Precise early warning to prevent problems before they escalate: Zhongyun Technology’s intelligent O&M platform successfully detected and warned of a loosening fault in the coupling of a high-purity hydrochloric acid pump.

Recently, on a key production line at a large chemical enterprise, the vibration data of a critical high-purity hydrochloric acid pump began to slowly rise during operation. Thanks to continuous monitoring and precise analysis, the Zhongyun Technology Intelligent Operations and Maintenance Platform promptly issued an early warning about the potential risk of coupling loosening and provided guidance for the enterprise to carry out preventive maintenance, successfully averting a cascade of equipment failures and unplanned shutdowns that could have been triggered by a coupling malfunction.

1. Real-time monitoring: Capturing early signals of slowly rising vibrations

From November to December 2025, the platform continuously monitored the vertical vibration velocity at the drive end of the hydrochloric acid pump motor, which gradually increased from 2 mm/s to 6 mm/s—exceeding the safety threshold and triggering a system alarm. Simultaneously, the system pushed out a “misalignment” diagnostic conclusion. The platform automatically sent alarm notifications to the operations and maintenance team, clearly indicating the alarmed equipment, its affiliated department, the alarm severity level, as well as the initial and latest alarm timestamps. This enabled early detection of latent faults and provided the operations and maintenance team with clear, timely risk guidance and actionable evidence for troubleshooting.

II. Intelligent Diagnosis and Precise Verification

After receiving the alert, the Zhongyun Diagnostic Team conducted a thorough analysis of the data, taking into account the operating speed of the equipment. Based on the operational structure of the hydrochloric acid pump, they initially determined that there was misalignment in the motor. The intelligent diagnostic results from the platform were highly consistent with the conclusions reached by manual diagnosis. It is recommended to promptly shut down the equipment and inspect the coupling for any abnormalities.

3. Closed-loop handling: Rapid verification from early warning to tightening.

1. Planned Shutdown and On-site Confirmation

Based on the platform’s alert, the company scheduled a shutdown for inspection on December 16, 2025. On-site inspection revealed that the coupling bolts were noticeably loose, which was consistent with the platform’s diagnostic findings.

2. Fault Handling and Effect Verification

The maintenance personnel tightened the coupling bolts. After the equipment was restarted on January 12, 2026, monitoring data showed that the vibration velocity at the motor-driven end had significantly decreased to below 3 mm/s, and the equipment operation has returned to smooth operation, completely eliminating the potential hazard.

4. The platform’s core value: aligning with the needs of the chemical industry.

This case of troubleshooting the high-purity hydrochloric acid pump coupling failure vividly demonstrates the three core values of the Wuhan Zhongyun Kangchong Intelligent Operation and Maintenance Monitoring Platform:

1. Break the limitations of routine inspections: Replace manual, periodic inspections with 24-hour real-time monitoring to precisely detect early, hidden faults and achieve “early fault detection.”
2. Reduce operational and maintenance costs: By leveraging data-driven, precise diagnostics, 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—validation” to help enterprises shift from “reactive maintenance” to “predictive maintenance” and accelerate the digital transformation of equipment management in the chemical industry.

In the future, Zhongyun Technology will continue to iterate its AI diagnostic algorithms and sensor technologies, providing industrial enterprises with end-to-end intelligent operation and maintenance solutions that offer “precise early warnings, efficient response, and stable assurance,” thereby helping the industry achieve digitalization in equipment management and intelligent decision-making in operations and maintenance.