The lubricant is dirty and showing extreme wear. The number of iron particles is 785 and should be 25 or less. The lubricant is listed as an AGMA 6 which should have a viscosity of 320 but it measures 265 cSt. There is a high PQ index indicating large amounts of ferrous materials being removed. The amount of water has tripled since the last sample. The additive package has changed significantly indicating this is not the same lubricant previously tested.​

CME asked customer to verify the lubricant and recommended a hot oil flush to remove the large amount of wear metals and refill with the correct lubricant. If that is not possible, the lubricant should be changed and a filtration system should be attached and filter with a 7 micron beta 1,000 filter.​

The customer changed the correct oil and 336 hours of downtime were prevented.​

The oil report analysis identified improper viscosity across multiple compressors​.

The CME collaborated with the customer to verify what lubricant was supposed to be used and recommended an oil change to the desired viscosity​.

The customer identified the lubricant as EP 320 and changed the oil, noting that they saved $5,000/unit on 5 units.

There was elevated vibration related to the gear mesh. The CME recommended taking an oil sample to check for wear metals. The Lubrication CME reviewed the oil analysis report and noted wear metals, particle count, and water content were all high.

Both CMEs collaborated with the customer on a plan to inspect the gearbox, check the oil level and then change the oil.

The customer found the input seal was leaking and there was very little oil in the gearbox. The seals were replaced and the oil was changed. The customer avoided replacing the gearbox and noted a savings of $50k.

There were high-frequency peaks with harmonics in the upper-frequency range of the motor ODE. There was also high SCR firing frequency peak at 21,560 CPM. This could indicate an issue with the brushes.

The CME suggested blowing brush dust out of the motor, checking brushes and springs for proper wear and tension, and inspecting the armature for any issues.

The customer cleaned and lubricated the motor and replaced the brushes, which saved 12 hours of downtime and $38,000.

The vibration data points indicated rotating looseness and the fan ODE side had a high 2x in the axial position. 2x running speed is an indication of an alignment issue.

The CME recommended checking the bearings and alignment at the next available downtime.​

The customer changed out both DE and ODE bearings, which avoided a failure and 64 hours of downtime.

There was high frequency haystacking that indicates a possible lack of good lubrication.

The CME recommended greasing both motor bearings.

The customer greased the bearings and avoided having to replace the motor.

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​