yellotec-com

Category: Case Studies

  • Improving Gearbox Test Consistency with Atten[2] OilWear Sensor

    Reliable gearbox validation with accurate oil cleanliness monitoring in bubbly conditions.

    This case study shows how Hyster Yale Material Handling improved gearbox validation by solving unreliable oil cleanliness testing caused by air bubbles.

    Incotech Ltd integrated the Atten[2] OilWear S sensor into a test bench, enabling real-time monitoring and accurate separation of bubbles from contaminants.

    This resulted in faster testing, reliable measurements, simpler system design, and improved confidence in gearbox quality before assembly.

    Article Highlights:

    • Hyster Yale Material Handling faced inconsistent gearbox testing due to air bubbles affecting oil cleanliness measurements.
    • Traditional particle counters struggled in low-pressure, aerated oil conditions.
    • Incotech Ltd integrated the Atten[2] OilWear S sensor into a custom test bench.
    • Real-time monitoring enabled accurate differentiation between air bubbles and contamination particles.
    • Eliminated the need for complex high-pressure systems to suppress bubbles.
    • Reduced testing time and improved repeatability of results.
    • Increased confidence in gearbox quality before assembly.
    • Scalable solution for other applications with foamy or aerated oil systems.

    Key Takeaway:

    Atten[2] OilWear S sensor enables accurate, real-time oil cleanliness measurement even in bubbly, low-pressure conditions—helping Hyster Yale Material Handling achieve faster, more consistent, and reliable gearbox validation without complex system modifications.

  • Electrical Signature Analysis for Pump Performance

    A power plant uses electrical signature analysis for performance assessment.

    In this All Test-Pro case study, a power plant used Electrical Signature Analysis (ESA) to investigate performance issues in aging water pump motors by measuring voltage and current signals to assess both electrical and mechanical conditions of the entire system. 

    The analysis revealed that the motors themselves were functioning properly, but identified turbulence in the water flow as the root cause of poor pump performance—something other diagnostic methods had missed.

    Read the Full Article

    Article Highlights:

    • Pump performance issues identified in aging system
    • ESA used to assess full motor and pump condition
    • Motors found electrically and mechanically sound
    • Turbulence detected as root cause of poor performance
    • Issue was missed by other diagnostic methods
    • ESA enabled targeted corrective action
    • Highlights value of predictive maintenance and combined diagnostics

    Key Takeaway:

    Electrical Signature Analysis (ESA) can detect hidden performance issues across the entire motor-driven system—even when both electrical and mechanical components appear healthy—making it a powerful tool for identifying root causes like flow turbulence and improving predictive maintenance.

  • Ball Mill Monitoring Case Study: Avoiding R14.4M in Downtime with Infrared Technology

    How Infrared Monitoring Helped Avoid a Costly Ball Mill Failure

    In the mining industry, maintaining the reliability of critical equipment is essential to ensuring continuous production and minimizing costly downtime. One such critical asset is the ball mill, a key component in mineral processing operations where material size reduction is achieved through impact and attrition.

    In addition to Vibration and Lubrication monitoring Yellotec implemented thermal monitoring of the external mill shell to improve the condition monitoring of the inter mill wear lining. By combining manual and continuous thermal imaging technologies, the operation gained deeper insight into mill lining performance, wear patterns, and potential failure points.

    The Challenge

    Ball mills operate under extreme mechanical and thermal stress, leading to friction, misalignment and wear issues over time. Traditional inspections, often limited to shutdowns or manual checks, can result in missed early faults, unplanned downtime, higher maintenance costs, and reduced equipment lifespan.

    The Solution

    Yellotec deployed a dual approach using the FLIR T540 initially and then the fixed FLIR A70 camera with online software to provide continious monitoring of both primary and secondary mill liner conditions.

    Manual Thermal Inspections

    The FLIR T540 was used to conduct detailed thermal inspections of the mill during operation. These inspections enabled the team to:

    • Identify high wear patterns on both primary and secondary mills
    • Detect abnormal heat signatures linked to friction and liner degradation
    • Pinpoint areas of concern, requiring maintenance attention

    Thermal imaging revealed clear variations in temperature across the mill shell, highlighting zones of excessive wear that would not have been visible through conventional methods.

