The video, presented by Tana Consulting Engineers, introduces their DigitalPoint solution—a real‑time, AI‑driven platform for monitoring and diagnosing heavy‑duty pumps across power, oil & gas, chemical, and infrastructure sectors. It first outlines the critical role of pumps in industrial plants and enumerates the factors that degrade performance, such as demand variability, cavitation, wear, system constraints, and resulting vibration or misalignment. The speaker then critiques conventional pump management, noting that while plants collect extensive sensor data (pressure, temperature, flow, current, vibration), most of it remains unused and root‑cause analysis is performed manually, leading to inefficiencies, excess noise, reduced component life, higher downtime, and elevated operational costs. The DigitalPoint solution addresses these gaps by leveraging stochastic and data‑driven methods to provide real‑time key performance indicators, performance predictions under varying conditions, early‑warning alerts, automated root‑cause analysis, and remaining‑useful‑life (RUL) estimates. These capabilities aim to keep pumps operating near their Best Efficiency Point, reduce auxiliary power consumption, prevent unplanned shutdowns, lower maintenance expenses, and improve overall reliability and plant profitability.
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Tana Consulting engineers with decades of domain expertise in plant engineering has leveraged artificial intelligence, machine learning, and data analytics to develop a digital point solution for pump performance monitoring and diagnosis. This digital point solution can be used to monitor heavy-duty pumps in various sectors such as power, oil and gas, chemical, and infrastructure. It can be applied for both greenfield and brownfield projects. Let's look at: pump system operation in a plant, conventional management of pump operation in a plant, possible bottlenecks in this approach, and finally, we will have a look at our innovative Digital Point solution. As we know, pumps are widely used in industrial, commercial, and residential applications to transfer different fluids. So pumps play an important role and are considered as one of the critical components in a plant. Some of the major factors that influence pump performance are difficulty in maintaining optimum head and flow because of variability in demand, Cavitation, age-related issues such as changes in internal clearance and wearing out of components, inefficient operation due to system constraints, unexpected energy loss during operation. All these factors degrade pump performance. Some of these reasons may lead to vibration, bearing issues, shaft misalignment, and imbalances in the pumps. Now let us look at how pump operation is managed currently. Pumps should be operated at its best efficiency point (BEP) for best performance. But pumps are rarely operated at its BEP due to high variability in process demand and other system constraints. This impacts the performance of pumps and leads to higher operational costs in terms of auxiliary power. Presently, pumping systems are well equipped with instruments to measure process parameters such such as pressure, temperature, flow, current, and vibration. These instruments are connected to control systems to monitor the critical performance parameters of the pump. Most of the data collected normally remains unused, and in case of any abnormality or failure, the data related to the event is retrieved and analyzed to find the root cause manually. This approach has few drawbacks. Now let's look at these shortcomings. These shortcomings are compromises in pump performance and efficiency, excessive noise and vibration, reduced component life and the need for excess spares, increased downtime, higher operational cost, and lack of optimum maintenance strategy. All these drawbacks can be addressed by using a combination of stochastic and data-driven approach. Now let us look at the DigitalPoint solution for pump performance monitoring and diagnosis. Its functions and features, and how it can help to overcome these drawbacks. With vast domain experience, TCE has developed a real-time digital point solution that can help the operator to analyze and optimize their pump performance. The digital point solution can provide real-time monitoring of pump key performance indicators. It can predict the pump performance for different operating conditions. The Digital Point solution also provides the early warning alerts for key parameters and root cause analysis for any performance deviations. The Digital Point solution will help to reduce auxiliary power consumption. It can predict the failures well in advance and would provide the remaining useful life based on operating conditions and historical trends. This approach avoids unplanned shutdown and hence reduces the maintenance cost. The recommendations from the Digital Point solution, along with the actions of the operator, will lead to optimum pump operations and better performance. These features collectively improve the reliability and availability of the pump, resulting in enhanced plant profitability. Tana Consulting Engineers, a trusted partner for digital solutions. Stay tuned to this space to know more about our upcoming DigitalPoint solutions.
