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See how AspenTech’s industry-leading Asset Performance Management (APM) solutions catch potential asset failures weeks, even months, ahead of time—delivering value for customers day after day.
30 "Catches" in 30 Days
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VALUE Aspen Mtell’s warning allowed early intervention that avoided a potentially catastrophic failure. Estimated savings of $500K USD by avoiding additional damages.
ACTION Shutdown and inspection revealed that incorrect axial alignment from the recent turnaround was causing the vibration issue. Immediate maintenance service corrected the issue. Compressor startup showed issue was solved.
ALERT/PRESCRIPTION Immediately on deployment, the two Agents detected multivariate patterns with combinations of increasing turbine vibration across many sensors. Agents requested inspection.
ASSET/AGENT OVERVIEW Chemical Industry Turbine on a Force Draft Fan Anomaly & Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
You Asked. We Listened. 30 "Catches" in 30 Days Has Arrived. Aspen Mtell Detects High Axial Vibration on a Turbine
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CATCH 2
VALUE Estimated savings of $2.7 M USD by avoiding production loss or equipment damage.
ACTION Investigation concluded that expander bearings must be replaced. Bearings had 4-month lead time from OEM so Agent gave plenty of warning to properly plan and schedule maintenance.
ALERT/PRESCRIPTION Anomaly Agent detected an increased bearing temperature on the methane expander. Agent requested inspection.
ASSET/AGENT OVERVIEW Oil and Gas Industry Methane Expander (Demethanizer Column) Anomaly Agent detects complex degradation patterns (across time & many sensors) warning much earlier than single tag DCS threshold alarm.
Keep Your Cool as the Temperature's Rising Aspen Mtell Detects Bearing Failure in Methane Expander
VALUE Taking early, less-intrusive action avoided a major asset breakdown and saved an estimated $500K USD in maintenance costs and production losses.
ACTION The inspection found a drive synchronization issue caused by a lubrication imbalance in the motor/gearbox system. Oil imbalance was corrected avoiding a gearbox and/or coupling failure.
ALERT/PRESCRIPTION Anomaly Agent detected an abnormal condition and revealed sensor ranking for one of the three motor currents as the most significant. Agent requested inspection.
ASSET/AGENT OVERVIEW Metals and Mining Industry Crusher Conveyor Anomaly Agent detects a deviation from normal operating patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
Anomaly Agents Keep Crushing It Aspen Mtell Detects Gearbox Failure on Primary Crusher Conveyor
CATCH 3
CATCH 4
VALUE Advanced warning allowed for more time to plan maintenance activities and reduce overall repair times, enabling customer to avoid untimely shutdown.
ACTION Planned a safe shutdown and found undesirable deposits of cleaning materials and polymer, which was impeding heat transfer. Cleaned heat exchanger and returned to service.
ALERT/PRESCRIPTION Failure Agent detected fouling on a reactor’s heat exchanger. Lead Time: 44 Days Agent requested inspection.
ASSET/AGENT OVERVIEW Chemicals Industry Heat Exchanger of Reactor Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
No More Crying "Foul!" Aspen Mtell Detects Fouling in Heat Exchanger
VALUE Alert enabled switchover to spare, avoiding production loss or an unplanned shutdown caused by equipment failure.
ACTION Valve sent for repairs. In-line spare blower was started, avoiding production loss.
ALERT/PRESCRIPTION Failure Agent detected a valve failure associated with the air blower. Lead Time: 12 Hours Agent requested inspection.
ASSET/AGENT OVERVIEW Oil and Gas Industry Air Blower in Sulphur Recovery Unit (SRU) Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
“Airing” on the Side of Caution Aspen Mtell Detects Valve Failure in Air Blower
CATCH 5
CATCH 6
VALUE Aspen Mtell helped customer avoid catastrophic failure and an entire mill shutdown, saving an estimated $10M USD.
ACTION O&M procedures adjusted to avoid failure. Developed new operator procedures to reduce stress on the recovery boiler.
ALERT/PRESCRIPTION Failure Agent predicted a tube failure on the recovery boiler. Lead Time: 30 Days Agent requested inspection.
ASSET/AGENT OVERVIEW Pulp and Paper Industry Recovery Boiler Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
A Watched Boiler Never Breaks Aspen Mtell Detects Tube Failure on Recovery Boiler
CATCH 7
VALUE Advanced warning allowed customer to shift from unplanned shutdown to scheduled maintenance, minimizing downtime and repair costs.