    Continuous Thermal Monitoring

    To enhance visibility even further, the FLIR A70 Smart Sensor was installed for real-time monitoring of the secondary mill. This provided:

    • Continuous thermal data of the mill shell
    • Early detection of temperature anomalies
    • Trend analysis for predictive maintenance planning

    With continuous thermal imaging, maintenance teams could monitor changes over time and respond to developing issues before they escalated into failures.

    Key Findings

    The implementation of thermal imaging uncovered several critical insights:

    • High wear patterns were identified on both primary and secondary mills
    • Temperature anomalies indicated uneven load distribution and potential internal issues
    • Secondary mill shell conditions were monitored in real time, improving decision-making

    These findings allowed for targeted maintenance interventions, reducing the need for reactive repairs.

    FLIR T540
    FLIR A70

    Results and Impact

    By integrating thermal imaging into their maintenance strategy, the operation achieved:

    • Improved asset reliability through early liner wear detection
    • Reduced unplanned downtime
    • Enhanced maintenance planning with data-driven insights
    • Significant cost avoidance by preventing major failures

    The ability to continuously monitor the mill without interrupting production marked a major shift toward greater reliance on predictive maintenance.

    Early detection of a potential shell failure prevented 72 hours of unplanned downtime, eliminating a major risk to production. While repair costs were minimal, the real impact was in avoiding an estimated R14.4 million in downtime-related losses.

    Conclusion

    Yellotec’s implementation of thermal imaging technology demonstrates how modern condition monitoring tools can transform maintenance strategies in the mining sector. By leveraging both manual inspections and continuous monitoring, operations can gain a comprehensive understanding of equipment health and act proactively.

    As mining operations continue to prioritize efficiency and uptime, thermal imaging is becoming an essential tool for maintaining a competitive edge.

  • Vibration Diagnostics on a Turbo Generator Train

    Advanced Vibration Diagnostics Reveal the True Cause of Turbo-Generator Blade Failure

    This OROS application note details a root cause investigation into a blade failure on a 15 MW turbo-generator at BASF. After an overhaul, the machine experienced unexpected blade damage, prompting a comprehensive vibration and rotor dynamic analysis using advanced diagnostic tools.

    Tests ruled out speed instability, torsional resonance, and balancing issues. The investigation concluded that excessive steam extraction in the exhaust system caused blade excitation and failure, highlighting the importance of in-depth vibration diagnostics in turbomachinery.

    Read the Full Article

    Article Highlights:

    • Root cause investigation of a blade failure on a 15 MW turbo-generator at BASF.
    • Advanced vibration diagnostics performed using OROS analyzer and ORBIGate software.
    • Speed stability, torsional vibration, torque, and shaft centerline behavior were all analyzed.
    • No issues found with speed regulator, torsional resonance, or balancing.
    • Slow-roll vibration traced to turning gear eccentricity — not a fault condition.
    • Root cause identified as excessive steam extraction in the exhaust system, leading to blade excitation and damage.
    • Highlights the value of detailed rotor dynamic and vibration analysis in preventing unplanned downtime.

    Key Takeaway:

    Comprehensive vibration and rotor dynamic analysis is essential for accurately diagnosing turbomachinery failures — in this case at BASF, advanced diagnostics ruled out mechanical and control issues and revealed that excessive steam extraction caused the blade damage, demonstrating the importance of detailed data-driven investigation to prevent unnecessary downtime and misdiagnosis.

  • How 3 Minutes Can Prevent Motor Failure

    Quick Diagnostics That Save Time and Money: The Value of 3 Minutes of Motor Failure Testing



    This All-Test Pro article highlights a hospital motor failure where initial basic testing pointed to the drive as the issue.

    After replacing the drive without resolving the problem, a motor circuit analysis test quickly identified an internal motor fault, demonstrating how proper, fast diagnostics can prevent unnecessary costs, downtime, and repairs.

