Client Overview
The client is an industrial organization operating an automated pump testing and monitoring setup. For reliable quality and performance data, the client needed every sensor, meter, and software indicator to work accurately and consistently.
As part of the automation project, the client required a complete on-site deployment covering panel installation, sensor integration, calibration, and software verification, all delivered with minimal disruption to operations.
Business Challenge
During the automation setup, fluctuations were observed in the suction pressure sensor readings. These inconsistencies affected system reliability and called for structured troubleshooting and calibration. The client needed a partner that could:
- Identify and resolve signal inconsistencies at the source
- Install and wire all sensors accurately, following safety norms
- Calibrate flow measurement for precise fluid readings
- Verify that software readings match real-time machine performance
- Complete the work within a short on-site schedule
Solution by Puja Controls
Puja Controls carried out a structured, multi-day on-site deployment covering installation, calibration, software integration, and final validation.
Day 1: Panel Installation
- Installed and aligned the electrical control panel
- Completed internal wiring with full safety compliance
Day 2: Sensor Installation
- Installed the suction pressure sensor, discharge pressure sensor, and RPM sensor
- Ensured precise mounting and proper wiring to prevent signal issues
Day 3: Calibration and Software Testing
- Calibrated flow meters for accurate fluid measurement
- Tested the LabVIEW-based software interface and verified all virtual instruments and indicators
Final Integration
- Integrated two energy meters into the VFD panel
- Verified software readings for voltage, current, power, and frequency
Handling an Unexpected Issue
A VFD fault halted testing and caused a one-day delay. The Puja Controls team diagnosed the problem, replaced the faulty VFD module, and resumed testing once the system was restored.
Final Testing and Correction
Initial testing showed minor discrepancies in the software-calculated outputs. The team reviewed the LabVIEW code, corrected the logic, and ran a second round of testing, which confirmed that all parameters were within expected ranges.
Results & Impact
- Stable and accurate readings achieved for all sensors
- Real-time data on pressure, flow rate, RPM, and energy matched live performance
- Software logic corrected and validated for dependable calculated outputs
- Quick recovery from the VFD fault with only a one-day delay
- Smooth operation of the setup, now under observation and running as per project requirements
Client Testimonial
“The team handled an unexpected fault professionally, and the final system gives us accurate, dependable readings.”
– Plant Engineer, Industrial Client
Key Takeaways
- Correct sensor mounting and wiring are essential for stable, accurate readings
- Calibration and software verification must go together to ensure data reliability
- A structured on-site process helps resolve unexpected issues quickly without compromising quality
- Reviewing software logic, not just hardware, is key to accurate system performance