From Alarm to Root Cause: Machinery Institute Resolves a Pelletizer Crisis with Viking Analytics

Machinery Institute used Viking Analytics to monitor a cement plant's Criticality 1 pelletizer. When vibration suddenly spiked, MultiViz flagged the anomaly and guided a two-phase investigation that uncovered both a VFD tuning error and an emerging bearing defect.

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Executive summary

MultiViz caught two problems traditional threshold-based tools would have missed.
Ernesto Primera

CTO, Machinery Institute

  • Customer

Cement Industry

  • Employees

  • Turnover

  • Location

USA

  • Production

Criticality 1 Pelletizer

  • Heat

  • Electricity

  • Avoided Costs

$200K+

  • Shutdown Avoided

2+ days

Machinery Institute used Viking Analytics to monitor a cement plant's Criticality 1 pelletizer. When vibration suddenly spiked, MultiViz flagged the anomaly and guided a two-phase investigation that uncovered both a VFD tuning error, driving dangerous gearbox oscillations, and an emerging bearing defect. The VFD fix immediately restored safe vibration levels; the bearing replacement was scheduled proactively. Avoided costs: over $200,000.
  • Solution

Continuous vibration monitoring with Viking Analytics AI

  • Challenge

Sudden high vibration on the plant's most critical asset - cause unknown

  • Assets

Pelletizer motor and gearbox with six triaxial wireless sensors

  • Result

VFD fault fixed immediately; bearing replacement planned; $200K+ in failure costs avoided

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