Predictive maintenance for pumps

Pumps keep your production and utility processes running.
AI-powered, real-time analysis enables the detection of anomalies at an early stage.
This identifies typical pump issues such as cavitation, imbalances, early-stage bearing and seal damage before they lead to performance losses, consequential damage, or unplanned downtime.
Start dashboard tour
Receive software demo
Logo Rausch

These parameters should be monitored:

Icon Schwingung
Vibration sensors (bearing housing/shaft)
Icon Druck
Pressure sensors (suction/discharge side)
Icon Motor
Motor data
(power consumption)
Icon Temperatur
Temperature sensors
(Bearing point)
Icon Durchfluss
Flow sensors
(flow rate monitoring)

Typical issues that occur in
pump systems

Impeller imbalance and wear
Shaft misalignment
Lack of lubricant
Clogged pipes or filters
Cavitation⁠

These industries benefit from pump monitoring

Pump in the chemical industry
Chemical & petrochemical industry
Pump in the food industry
Food & beverages industry
Pump at energy suppliers
Energy suppliers
Pump in the oil industry
Oil & gas industry
Pump in the water industry
Water & sewage industry
Pump in the process engineering industry
Process engineering & plant engineering
Around 20% of global electricity consumption is accounted for by pump systems.
Efficient solutions are a key factor for reducing CO₂ emissions.
* A comprehensive review on energy efficiency enhancement initiatives in centrifugal pumping systems (Applied Energy 2016)

Pumps in the cogeneration plant

Our client monitors their KSB pumps using our AI software. By intelligently combining process and vibration data, our software detects for example wear at an early stage.
Early-detected anomalies through vibration analysis, efficiency monitoring, temperature analysis, pressure, flow, and power monitoring:
Bearing deterioration
Insufficient bearing lubrication
Impeller imbalance caused by deposits or damage
Caviation

Which product is right for you?

Do you want to retrofit sensors and monitor vibrations and temperature?
Our product recommendation:
Retrofit
Plug and Play System
Do you already have relevant sensors and would like to monitor further sensor or process data?
Our product recommendation:
Retrofit & Predict
Sensor-independent

Our unique selling points

Predictive maintenance for the industry

AI in a production context instead of rigid​  threshold values

Detection of different
recipes and operating states​

Implemented in just a few days without complex IT project

Easy scalability to
additional assets

Manufacturer- independent and​  flexible to use

Suitable for standalone
machines and complex
production lines

FAQ: Predictive maintenance for pumps

What are the signs that my pump is about to break down or needs repairing?

Typical signs include unusual noises, changes in pressure readings, or increased vibrations. With the right sensors, such changes can be detected at an early stage, before the machine breaks down.

Which pump types can be monitored (piston pump, screw pump, centrifugal pump)?

Predictive maintenance can be used for all types of pumps. The ideal sensors and evaluations depend on the design, speed, application, and available process signals.

What data is required to start with pump monitoring?

Combining vibration data (e.g., from the bearing housing) with process data such as suction/discharge pressure, flow rate, temperature, and motor power provides a solid foundation for diagnostics. Combining vibration and process data significantly improves the reliability of diagnostics.

Does the plant need to be shut down to implement predictive maintenance for the pumps?

No. Many sensors can be retrofitted during planned maintenance windows or while in operation. If sensors are already in place, the pump can continue operating as normal.

What is the difference between pump monitoring and pure motor monitoring?

Pumps in particular benefit from the combination of mechanical vibrations and hydraulic process values. While pure motor monitoring recognizes electrical and mechanical issues in the drive, it often fails to identify the hydraulic cause, such as cavitation, suction problems, or blockages.

What are the benefits of predictive maintenance for pumps (ROI)?

Fewer unplanned downtimes, lower repair and follow-up costs and improved maintenance planning are typical when hydraulic inefficiencies are detected early.

Is predictive maintenance also recommended for smaller pumps?

Yes, predictive maintenance is also recommended for smaller pumps. The decisive factor is not the size of the pump, but its influence on your operation. If a failure causes downtime, affects the supply, or results in subsequent damage to the bearing, seal, or impeller, our AI-powered analyses provide early-stage transparency and enable maintenance to be planned.
Lena Weirauch
Not sure where to start?
In our free machine and use case analysis,
we evaluate your potential for implementing Predictive Maintenance.
Schedule your analysis
Machine Monitoring
Maintenance Software
Condition Monitoring
Predictive Maintenance
Prices
Solutions
Proof of Concept
Workshop
Historical Data Analysis
Company
Career
Magazine
News & Press
FAQ
Contact
Legal
Terms & Conditions
Privacy Policy
Imprint
© 2026 Copyright ai-omatic solutions GmbH