PlusSmart · PlusSmart’s own pump-control technology
ReliaPump™ – smart control for VFD-driven pumps that stops seal failures and saves energy
ReliaPump uses the drive’s own data (speed, current, torque, power) to know where the pump is operating on its curve, protects it against dry running, dead-heading and run-out, and balances load across multi-pump stations – without adding flow meters or pressure sensors.
- Dry-run protection
- Dead-head protection
- Run-out protection
- Flow balancing
- Energy saving
Why do pumps keep failing seals and bearings?
Every centrifugal pump is designed to operate around its best efficiency point (BEP). ANSI/HI 9.6.3 recommends a preferred operating region (POR) typically around 70–120% of BEP flow. Outside it, radial loads increase, the shaft deflects, and seals and bearings carry uneven loads – so the pump fails early even with on-schedule maintenance.
| Bad operating condition | What happens inside the pump | Consequence |
|---|---|---|
| Dead-head – running against a closed discharge valve or system pressure above pump head | Flow near zero; all power becomes heat in the casing; recirculation, high radial load | Liquid flashes at the seal faces; shaft deflection, bearing damage |
| Dry running – empty sump, loss of prime, air in suction | Seal faces lose their lubricating film; wear rings rub | Seal faces crack within minutes |
| Run-out – far right on the curve | Insufficient NPSH, cavitation; motor may overload | Pitted impeller, vibration, gravel-like noise |
| Prolonged low flow | Suction and discharge recirculation, pressure pulsation | Low-frequency vibration, impeller wear, bearing failure |
| Abrupt start/stop, valve slam | Pressure waves travel through the pipeline | Water hammer, cracked pipes, check-valve damage |
The drive is a sensor you already have
Centrifugal pumps follow the affinity laws: flow is proportional to speed (Q ∝ n), head to speed squared (H ∝ n²) and power to speed cubed (P ∝ n³). The drive already knows actual speed and power or torque; combined with that pump’s curve, flow and head can be estimated – the basis of sensorless control.
The cube law also explains VFD energy savings: reducing speed by 20% theoretically cuts shaft power to about 0.8³ ≈ 51%. Real savings are smaller when the system has a large static head, so control must be optimised against the real system curve, not just speed.
ReliaPump modules
ReliapumpIQ™
Sensorless pump analytics and protection.
- Dry-run detection without false trips on transient air
- Dead-head protection – root cause of many seal failures
- Run-out protection
- Right fault, right alarm, right trip
ReliapumpOS™
A complete pump operating system: control, data, automation.
- Sensorless flow control (Digital Flow, hardware dependent)
- Control optimisation
- Control-valve automation
- Tank stripping cycles
ReliapumpSync™
Advanced coordination for parallel pump stations.
- Balances flow, not just speed
- Compensates for wear differences between old and new pumps
- Fewer pumps running while meeting demand
Reliapump360™
Monitoring, control and lifecycle tracking.
- Hardware control plus cloud or data-lake monitoring
- Reliability, prediction, maintenance, energy, performance analytics
- Turns drive data into savings
Why equal speed is not enough for parallel pumps
Parallel pumps are commonly run at the same speed. But a worn pump has a lower curve than a new one: at equal speed the new pump carries most of the flow while the old one may be pushed towards dead-head – heating up and destroying its seal while the HMI shows every pump “running normally”. ReliapumpSync balances by flow for each pump, compensates for wear and selects the optimal number of running pumps for each demand level.
Results
Frequently asked questions
Which drive brands are supported?
ReliaPump works with common industrial drives; some features (sensorless flow control, flow balancing) depend on hardware – PlusSmart checks this during the assessment.
Do we need to replace our PLC or DCS?
No. ReliaPump integrates with the existing control system; a 24-pump geothermal project was upgraded without a plant shutdown and without original documentation.
What are the main benefits?
No more seal failures from dead-heading or dry running, no water hammer, fewer pumps running, lower energy use and data for predictive maintenance.
Works with
- Flexaseal – the right mechanical seal for the duty
- PlusSmart Analytics – engineer-led pump data analysis
- i-ALERT® – wireless vibration and temperature
Send DCS or drive trends from your pump station
PlusSmart will tell you whether the pump group is at risk of unplanned failure and whether the Sync or IQ module would help – before you invest anything.
Hoan Tran – Sales Director, PlusSmart Vietnam
Phone/Zalo: +84 879 848 668 · Email: sales@hoantrantdh.com