Chilled Water Pump Condition Monitoring Case Study

This case study details the implementation of a structured condition monitoring program for a chilled water circulation pump that supports a batch production process. The objective of the program was to establish early fault detection capabilities through weekly remote vibration analysis, which proved essential for maintaining operational continuity and preventing costly downtime. The findings revealed significant wear on both motor bearings and shaft damage due to progressive deterioration, which was detected early enough to avoid catastrophic failure. The monitoring program, initiated in September 2025, led to a cost-saving of £56,000 as a result of early fault detection and planned motor replacement, which was completed before any production failure occurred. The total cost of implementing the program was £25,000, resulting in a return on investment within two months. This case illustrates how effective condition monitoring can enhance asset reliability and deliver measurable financial benefits.