Predictive Thermal & Vibration Risk Monitoring in Rotary Equipment
A major power generation and water utility managing 240 high capacity centrifugal pumps, steam turbines, and industrial compressor units.
Run on Yantra · Plant Operations & Safety
The challenge
Turbine and pump maintenance was performed on rigid calendar intervals, resulting in unnecessary servicing of healthy assets and unexpected bearing failures.
Vibration and bearing temperature anomalies developed rapidly between quarterly manual technician inspections, causing catastrophic shaft seizures.
Replacing a damaged high pressure pump shaft cost $180,000 in emergency machining and 5 days of lost utility pumping capacity.
How Yantra solves it
Continuous High Frequency Telemetry Processing
Yantra samples tri axial vibration accelerometers and bearing thermal sensors at high frequency rates continuously.
Fast Fourier Transform Spectral Analysis
Performs real time FFT frequency decomposition to identify bearing inner race defect frequencies, misalignment, and impeller cavitation.
Remaining Useful Life (RUL) Degradation Curves
Projects asset mechanical health decay curves, calculating the exact operational hours remaining before critical failure.
Dynamic Speed & Load Derating Recommendations
Recommends automated operational speed adjustments to safely extend asset life until scheduled maintenance windows.
Computerized Maintenance Management System Integration
Schedules technician work orders, tooling reservations, and replacement bearing parts automatically.
The outcome
- catastrophic rotary equipment mechanical failures reduced
- 0%catastrophic rotary equipment mechanical failures reduced
- equipment maintenance expenditure reduced
- 0%equipment maintenance expenditure reduced
Catastrophic rotary equipment mechanical failures reduced by 92%.
Equipment maintenance expenditure reduced by 34% by transitioning from calendar to condition based servicing.
Extended average rotary asset operating lifespan by 3.5 years across the utility fleet.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
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