Power Plant Pulley Repair
Project Scale & Technical Specifications
Assets Monitored
The system monitors the motors and pumps driving a heavy-duty conveyor belt system.
Deployed Sensors
Wireless Sensors: Battery-powered sensors affixed directly to the machinery to capture vibration, temperature, and acoustic data.
Connectivity: Data is transmitted via the XTRA Gateway to the cloud/edge-computer for real-time processing.
Annual Data Collection
Need Data
Installation Period
Plug&Sense system installed in 4 days
This was followed by a 3 week baseline calibration period
After calibration the system is fully calibrated to the data centers unique vibrational fingerprint
The Challenge
The Challenge
The client faced the "Run-to-Failure" trap. Traditional, periodic human inspections were unable to detect subtle, developing mechanical issues - such as bearing faults -until they resulted in catastrophic and costly failure.
The primary objective was to deploy a solution that could catch these invisible issues months in advance, allowing the facility to shift from expensive emergency shutdowns to cost-effective scheduled repairs.
The System
The System
01
Rapid Deployment
The Plug&Sense System is a non-intrusive setup allowing for immediate continuous monitoring of vibration, temperature, and acoustic data without complex wiring.
02
Proprietary Health Index
XpiderWeb AI applies a Proprietary Machine Health Index to incoming data. This sophisticated filtering successfully distinguishes between normal machine operation and the specific signatures of developing faults.
03
6-Month Early Warning
The system is engineered for long-range detection. In this deployment, it generated a confirmed alert 6 months (180 days) before the actual physical failure would have occurred.
04
ESG & Efficiency
Beyond safety, the system supports ESG goals. By preventing catastrophic damage, the client saw an extended asset life of over 25% and reduced energy consumption by more than 18%
The Results
XpiderWeb detected an upcoming failure 6 months before it would happen - leading to a timely, planned repair
180
6-month early detection
The client saw an extended asset life of over 25% and reduced energy consumption by more than 18%
ESG
ESG Goals
Conclusion
Conclusion
Predicting the "Invisible" FractureTurning Data into Disaster Prevention
The value of the system was proven when it flagged a critical anomaly half a year before it could cause a breakdown.
The 180 Day Save
The XpiderWeb system identified a developing fault 6 months in advance. Following the data-driven alert, maintenance teams later confirmed the physical issue: a specific 1 x 2 cm chipping in the bearing casing.
From Emergency to Routine
By catching this issue early, the client avoided a costly emergency shutdown. Instead, they performed a scheduled repair, achieving an expected 2–10x ROI.
Testimonial
"From the initial consultation to the final implementation... the project was completed on time, within budget, and successfully identified anomalies before it turns to fault. Based on my experience, I would highly recommend your services."
— W. K. Chan, Generation Division Electrical Maintenance Section, The Hong Kong Electric Co., Ltd.