ACTION Customer planned a scheduled shutdown to replace lube oil filter.
ALERT/PRESCRIPTION Anomaly Agent detected an increase in differential pressure on the lube oil system of a compressor. Agent requested inspection.
ASSET/AGENT OVERVIEW Oil & Gas Industry Lube Oil System on Compressor Anomaly Agent detects complex degradation patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
Okay to Drive with the Oil Filter Light On? Aspen Mtell Detects Lube Oil Failure on Compressor
CATCH 8
VALUE Early intervention helped the customer avert a major catastrophe—saving an estimated $400K USD in avoided production losses and maintenance costs.
ACTION Inspection found empty grease pot due to grease/dirt blocking feed valve. Replaced valve to avoid severe scrubber assembly damage.
ALERT/PRESCRIPTION Failure Agent predicted a grease drum failure. A high priority alert persisted for two-months. Lead Time: 60 Days Agent requested inspection.
ASSET/AGENT OVERVIEW Metals and Mining Industry Rotary Scrubber Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
Grease Is the Word Aspen Mtell Detects Valve Failure on Rotary Scrubber
CATCH 9
VALUE Customer avoided light component losses to flare worth over $1M per year, eliminating the need for an additional CAPEX project.
ACTION The customer’s staff made process optimization changes to prevent pressurization. Aspen ProMV’s real-time Agents warn of recurring issues, enabling early mitigation actions.
ALERT/PRESCRIPTION Debutanizer production was being lost to flare due to pressurization from an unknown source. A larger capacity reboiler project was planned. Before initiating this high-dollar CAPEX project, the client used Aspen ProMV offline to assess other opportunities first.
ASSET/AGENT OVERVIEW Chemicals Industry Debutanizer Process Health Analysis identified key causes of losses to flare and monitored for behaviors preventing future losses.
Performing Under Pressure Aspen ProMV™ Detects Root Cause of Debutanizer Flaring
CATCH 10
VALUE Estimated savings of $750K USD by avoiding a pipeline rupture. Customer also minimized likelihood of related safety and environmental issues/fines.
ACTION Customer implemented operational changes to reduce pressure cycling. New Failure Agent created to catch future events.
ALERT/PRESCRIPTION Anomaly Agent triggered an alert. The discharge pressure sensor dropped over 400 psi when the unit was shut down. Agent requested inspection.
ASSET/AGENT OVERVIEW Oil and Gas Industry Pipeline Segment Anomaly Agent detects complex degradation patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
What Lurks in Your Pipes? Aspen Mtell Prevents Pipeline Rupture
CATCH 11
VALUE Reduced lifecycle maintenance costs by 60%, increased facility capacity and saved customer $10M USD in additional CAPEX costs.
ACTION Changed frequency of seal replacements from every 8 batches to only when needed (nearly every 25 batches). With bead mills operating at higher availability, customer is no longer required to purchase additional bead mills to increase capacity.
ALERT/PRESCRIPTION The seal was being replaced after eight batches to avoid costly production losses. Failure Agent detected seal failure with a two-day warning. Lead Time: 2 Days Agent requested inspection.
ASSET/AGENT OVERVIEW Pharmaceutics Industry Bead Mill Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
Another Seal of Approval Aspen Mtell Detects Seal Failure in Bead Mill
CATCH 12
VALUE Avoided process downtime and costly repairs. Plant operations and feed quality adjusted to extend asset life.
ACTION Inspection determined that the anomaly was caused by turbine fouling/scaling. Customer changed operations to correct. New Failure Agent was created using Anomaly Agent data to further extend lead times.
ALERT/PRESCRIPTION Anomaly Agent detected an increase of internal pressure while at the same steam conditions. Agent requested inspection.
ASSET/AGENT OVERVIEW Oil and Gas Industry Steam Turbine Anomaly Agent detects complex degradation patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
Steamed, Not Fried Aspen Mtell Detects Turbine Fouling Event
CATCH 13
VALUE Agent alert allowed customer more time to order spare parts and plan maintenance activities. Repair times were reduced by 30%.
ACTION Inspection found a problem with motor’s non drive end bearing; equipment will be monitored weekly with vibration measurement in the field and online. Component replacement will occur in next scheduled plant shutdown. A new Failure Agent will warn much earlier of a recurring problem.