    Read the Full Article

    Article Highlights:

    • A 17 kW hospital roof fan motor in the Netherlands failed less than a year after installation.
    • Basic tests (insulation & resistance) showed no faults, so the VFD was replaced — but the issue remained.
    • The motor was later tested using the ALL-TEST PRO7™ (AT7™ PRO)   Motor Circuit Analysis tool.
    • In just 3 minutes, testing revealed an internal phase fault that standard tests missed.
    • The hospital incurred unnecessary costs (VFD replacement, crane rental, downtime).
    • Proper motor circuit testing can quickly identify real faults and prevent costly misdiagnosis.
    • Key message: A few minutes of advanced testing can save significant time, money, and downtime.

    Key Takeaway:

    Spending just about 3 minutes using a proper motor diagnostic tool like Motor Circuit Analysis (MCA) can identify the real cause of a motor failure—saving significant time, money, and unnecessary equipment replacements. In the case study, basic tests misled technicians and led to a faulty VFD replacement and costly motor removal, whereas a quick MCA test pinpointed the actual motor fault right away.

  • A Realistic and Trusted Look at a Career in Vibration Analysis and Vibration Monitoring in 2026

    Beyond the Viral Moment

    Following a recent viral TikTok post by Seramphuti, renewed attention has been drawn to short courses and specialized technical careers, including high-demand fields like vibration monitoring. The video sparked widespread conversation around opportunities in high-skill trades—sectors that often operate outside the mainstream spotlight yet play a critical role in global industrial reliability.

    While the content highlighted the earning potential within this space, it’s equally important to balance that excitement with a realistic and responsible career roadmap. For those looking to enter the world of vibration monitoring, understanding the required ISO certifications, technical foundations, and long-term development paths is essential for a successful career in predictive maintenance.

    Why Vibration Monitoring and Analysis Is Different

    Vibration Analysis is a highly technical and niche discipline. To put this into perspective, South Africa currently has fewer than ±3,000 qualified ISO Category I vibration analysts. This small number reflects the specialist nature of the field, especially when compared to larger semi-skilled or skilled sectors such as fibre or network technicians, which are estimated to include 40,000–60,000 practitioners.

    This scarcity is not accidental. Vibration Monitoring and Vibration Analysis demands deep technical understanding, disciplined field experience, and long-term professional commitment.

    Our Approach to Training: Integrity Over Hype

    It’s important to be clear: we do not view training as a profit-making exercise. We have no interest in capitalising on internet hype or viral trends. Our responsibility is to uphold the integrity of the profession and ensure that individuals entering this field are set up for long-term success—not disappointment.

    For this reason, we must state honestly: a 5-day course does not guarantee employment.

    Professional credibility in this industry is built through experience, competence, and accountability. Any suggestion that a short course alone can unlock a high-paying career does a disservice to both learners and the profession itself.

    The Real Career Path: A Five-Stage Progression

    In vibration analysis, field experience outweighs classroom learning. Technical competence is developed through structured exposure, repetition, and application in real industrial environments. The typical progression looks like this:

    1. Industrial Maintenance and Safety

    Most professionals begin as assistants, learners, or apprentices. This stage focuses on understanding industrial plants, machinery components, safety protocols, and correct workplace behaviour.

    2. Supervised Data Collection

    Once familiar with plant operations, individuals begin collecting vibration data under the supervision of a qualified analyst. This hands-on phase ensures correct sensor placement, data accuracy, repeatability, and reliable results.

    3. Internal Practical Training

    At this stage, individuals receive structured in-house training focused on the specific diagnostic tools, software platforms, and methodologies used by their employer.

    4. ISO 18436-2 Category I Certification

    Only after gaining sufficient field exposure are individuals typically eligible for the 5-day ISO Category I course. This training formalises existing knowledge—it does not replace experience.
    A minimum of six months of documented relevant experience is required to obtain official ISO certification. Attending the course alone does not make one certified, nor is it a shortcut to employment.

    5. Advanced Professional Growth (Category II–IV)

    Beyond Category I, the technical difficulty increases significantly. Category III and IV levels require either a strong STEM qualification or many years of disciplined self-study to master the advanced engineering physics involved.

    Practical Advice for Those Seriously Considering This Career

    If you are genuinely interested in vibration analysis, we recommend starting with free self-study resources available online. This allows you to build foundational knowledge and test your interest before committing financially.

    We also strongly encourage seeking assistant, learnership, or apprenticeship roles. These opportunities provide essential machine exposure and demonstrate commitment and work ethic to potential employers.

