Dual hidden risks drive vibration levels upward; the Zhongyun platform delivers precise diagnostics and efficient remediation.

In chemical production, packed‑tower circulation pumps are critical equipment that ensure reliable material transfer and process stability. Recently, at a polymer‑materials company, the vibration of one packed‑tower pump steadily increased during operation, peaking at 22.54 mm/s. Using trend monitoring and feature analysis, Zhongyun Technology’s intelligent operations‑and‑maintenance platform accurately identified underlying foundation looseness accompanied by coupling misalignment, guiding the plant to tighten bolts and realign the coupling. As a result, vibration levels promptly dropped back into the safe range of 5–6 mm/s, ensuring uninterrupted production.

I. Vibration-induced degradation, with real-time platform monitoring

Following the commissioning of the equipment on April 8, 2026, the platform detected a synchronous, gradual increase in both vibration acceleration and velocity at the motor’s drive end. From April 16 to 17, the trend in vibration levels deteriorated more rapidly, with the velocity RMS repeatedly exceeding the threshold, reaching a peak of 22.54 mm/s. The system automatically issued alarm notifications, clearly indicating the sensor location, the exceeded threshold values, and the corresponding time stamps, thereby ensuring that no potential hazards are overlooked.

II. Diagnosis: Identifying the Root Causes of Dual Faults

Based on the equipment’s rotational speed and vibration characteristics, the diagnostic team determined that the motor drive end exhibits foundation looseness and coupling misalignment. The combined effect of these issues has led to a progressive deterioration in vibration levels. It is recommended that the plant promptly shut down the equipment and conduct a thorough inspection of the anchor bolts, coupling bolts, and alignment condition.

III. On-site Correction and Verification: Vibration Rapidly Declines

Based on the platform’s recommendations, the enterprise scheduled a shutdown for inspection on April 17 and identified slight loosening of the motor base mounting bolts, which closely matched the diagnostic findings. Maintenance personnel tightened the bolts and performed alignment adjustments, and the equipment was restarted on April 21. Platform monitoring data show that the RMS vibration velocity has decreased significantly, stabilizing within the normal range of 5–6 mm/s, and the equipment is now operating smoothly.

IV. Core Value: Leaving “Complex Faults” with Nowhere to Hide

The successful handling of the combined fault of pump loosening and misalignment in this packed tower underscores the unique value of the Zhongyun platform:

1. 24/7 Monitoring: From gradual degradation to accelerated deterioration, the platform continuously tracks trend changes and issues timely alerts at critical inflection points.
2. Precise Root-Cause Analysis: Distinguish between single‑point looseness and misalignment–induced composite faults to prevent misdiagnosis, enabling on‑site simultaneous correction of both issues.
3. Rapid closed-loop management: From alarm detection and diagnosis to corrective action and verification, operations are executed efficiently, mitigating potential downtime risks within scheduled maintenance windows.

Zhongyun Technology will continue to iteratively advance its intelligent diagnostics capabilities, delivering end-to-end smart operations and maintenance solutions—featuring “precise early warning, efficient response, and robust reliability”—to industries such as chemicals and polymer materials, thereby helping enterprises fortify their equipment‑safety defenses.