ALERT/PRESCRIPTION Anomaly Agent detected abnormal deviations on the coupling’s vibrations sensors, indicating the probability of failure was rising. Lead Time: 20 Days Agent requested inspection.
ASSET/AGENT OVERVIEW Metals and Mining Industry Vertical Mill Anomaly Agent detects a deviation from normal operating patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
We Just Can't Bear Failure Aspen Mtell Detects Bearing Failure on Vertical Mill
CATCH 14
VALUE Enabled customer to be more proactive. Estimated savings of $100K USD/week in materials recovery.
ACTION Aspen ProMV offline analysis indicated a temperature control issue that was immediately corrected resulting in a successful and proper recovery of unreacted materials. Aspen ProMV deployed in real-time to prevent repeat occurrences.
ALERT/PRESCRIPTION Six weeks of customer analysis could not explain a sudden drop in the recovery of unreacted materials. Customer requested AspenTech’s help with Aspen ProMV.
ASSET/AGENT OVERVIEW Polymers Industry Raw Material Recovery Process Health Analysis pinned down the elusive source of unreacted product reducing raw material waste.
Expect a Full Recovery Aspen ProMV Detects Root Cause of Unreacted Raw Materials
CATCH 15
VALUE Customer avoided a plant shutdown and avoided losing 7 days of production opportunity. Estimated savings of $3M USD and 15 batches.
ACTION Advance warning of 35 days allowed maintenance to schedule repairs during batch transition time/non-productive time. Rapid deployment of these learned failure patterns to all water purification systems across the Enterprise.
ALERT/PRESCRIPTION Failure Agent predicted deionizer failure using prior learnings of late-stage deterioration patterns. Lead Time: 35 Days Agent requested inspection.
ASSET/AGENT OVERVIEW Pharmaceutics Industry Purification System Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
Bridge Over Troubled Water Aspen Mtell Detects Deionizer Failure in Water Purification System
CATCH 16
VALUE Customer ignored initial alert due to inexperience. Responding to the alert could have avoided an unplanned outage.
ACTION After the second alert, the thickener had to be shutdown due to high torque and noise affecting production. New Failure Agent will warn much earlier of a recurring problem.
ALERT/PRESCRIPTION Anomaly Agent detected abnormal operations on thickener on two different occasions. The first alarm warned of increasing vibration, action was not taken. Four days later, a second alert fired. Lead Time: 4 Days Agent ordered inspection.
ASSET/AGENT OVERVIEW Metals and Mining Industry Thickener Anomaly Agent detects a deviation from normal operating patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
The Thickener-Picker-Upper Aspen Mtell Detects Failure on Thickener
CATCH 17
VALUE Customer avoided significant product losses and potential failure, saving an estimated $150K USD. Increased plant availability 35% and reduced downtime periods 45% only two months after deployment.
ACTION Inspection of the compressor with a manually-driven cooling test revealed fouling causing poor cooling of 1°C. Immediate cleaning improved performance. Decision made to replace the cooling coils at the next turnaround.
ALERT/PRESCRIPTION Anomaly Agent detected complex multi-variate signals showing patterns deviating from normal behavior on the compressor with three cooling coil outlet temperatures showing the highest contributions to the deviation pattern. Agents requested inspection.
ASSET/AGENT OVERVIEW Chemicals Industry Hyper Compressor Anomaly Agent detects complex degradation patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
Keep Your Cool Aspen Mtell Detects Cooling Oil Failure on Hyper Compressor
CATCH 18
VALUE $70K Catch. Prior to using Aspen Mtell, the customer had spent $485K USD on pump repairs (six bearing and seal failures, dating back to Jan 2000).
ACTION Customer investigation found that operating below a certain minimum flow rate caused an increase in vibration. Customer will set new minimum flow rate to avoid vibration and resulting bearing and seal failures.
ALERT/PRESCRIPTION CBM Agent detected increased vibration on the outer bearing of a pump.
ASSET/AGENT OVERVIEW Oil and Gas Industry Pipeline Pump Condition Based Monitoring (CBM) / Rule Agent detects user specified rule-based degradation patterns.
Picking up (Not So) Good Vibrations Aspen Mtell Detects High Vibration on Pump
CATCH 19
VALUE By reducing amount of off-spec product, customer is saving an estimated $500K USD per year per production line.
