Sensors, Vol. 25, Pages 6916: PumpSpectra: An MCSA-Based Platform for Fault Detection in Centrifugal Pump Systems

Sensors doi: 10.3390/s25226916

Authors:
Hamza Adaika
Zoheir Tir
Mohamed Sahraoui
Khaled Laadjal

Reliable detection of faults in centrifugal pump systems is challenging in industrial environments due to harsh operating conditions, limited sensor access, and the need for fast, explainable decisions. We developed PumpSpectra, an industrial Motor Current Signature Analysis (MCSA) platform that processes uploaded stator-current CSV files using FFT/STFT with transparent, rule based models designed to identify mechanical faults including misalignment, bearing defects, and impeller anomalies; field validation demonstrated misalignment detection. In a case study at the El Oued desalination plant (Algeria; n = 40 operating points), PumpSpectra achieved 91.2% diagnostic accuracy with a 95% reduction in analysis time compared to manual MCSA post-processing, and a false-positive rate of 3.8% at 0.1 Hz resolution. These results suggest that current-only, explainable analytics can support predictive maintenance programs by accelerating fault triage, improving traceability of decisions, and reducing avoided maintenance costs in pump-driven industrial assets.

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Hamza Adaika www.mdpi.com