Pump Test Software Modernisation

Industry: Industrial manufacturing, pump testing and certification
Organisation: International pump and fluid technology manufacturer
Solution type: Legacy software modernisation and plant floor integration
Core technology: .NET, SQL Server, PLC integration, OPC UA
Engagement: Assessment, remediation, migration, enhancement and ongoing support

Headline resultImpossible readings caught at the source and every certificate value traceable to raw data

Overview

Every pump this manufacturer ships is tested on a rig, and the results produce the performance certificate sent to the customer. Its legacy test platform had started producing incorrect and sometimes physically impossible results. Through our legacy system modernisation services, we modernised the software, kept its proven calculation logic, consolidated its databases and added full traceability from rig to certificate.

The Business Problem

The test application controlled the rigs, captured instrument readings and calculated pump performance. Over many years of changes it had become unreliable and hard to diagnose. Engineers saw results such as impossible head values, zero shaft speed during runs and blank instrument channels, but could not tell whether the cause was sensor scaling, PLC settings or the calculation itself. Often the only option was to retest the pump.

Untrusted resultsUntrustworthy test results on customer certificates
Scattered quality recordsQuality records spread across five Microsoft Access databases
Weak access controlWeak access control, unreliable concurrent use and no practical recovery path
Risky to changeAn application considered too risky to change

Our Solution

We started by making the system diagnosable. Every step was instrumented, from raw transducer values and PLC parameters to the final certificate figure, creating an audit trail for each test. Rather than replacing the calculation engine, which held years of engineering knowledge, we fixed scaling issues, unread channels and edge cases, and added validation during data capture.

The five Access databases were reconciled and merged into one SQL Server database with enforced relationships. OPC UA communication now sends flow setpoints, monitors rig stabilisation and reads the full instrument bank, with configurable tag mapping and connection monitoring. Once the platform was stable, we extended test point calculations, streamlined the test sequence and redesigned reporting screens and certificates.

Rig test starts
Readings captured over OPC UA
Calculations traced step by step
Results stored in SQL Server
Certificate issued with an audit trail

Modernised pump testing software for industrial testing

Key Features

Full traceability from certificate values back to raw sensor readings
Validation during acquisition to catch impossible readings immediately
Automated ISO 9906 acceptance grading
Operator review of raw and speed corrected results
Reviewer sign off before certificates are released
Complete data export stored with each certificate
Authentication, role based access and point in time recovery
Operator alerts and logging for communication failures

Outcomes

The platform is in production on the manufacturer’s test rigs
The defect backlog that triggered the engagement has been closed
Faults are diagnosed from the original test record without retesting pumps
Hundreds of pump models and curves managed in one reference library
New rigs and instrument setups can be added without rebuilding the application

Technology Stack

Application1 technology

.NET

Database1 technology

SQL Server

Industrial integration2 technologies

PLCs

OPC UA

Data4 technologies

Pump Curve Library

Motor Performance Data

Test History

Rig Configuration

Who This Solution Suits

This approach suits manufacturers, engineering firms and industrial operators running ageing desktop software connected to PLCs and test equipment, especially where data sits in Access databases or spreadsheets.