Resolve the crisis of high-purity hydrochloric acid pump failures! Zhongyun Technology's intelligent operation and maintenance monitoring platform ensures safe and reliable production for chemical enterprises.

Recently, a high-purity hydrochloric acid pump drive-end bearing wear failure at a certain chemical enterprise was accurately detected by the intelligent equipment monitoring platform developed by Wuhan Zhongyun Kangchong Technology Co., Ltd. (hereafter referred to as "Zhongyun Technology"). Leveraging the early warning information, the company carried out a planned shutdown for maintenance, effectively preventing the fault from escalating while ensuring continuous production. This incident clearly highlights the platform's indispensable role in predictive maintenance for equipment in the chemical industry.

1. Real-time monitoring and early warning to detect risks at their onset

Traditional chemical enterprises rely on manual inspections for pump management, making it difficult to detect early, hidden faults. In contrast, Zhongyun Technology’s intelligent operations and maintenance monitoring platform uses high-precision sensors deployed at critical measurement points to enable 24-hour, uninterrupted data collection and dynamic analysis.

During August 2025, the platform detected an abnormal trend in vibration data from the drive end of High-Purity Hydrochloric Acid Pump A: the vertical vibration velocity continuously increased, reaching 14 mm/s and triggering an alert on the platform. The alert clearly specifies the equipment involved, the specific monitoring point, the alert type (fixed-threshold alarm or AI-model-based alert), as well as the initial and most recent alarm times, providing业主运维人员 with clear risk guidance.

II. Precise Data Diagnosis to Pinpoint the Root Cause of the Fault

After receiving the alert, the Diagnostics and Operations Team at Zhongyun Technology conducted an in-depth analysis of the vibration data from the pump drive end. Combining waveform and spectrum analyses, they preliminarily determined that the root cause of the issue was either mechanical looseness or wear in the bearing at the pump drive end—and provided targeted maintenance recommendations accordingly.

Diagnostic conclusion: The pump drive-end bearing is operating in a warning state, indicating a potential risk of mechanical looseness or wear.

Maintenance recommendations: Monitor bearing abnormal noises and vibration levels in real time, and during shutdowns, carefully inspect for loose anchor bolts, bearing wear, and any loosening in component fits.

3. Implement closed-loop management to reduce corporate losses.

The platform builds a closed-loop process covering "early warning - diagnosis - handling - verification," ensuring efficient fault resolution and controllable outcomes.

Planned shutdown minimizes impact: Following the diagnostic recommendations, the factory scheduled equipment shutdown for inspection on August 11. On-site inspection confirmed significant wear on the outer race of the pump drive-end bearing, causing the rolling elements to loosen within the outer race. The bearing was promptly replaced, and the entire process was completed without interrupting the core production period, thereby avoiding any unplanned downtime and the associated loss of production capacity.

Data validation ensures effectiveness: After the equipment was restarted on August 12, real-time monitoring on the platform showed a significant drop in vibration velocity at the pump drive end—specifically, the vertical-direction velocity fell below 4 mm/s. Meanwhile, the trend of vibration velocity values remained stable, and all abnormal frequency components completely disappeared from the spectrum, confirming that the equipment has returned to a steady operational state.

4. The platform's core value drives industry transformation.

This case of handling the high-purity hydrochloric acid pump equipment failure demonstrates the three core values of Zhongyun Technology's intelligent operation and maintenance monitoring platform:

1. Break the limitations of routine inspections : Replacing manual periodic inspections with 24-hour real-time monitoring to precisely detect early, hidden faults, enabling "early fault detection";
2. Reduce operational and maintenance costs : By leveraging data-driven precision diagnostics, we can avoid unnecessary disassembly and repairs, reduce component wear, extend equipment lifespan, and achieve "low-cost maintenance";
3. Upgrade the management model : By implementing a closed-loop system of "early warning - diagnosis - response - verification," we help enterprises transition from "reactive maintenance" to "predictive maintenance," accelerating the digital transformation and upgrade of equipment management in the chemical industry.

Looking ahead, Zhongyun Technology will continuously iterate its AI diagnostic algorithms and sensor technologies, further expanding its application footprint in the chemical industry. With intelligent equipment maintenance solutions that are safe, efficient, and cost-effective, we will help more enterprises strengthen their production safeguards.