Skyler Case Studies
How a quick fix saved a cement plant’s pumps from permanent damage.
The plant relies on two 150HP centrifugal pumps for critical process water handling. When vibration velocity and acceleration trends began to rise simultaneously on both pumps, the classic signs of cavitation were clear. A report was sent to the...
Grain mill gearbox frequent damage — root cause eliminated
Before Skyler sensors were installed, the grain mill gearbox experienced critical failures approximately every 6 to 9 months. Although the gearbox was replaced multiple times, the underlying cause remained unidentified. Each repair of this type of...
Online vibration monitoring meets on-the-ground insights
A loose motor bearing was identified through online vibration monitoring on a power grinder at a meat processing facility. Field technicians conducted additional on-site tests to confirm the diagnosis. This helped avoid an unnecessary gearbox...
Skyler Prevents Catastrophic Gearbox Failure in Centrifugal Separator
Skyler sensors were monitoring a centrifugal separator critical to the finish mill line—powered by a 125 HP motor with a pulley-driven drivetrain and right-angle reducer gearbox. During regular operation, an unexpected thermal spike was detected:...
Early warning saves engine plant from critical downtime
Just 7 days after install, a major fault was detected in a critical air compressor at an engine plant. Real-time monitoring flagged foundation cracks before they led to costly downtime. Six 500 HP air compressors, critical to plant operations, had...
Proactive Detection Saves $22,461 in Downtime Costs
A critical fan began showing rapid signs of degradation. Relying solely on periodic manual checks meant the risk of missing early fault indicators—potentially leading to a line-stopping failure and costly downtime.On October 11, Skyler's continuous...
Fast feedback saves the critical Kiln Nose Fan.
Skyler caught structural looseness back in 2024. The damage level was so bad that the motor base had to be moved to the other side of the fan. New base plate mounted during outage Feb 2025. Initial vibration levels low, start creeping up...
Clinker Cooling Fan Cone and Damper Erosion Detection
1. Slow increase in the acceleration velocity vibration since Jan 2025.2. Reached 0.6 IPS 27th February, severe degradation report sent with airflow issue suspicion.Asset was monitored by both Skyler and a different PdM provider. Skyler correctly...
Early Detection on Screw Pump Avoids Failure, Saves $50K+
At a major cement producer, a critical screw pump began showing rising vibration trends that scheduled checks would likely miss. The risk was seal damage, premature bearing wear, and an unplanned stop.Skyler's continuous monitoring flagged the...
Skyler Brings Vibration Monitoring Back—After 20 Years of Silence
At a remote peaker plant running four GE 7E gas turbines, starter motors had been operating sporadically and unpredictably for over 20 years. These powerful 800-horsepower motors rely on a Voith turbo torque converter to kickstart each turbine...
Skyler Identifies Critical Imbalance in Gas Turbine Torque Converter
At a peaker plant with four GE 7E gas turbines, 800 HP starter motors engage Voith torque converters. These systems run on irregular, demand-driven schedules—ramping from cold to full powerin under 30 minutes. Route-based vibration monitoring...
Detected in 48 hours, preventing a widescale water-system failure for 80,000+ people
The facility relies on three centrifugal pumps powered by 500-HP motors. To maintain continuous service, at least two pumps must operate at all times. This tight operating margin leaves the plant vulnerable: any undetected fault can quickly...
Early Bearing Fault Detection Prevents Damage in Gas Turbine Starter Motor
At a peaker plant with four GE 7E gas turbines, 800 HP starter motors engage Voith torque converters. These systems run on irregular, demand-driven schedules—ramping from cold to full power in under 30 minutes. Route-based vibration monitoring...
Skyler Detects Advanced Bearing Fault in Gas Turbine Starter Motor
A remote peaker plant with four GE 7E gas turbines had no way to monitor its 800HP starter motors. These systems run on irregular, demand-driven schedules ramping from cold to full power in under 30 minutes. Route-based vibration monitoring wasn’t...
Multiple assets runtime extended by vibration-based timely bearing lubrication
Detecting bearing fault frequencies and identifying trend increases is relatively straightforward with Skyler. However, for predictive maintenance programs to be truly effective, these detections must translate into actionable insights.For example,...
Proactive alert on a conveyor drive prevents unplanned downtime for a building materials manufacturer
This belt-driven, variable-load conveyor drive feeds a critical process that any unplanned stop here halts upstream loading and starves downstream units. The result can cause shutdowns, lost production, and long restarts. A belt-driven,...
Fix the root cause, not the symptom.
Effective predictive maintenance requires identifying root causes, not just treating symptoms. Superficial fixes lead to recurring failures and unnecessary downtime. A truly intelligent monitoring system must guide customers to the underlying...
Early Imbalance Detection on Silo Depressure Fan Prevents Costly Bearing Failure and Downtime
The fan is installed on top of a cement silo in a high and had-to-reach location, making regular inspection difficult. A feilure could lead to silo overpressure, dust emission, and interruptions in the loading process. Overall Velocity RMS levels...
Early Imbalance Detection on Inlet Fan Prevents Unplanned Downtime in Dairy Production
Early-stage fan imbalance caused by gradual dirt build-up is difficult to detect with periodic inspections. Without continuous monitoring, it can quickly escalate into bearing damage, unplanned downtime, and production disruption.Skyler detected...