【Haichuan’s Best Practices】All 1,346 high-risk pumps are subject to online, real-time, intelligent monitoring through a pump condition monitoring system

Thread Content

On August 17, more than half a month after its deployment, the pump condition monitoring system at Dushanzi Petrochemical Company was operating smoothly. All 1,346 high-risk pumps were now under online, real-time intelligent monitoring, which reduced the workload on employees and enhanced the capabilities for ensuring safe production. 　　Through platform support, practical implementation in specific scenarios, and IT empowerment, the pump status monitoring system enables the completion of all management tasks within a single system. This system is fully functional, including full-life-cycle management of pumps, intelligent fault diagnosis and early warning, automatic calculation and sorting of daily equipment management metrics, automatic report generation, and easy access to information on various types of equipment, thereby enabling an intelligent approach to the operation and maintenance of pumps. 　　The pump status monitoring system integrates data such as the master data of equipment, notification forms, and work orders within the ERP platform. Through automatic data extraction and calculation, it establishes various performance management indicators for evaluating the reliability of equipment operation as well as its economic efficiency, thereby enabling streamlined and efficient business management processes. 　　After the operation of the pump status monitoring system, it has essentially achieved five objectives: comprehensive utilization of pump data, quantification of management indicators, improvement in risk control and early warning capabilities, customization of personalized dashboards, and reduction of the workload for employees. This system meets the varying visual presentation needs of different users. By creating visual models of the company, various operational departments, and production equipment, it enables managers at all levels to obtain operation interfaces tailored to their specific requirements. It also presents comprehensive data based on key indicators of equipment status, allowing leaders and managers at all levels to keep track of real-time operational conditions and equipment performance. 　　Liu Zehan, deputy chief engineer of Unit 1 for ethylene production at Duhu Petrochemical, said, “Continuous 24/7 monitoring of the equipment’s operation ensures no blind spots; this allows for a savings of around 100 hours per day in terms of labor time for operators on site, as well as a reduction of about 20 minutes per person in the time required for data sorting and entry.” ”