Equipment Type
Pump
Equipment Name
Acid/Alkali Tower Pump
Faults
Foundation Looseness
Early Detection of Acid/Alkali Tower Pump Foundation Looseness Fault
How AI Ensured Continuous Operation in a Chemical Plant
Chemical
Introduction
This case study details the diagnosis of a foundation looseness fault in a critical Acid/Alkali Tower Pump at a chemical plant. This pump is a core component in industrial waste gas/wastewater systems, used to transport and circulate acid and alkali liquids for purification and treatment. Its continuous, healthy operation is vital for maintaining process stability and environmental compliance. This example demonstrates how an AI-powered condition monitoring solution detected an early-stage fault, enabling proactive maintenance and validating the system’s diagnostic accuracy.
Equipment Overview
The Acid/Alkali Tower Pump, also known as the Acid Mist Purification Tower Pump or Spray Tower Circulation Pump, is a core component in industrial waste gas and wastewater systems. It uses the rotation of an impeller to generate centrifugal force, pumping the liquid from a storage tank to the top of the spray tower. The liquid is then sprayed uniformly through nozzles, forming droplets that fully contact the rising waste gas to react and form harmless substances. The purified gas is emitted to the atmosphere, and the absorbent liquid is returned to the tank for circulation.
The Challenge
In chemical plants, equipment failure can lead to production disruptions, environmental compliance issues, and safety risks. As a core component, the pump's mechanical condition is paramount. A fault like foundation looseness, if undetected, causes excessive vibration and accelerated wear, increasing the risk of sudden shutdown. Early detection is critical to maintain process stability and operational continuity.
Wisper Solution
Wisper CMS system monitored the health status of the pump. Shortly after system deployment in mid-November 2024, it detected an abnormal feature on the motor drive end, diagnosing it as a Foundation Looseness fault. A diagnostic report was triggered, advising the user to monitor and maintain the equipment. Although the status briefly improved due to a change in operating conditions, the indicator score again deteriorated and exceeded the Warning state in early December.
Wisper CMS diagnostic report (Nov 14, 2024)
Timeline of Events
The outcome
Following the maintenance (bearing replacement and recalibration), the foundation looseness feature at the motor drive end significantly decreased, and the score returned to an Available status. The customer reported that some base instability still existed on-site, and the inspection results fully verified the accuracy of the AI diagnosis.
understanding the root cause
Foundation looseness can be attributed to the following potential causes:
Loose or broken anchor bolts and coupling bolts.
Structural looseness or insufficient strength of the equipment base, baseplate, and concrete foundation.
Deterioration or breakage of the grout.
Deformation of the frame or base.
