PlusSmart · Engineer-led analytics service
PlusSmart Analytics – turn the pump data you already have into actions
Only a tiny fraction of plant data is ever analysed. PlusSmart takes the data already in your historian, DCS, SCADA, drives and sensors – even handwritten logs – and has pump engineers read it: ranking every asset from good to bad, pointing out machines about to fail, and forecasting costs for the maintenance budget. No waiting for an AI to “learn” from many failures.
- Historian · DCS · SCADA
- Asset ranking
- Bad actors
- Budget forecasting
- ISO 50001
What data does your plant already have?
| Source | Typical content | What it says about the pump |
|---|---|---|
| Variable speed drive | Speed, current, torque, power, faults | Operating point, abnormal load, dry running, energy use |
| DCS / SCADA / historian | Suction and discharge pressure, flow, sump level, run status | Actual head, efficiency, starts, run hours |
| Protection relays, power meters | Three-phase current, energy, power factor | Phase imbalance, overload, specific energy |
| CMMS / maintenance records | Work orders, parts replaced, failure dates | MTBF, cost per machine, repeat failure modes |
| Handwritten shift logs | Pressures, temperatures, unusual noise | Long-term trends before digitalisation |
KPIs pump engineers use for ranking
- MTBF and MTTR – which machines fail most often and how long each repair takes.
- Flow as a percentage of BEP – pumps running long outside about 70–120% of BEP are seal and bearing failure candidates.
- Specific energy (kWh/m³) and wire-to-water efficiency – compare pumps on the same duty to find worn, energy-hungry units.
- Starts per hour – too many starts overheat motors and cause water hammer.
- Life-cycle cost – energy is usually the largest part of pump ownership cost, far above purchase price.
What PlusSmart Analytics delivers
Asset ranking
Every pump and motor ranked from good to bad with its own KPIs; deviations highlighted against your procedures.
Find bad actors early
Usually bad actors are only known after many failures. PlusSmart identifies them while they still “look fine”.
Knock-on effects
A process change in area A two months ago raised failure risk in area B – maintenance rarely knows; the data shows it.
Forecasting and budgets
History shows where each machine is in its life cycle, remaining life, risk and cost – for maintenance and staffing budgets.
No black-box machine learning
Built on pump expertise from energy, mining and petrochemical work – causes are explained, not just flagged.
Many KPIs from one stream
Reliability, efficiency, energy and life – from signals already in your systems.
Service packages
| Package | Scope | Deliverable |
|---|---|---|
| Pump Health Check | Review existing data, site survey, ranking | Immediate action list: alignment, throttling discharge valves… stabilise operation first, then schedule maintenance |
| Custom analytics and integration | KPIs and reports per asset and team; cloud platform; sensor integration; CMMS connection | Data anywhere, automatic work orders, continuous improvement |
| Pump expertise for your team | Commissioning VFD pump systems, optimising and rewriting PLC pump control, ISO 50001 energy management | Pump systems running as designed, data-driven budgets |
Frequently asked questions
Does plant data have to leave our site?
You decide the scope; you can start with trend exports from the DCS or drives of a few pumps. Cloud or customer-owned data-lake deployments are both supported.
Can handwritten or irregular data be used?
Yes. PlusSmart accepts handwritten logs and operating records; many plants start that way.
How is this different from AI predictive-maintenance software?
Pure machine learning needs many failures to learn – and critical machines are rarely allowed to fail often. PlusSmart starts from pump physics (curves, BEP, NPSH, affinity laws), recognises problems from the first data and explains the cause.
Works with
- i-ALERT® – add vibration data where none exists
- ReliaPump™ – turn analysis into better pump control
- ElectroSine – electrical signatures for motors and driven equipment
- Knowledge: SCADA vs HMI
Propose a pilot group for pump data analysis
Tell us which pumps already have DCS or drive data. PlusSmart proposes a small pilot group for engineers to analyse and report back – you see what your own data is saying.
Hoan Tran – Sales Director, PlusSmart Vietnam
Phone/Zalo: +84 879 848 668 · Email: sales@hoantrantdh.com