ACTION Aspen ProMV eliminated lag time waiting for lab analysis results. Customer tested Aspen ProMV against the lab to assure accuracy. Once validated, Aspen ProMV runs in real-time providing earlier warnings and prescribing specific actions to prevent quality issues.
ALERT/PRESCRIPTION Aspen ProMV detected multiple product quality issues in real-time without the delays in waiting for lab analysis results.
ASSET/AGENT OVERVIEW Agricultural Industry Lab Testing Quality Prediction Analysis enabled avoidance of shipping delays without risking customer satisfaction.
Waste Not, Want Not Aspen ProMV Detects Off-Spec Product in Real-Time
CATCH 20
VALUE Avoided process downtime and costly repairs; adjusted plant operations to extend asset life.
ACTION Customer changed operations by reducing speed, modifying upstream knockout vessel levels, flows and value openings.
ALERT/PRESCRIPTION Anomaly Agent detected a compressor surge event. Agent requested inspection.
ASSET/AGENT OVERVIEW Oil and Gas Industry Turbine Driven Compressor Anomaly Agent detects complex degradation patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
Was There a Power Surge Last Night? Aspen Mtell Detects Surge Event on a Turbine Driven Compressor
CATCH 21
VALUE After deployment, customer is having mostly less extensive, less disruptive equipment repairs with lower production losses and costs.
ACTION Failure Agent analyzed data patterns preceding failure and linked to an exact failure mode. Sufficient warning time for a safe and precise maintenance intervention. Avoided complete breakdown and resulting damage.
ALERT/PRESCRIPTION Failure Agent predicted a valve failure in the Primary Arm. Lead Time: 23 Days Agent requested inspection.
ASSET/AGENT OVERVIEW Pulp and Paper Industry Paper Machine Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
Hot off the Press Aspen Mtell Detects Primary Arm Valve Failure on Paper Machine
CATCH 22
VALUE Customer reduced reactor’s cleaning frequency from every 100 days to 460+ days, increased net plant production output (75 days of additional production every two years) and increased process stability 27%.
ACTION Aspen ProMV was deployed online to detect, alert and prescribe specific variables to change to avoid fouling.
ALERT/PRESCRIPTION HDPE reactor required preventative cleaning every 100 days due to potential fouling (15-day plant shutdown each time). Customer requested AspenTech’ s help. Aspen ProMV identified the interactions of the 20 most important variables causing excessive fouling.
ASSET/AGENT OVERVIEW Chemicals Industry High Density Polyethylene Reactor (HDPE) Quality Prediction Analysis projected critical system conditions allowing for avoidance of maintenance downtime.
Why the Foul Mood? … Reactor's Clean! Aspen ProMV Detects Reactor Fouling
CATCH 23
VALUE Failure Agent provided early warning of a known failure mode. Customer ignored alert due to inexperience, resulting in two days of avoidable unplanned downtime.
ACTION Due to inexperience, the customer ignored initial warnings. Two days later, a motor trip caused an unplanned shutdown.
ALERT/PRESCRIPTION Two Failure Agent alerts began to sound, loudly. Lead Time: 2 Days Agents predicted both a motor and a bearing failure.
ASSET/AGENT OVERVIEW Metals and Mining Industry Blower Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
Simple Bear Necessities Aspen Mtell Detects Motor and Bearing Failure on Blower
CATCH 24
VALUE Customer saved an estimated €130K by avoiding production losses and repair costs and improved wind farm productivity by rescheduling required maintenance work to occur during low-wind periods.
ACTION Planned maintenance scheduled for next low wind period. Learned failure patterns from any windmill are rapidly applied to others, providing the same safety and breakdown protection for all windmills at the site.
ALERT/PRESCRIPTION Failure Agents predicted a mechanical failure for a gearbox and two generators across multiple wind turbines. Warnings were between 2-5 months lead time.
ASSET/AGENT OVERVIEW Renewable Energy Industry Wind Turbines Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
When the Wind Blows Aspen Mtell Detects Failure of Wind Turbine
CATCH 25
VALUE Customer saved an estimated $600K USD by predicting (and reducing total number of) seal failures, and trimming spare parts / maintenance costs.
ACTION Learned failure patterns from any seal failure were rapidly applied to all 150 dry and wet mechanical seals used to seal agitator shafts on vessels.
