Quick Wins

RMS acceleration readings suddenly spiked on both of the compressor ODE monitoring points. There was an extreme degree of high-frequency harmonics, which could indicate thrust bearing wear.

The CME advised the customer to inspect the compressor for signs of thrust bearing wear and plan for the replacement of the thrust bearings. It was also recommended that If vibration readings continued to climb over the next several days, the compressor would need to be shut down to avoid more extensive damage.

The male thrust bearing on the ODE side of the compressor was replaced. Post-replacement, vibration readings returned to the normal range. The customer noted that they saved $150,000 and avoided a shutdown.

High vibration at crusher speed was detected on the motor, indicating possible sheave misalignment and/or incorrect belt tension.​

The CME recommended inspecting the sheaves for proper alignment and ensuring proper belt tension​.

The customer replaced the motor, belts, and sheaves, which saved 24 hours of downtime and $240k.

Condition monitoring engineer observes vibration on agitator ODE, issues maintenance recommendation

Sheaves and belt replaced, but condition monitoring engineer calls out worsening sheave misalignment

The sheave pulley bore was found to be too big, and the ODE bearing was hot. Replaced taper lock and bearings. Issue resolved, $150k saved.​

Condition monitoring engineer observes increased amplitude in rotor bar activity with turning speed sidebands, indicating electrical issue​

Condition monitoring engineer issues maintenance recommendations to check all electrical connections and measurements, scan with a thermal gun, and replace the motor if not an external issue.​

Motor replaced before failure, customer calls out $250k save​

AI alerts condition monitoring engineer; observes harmonics 1x turning speed and >50 g’s pk-pk at turning speed, indicating excessive looseness.​

Condition monitoring engineer issues maintenance recommendation for to perform lift check on Fan ODE​

Excessive wear damage was found (0.025” overall) on the housing and bearing; both replaced, avoiding catastrophic failure ​

AI observes +60°F rapid change on motor ODE​

Condition monitoring engineer issues maintenance recommendation

Motor cooling fan sudden failure was detected and repaired​