    We have seen cases where individuals paid for training upfront, only to struggle for years to secure employment due to a lack of practical experience. Please also note that Yellotec’s private course fees are payable upon registration and are non-refundable.

    Making an Informed Decision

    Our intention is not to discourage interest—but to ensure informed decision-making. Entering a specialist technical field without understanding the required commitment can lead to costly miscalculations.
    If you have carefully considered these factors and still wish to pursue this path, you will find our course information below.

    Vibration Monitoring and analysis is a rewarding and respected profession—but like all true specialist careers, it is built over time, not overnight.

  • When “More” Becomes a Risk: The Hidden Cost of Over-Lubrication

    Discover How Excess Lubrication Leads to Higher Costs, Equipment Damage, and Unplanned Downtime.

    In this Atten2 Original Case Study, over-lubrication is shown to be just as damaging as insufficient lubrication, disrupting optimal machine operation.

    Excess lubricant leads to leaks, contamination, increased energy consumption, heat buildup, seal damage, and even electric motor failures—resulting in unplanned downtime, higher maintenance costs, and environmental risks.

    Read the Full Article

    Article Highlights:

    • Over-lubrication is as damaging as under-lubrication, leading to premature equipment failure.
    • Excess lubricant increases pressure, causing seal damage, leaks, and contamination ingress.
    • Higher energy consumption occurs as lubrication moves away from optimal operating conditions.
    • Dirt and contaminants accumulate when surplus lubricant is exposed to the environment.
    • Heat buildup and oil degradation accelerate wear and reduce lubricant effectiveness.
    • Electric motors are at risk, as excess grease can enter windings and cause overheating or failure.
    • Unplanned downtime and environmental costs rise due to leaks, cleanup, and maintenance issues.

    Key Takeaway:

    An excess of industrial lubricants, just like too little lubrication—can seriously harm machinery by disrupting optimal lubrication conditions, leading to leaks, increased energy use, contamination, accelerated wear, and even equipment failure. This highlights the importance of precise lubrication control and monitoring to maintain machine performance, reduce breakdowns, and avoid environmental and operational costs. 

  • Condition Monitoring with VibGuard IIoT Helped Two Customers Avoid Over $1.7M in Damage and Downtime

    Discover how VibGuard IIoT enabled condition monitoring that helped two customers prevent critical damage and unplanned downtime.

    In this case study, real-time condition monitoring with VibGuard IIoT helped two industrial customers detect early equipment faults that periodic inspections would have missed, enabling timely identification of electrical and mechanical issues on critical assets.

    Early, informed intervention allowed planned repairs instead of emergency failures, helping both customers avoid major equipment damage, unplanned downtime, and significant financial losses—demonstrating the value of proactive, data-driven maintenance.

    Read the Full Article

    Article Highlights:

    • Continuous condition monitoring with VibGuard IIoT enables early fault detection beyond periodic inspections.
    • High-resolution vibration data and advanced diagnostics identify subtle mechanical and electrical issues before failure.
    • Early detection on critical assets allowed maintenance teams to intervene proactively and avoid unplanned shutdowns.
    • Real-world case studies demonstrate how VibGuard IIoT supports a shift from reactive to predictive maintenance.

    Key Takeaway:

    Real-time condition monitoring with VibGuard IIoT enabled early detection and diagnosis of emerging machine faults, allowing maintenance teams to intervene proactively and prevent major equipment failures and unplanned downtime that would have otherwise resulted in significant operational losses.

    The VibGuard IIoT:

  • Maximizing Wind Asset Performance: Insights from the United Wind Force and Atten2 Webinar.

    Insights on Improving Wind Turbine Uptime Through Proactive Condition Monitoring

    In today’s fast-paced renewable energy sector, wind power operators face constant pressure to boost efficiency and minimize downtime. On November 21, 2025, Atten2, in collaboration with United Wind Force (UWF), hosted an insightful webinar titled “Maximizing Wind Asset Performance.”

    The session explored innovative strategies for managing onshore and offshore wind assets more effectively, with a spotlight on how advanced monitoring technologies can help operators reduce lost wind power and optimize turbine performance.

    Below are the key takeaways and insights.

