Bubbles That Bite: Detecting Cavitation in a Power Plant Extraction Pump
Cavitation has a reputation as a noise, “like pumping gravel”, but by the time you can hear it clearly, the damage has usually started. At a combined-cycle..
The 20% Energy Leak: How Corroded Connections Were Making a Blower Burn Money
Positive displacement (PD) blowers are the lungs of many wastewater treatment plants. They supply air to the aeration basins and run around the clock. That also makes..
The Motor That Kept Warning Us: A Year-Long Story of Insulation, Overhauls and a Re-Learn
Some faults are fixed in an afternoon. This one took almost a year, and it is a good illustration of how online monitoring supports every stage of..
9% Unbalanced: How a 710 kW Motor’s Stator Fault Was Caught While It Was Still Running
The 710 kW motor had been running for years without trouble. It was the kind of machine that appears in the maintenance plan only as an annual..
From 7 mm/s to 2.6 mm/s: A Crusher Motor, a Bad Bearing, and the Fault Behind It
In a cement plant the crusher is where the day starts. Limestone comes in as boulders and leaves as something the rest of the process can handle…
Take It Offline Now” — or Not? How a Chiller Gearbox Fault Was Pinpointed Before the Cooling Season
May is a bad month for a chiller to fail. At a large coatings manufacturer in the north-eastern United States, the cooling season was only weeks away..
A Piece of Wood Far Below Ground: Diagnosing Driven Equipment Faults You Can’t See
Deep well pumps are the definition of “out of sight, out of mind”. The motor and pump sit far below ground, submerged in the water they are..
The Belt That Whispered: Reading Transmission Faults on a University Campus Fan
University campuses are full of machines nobody thinks about until they fail. Air handlers, exhaust fans and chilled water pumps keep lecture halls, labs and dormitories comfortable…
Two Millimetres: How a Tiny Misalignment Was Behind Four Different Alarms
The blower at the solvent plant had become everyone’s least favourite machine. It was a 22 kW, 440 V motor running at 1760 rpm and driving a..
The Fan That Hummed a Warning: Catching Loose Foundations Before They Shake a Plant Apart
It was the night shift that noticed it first. On the roof of a semiconductor fab, one of the cooling tower fans had started making a sound..











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