We know how your assets fail, component by component.

Covered by Blueprints

1. Gearbox: bearing and gear damage Downtime Cost
2. Main bearing: wear and spalling Downtime Cost
3. Generator: bearing wear Downtime Cost
4. Pitch system: hydraulic leaks, sensor faults Downtime Safety/Env
5. Converter: cooling failure Downtime

Covered by Blueprints

1. Inverter: IGBT power module overheating Downtime Cost
2. Inverter cooling: fan and filter failure, derating Downtime
3. DC side: insulation loss, ground faults Downtime Safety/Env
4. Trackers: actuator and sensor faults Downtime Cost
5. MV transformer: overheating Downtime Cost Safety/Env

Covered by Blueprints

1. Guide and thrust bearings: wear, loss of oil film Downtime Cost
2. Runner: cavitation, efficiency loss Downtime Cost
3. Generator stator: winding overheating Downtime Cost
4. Governor: hydraulic power unit faults Downtime Safety/Env
5. Spiral case: clogging Downtime

Main failure modes

1. Injectors: wear, dripping Cost Safety/Env
2. Turbocharger: bearing wear, fouling Downtime Cost
3. Main and big-end bearings: wear, seizure Downtime Cost Safety/Env
4. Valves, rings and liners: burnt valves, blow-by Downtime Cost Safety/Env
5. HT/LT cooling: heat exchanger fouling, water pump failure Downtime

Main failure modes

1. Lift pump: bearing wear, cavitation Downtime Cost
2. Sewage pump: impeller clogging (rags, wipes) Downtime Safety/Env
3. Lobe or screw blower: timing gear and bearing wear Downtime Cost
4. Sludge decanter: bowl bearing wear, unbalance Downtime Cost
5. Aeration diffusers: membrane fouling Cost

Main failure modes

1. Induced draught fan: unbalance from deposits, bearing wear Downtime Cost
2. Boiler superheater: tube thinning from corrosion, erosion Downtime Cost Safety/Env
3. Bag filter: bag rupture or clogging Downtime Safety/Env
4. Combustion grate: grate bar wear, hydraulic cylinder faults Downtime Cost
5. Steam turbine, feed pumps: bearing wear, cavitation, seal leaks Downtime Cost

Main failure modes

1. Boiler feed pump: wear ring and bearing wear, cavitation Downtime Cost
2. Gas turbine compressor: fouling Cost
3. Combustors: combustion instability, burner damage Downtime Cost Safety/Env
4. Condenser: fouling, air in-leakage Cost
5. Cooling tower fans: bearing and gearbox wear Downtime Cost

Main failure modes

1. MV circuit breaker: slow or stuck operating mechanism Downtime Safety/Env
2. Busbar joints, contacts: overheating Downtime Safety/Env
3. MV/LV transformer: thermal ageing from overload Downtime Cost
4. Gas-insulated switchgear: insulating gas leak Cost Safety/Env
5. RTU auxiliary supply: battery degradation Downtime

Main failure modes

1. Bearings: wear, poor lubrication Downtime Cost
2. Stator: insulation breakdown Downtime Cost Safety/Env
3. Rotor: broken bars, unbalance Downtime Cost
4. Coupling: misalignment Cost
5. Bearings (inverter-fed motors): shaft currents, fluting Downtime Cost

Main failure modes

1. Impeller: cavitation Downtime Cost
2. Bearings: wear, contaminated lubricant Downtime Cost
3. Mechanical seal: leaks, dry running Downtime Safety/Env
4. Wear rings: wear, efficiency loss Cost
5. Operating point: running far from BEP Cost

Main failure modes

1. Screw airend: bearing wear, rotor contact Downtime Cost
2. Valves: breakage, leaks (reciprocating) Downtime
3. Oil separator: clogging, oil carry-over Cost
4. Motor and transmission: bearing wear, misalignment Downtime Cost
5. Cooling and intake: clogged cooler or filter Downtime Cost

Main failure modes

1. Impeller: unbalance from build-up or erosion Downtime Safety/Env
2. Bearings: wear, poor lubrication Downtime Cost
3. Belt drive: loose or worn belts, pulley misalignment Downtime
4. Structure: looseness, resonance Downtime Cost
5. Lobe blowers: timing gear wear Downtime Cost

