The DECOB project validates a predictive methodology to anticipate possible incidents in submersible pumping systems

The reliability of groundwater extraction systems is a key factor in ensuring water supply to municipalities, cities, and industries, especially in a context marked by pressure on water resources and aging infrastructure. In this scenario, the DECOB project (Development of a methodology to prevent the wear of the axial bearing in submersible pumps) It has culminated in the development and validation of a predictive diagnostic tool that allows for anticipating failures in submersible pumps before serious breakdowns occur.

The teams from Facsa, the project's leading company, along with those from the Polytechnic University of Valencia and the University of Valladolid, have worked for the past three years on developing a solution to improve the maintenance of submersible pumps. The DECOB project builds upon the EMBER project, developed with the same partners, and delves deeper into the early detection of axial bearing wear, one of the most critical and expensive components of this equipment, whose degradation can cause secondary damage and unexpected service interruptions.

From corrective maintenance to preventive maintenance

One of the key differentiators of the DECOB project compared to other existing solutions is its methodology, which is based on the analysis of electrical voltages and currents measured at the surface. This allows for the evaluation of the internal condition of motors submerged at great depths without the need for direct intervention on the equipment. This approach makes it possible to anticipate deterioration, prevent further damage to the motor, and significantly reduce maintenance costs. The innovative nature of the methodology has led to the initiation of the patent protection process.

“DECOB’s main value is that it allows us to evolve from reactive maintenance to truly predictive maintenance,” says Miguel Ortiz, Deputy Technical Director of Supply at Facsa. “Anticipating the failure of a critical component not only reduces operating costs but also minimizes the risk of supply interruptions, a key aspect for supply services.”

Throughout the project, laboratory tests were conducted under varying levels of wear, along with advanced simulations and pilot tests at ten real pumping stations. This allowed for the validation of the methodology's reliability and robustness under operational conditions. As a result, DECOB has yielded both a proven method for predicting failures and the design of more affordable monitoring systems, with an estimated cost reduction of at least 50% compared to similar solutions available on the market.

The project had a total budget of 739.310,98 euros and was financed through Project CPP2021-008621, by the Ministry of Science and Innovation / State Research Agency (MCIN/AEI/10.13039/501100011033) and by the European Union – NextGenerationEU / PRTR.