PLANT & MACHINERY / ROTATING ASSETS
Pump and motor condition monitoring
Hear a bearing fail weeks before it seizes
Motors and pumps are the most common mechanical system on any site and the most common unplanned stoppage. The failure mode is almost never sudden: a bearing starts to spall, vibration amplitude climbs at a characteristic frequency, the housing runs a few degrees warmer, and weeks later the unit seizes in the middle of a shift. Nobody sees the ramp because nobody is standing next to the pump with an accelerometer. Route-based condition monitoring catches it only if the route happens to fall in the window, and most sites run that route quarterly at best on the assets somebody remembered to list. So the first real signal is noise, heat or a trip, and by then the choice is an emergency callout and a rebuild rather than a planned bearing change.
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The difference
Pump condition monitoring: what changes the day it goes live
Motors and pumps are the most common mechanical system on any site and the most common unplanned stoppage. The failure mode is almost never sudden: a bearing starts to spall, vibration amplitude climbs at a characteristic frequency, the housing runs a few degrees warmer, and weeks later the unit seizes in the middle of a shift. Nobody sees the ramp because nobody is standing next to the pump with an accelerometer. Route-based condition monitoring catches it only if the route happens to fall in the window, and most sites run that route quarterly at best on the assets somebody remembered to list. So the first real signal is noise, heat or a trip, and by then the choice is an emergency callout and a rebuild rather than a planned bearing change.
- Three-axis vibration amplitude plus the frequency peaks that identify which fault is developing, sampled every ten minutes rather than once a quarter on a clipboard route
- Bearing and housing temperature from a probe on the actual metal, so a thermal ramp corroborates the vibration signature instead of leaving you guessing
- Threshold and rate-of-change alarms that reach the duty engineer while a bearing change is still a planned job rather than an emergency rebuild
- A per-asset history you can take to a maintenance review to argue for or against a replacement, rather than relying on the fitter who remembers this pump being noisy
What you get
- 01
Three-axis vibration amplitude plus the frequency peaks that identify which fault is developing, sampled every ten minutes rather than once a quarter on a clipboard route
- 02
Bearing and housing temperature from a probe on the actual metal, so a thermal ramp corroborates the vibration signature instead of leaving you guessing
- 03
Threshold and rate-of-change alarms that reach the duty engineer while a bearing change is still a planned job rather than an emergency rebuild
- 04
A per-asset history you can take to a maintenance review to argue for or against a replacement, rather than relying on the fitter who remembers this pump being noisy
The full stack, applied here
All five layers, one accountable system
Every Indiott build runs all five layers as one accountable system. Follow a single live signal from the sensor that catches it to the report that proves it.
Turnkey LoRaWAN and industrial sensors read the physical world at the edge, on battery, without rewiring the site.
Hands a reading to CONNECT ↓
Gateways, industrial routers and serial device servers carry every reading back over LoRaWAN, 4G, 5G, Ethernet or satellite, so the far edge reports as reliably as the plant room.
Hands a signed stream to SECURE ↓
OT security by design: managed switching, VPN and firewall routers, protocol gateways and hardware data diodes keep the network segmented and the data tamper-evident to IEC 62443.
Hands a trusted stream to CONTROL ↓
When you want the system to act, remote IO, wireless valves and the bespoke Indiott Engineering line close the loop, dose, switch, isolate or interlock, with no human in the middle.
Hands an action to MANAGE ↓
The software layer turns it into decisions: live dashboards, mapping, alarming and analytics, with one-tap reports and clean feeds into your SCADA, BMS or existing platform.
The loop is closed ✓
How teams start
From a single pilot to the whole portfolio
You do not boil the ocean. Nearly every rollout runs the same four moves, and you own a working, evidenced result at the end of the first one.
Scope & risk map
We walk the sites, list the assets and pin the one constraint that matters, then agree what a good result looks like before a single sensor is bought.
Pilot on one site
A focused set of sensors goes onto one site or asset group, live on our telemetry and dashboards, wired to the people who need the alert.
Validate & standardise
We tune thresholds, kill false positives, confirm the integration into your SCADA, BMS or CAFM, and write the standard design down so it repeats.
