Smart Equipment Monitoring and Your Digital Transformation

For industries seeking a path to digital transformation, adopting smart monitoring devices and IoT solutions for automatic equipment health reporting is a cost-effective place to start. For example, most manufacturers are looking for ways to protect their operations from downtime, often while facing the challenge of maintaining systems with a smaller workforce. 

Integrating Alfa Laval condition monitors into your pump maintenance plan and connecting them to the AI-backed Alfa Laval cloud is a sound, practical step in the digital transformation process within your plant. Condition monitors provide continuous oversight of pump operation while delivering prompt notifications in case of anomalies and streamlining your overall maintenance procedures.

Condition Monitoring

BENEFITS OF CONDITION MONITORING

  • Helps operations prioritize service for pumps based on precise data and intelligent diagnostics
  • Reduces unplanned downtime by supporting planned and predictive maintenance
  • Minimizes staff overtime and rush orders for spare parts
  • Extends pump lifetime
  • Lowers total cost of equipment ownership
CM Condition Monitor

What is the Condition Monitor Sensor?

The Alfa Laval Condition Monitor Sensor (CM) is a wireless device designed to monitor the operations status of pumps. With accelerometers measuring vibration in three axes and an internal temperature sensor, this industry-revolutionizing device attaches to a pump and collects data 24/7. Because the sensor is easy to install and use, customers now have fewer barriers to entering the world of digital monitoring and protection.

CM Operation
  1. Collects vibrational and temperature data from the connected rotating machinery
  2. Records data digitally
  3. Transmits recorded data to CM Connect via Bluetooth

In some installation situations, the Condition Monitor cannot be connected to the AI-backed CM Connect network. However, it remains capable of providing important pump data for customer insights.

In many cases, preventative maintenance practices fall short because while there are published intervals for maintaining items, the amount of time a piece of equipment has been in operation is unknown. The standalone Condition Monitor can provide baseline information such as start and stop counts and cumulative run time through the Alfa Laval CM app.

Alfa Laval CM and App
Alfa Laval CM and App
CM Connect
CM Connect

CM Connect for Analytics Connectivity

While standalone Condition Monitors can provide some information and comfort to customers, it is not until the Condition Monitors are connected to AI-backed CM Connect that digital monitoring truly exhibits its potential. 

CM Connect gathers information from up to 10 Alfa Laval Condition Monitors within Bluetooth range and transmits raw data to the Alfa Laval cloud via 4G cellular service. At this point the data is processed through a sophisticated AI algorithm—tailored to the specific pump type for targeted analysis to determine the most likely state of the monitored equipment. The data can then reveal whether the equipment is operating as expected or whether something is worrisome regarding the process, installation, or mechanical condition.

Using an online portal, users have real-time access to equipment performance data. The system is configured to automatically send notifications to specified users when events occur. Notifications give customers continuous insight to equipment status for making informed decisions about when to schedule maintenance.

Condition monitoring isn't merely about detecting issues as they arise; it is the cornerstone of cost-effective, proactive maintenance. Regular maintenance enhances production uptime, elevates quality and output, and fosters a safe and efficient workplace. CSI offers personalized preventative maintenance schedules to accommodate various budgets, with OEM-trained technicians performing on-site maintenance and adhering to manufacturer guidelines and customer preferences regarding serviced equipment.

Sample Equipment Report

Sample Equipment Report

Condition Monitoring in Action

CSI has a customer in the liquid milk industry with a substantial installation base of Alfa Laval pumps featuring the Condition Monitor, connected via CM Connect to the Alfa Laval AI-backed cloud service.

Recently, this customer was notified of ‘Impeller wear and/or imbalance.’ Because the notification from the condition monitoring was specific and timely, the customer was able to find a quick resolution to the issue. They got to a suitable stopping point in their process and, upon opening the pump, discovered that the impeller was making contact and the pump needed to be serviced. 

The timeliness of discovery meant that the pump could be salvaged. Without condition monitoring, it likely would have gone undetected until the pump failed.

The customer is adding CM and CM Connect to additional Alfa Laval pumps to take advantage of the digital protection that condition monitoring can provide.

Sample Event Notification
Alfa Laval Master Service Provider
CSI is a Master Distributor and Master Service Provider for Alfa Laval, a developer of advanced condition monitoring equipment for the liquid hygienic industry with expertise that can play a pivotal role in making the technology accessible. CSI offers on-site service for Alfa Laval and CSI equipment, including new and legacy pumps, heat exchangers, and valves.

Embracing Digital Transformation

In an industry that can be slow to adapt, CSI and Alfa Laval are leading the way in simplifying and advancing digital transformation. If you want to enhance your manufacturing processes, boost efficiency, and minimize unplanned downtime, consider exploring the possibilities of condition monitoring. Contact CSI today to initiate a discussion on how this technology can elevate your operations.

Next Steps

Contact us today to explore how condition monitoring can revolutionize your processes. Let's discuss your specific needs and how our solutions can be tailored to unlock maximum performance and cost savings for your business.

Call Michael David at (417) 831-1411.

Don't let unplanned downtime disrupt your operations. Take the first step towards operational excellence. Reach out now and let us help you make informed decisions that propel your business forward.

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Contributing Author

MD - Contributing Author
Michael David is the Manager of Pump and Heat Exchange Solutions at CSI. Michael received his B.S. degree in Mechanical Engineering from the Missouri University of Science and Technology, and brings over 17 years of experience in engineering, process design, fluid dynamics, and maintaining equipment for the food, dairy, beverage, biopharm and biotech markets. Michael supports a team of application specialists who focus on Pump and Heat Exchange solutions. He also leads many training initiatives for internal and external customers aimed at developing competence and confidence in the worlds of pumps and heat exchange technology.

ABOUT CSI

Central States Industrial Equipment (CSI) is a leader in distribution of hygienic pipe, valves, fittings, pumps, heat exchangers, and MRO supplies for hygienic industrial processors, with four distribution facilities across the U.S. CSI also provides detail design and execution for hygienic process systems in the food, dairy, beverage, pharmaceutical, biotechnology, and personal care industries. Specializing in process piping, system start-ups, and cleaning systems, CSI leverages technology, intellectual property, and industry expertise to deliver solutions to processing problems. More information can be found at www.csidesigns.com.

ABOUT CSI

Central States Industrial Equipment (CSI) is a leader in distribution of hygienic pipe, valves, fittings, pumps, heat exchangers, and MRO supplies for hygienic industrial processors, with four distribution facilities across the U.S. CSI also provides detail design and execution for hygienic process systems in the food, dairy, beverage, pharmaceutical, biotechnology, and personal care industries. Specializing in process piping, system start-ups, and cleaning systems, CSI leverages technology, intellectual property, and industry expertise to deliver solutions to processing problems. More information can be found at www.csidesigns.com.