Condition Monitoring Identifies Process Leak

Working to Achieve

AVT Reliability® supports the site through a structured condition monitoring programme designed to improve reliability, identify developing asset issues, and reduce the risk of unplanned downtime. In addition to vibration analysis, routine inspections provide valuable opportunities to identify process.

The Challenge

The monitored asset formed part of a chemical transfer process within the facility. The pump operates regularly to transfer process chemicals throughout the plant and plays an important role in maintaining production flow. Although a standby unit was available, any unexpected failure or loss of containment could create maintenance challenges, increase operational risk, and require unplanned intervention.

Our Approach

As part of an ongoing reliability contract, AVT Reliability® performs vibration data collection, analysis, and visual inspections on a four-weekly basis using the Machine Sentry® platform. During each visit, engineers assess both machine condition and visible equipment integrity.

Vibration readings are collected using a Machine Sentry® Mobile (MSM) sensor and analysed alongside observations recorded within the Machine Sentry® application. This combined approach helps identify both mechanical defects and emerging operational issues that may not be evident from vibration data alone.

Our Findings

During a routine inspection, vibration levels on the pump were found to be satisfactory and within expected operating limits. However, while carrying out the visual inspection, the AVT engineer identified evidence of leakage from pipework connected to the pump.

The affected flange showed signs of chemical ingress, with visible deterioration and discolouration of the surrounding paintwork suggesting the process fluid was escaping past the sealed connection. The issue had not previously been identified by operators and was immediately highlighted to the site contact. An Action Note was raised within Machine Sentry® to ensure the issue was formally recorded and reviewed.

The Solution

Following notification, the site maintenance team incorporated the repair into its planned maintenance schedule. The affected pump was located within a bunded area, ensuring any leakage remained safely contained while corrective actions were planned. The proposed repair includes replacement of the flange sealing arrangement and further investigation into material compatibility should the process chemical be found to be reacting with the existing components.

Follow-Up

AVT Reliability® will review the asset during the next scheduled site visit and discuss any corrective actions undertaken by the maintenance team. This case highlights the importance of combining condition monitoring with routine visual inspections. While vibration data confirmed the pump was operating satisfactorily, the inspection identified a developing process issue that could have progressed into a larger maintenance, environmental, or safety concern if left unaddressed.