Case study
A failing diaphragm pump, caught before it failed
Predictive maintenanceWaterBreweries & Beverage
A failing diaphragm pump caught before it failed, and 540,000 L/day of loss prevented.
Carlsberg Canada
Carlsberg Canada
How it went.
Every study on this site runs the same four beats, in the same order.
01
Alert
Diaphragm pumps degrade before they fail, and the degradation is invisible to the naked eye.
02
Cost
540,000 L per day. Identified loss, and over $1,333/day in prevented cost.
03
Fix
Flow monitoring on the transfer line · Baseline and flow-signature tracking in the dashboard · SMS and email alerting on drift off baseline
04
Restored
A scheduled diaphragm replacement, no production impact
In full.
The problem
“Diaphragm pumps don’t fail all at once. They degrade. And when they degrade, the flow signature changes — subtle, gradual, invisible to the naked eye. But not to a sensor.”
What we installed
Flow monitoring on the transfer line, with the baseline and the flow signature tracked continuously in the dashboard, and alerting the moment the trace moved off baseline.
What the data showed
“We saw the pattern change on a Carlsberg transfer line. Flagged it. Maintenance found the diaphragm failing — not failed, failing. They replaced it. Scheduled. Orderly. No production impact.”
The number
540,000 L/day of identified loss. Over $1,333/day in prevented cost. Source: NB Power RFP 0770-25-S510, Reference 3.
What it buys you
“This is what monitoring buys you. Not the repair — the timing.”
What the data looked like.
Hover or arrow-key across the trace to read any interval. The flagged point is the one that started the conversation.
| Interval | Transfer line (L/min) |
|---|---|
| 00:00 | 12 |
| 00:30 | 117 |
| 01:00 | 119 |
| 01:30 | 11 |
| 02:00 | 11 |
| 02:30 | 118 |
| 03:00 | 118 |
| 03:30 | 12 |
| 04:00 | 13 |
| 04:30 | 120 |
| 05:00 | 116 |
| 05:30 | 14 |
| 06:00 | 13 |
| 06:30 | 115 |
| 07:00 | 114 |
| 07:30 | 12 |
| 08:00 | 15 |
| 08:30 | 112 |
| 09:00 | 110 |
| 09:30 | 16 |
| 10:00 | 18 |
| 10:30 | 107 |
| 11:00 | 107 |
| 11:30 | 18 |
| 12:00 | 18 |
| 12:30 | 104 |
| 13:00 | 104 |
| 13:30 | 19 |
| 14:00 | 19 |
| 14:30 | 100 |
| 15:00 | 98 |
| 15:30 | 21 |
| 16:00 | 21 |
| 16:30 | 96 |
| 17:00 | 95 |
| 17:30 | 25 |
| 18:00 | 24 |
| 18:30 | 91 |
| 19:00 | 90 |
| 19:30 | 27 |
| 20:00 | 28 |
| 20:30 | 88 |
| 21:00 | 85 |
| 21:30 | 28 |
| 22:00 | 29 |
| 22:30 | 84 |
| 23:00 | 83 |
| 23:30 | 30 |
| Before | A flow signature drifting, unnoticed, toward a shutdown |
|---|---|
| After | A scheduled diaphragm replacement, no production impact |
The published totals are the figures in the proof register, with their sources. The interval shape is a representative reconstruction and is flagged as such in the dataset.
What changed.
Before
A flow signature drifting, unnoticed, toward a shutdown
After
A scheduled diaphragm replacement, no production impact
540,000 L
per day
Identified loss, and over $1,333/day in prevented cost.
Source: NB Power RFP 0770-25-S510 FINAL, Reference 3
Where to go next.
The sector, the sibling studies, and the calculator that runs this same arithmetic on your own numbers.
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