Today, modern pumping systems come with alarms that alert pump operators when it exceeds optimal operating conditions or if a component malfunctions. These alarms alert you to things gone wrong in your pumping system. What if your pumping system could alert you before problems occur? This is where “Remote Pump Monitoring” comes into the picture. Thanks to innovations in IIoT (Industrial Internet of Things), wireless sensors and intelligent monitoring systems can remotely monitor your pumps. Remote monitoring opens up an array of opportunities that were not previously available. Here, in this guide, we walk you through the benefits of remote pump monitoring and highlight how it can benefit your pump system.
What is Remote Pump Monitoring?
As the term implies, it’s keeping an eye on your pump systems 24 x 7 without being physically present. It uses sophisticated and wireless cloud-connected devices like sensors, data trackers, and other smart devices to prevent equipment failure, minimize pump downtime, and extend pump life.
Monitoring industrial pumps is highly challenging. Unexpected events like power outages, variations in the transferred fluid can lead to a pump failure at critical times. With remote monitoring, pump operators are provided real-time alerts on operating conditions, which maximizes the efficiency of the pump. If the pump reaches critical operating points, the remote monitoring system immediately alerts the pump operators. The remote monitoring system also provides operators with real-time data to accurately diagnose the situation and take the necessary corrective action.
Another massive benefit of remote monitoring systems is that it reduces maintenance and travel costs. It prevents the need to drive to remote locations to constantly monitor pump operating conditions.
Incredible Benefits of Remote Pump Monitoring
#1: Predict Equipment Failures Before They Occur
Theoretically, a well-designed pumping system should function efficiently for years to come. However, the reality is that several ground factors negatively impact pump life. Several factors can go wrong:
- Clogged suction valves
- Cavitation
- Wear and tear of bearings
- Dry pumps
- Dead head
- Impeller jams, etc.
#2: Monitor Vibration
Auxiliary and critical pump systems often give us hints on when something is wrong under the hood. The key signal to watch out here is – excessive vibrations. Every part of a pumping system has its characteristic vibration pattern, and when something is wrong, these vibrations change.
For instance, if a bearing or seal is about to fail, or if an impeller is on the verge of a breakdown, the vibrations increase. Changes in vibration that are not noticeable to the human eye or ear can be easily spotted by placing a vibration sensor on the pump. The sensor tracks the acoustics of the pump 24 x 7 and detects imbalances, thereby providing early warnings regarding pump issues.
#3: Monitor Pressure
Monitoring the pressure of a pump is a crucial method to identify a pump’s characteristics while increasing its lifecycle. Ideally, a pump should operate at flows (+ or -) 10% of the BEP. Remote pressure sensors can help in identifying critical problems that prevent the pump from running within the BEP.
When a pump strays away from its BEP, the temperature of the motor increases, leading to more stress on seals, bearings, and impellers, which in turn, reduce pump life. It can even lead to premature of the entire pumping system. Pressure sensors can monitor if the pump operates within the BEP limits. Additionally, it can also track pump discharge and alert the operator if there is a drop in suction pressure. This measure prevents the pump from running dry.
#4: Monitor Current Voltage and Amperage
Besides monitoring power failures, remote monitoring systems can also track the pump’s motor current and identify looming problems. When a pump operates at higher power, it leads to overheating, which damages critical internal parts. Other problems caused by over-currents are failed bearings, clogged suction lines, jammed materials, etc.
All current related problems can be detected within milliseconds of its occurrence by using a remote monitoring system.
#5: Monitor Pulse Counts and Run times
Besides detecting problems in the system, remote monitoring equipment comes with sophisticated data systems that indicate the system’s overall functioning. Pump operators can collect, record precise data like flow rates, run times, etc. All these data give more accurate insight regarding your pump system, without any ambiguities.
Wrapping Up
As an industrialist, you spend tens of thousands of rupees on initial pump purchase and installation. To get the maximum value out of your investment, you need to ensure that the pump system operates at maximum efficiency.
A remote monitoring system can help keep your pump optimised while ensuring that it stays out of trouble with effective predictive care and maintenance. The sensors of the remote monitoring system provide a clear picture of the pump parameters and uncover pump failures and breakdowns before they occur.
Get in touch with our team to download our latest industrial pump catalogue. Sintech is the leading industrial pump manufacturer and exporter in India. With years of experience, we ensure that our pumps offer the best value for our diverse customers.