Scale the portfolio
The proven design rolls out across the estate, reusing the same hardware standards and data models so every site reads the same way.
The pump condition monitoring kit we deploy
Full catalogue
Urban.io Activity Sensor
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Urban.io Ambient Temperature Sensor
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Urban.io Battery Test Sensor
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Urban.io Current Sensor
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Urban.io Delta Pressure Sensor
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Urban.io Gateway
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Urban.io Humidity Sensor
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Urban.io Light Sensor
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| Model | Key specification | Price ex VAT | Availability |
|---|---|---|---|
| Urban.io Activity Sensor | — | Price on request | Quote only |
| Urban.io Ambient Temperature Sensor | — | Price on request | Quote only |
| Urban.io Battery Test Sensor | — | Price on request | Quote only |
| Urban.io Current Sensor | — | Price on request | Quote only |
| Urban.io Delta Pressure Sensor | — | Price on request | Quote only |
| Urban.io Gateway | — | Price on request | Quote only |
| Urban.io Humidity Sensor | — | Price on request | Quote only |
| Urban.io Light Sensor | — | Price on request | Quote only |
Brands in this kit: Urban.io
Why Indiott
A specialist stack, not a box-shifter
Brand-agnostic by design
We pick the best of each brand for the layer and the environment, not one vendor catalogue. Milesight, AquaIoT, Atop, Browan, SpecSens and Urban.io, chosen on merit.
The whole stack, one supplier
Sensing, connectivity, OT security, control and the dashboard come from one accountable team, so there is no finger-pointing when something needs to talk to something else.
Specified and supported in Britain
UK-based engineers scope the site, quote the kit and stand behind it, with compliance mapped to the regimes your auditors actually cite.
Honest kit, honest pricing
Prices are shown where we can, quoted fast where we cannot, and you get a straight answer and a bill of materials within one working day.
DEPLOYED IN THE FIELD
Compliance this answers to
| Standard | What it requires |
|---|---|
| ISO 10816 / ISO 20816 | vibration severity zones for rotating machinery give you a defensible basis for the alarm thresholds rather than a number somebody picked |
| PUWER 1998 | continuous condition data evidences that work equipment is maintained in an efficient state and in good repair |
| ISO 55000 | asset-condition records support a documented asset-management regime and lifecycle decisions |
What it costs, roughly
A single pump skid with a vibration sensor and a bearing probe, sharing a gateway with the rest of the plant room, lands in the low hundreds of pounds per asset once the gateway is in. The gateway is the one-off; each additional machine after it is incremental. A twenty-asset plant room is materially cheaper per point than a single monitored pump. Exact figures come back itemised per asset within one working day.
Pump condition monitoring: asked before buying
Is ten-minute sampling really enough to catch a bearing fault?
For the developing faults that cause unplanned downtime, yes. Spalling, imbalance, misalignment and looseness develop over days and weeks, so a ten-minute sample captures the ramp with a lot of margin. What this will not do is catch a transient shock event between samples, and it is not a replacement for protection instrumentation on a critical turbomachine. If you need continuous protection-grade monitoring on a specific asset, say so and we will scope that separately rather than pretending this covers it.
Do we have to stop the machine to fit it?
No. Both sensors are external and magnet-mounted, so they go on a running machine in a few minutes. The only judgement is placement: the vibration sensor wants to be on the bearing housing in the load zone, not on a fan cowl or a guard, or you will measure the cover rather than the bearing.
Can this feed our existing maintenance system rather than another portal?
Yes. Readings are available over REST and MQTT and there are direct connectors into AWS IoT Core and Azure IoT Hub, so alarms can raise work orders in your CMMS. The dashboard is there if you want it, but it does not have to be where your team lives.
Related solutions
Next step
Scope it with an engineer.
Tell us the site, the assets and the constraint. You get a bill of materials and a straight answer within one working day.
- A bill of materials sized to your site
- Priced ex VAT, UK entity, no login wall
Rather talk it through? Call 023 9223 3611
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You will hear back within one working day with the parts, the prices and the lead time. A confirmation is on its way to your inbox.
If it is urgent, call 023 9223 3611.