Case Studies

Challenge

• Decades-long issues with compressors failing in spite of $millions on vibration systems & RCM
• Regular, periodic failures requiring $multi-million overhauls and production losses several time larger
• The goal to find root cause very early before major damage

Solution

• Autonomous Agents™ cast a “wider net” around equipment to cover process & machine issues
• Root cause detected = Liquid carry-over
• Chief Rotating Engineer: “You can do that? I cannot apply enough people to do that level of monitoring & analysis.”

Benefit

• Third-stage valve issues detected
• Alert to Cause = 8 weeks: 7 weeks before vibration suggests damage
• Savings: $MM Repairs and Loss of Product

Challenge

• Refinery; Long time proponent of RCM, Mtell user since 2011
• Lightly Instrumented Pumps – Only 4 signals; Fluid Pressure in/out, Temperature and Motor Amps

Solution

• Complete change in maintenance culture now SWOT team responding to agent alerts 4000+ agents on 400+ asset classes
• ONLY Mtell detects the cause with limited inputs

Benefit

• Learns behavioural differences during seasons; summer, winter, etc.
• Early warning of motor burn up 2 weeks in advance
• Value: One unit saves;
  • Year 1 – $1.5 MM
  • Year 2 – $3 MM

Challenge

• At a large-scale pharmaceutical plant several large chillers and compressors are critical equipment infrastructure. Despite all six sigma efforts, failures still caused enormous losses.
• Aging equipment, increasing energy usage, higher maintenance (where 35% is corrective and 65% preventive), and inadequate equipment health status reporting contributed to the problem.

Solution

• Mtell’s industrialized machine-learning reversed the situation.
• Autonomous Agents turned corrective and preventive maintenance into prescriptive maintenance.
• Autonomous agents now advise when equipment should be maintained with early warning of impending failures.

Benefit

• This gives sufficient notice for orderly, rapid problem correction at the lowest cost.
• Additionally, the Mtell View client application increases situational awareness of the current and future health of machines with direct work order creation, asset performance displays and reports, and health/status alerts and notifications.
• Overall production has improved dramatically, valued at $millions/year.