their BEP, improving reliability and reducing or eliminating unplanned downtime. Furthermore, the system eliminates guesswork, offering clarity and actionable insights for better decision-making.
While vibration monitoring is a valuable tool, it is not a comprehensive solution for pump reliability. A process-first approach, like the one enabled by Chesterton Connect™, provides a complete picture, enabling early detection of issues and minimizing downtime. For facilities aiming to stay ahead of costly repairs, investing in advanced process monitoring is a critical step forward in predictive maintenance.
Want to proactively manage your pump reliability? Contact a Chesterton Specialist today to learn more about their innovative solutions. Learn more: https://chesterton.com/equipment-monitoring/chesterton-connect-iiot-home
