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Challenge

Over-maintenance due to scheduled maintenance, lack of transparency regarding machine health, root cause analyses based on assumptions

Solution

Sensors measure vibrations in river water pumps and enable targeted maintenance before a failure occurs

Highlights

  • 3 pumps, 6 sensors
  • Downtime reduced by 70%
  • 30% longer service life
  • 16 weeks from kick-off to go-live

Starting Point

At CHEMPARK, CURRENTA operates numerous rotating machines, such as pumps, motors and fans, which are essential for the supply of water. The pumps at the Krefeld-Uerdingen river water treatment plant were serviced at regular intervals — regardless of their actual condition. Failures occurred unexpectedly and led to unplanned downtime, high costs and safety risks.

Challenged problems

  • No status data available
    Pumps and fans were maintained on a strictly time-based schedule — regardless of actual wear and tear
  • High maintenance costs and safety risks
    Problems were detected too late and repairs were costly and caused downtime.

Solution

Smart sensor technology for rotating machinery – maintenance-free, retrofittable and featuring AI-powered fault analysis.

  • Retrofitting
    Installation of battery-powered vibration sensors (ATEX-certified) on three pumps at the Krefeld-Uerdingen river water treatment plant — without any wiring.
  • Wireless condition monitoring via LoRaWAN
    The sensors continuously measure temperature and vibrations and securely transmit the data to the cloud.
  • Prediction of potential failures
    Issues such as imbalance or bearing play are detected early on using FFT and threshold logic — supported by AI and vibration expertise.
  • Visualization & Optimization
    A central web dashboard sends alerts, identifies trends, visualizes machine health, flags anomalies and provides actionable insights.
River water pumps at the CURRENTA River Water Treatment Plant in Krefeld-Uerdingen
River water pumps at the CURRENTA River Water Treatment Plant in Krefeld-Uerdingen
Retrofitting LoRaWAN® sensors
Retrofitting LoRaWAN® sensors
LoRaWAN® sensors on the river water pump
LoRaWAN® sensors on the river water pump

Outcome

  • 70% less downtime
  • 30% longer service life
  • Improved operational reliability

Are you facing a similar situation?

Together, we'll tailor the application to your needs.

Murat MutluMurat Mutlu, Solution Portfolio Manager
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Used Services

IoT Solutions