Pump Health Monitoring
Pumps are the circulatory system of every process plant. Fizix detects cavitation, bearing wear, seal degradation and misalignment before they interrupt production or destroy an impeller.
Hearing Cavitation Before It Eats Your Impeller
Cavitation is the pump killer: vapour bubbles collapse against the impeller with enough energy to erode metal, yet it barely registers on vibration until damage is done. Run a pump off its Best Efficiency Point and you invite it — plus recirculation, seal wear and wasted energy.
1 80 kHz acoustic emission detects the high-frequency signature of cavitation at onset — before impeller erosion begins.
2 Off-BEP operation and hydraulic instability are surfaced in Mate so you can correct duty point and recover energy.
3 Seal & coupling protection catches misalignment-driven wear before a leak contaminates the area.
The Silent Killer of Industrial Processes
Pumps are among the most failure-prone rotating machines — and their failures are often the most damaging and the hardest to catch early. Cavitation, the most destructive pump fault, generates high-frequency energy that erodes impellers fast, and it usually goes unseen without acoustic monitoring.
Fizix's acoustic-emission channel, running up to 80 kHz, is highly effective for early cavitation detection. Combined with 3-axis vibration, temperature and flux, it covers both mechanical and fluid-dynamic faults in a single smart multi-sensor device.
Whether it's a centrifugal process pump in a chemical plant, a transfer pump in oil & gas, or a cooling-water pump in a power station, every pump in your facility gets the same level of intelligence.
PUMP TYPES MONITORED
What Fizix Detects on Your Pumps?
Each fault leaves a distinct signature across vibration, acoustic emission, magnetic flux or temperature. Fizix catches them weeks before failure — and tells you which smart multi-sensor device saw it.
Cavitation
Destructive bubble collapse detected via high-frequency acoustic emission before impeller erosion or casing damage.
Bearing Failures
Inner-ring, outer-ring, ball and cage defects caught at the earliest stage.
Shaft Misalignment
Motor-pump coupling misalignment driving vibration and rapid seal wear.
Impeller Imbalance
Impeller damage, buildup or wear producing 1x vibration and hydraulic instability.
Blade-Pass / Hydraulic Faults
Impeller-volute interaction and recirculation signatures from off-BEP operation.
Mechanical Seal Degradation
Early seal wear detected through vibration changes before leakage and contamination.
Suction / NPSH Issues
Recirculation, low NPSH and off-BEP running exposed before they damage the pump.
Overheating
Dry-running, bearing or seal overheating verified by on-device temperature.
Reactive Maintenance vs Fizix
Most plants still run pumps on calendar schedules and walk-around checks. Here's what changes when your pumps talk to you.
One Platform, Value For Every Role
From the boardroom to the shop floor, pump monitoring delivers something different — and useful — to everyone who keeps production running.
Plant & Reliability Leaders
Turn unplanned pump failures into planned, budgeted work
A clear ROI and payback you can take to finance and the board
Fleet-wide visibility across every pump — one plant or many
Lower safety exposure and fewer emergency interventions
Predictable spend, less capital tied up in spares
Operations & Production Teams
Keep the line running — no process interruption to install
A simple health score per pump, readable without expertise
Alerts before a trip, so you shut down on your terms
Know which asset actually needs attention first
Web & mobile dashboards for the whole shift team
Maintenance & Reliability Engineers
Pinpoint the fault type and location on each pump
Plan repairs into routine stops, not emergencies
Order the right spare at the right time — no over-stocking
Guided diagnostics without deep vibration expertise
Remote checks — fewer trips into hot, hazardous zones
See What Fizix Could Save You
Move the sliders to match your pump fleet. This is an indicative estimate — book a free consultation for a validated, site-specific business case.
Defaults reflect a typical pump-heavy plant. Adjust to your own figures.
Based on Fizix reference outcomes: up to 50% less downtime, 35% lower maintenance cost, ~134 kg CO₂/day per 200 kWh motor. Indicative only.
