Illustrative scenario
Pump cavitation caught three weeks early
Illustrative scenario — representative of common industrial IoT applications
Predictive maintenanceMunicipal & Public Utilities
The vibration signature changed about three weeks before anyone would have heard it.
A municipal water facility
How it went.
Every study on this site runs the same four beats, in the same order.
01
Alert
Cavitation destroys an impeller slowly. By the time it is audible on the floor, the damage is done and the outage is unplanned.
02
Cost
3 weeks of warning — Between the first signature change and the point of audible failure.
03
Fix
Three-axis vibration sensor on the pump bearing housing · Temperature probe on the housing · Trend-based anomaly alerting
04
Restored
A repair scheduled by calendar
In full.
Illustrative scenario — representative of common industrial IoT applications.
The problem
Cavitation destroys an impeller slowly. By the time it is audible on the floor, the damage is done and the outage is unplanned.
What would be installed
- Three-axis vibration sensor on the pump bearing housing
- Temperature probe on the housing
- Trend-based anomaly alerting
What changes
Before — A repair scheduled by failure After — A repair scheduled by calendar
The number
3 weeks of warning — Between the first signature change and the point of audible failure. Illustrative scenario, not a client result. Figure is representative, not measured. [TOM-REVIEW]
In one line
The shift is invisible to the human senses and unmistakable in the trend.
What the data looked like.
Hover or arrow-key across the trace to read any interval. The flagged point is the one that started the conversation.
| Interval | Pump 4 · RMS (mm/s) |
|---|---|
| D1 | 2.81 |
| D2 | 2.73 |
| D3 | 2.71 |
| D4 | 2.75 |
| D5 | 2.67 |
| D6 | 2.81 |
| D7 | 2.73 |
| D8 | 2.63 |
| D9 | 2.79 |
| D10 | 2.59 |
| D11 | 2.61 |
| D12 | 2.78 |
| D13 | 2.63 |
| D14 | 2.70 |
| D15 | 2.70 |
| D16 | 2.80 |
| D17 | 2.68 |
| D18 | 2.61 |
| D19 | 2.81 |
| D20 | 2.59 |
| D21 | 3.22 |
| D22 | 3.50 |
| D23 | 3.88 |
| D24 | 4.40 |
| D25 | 4.71 |
| D26 | 5.19 |
| D27 | 5.60 |
| D28 | 6.10 |
| D29 | 6.43 |
| D30 | 6.88 |
| Before | A repair scheduled by failure |
|---|---|
| After | A repair scheduled by calendar |
Illustrative dataset — a representative operational profile, seeded and deterministic, not measured at any site.
What changed.
Before
A repair scheduled by failure
After
A repair scheduled by calendar
3 weeks
of warning
Between the first signature change and the point of audible failure.
Source: Illustrative scenario, not a client result. Figure is representative, not measured. [TOM-REVIEW]
Where to go next.
The sector, the sibling studies, and the calculator that runs this same arithmetic on your own numbers.
Predictive maintenanceBulk Handling & Rail LogisticsManufacturing — automotive, plastics & rubber
Conveyor drive bearing degradation caught six weeks early
A bulk handling facility
A bearing changed its signature about six weeks before it would have seized.
6 weeksof warning
Illustrative scenario — representative of common industrial IoT applications
Predictive maintenanceWaterBreweries & Beverage
A failing diaphragm pump, caught before it failed
Carlsberg Canada
A failing diaphragm pump caught before it failed — 540,000 L/day of loss prevented.
540,000 Lper day
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