Reading a pump fault from its vibration
A digital twin of a cooling water pump: vibration, temperature and process data from four bearings, and a diagnosis engine that reads them and says what is wrong and what to do about it. The data is simulated; inject faults yourself and see what the system concludes.
Cooling water pump
37 kW 4-pole motor on a VFD · end-suction pump, 6-vane impeller Simulated data
Findings
Components
Measurement points
| Point | H | V | A | Env | Temp |
|---|
Velocity in mm/s RMS, 10–1000 Hz. Zones per ISO 20816-3, group 2, rigid foundation: A/B 1.4 · B/C 2.8 · C/D 4.5. Envelope in gE, alert 0.8 · alarm 2.0. Temperature alert 75 °C.
Velocity spectrum
Largest peaks click a row to put the cursor on it
Inject faults severity 0–100 %
Operating point
Frequencies move with speed. Switch the spectrum to orders to keep them lined up.
Simulation
A blind test injects a hidden fault. Read the signals, make your call, then reveal it and compare with the engine.
What is on screen
- The 3D model. The sensor label on each bearing shows its current vibration level and status. Motion amplification makes the machine sway the way the measured vibration says it does; the thermal view paints bearing and motor temperatures onto the model.
- Diagnosis. Every finding comes with the measurements behind it (spectrum peaks, phase differences, temperature, suction pressure) and a recommended action. Priority follows the ISO 20816-3 vibration zones and the stage of any bearing damage.
- Signals. Velocity and envelope spectra, the acceleration waveform and the last five minutes of trends. Each spectrum draws the machine's healthy signature at the current speed as a reference.
How to try it
- Inject a fault from the Scenario tab: unbalance, misalignment, looseness, bearing damage or cavitation.
- Watch the finding form in the Diagnosis tab. "Show evidence" takes you to the spectrum behind it, "Locate in 3D" marks the faulty part.
- Try a blind test: the system injects a hidden fault, you find it in the signals, then compare with the engine.
In a real installation
Everything on this page is simulated: the machine, the faults and the signals. On a real machine the data comes from triaxial vibration sensors mounted on the bearing housings, plus the pressure, flow and motor current signals already in the PLC or SCADA. The diagnosis rules are tuned to the machine type, its bearing sizes and its operating conditions.
The demo simplifies the rules to show how they work; it does not replace a vibration analyst's judgement on site. If you are considering a monitoring layer like this for your own equipment, write to us with your machine list.