Pumps and motor pump sets are essential assets in many industrial processes. They are also responsible for high energy consumption and high maintenance costs. Therefore, as they are expensive but indispensable assets, it is necessary to frequently monitor the condition of this equipment, to guarantee optimum performance.
However, periodic monitoring of industrial pump health indicators, such as vibration and temperature data, may not be enough to give a complete picture of their operating status, since this only provides a specific moment in a continuous process.
Therefore, 24/7 continuous monitoring of industrial pump health indicators is the best way to prevent failures and increase the reliability of these assets. Keep reading and see how the Dynamox Solution can identify early signs of wear and potential failures in these machines, thus helping to raise the reliability and availability levels of industrial plants.
Industrial pumps: types, characteristics and applications
Pumps are an asset in most industrial sectors. Their role is to pump fluids and transfer them by displacing a liquid. To transform mechanical work into energy, pumps operate by means of a motor or turbine and are thus able to move the fluid. There are various types of industrial pumps and each one has specific characteristics according to the branch of operation, type of fluid and process characteristics.
Here are some of the types of industrial pumps already monitored by the Dynamox Solution:
Vertical pumps are designed to pump and transport a variety of fluids that require high pressure, high temperature, aggressive liquids and more. They are widely used in water processing systems, ultrafine systems in washing and cleaning systems and acid pumping.
These are industrial pumps designed to move fluids by mechanically engaging gears. For this reason, they are very common in various sectors, including the chemical industry, oil and gas, food and beverages, among others.
This asset promotes the pumping of fluids through the movement of pistons. Piston pumps have many applications in industry and are generally used in hydrostatic transmissions.
The function of this asset is to remove air from a closed volume, generating a vacuum. Vacuum pumps can be used in a variety of areas, including food, pharmaceutical and chemical manufacturing.
This asset is a type of hydraulic pump used to move fluids such as liquids and gases. It consists of vanes that are fitted to a rotor that promotes circulation with the main cavity, thus allowing the liquid to be propelled through pipes or ducts. This asset also has many industrial applications due to its ability to handle different types of fluids.
The centrifugal pump is a type of water pump used for transferring volumes of fluids. Hence, they are often found in the food, pharmaceutical, chemical and agricultural industries.
Monitoring industrial pumps with the Dynamox solution
All the types of industrial pumps mentioned above, and many others, can be monitored by the Dynamox Solution. But how does Dynamox’s automated detection work?
Success case: Water treatment plant detects anomaly in pump
Wireless vibration and temperature sensors
The Dynamox solution is made up of wireless vibration and temperature sensors (DynaLoggers), which continuously monitor asset health indexes. For pumps and motor pump sets, 4 to 10 sensors are recommended, depending on the configuration of each pump. In addition, with IP66 / IP68 / IP69 / EX certified sensors, the Dynamox system detects more than 25 pump failure modes while assisting in industrial plant management.
Automated data collector gateway
To collect the data from these sensors, an automated collector (DynaGateway) is used, connected via Ethernet or Wi-Fi. It communicates with the DynaLoggers, sending the information collected by the sensors directly for analysis on the Dynamox Web Platform. There is no limit to the number of sensors per gateway, making it possible for a single device to collect data from dozens or hundreds of sensors simultaneously. The solution also has an Ex Gateway for classified areas.
Web platform for analysis and diagnosis
After applying the DynaLoggers sensors to the industrial pumps and installing the Gateway around the perimeter of the plant, it’s time to configure the Dynamox Web Platform and App. The automated detection module (DynaDetect) and the sensitive inspection module (DynaSens) ensure greater reliability and precision for the health, performance, and maintenance management of industrial pumps.
DynaDetect – Automated Detection Module
The DynaDetect automated detection module uses information input by the user, such as the type of asset, the machine’s technical data and the monitoring location, combined with data from remote sensing to generate automated diagnostics. This enables the detection of critical mechanical, electrical, and hydraulic faults, such as: unbalance, bearing wear, and gear defects, among others.
In other words, with DynaDetect, it is possible to view automatic diagnostics that highlight the assets at greatest risk of possible failure, as well as identify their severity. These automated diagnoses aim to increase productivity and assertiveness in analysis, as well as to support managers in planning maintenance actions for the assets in their industrial plant.
In addition, the automated detection module analyses and identifies signs of faults in pumps and their components, creating warnings categorized by degree of criticality. In other words, semi-automated reports can be generated from the diagnosis, ensuring more agility in maintenance planning.
DynaSens – Sensitive Inspection Module
The DynaSens sensitive inspection module is an online management service for sensitive inspection routes. The aim is to identify faults in assets by planning, managing, and analyzing route data and checklists, created and configured via the Dynamox Web Platform. It is possible to consult and visualize data from reports generated in the field via dashboards, which give an overview of the situation of each route and the “health” of the equipment.
DynaPump – Specialized Industrial Pump Dashboard
The Dynamox Solution’s specialized pump dashboard allows you to monitor specific metrics for this type of asset. This increases the efficiency of the asset management and maintenance process and contributes to greater industrial plant reliability.
In addition, through advanced filtering and component selection features for motor pumps and industrial pumps, analysis, and warning, the dashboard allows you to identify problems early on and cross-reference information between other machine monitoring points. This allows you to take proactive measures to avoid critical failures, reduce maintenance costs, and minimize shutdowns.
DynaNeo – Visual Management Dashboard
Using the DynaNeo visual management dashboard, it is possible to create dashboards with the most relevant flows for the type of asset or industrial segment. Visualize the main indicators of your production process in real-time, identify which assets need your immediate attention, and access asset health data in a clear and centralized way, speeding up decision-making.
Furthermore, DynaNeo makes it much easier to manage the priorities of your asset management and maintenance process. Select the most important equipment and indicators to set up a personalized flow, and predict the consequences of a shutdown by analyzing the process in a unified way. Quickly find your alarmed assets and identify where your maintenance team should act.
This way, you can drastically reduce the time it takes to identify and solve faults throughout the entire production chain, and guide decisions according to the potential of each asset without interrupting the entire process in case of a failure.
Success Case: Detecting water pump bearing failure
Get to know Dynamox’s complete portfolio of industrial pumps
Check out the complete portfolio about industrial pump monitoring and see all the detectable failure modes, as well as explanations of operation, practical examples, and a case study showing the Dynamox Solution in action!
Do you want to increase the availability and reliability of your industry’s plant assets? Through 24/7 online monitoring and periodic sensitive inspection, Dynamox’s solution identifies early signs of wear and potential failures in industrial pumps and many other types of assets, helping to raise productivity levels and optimize equipment.