Predictive Failure Detection for a Mining Pump Station

In a mining operation, a client was experiencing recurring failures on a critical pumping station valued at $1.2 million, consisting of four 600 HP MH200-250 stationary pumps. The client agreed to participate on the development of an operational monitoring solution, in collaboration with Optis Engineering. The goal was straightforward: understand the root causes of the failures, improve operational reliability, and gain greater visibility into actual operating conditions.

Results

Using Optis Engineering’s LiveFlo® connected service, the team developed a structured approach to analyze pumping conditions in real time. By integrating field data with the existing PLC infrastructure and adding our own instrumentation, the team implemented 24/7 continuous monitoring of key performance indicators. Further analysis revealed a direct relationship between mechanical pump anomalies and actual pumping conditions.

This work identified high-risk operating zones and led to practical recommendations that could be directly implemented by the client. Additional solutions were also proposed to improve energy efficiency. The LiveFlo® platform served as a powerful analytical tool, integrated into our field-driven approach to transform raw data into informed operational decisions.

The results were both rapid and measurable. A major failure was detected 41 days before it occurred. In addition, cavitation caused by operation outside the pump’s optimal range was clearly identified. Abnormal recirculation within the piping network was also observed, resulting in approximately $60,000 in annual energy losses. Furthermore, we determined that taking corrective action at the right time can avoid roughly $25,000 in repair costs per incident. Ultimately, the client shifted from a fully reactive maintenance approach to a controlled, data-driven operation, achieving tangible reductions in losses and greater predictability across its pumping system.