Main failure modes

1. Spindle: bearing degradation Downtime Cost
2. Ball screws: wear, loss of preload Downtime Cost
3. Tool changer: positioning and gripping faults Downtime
4. Hydraulics and lubrication: pressure loss, pump wear Downtime Safety/Env
5. Coolant system: clogged filters, fluid degradation Cost Safety/Env

Main failure modes

1. Blow moulding valves: seal wear, slow pilot valve Downtime Cost
2. Filling valves: seal and spring wear, fill level drift Cost
3. Capping heads: clutch, seal and bearing wear Cost Safety/Env
4. Carousel slewing ring: wear, poor lubrication Downtime Cost
5. End-of-line drives: gearbox, chain and motor wear Downtime

Main failure modes

1. Cams and followers: wear, pitting, backlash Downtime Cost
2. Gearboxes, bearings: gear and bearing wear Downtime Cost
3. Conveyor chains, belts: elongation, tooth wear Downtime
4. Vacuum pumps: vane wear, flow loss Downtime Cost
5. Servo axes: overheating, screw wear Downtime

Main failure modes

1. Screw, check valve: wear, falling cushion Cost
2. Hydraulic pump: wear, cavitation Downtime Cost
3. Toggle clamp: bushing and pin wear Downtime Cost
4. Hydraulic oil: contamination, overheating Downtime Cost
5. Extruder gearbox: gear and thrust bearing wear Downtime Cost

Main failure modes

1. Separator spindle: bearing wear Downtime Cost
2. Separator bowl: unbalance Downtime Safety/Env
3. Homogeniser head: piston seal and valve wear Downtime Cost
4. Homogeniser crankcase: bearing wear Downtime Cost
5. Pasteuriser heat exchanger: fouling Cost Safety/Env

Main failure modes

1. Dryer cylinders: bearing wear, seizure Downtime Cost
2. Felt rolls: bearing wear Downtime Cost
3. Vacuum pumps: wear, cavitation Downtime Cost
4. Press rolls: vibration, bearing wear Downtime Cost
5. Rewinder drives: gearbox and bearing wear Downtime

Main failure modes

1. Kiln rollers: bending, breakage Downtime Cost
2. Kiln and dryer fans: bearing wear, unbalance Downtime Cost
3. Press hydraulic unit: pump wear, hot or dirty oil Downtime Cost
4. Roller drive: gearmotor and chain wear Downtime
5. Glaze pumps: abrasive wear Cost

Main failure modes

1. Decanter gearbox: bearing and gear wear, oil loss Downtime Cost
2. Decanter main bearings: wear, poor lubrication Downtime Cost
3. Bowl and scroll: unbalance, scroll wear Downtime Cost
4. Vertical separator: spindle bearing wear, erratic discharge Downtime Cost
5. Crusher: hammer and screen wear, rotor unbalance Downtime Cost

Main failure modes

1. Refrigerant circuit: refrigerant leak Cost Safety/Env
2. Compressor: valve breakage, mechanical wear Downtime Cost
3. Evaporator: icing, poor defrost Cost
4. Condenser: fouling Cost
5. Evaporator and condenser fans: bearing wear Downtime Cost

Main failure modes

1. Pump: cavitation Downtime Cost
2. Pump and motor: bearing wear Downtime Cost
3. Filters: clogging, poor backwash Downtime
4. Pivot tower drives: gearmotor wear, water ingress Downtime Cost
5. Diesel pump set: cooling, injection, starting faults Downtime Cost

Main failure modes

1. Press membrane: puncture, wear Downtime Cost
2. Tank glycol valve: stuck valve Cost
3. Chiller: refrigerant leak, compressor wear Downtime Cost Safety/Env
4. Press drum gearbox: wear Downtime Cost
5. Glycol and transfer pumps: bearing and seal wear, cavitation Downtime Cost

Main failure modes

1. Digester agitator: seal or bearing failure Downtime Cost Safety/Env
2. Milking vacuum pump: wear, unstable vacuum Downtime Safety/Env
3. Feed mixer gearbox: gear and bearing wear Downtime Cost
4. Biogas feed pumps: stator and rotor wear Downtime Cost
5. Milking pulsators: pulsation curve out of tolerance Safety/Env