The Zhongyun Technology Intelligent Operations and Maintenance Monitoring Platform Empowers Wastewater Treatment Enterprises—Successfully Resolved Pump Failure at Inflow Pump Station, Ensuring Continuous Production

Recently, a wastewater treatment company leveraged the intelligent operation and maintenance platform of Wuhan Zhongyun Kangchong Technology Co., Ltd. (hereinafter referred to as “Zhongyun Technology”) to accurately predict and efficiently resolve a fault involving loose impeller blades in an inflow pump station. The issue was addressed through targeted tightening and repair work, with no disruption whatsoever to the core wastewater lifting process throughout the entire operation. This case not only validated the platform’s capability to ensure equipment reliability in the wastewater industry but also helped the company overcome... “Manual inspections struggle to detect early-stage faults, and sudden shutdowns lead to sewage buildup.” Addressing industry pain points and providing a practical model for intelligent operation and maintenance of wastewater treatment equipment.

1. Real-time monitoring and early warning to detect equipment anomalies.

The pump is the core equipment in the wastewater lifting process of this facility, responsible for daily wastewater transportation. Traditional manual inspections struggle to detect subtle changes in vibration parameters. The intelligent operation and maintenance platform developed by Zhongyun Technology achieves 24-hour uninterrupted acquisition and dynamic analysis of vibration velocity and acceleration by deploying corrosion-resistant, high-precision sensors radially on the bearings at the impeller side of the pump. This solution precisely adapts to the high-humidity and highly corrosive operating conditions typical of wastewater equipment.

Starting August 26, 2025, the platform gradually detected abnormal signals: The radial vibration velocity of the bearing on the impeller side of the pump slowly increased from a normal value of 5 mm/s to 10 mm/s, first triggering an alarm based on a fixed vibration threshold, and subsequently triggering another alarm indicating “bearing wear / loosening mechanism.” The system clearly labels “alarm device, associated area, alarm level, initial alarm time, and latest alarm time,” providing the operations and maintenance team with clear risk guidance.

II. Precise data diagnosis to pinpoint the root cause of the fault.

After receiving the alert, the diagnostic team from Zhongyun Technology conducted an in-depth analysis of the vibration data, taking into account the pump’s rated speed (585 r/min) and the operational characteristics of sewage conveyance. They ruled out non-rotational-frequency-related faults such as impeller imbalance and pipeline cavitation. Ultimately, they precisely identified the root cause of the fault as “loose pump impeller and abnormal bearing clearance.”

Diagnostic conclusion: The pump impeller is loose, and the equipment is operating in a warning state.

Maintenance recommendation: Arrange for a shutdown and inspection as soon as possible, with particular attention paid to checking for loose impellers.

III. Implement closed-loop management to mitigate the risk of production disruptions.

The platform features a closed-loop, end-to-end process of “early warning—diagnosis—intervention—validation,” which is tailored to meet the core requirement of wastewater treatment—“24-hour continuous operation”—and ensures efficient fault handling.

1. Planned shutdown for replacement with targeted measures: Based on the diagnostic recommendations, the company scheduled a equipment shutdown inspection for September 15, 2025. On-site inspection confirmed “loose impeller fit.” The operations and maintenance team immediately issued an equipment repair plan and proceeded to address the loose impeller.

2. Regarding the effectiveness of data validation, after the equipment was restarted and put back into operation on November 8, 2025, platform monitoring showed that the radial vibration velocity of the bearing on the impeller side had dropped below 6 mm/s, and all operational parameters had returned to their normal ranges.

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4. The platform’s core value: aligning with the operation and maintenance needs of the wastewater industry.

This case of handling the submersible pump failure vividly demonstrates the three core values of Zhongyun Technology’s intelligent operations and maintenance platform:

1. Break the limitations of routine inspections: Replace manual, periodic inspections with 24-hour real-time monitoring to precisely detect hidden equipment faults and achieve "early fault detection."
2. Reduce O&M costs: By leveraging data-driven, precise diagnostics, we can avoid unnecessary disassembly and repairs, minimize component wear and tear, extend equipment lifespan, and achieve "low-cost maintenance."
3. Upgrade the management model: Adopt a closed-loop approach of “early warning—diagnosis—intervention—verification” to help enterprises shift from “reactive maintenance” to “predictive maintenance” and accelerate the digital transformation of equipment management in the wastewater treatment industry.

In the future, Zhongyun Technology will continue to iterate its AI diagnostic algorithms and sensor technologies, further expanding their application in core equipment within the wastewater industry. We will provide more urban wastewater treatment operators with end-to-end intelligent operation and maintenance solutions that offer “precise early warnings, efficient handling, and stable assurance,” helping the industry achieve digitalization of equipment management and intelligent decision-making in operations and maintenance.