Benefits of pump monitoring systems to optimise pump performance

Pump monitoring systems are a tool used in industries as part of best practices employed to prevent failures that lead to significant losses within their production process, so implementing methodologies that minimise risks is essential when it comes to production.

For any industry, pump monitoring systems are an essential part of preventing downtime or deferred production, meaning that detecting faults in a timely manner translates only into benefits and profits.

In this article, we will be showing the benefits of pump monitoring systems for optimising their operation. We will also mention the most common failures that occur in pumps and how predictive or preventive maintenance avoids the risks of plant shutdowns or even fires.

These are the benefits generated by the implementation of pump monitoring systems.

• Pump monitoring systems minimise unnecessary maintenance common with preventive maintenance (based on time), saving costs and downtime for industry.
• With the use of the Online condition monitoring technologies The maintenance cost of a plant or refinery is significantly reduced as it is estimated that pumps represent 7% of the total operating costs, and pump failures are responsible for 0.2 % of production losses.
• Implementing a pump monitoring system prevents catastrophic failures that can lead to costly repairs, such as fires and plant downtime, or in the case of oil wells, the shutdown of the well.
• Manual rounds by operational technicians to collect data and assess pump condition are reduced.
• The use of pump monitoring systems can predict seal leaks and vibration-related failures, thereby helping to minimise environmental and business risks and impact.
• Another benefit of these systems is the online verification of the conditions under which the pump is operating, which leads to an alert for the activation of auxiliary pumps in case of abnormal operating conditions of the pump.
• For events where pumps have previously experienced cavitation, vibration and differential pressure sensors are included, achieving early detection of future failures.
• With online monitoring systems for pumping equipment, the level of protection is expanded to include leak detection or level measurement, allowing for the detection of any sealing failures. 
• Implementing pump monitoring systems can detect bearing failures caused by electrical discharges; allowing preventive measures to be taken, such as the use of grounding rings, if the failure is detected in time.
• Maintenance managers will be able to define the equipment and spare parts needed in advance to prevent system downtime.
• Obtaining information through applications that generate resources such as: reports, trend graphs, variable histories, calculations, predictions, etc.

Many failures of pumping equipment can be predicted using modern monitoring techniques and tools, such as the use of rotating machine alignment systems, Therefore, new and innovative reliability-focused practices for pump monitoring are of great interest to industries; as if you have not initially invested in these systems, it is advisable to consider doing so, to avoid high costs and time spent on maintenance and repair costs due to damage to the system in general.

Pump monitoring systems can prevent the following pump failures:

• Vacuum operation, this is one of the main causes of pump failures and is known as cavitation in its components. It is due to a loss of fluid pressure, and as a consequence, it can burn out the pump. However, this can be avoided with the implementation of a monitoring system.
• Training or sediment deposits. Any type of pump that is exposed to sediment is prone to failure, due to the friction that occurs in its components. Pump monitoring systems generate an alert when they detect the presence of solids or friction between the bearings.
• Elastomer swelling, In the case of progressive cavity pumps, if they are exposed to high temperatures, this is the cause that leads to swelling and/or detachment of the same.
• Lubricant losses, may cause leakage in the seals and friction between the pump elements, preventing it from functioning correctly.

A common failure in a pumping system can cost hundreds of thousands of dollars, and the larger the incident, the much greater the production costs can be. Furthermore, serious issues arise that can affect the safety of plant personnel and nearby communities. In reality, this would be the greatest of all risks that can be avoided by using techniques and methodologies such as monitoring systems that minimise the occurrence of failures.

So, what are the keys to determining the optimal operation of pumps through a monitoring system? First, knowing what needs to be measured, how to interpret it, and when to put that knowledge into practice. All of this can be achieved by obtaining online information, available from any mobile device such as a smartphone.

If you are interested in learning more about other monitoring systems for your plant and how they can help you identify faults, I invite you to subscribe to the Technology newsletter for industry, where you can find interesting information corresponding to the various technologies used in industrial processes.