Condition monitoring has become one of the most valuable tools in modern pump management. At APE Pumps, it goes beyond detecting faults and predicting failures – it’s about extending a pump’s life, improving efficiency, and building stronger, long-term customer partnerships.

“In simple terms, condition monitoring involves checking the health of a pump by collecting baseline data during installation and then measuring against it over time. It involves an analysis of how the pump is performing over a period of time and may flag issues such as misalignment, cavitation and bearing wear. Very often, condition monitoring may detect a system’s issue that is not related to the pump itself,” explains Johan van den Berg, service technician, APE Pumps.

A pump never operates in isolation; it is one component in a larger system, where its performance is directly influenced by motors, piping, valves, and site conditions. Effective condition monitoring, therefore, considers not only the pump itself but the wider system interactions that affect reliability.

“Often, condition monitoring exposes system issues such as poor valve performance, blocked suction lines, or resonance caused by neighbouring pumps. Vibrations from a motor may negatively affect the pump, and vibrations from a pump may negatively affect a motor. In large installations, multiple pumps run side by side, and their resonance can affect one another. Skilled analysis is therefore critical to distinguish between equipment-specific faults and system-induced faults,” adds van den Berg.

The scope

Condition monitoring is a broad discipline. Vibration analysis and laser alignment form its backbone, supplemented by techniques such as oil sampling and ultrasonic testing when needed. Then there is the analytical or diagnostic part, which identifies the reasons behind, for example, excessive vibration or misalignment.

Van den Berg has successfully passed his VCAT-2 Vibration Analysis exams, that has taught him to diagnose a wide range of fault conditions by collecting the right data and will continue to study up to the highest level – VCAT-4.

Some condition assessments can be done remotely, but this is often costly, as it requires installing multiple sensors across the system along with a reliable Wi-Fi connection. “However, data alone rarely provides the full picture – site visits are still essential to understand the real conditions. Often, the most valuable insights come not from instrumentation but from conversations with the people on the ground – like the floor sweeper who notices leaks and spillages that others may ignore. Site conditions like water ingression, dust, and low reservoir levels often reveal the underlying reasons for pump inefficiency.

Recognising the warning signs

The most common red flags include excessive vibration, cavitation, and bearing failure. Cavitation, caused by restricted flow or faulty valves, produces a distinct sound—like stones rattling inside the pump. Left unchecked, it rapidly damages impellers and bearings. Over-greasing is another frequent issue, as operators attempt to prevent bearing failure but end up causing it.

Temperature rises are usually a symptom rather than a cause, signalling underlying issues such as lubrication failure or cavitation. In extreme cases, seized bearings can lead to snapped shafts, damaged couplings, and even structural damage. There was an instance where a failed gearbox coupling was propelled through the roof—an incident that highlights the dangers of unchecked vibration.

Tools of the trade

Condition monitoring requires investment in advanced, costly equipment. While the financial outlay for APE Pumps is significant, committing capital to technology reflects a strategic decision to go beyond traditional break–fix maintenance.

“APE views it as an investment rather than a cost. Owning and operating advanced monitoring equipment enables the company to offer higher-value services,” states van den Berg.

For condition monitoring, APE Pumps at times uses a flowmeter. This provides a direct measurement of the actual flow rate in the system. By comparing flow readings with pressure measurements, van den Berg can assess whether a pump is operating on its correct performance curve or if problems such as blocked valves, cavitation or other system restrictions are limiting efficiency.

A portable vibration monitoring data collector is also used on any rotating equipment, as well as pressure gauges that take suction and discharge readings, so that technicians can assess the pump’s head and efficiency.

Report

Reports are designed to be accessible. Rather than overwhelming clients with technical graphs, technicians summarise key findings, add annotated images, and provide clear recommendations.

Each report outlines the background and service history of the equipment, records key measurements such as vibration, alignment, pressure, and flow, and highlights any site conditions that may affect performance. Findings are presented with supporting evidence – including spectra, photos, and alignment data – to clearly show issues like cavitation, misalignment, or bearing wear. Importantly, the report always includes tailored maintenance recommendations.

APE recommends conducting a monthly condition monitoring assessment on critical equipment and a quarterly condition assessment on non-critical equipment.

“Sometimes, our customers deploy their own condition monitoring teams to conduct assessments on pumps. This then provides us with an opportunity to compare our data with their data to catch errors and ensure accuracy. Our role as an independent partner provides an additional layer of assurance,” says van den Berg.

Why it matters

The benefits for customers are clear. Condition monitoring prevents costly breakdowns by identifying early warning signs and allowing maintenance teams to intervene before catastrophic failure occurs. For APE Pumps, it eliminates the reactive scramble to fix pumps after they have already failed, replacing crisis management with planned maintenance.

Baseline reports also serve as evidence. Not all customers conduct regular maintenance on their pumps. When clients query sudden failures, APE Pumps can refer back to data collected months earlier to show the developing fault.

“This builds trust with our customers who see that we take long-term responsibility for our pumps. We don’t simply sell a product – we commit to supporting the customer throughout the pump’s lifecycle,” adds van den Berg.