Skyler Prevents Catastrophic Gearbox Failure in Centrifugal Separator
Case Study
The Challenge
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: the reducer casing temperature rose from 160°F to 225°F in just nine hours, triggering an automated alert.
Shortly after the temperature warning, Skyler detected abnormal vibration activity—specifically gear mesh frequency harmonics in the acceleration spectrum.
During regular operation, an unexpected thermal spike was detected:
the reducer casing temperature rose from 160°F to 225°F in just nine hours, triggering an automated alert.
The Skyler Solution
The plant team acted within an hour. An inspection revealed a broken oil level indicator, which had allowed continuous oil drainage.
The asset was stopped. Technicians replaced the indicator, refilled the oil, and restarted the unit. Surface temperature dropped, and the vibration signature normalized—confirming friction had been resolved.
Thanks to rapid detection and fast action, permanent gearbox damage was avoided, and operation resume with extended downtime.
The Result?
$35,260 in estimated savings for downtime, and gearbox replacement.
Talk to an Expert
Discover what’s possible for your business, talk to one of our experts