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Case Studies
Preventing Pump Failures: How Smart Monitoring Cut Costs by $102K Annually
Challenge
Issue
A Singapore chemical plant faces frequent pump failures due to mechanical seal dry running. Three pumps, located in a pit with ladder access, share a common suction and discharge header with individual filters. With only vibration monitoring and manual daily filter checks, early blockages may go unnoticed, leading to failures.
Each pump removal requires a crane, workshop repairs, reinstallation, and alignment, costing $25,500 per incident—totaling $102,000 annually ($=USD).
Real-time filter and seal monitoring could prevent failures, reducing downtime and costs.
Three pit pumps, with Chesterton Connect installed on Pump two for monitoring.
Solution
Application
To enhance pump monitoring, Chesterton Connect™ was installed on one of the pumps to collect real-time operational data. A sensor was placed on the mechanical seal flush line, allowing for continuous monitoring of seal performance.
The collected data was then transmitted to the cloud, where it was remotely monitored by experts in Australia. This setup provided real-time insights into pump conditions, enabling proactive maintenance and reducing the risk of unexpected failures.
The Chesterton Connect™ line of products are simple-to-use data acquisition tools that enable operators to safely and conveniently monitor the condition of pumps and other rotating equipment.
Results
Smart Monitoring Saves $102K Annually by Preventing Hidden Failures
Cloud data revealed a gradual pressure drop, which, if undetected, could lead to pump cavitation and seal dry running. However, vibration readings remained normal, masking the issue.
Further investigation uncovered that filter blockage monitoring was neglected, causing repeated seal failures. By investing $4,000 in Chesterton Connect, the plant saved $98,000 in the first year and continues to save $102,000 annually ($=USD).
Cloud data showing reducing suction pressure but no change in vibration.
About Us
Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service. Chesterton product range includes mechanical seals, packing and gaskets, industrial lubricants and coatings.
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APAC0101. Issued 02/2025.
Technical data reflects results of laboratory tests and is intended to indicate general characteristics only. A.W. Chesterton Company disclaims all warranties expressed or implied, including warranties of merchantability and fitness for a particular purpose. Liability, if any, is limited to product replacement only. Any images contained herein are for general illustrative or aesthetic purposes only and are not intended to convey any instructional, safety, handling, or usage information or advice respecting any product or equipment. Please refer to relevant Safety Data Sheets, Product Data Sheets, and/or Product Labels for safe use, storage, handling, and disposal of products, or consult with your local Chesterton sales representative.