From Smart Multi-Sensor Device to Insight
An end-to-end solution connecting your pumps to actionable intelligence in real time — installed in minutes, with no process interruption.
Mount in <15 min
The smart multi-sensor device attaches near the pump bearing or on the casing — process keeps running.
Listen at 80 kHz
Acoustic emission and vibration captured 24/7 and processed at the edge.
Cavitation + hydraulics
Mate flags cavitation onset, off-BEP operation and seal wear automatically.
Act before erosion
Alerts arrive while the impeller is still intact — correct duty point or plan the repair.
How Fizix Protects Your Pumps?
Smart multi-sensor devices in the field capture four signals — analyzed on the cloud-based Fizix Mate platform.
Cavitation Detection
The 80 kHz acoustic-emission channel detects cavitation's high-frequency signature in its earliest stage — before impeller erosion or casing damage.
Guided Impeller Diagnosis
Mate's dedicated guided tools for pump blade and impeller faults enable root-cause identification without specialist expertise.
Seal & Coupling Protection
Misalignment-induced seal wear is caught early through characteristic vibration patterns, preventing costly leaks and contamination.
Energy Efficiency
Off-BEP operation, cavitation and mechanical faults all raise power draw. Fizix identifies and corrects them to cut energy cost.
Safe in Hazardous Areas
ATEX-certified sensors monitor pumps in explosive atmospheres — oil & gas, chemical, petrochemical — with no safety compromise.
Performance Trending
Track pump health score, vibration trend and temperature over time to predict maintenance weeks or months ahead.
What We Detect & Measure?
Fizix combines multiple measurement technologies to give complete pump health visibility.
Acoustic Emission
Cavitation and early bearing faults up to 80 kHz.
Vibration Analysis
Waveform, spectrum, envelope and waterfall up to 26.6 kHz.
Hydraulic / BPF
Blade-pass and recirculation signatures for impeller faults.
Temperature
Dry-run, bearing and seal overheating detection.
RPM Estimation
Speed tracking for load-normalized trending.
Statistical Indices
RMS, Crest Factor, Kurtosis, Peak — on-device.
Fizix Smart Multi-Sensor Devices for Pump Monitoring
Choose the right smart multi-sensor device for each pump's criticality and environment.
Best for Critical Assets
Wired power for 24/7 continuous streaming. For high-criticality assets where any downtime is unacceptable.
Best for Important Assets
Battery-powered with up to 5-year life. ATEX-certified for hazardous areas. Wireless and quick to install.
Best for Balance-of-Plant
Bluetooth, compact and economical. Ideal for monitoring many assets across a facility cost-effectively.
Impact on Pump Reliability
Typical outcomes reported across Fizix deployments. Actual results vary by asset condition and baseline.
Figures reflect "up to" improvements observed across Fizix installations and the 200 kWh reference calculation for CO₂. Company-wide figures (150M+ monitoring hours, 40,000+ connected machines, 18+ sectors) are as of 2025. Asset-specific results should be validated during a pilot.
For pumps, the first symptom is a sound.
A single Fizix smart multi-sensor device captures 3-axis vibration, acoustic emission, magnetic flux and temperature. For pumps the acoustic-emission channel leads — cavitation and early bearing contact show up there long before vibration moves.
Data streams to the AI-powered Mate platform, where a digital twin and fault library classify the fault, its severity, and what to do next.
Request a Free Expert Consultation
Tell us about your pumps and what you want to protect. A Fizix specialist will get back to you within one business day to discuss your goals and outline a tailored path forward — with no obligation.
Free 1:1 consultation with a reliability expert
Assessment of your critical pumps
Tailored sensor & Mate platform recommendation
Optional pilot to prove ROI before scaling
Protect Your Pumps Before They Fail
Detect cavitation, bearing wear and misalignment in any pump — centrifugal, reciprocating or submersible.
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