ALERT/PRESCRIPTION Failure Agent detected the early signs of seal failure via machine learning of similar failure patterns.
ASSET/AGENT OVERVIEW Pharmaceutical Industry Mixer Agitators Failure Agent detects a complex failure signature (across time & many sensors) providing early warning of a pending failure.
Signed, Sealed, Delivered Aspen Mtell Detects Seal Failure on Mixer Agitators
CATCH 26
VALUE Customer avoided an unplanned shutdown and reduced maintenance costs (saving an estimated $175K USD) and, avoided accompanying safety and environmental issues/fees.
ACTION Lab analysis showed oil contamination due to mixed oils. Maintenance scheduled lube oil flush and filter change. Added DCS alarm to Seal Oil Differential Pressure as none existed before.
ALERT/PRESCRIPTION Anomaly Agent detected rising seal oil differential pressure along with decreasing suction pressure. Agent requested inspection. Note: Without Aspen Mtell, unplanned shutdown highly likely and perhaps even a blown seal.
ASSET/AGENT OVERVIEW Refining Industry Recycle Gas Compressor Anomaly Agent detects complex degradation patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
Don't Blow a Gasket! Aspen Mtell Detects Rising Differential Pressure in Seal Oil Filter
CATCH 27
VALUE Customer avoided substantial product losses (estimated at between 5% and 10% of overall production), by identifying the root cause of sporadic off-spec materials.
ACTION Inspection found off-spec material caused by cavitation from the agitator. Blade redesign prevented cavitation and off-spec product.
ALERT/PRESCRIPTION Recurring, sporadic off-spec materials. Customer spent months looking for the root cause, could not solve issue. Aspen ProMV detected an agitator performance anomaly and requested inspection.
ASSET/AGENT OVERVIEW Synthetic Rubber Industry Agitator Process Health Analysis led to detection of a design flaw.
Look Ma, No Cavities Aspen ProMV Detects Cavitation in Agitator
CATCH 28
VALUE Advance warning enabled customer to switch to a spare pump. By shifting from an unplanned shutdown to scheduled maintenance, customer minimized downtime and avoided a site restart.
ACTION Customer inspected the pump and replaced the slinger ring and thrust bearings. In-line spare pump was started avoiding production loss.
ALERT/PRESCRIPTION Anomaly Agent triggered an alert based on increasing pump case temperature. Customer didn’t receive an alert from DCS system or other monitoring systems used. Agent requested inspection.
ASSET/AGENT OVERVIEW Oil and Gas Industry Pump in a Refinery Anomaly Agent detects complex degradation patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
Ring the Alarm! Aspen Mtell Detects Slinger Ring Failure on Pump
CATCH 29
VALUE Customer saved an estimated $1.1M USD in avoided production losses and maintenance costs.
ACTION The inspection found oil leaking from the motor; the pressure was too high and causing the problem. Levels, flows, and valve openings around the compressor were adjusted to prevent future damage. New Failure Agent will warn much earlier of a recurring problem.
ALERT/PRESCRIPTION Anomaly Agent detected and warned of an abnormal condition of an increasing pressure issue. Such an extreme early warning is not possible with a single variable threshold DCS alarm. Inspection requested to determine if the abnormal condition was a process or mechanical issue.
ASSET/AGENT OVERVIEW Oil and Gas Industry Refinery Compressor Anomaly Agent detects complex degradation patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
The Pressure’s Off Aspen Mtell Detects Oil Leakage Failure on Compressor
CATCH 30
VALUE Customer avoided two days of downtime per year per furnace (the equivalent of €1.7M in avoided losses). Advance warning also resulted in additional energy savings and extended the lifetime of the furnace.
ACTION Inspection confirmed furnace fouling. Maintenance intervention was strategically scheduled to minimize production impacts while reducing downtime due to required repairs. Aspen Mtell to be used to predict need for furnace maintenance in real-time.
ALERT/PRESCRIPTION Anomaly and Failure Agents detected multivariate signals showing process degradation of the cracker furnace. Agents requested inspection.
ASSET/AGENT OVERVIEW Chemicals Industry Steam Cracker Furnace Anomaly & Failure Agents detect complex degradation patterns (across time & many sensors) warning far earlier than single tag DCS threshold alarm.
Don’t Get Steamed, but It’s the Last Catch Aspen Mtell Detects Fouling in Steam Cracker Furnace