Putting Monitoring to the Test: Four Faults That Matter

We tested the systems against four key fault scenarios: damaged bearings, cavitation, misalignment and loose mounting foot. These represent real-world risks that, when left undetected, can lead to efficiency losses or system failure.

1. Damaged Bearings

   To simulate a degraded bearing, we cut a groove into the outer race of the front taper bearing. Over 40 hours, the damage worsened. Vibration readings gradually intensified, and both systems responded accordingly. This highlights how early detection is possible—when the system’s thresholds are correctly configured.

2. Cavitation

   Known as one of the most common process challenges and for its destructive effects on pump internals, cavitation showed up as high-frequency vibration spikes. Both systems flagged the condition, signaling their capability to detect early-stage cavitation. This gives operators time to make adjustments before damage sets in.

3. Misalignment

   We introduced a 5-degree motor-to-pump misalignment while maintaining coupling connection. Both systems picked up on the resulting vibration deviation. This test validated their ability to detect mechanical stress early, a key to avoiding costly coupling and shaft wear.

4. Loose Foot Condition

   Loosening one side of the pump’s mounting bolts disrupted the clamp force. The sensor system detected vibration changes quickly. This confirmed the importance of identifying minor shifts in structural integrity—changes that might go unnoticed without the right monitoring tools.

The Role of Sensor Placement and Calibration

One of the most revealing insights wasn’t just what the systems could detect—it was how sensor placement and calibration impacted that detection. Sensors mounted on the pump cover, gearcase and body yielded different results, with some placements offering clearer signals for specific fault types. The sensors' settings were also adjusted from their default setup to be more compatible with the WCB pump operation and more accurately detect the fault conditions. The takeaway? Even the best system underperforms without thoughtful sensor placement and proper calibration.

We can work with operators to map out sensor strategies that match pump design and site-specific needs.

Signal Threshold vs. AI-Based Monitoring

The two systems we tested used different approaches:

• One used static thresholds to trigger alerts when vibration exceeded a certain amplitude.
• The other used AI-based signal analysis, designed to learn normal operating conditions and flag deviations.

Both had strengths. Threshold-based systems were consistent and straightforward. AI-based systems adapted over time and were better at picking up subtle trends. The right fit depends on whether the need is for speed, simplicity or smarter long-term analysis.

Takeaways for Plant Operations Teams

• Condition monitoring works—when fault conditions were present, both systems detected them.
• Sensor placement and calibration is critical—it directly impacts the quality of the data.
• AI-based monitoring offers future potential—especially in learning system baselines and identifying gradual issues.
• Early detection prevents major failures—it avoids costly downtime and makes maintenance planning more predictable.

The Path Forward

The more we test, the more we learn. At SPX FLOW, we’re not only building better equipment—we’re supporting smarter operations. Whether you’re running a single WCB pump or managing an integrated process line with a variety of equipment, our solution makers will help you choose the right monitoring strategy.

From simple sensor setups to AI-supported analysis, our team of solution makers is here to guide you. Let’s talk about how condition monitoring can work in your operation—on your terms, for your goals.

Commitment to Advancing IoT Monitoring

SPX FLOW’s commitment to innovation goes beyond testing condition monitoring systems. As highlighted in a recent MxD news release, SPX FLOW is collaborating with Siemens to pioneer digital twin and AI-driven design capabilities—advancing how we model, monitor and improve equipment performance. These initiatives are part of a broader effort to explore IoT-based monitoring solutions that unlock smarter diagnostics, predictive insights and greater reliability for customers worldwide.

Contact Us for Smarter Monitoring Solutions

For more insights or to explore tailored sensor strategies, contact us today.