    The Core Challenge: Lost Power and Limited Visibility

    Wind operators increasingly deal with:

    • Lost revenue from turbine downtime
    • Competition in the spare parts market
    • Difficulty accessing trustworthy condition data

    With 67% of spares now non-OEM, owners are shifting away from rigid OEM models toward flexible, proactive maintenance strategies.

    UWF’s Role: A Bridge Across the Aftermarket

    UWF supports more than 47,500 turbines across Europe and Latin America by connecting turbine owners, OEMs, Independent Service Providers, and parts distributors.

    Their supply mix highlights a diverse, responsive network:

    • 54% direct
    • 33% OEM
    • 14% ISP

    UWF partners with major industry players such as Vestas, Siemens Gamesa, GE Renewable Energy, Eickhoff, AMSOIL and more.

    What this delivers: Faster access to parts, deeper technical expertise, and reduced downtime — all helping operators fight lost wind power.

    Atten2’s Contribution: Turning Oil Data into Decisions

    Atten2 specialises in real-time oil condition monitoring, with more than 3,000 installed sensors and over two decades of development.

    Their monitoring philosophy is clear: Seeing transforms uncertainty into knowledge — and knowledge into better decisions.

    Their flagship wind solution is the Wind Oil Sensor (WOS).

    Wind Oil Sensor (WOS): Early Warning for Critical Components

    The WOS, powered by Atten2’s OilWear® S technology (SHAPE SERIES), is an online sensor detecting particles and bubbles >4 microns in hydraulic fluids and lubricants. It converts raw fluid data into actionable insights on wear, contamination, and degradation, actively protecting gearboxes, hydraulic pitch systems, and yaw mechanisms.

    Key Features:

    • Particle Counting & Classification: ISO 4406, six size ranges (>4–>70 microns), supports NAS 1638.
    • Advanced Analysis: Identifies wear type (fatigue, sliding, cutting) for particles >20 microns and discriminates bubbles.
    • Oil Health Monitoring: Tracks degradation (%OD)
    • Fluid Image storing: Supply images of oil being monitored.
    • Easy Integration: IP65 casing, Ethernet RJ45 (Modbus TCP/IP, FTP), RS485 (Modbus RTU) for SCADA/PC/PLC connectivity.

    Top Benefits:

    • Fast, Accurate Insights: Up to 7× quicker condition assessments, +/-1 ISO code accuracy.
    • Proactive Maintenance: Early detection prevents failures and downtime.
    • Extended Fluid Life: Detects degradation and contamination.
    • Operational Efficiency: Simple commissioning, turbine-ready deployment, lower maintenance costs.
    • Data-Driven Decisions: Stores 10,000 tests, 100 images, with temperature monitoring.

    Real-World Application Cases

    Two case studies demonstrated how Atten2’s sensors enable proactive, data-driven maintenance.

    Case 1: Gearbox Damage Monitoring

    • Background: A ZF GPV442 gearbox showed advanced macropitting (ISO 15243 Category 4) confirmed via boroscope.
    • Monitoring: RSMK tracked oil cleanliness over 93 days (Aug 22–Oct 11) at full turbine power.
    • Findings: Stable particle levels indicated no further damage progression, later verified by boroscope images.
    • Outcome: Combined online monitoring and periodic inspections ensured safe operation and informed planning.

    Case 2: Particle Counting in Gearbox Testing

    For a major wind gearbox manufacturer, long flushing and testing periods were a challenge.

    Benefits: Faster testing, improved filtration performance, and reduced operational strain.

    Objective: Achieve ISO 4406 cleanliness of 16/14/11.

    Solution: Atten2’s particle counters outperformed competitors (HYDAC, Laser), with significantly lower counts during testing.

    The webinar made it clear that the future of wind asset performance lies in preventing issues before they cause downtime. Real-time visibility into turbine condition enables operators to plan maintenance confidently, protect key components, and keep turbines producing power. Ultimately, reducing lost wind power is less about reacting to failures and more about using accurate data to stay ahead of them — improving uptime, reliability, and overall return on investment.

    Atten2’s Additional Solutions:

    Atten2 OilWear
    OilWear: Real-time particle quantity and quality measurement.
    SMK: OilWear tech integrated into filter carts.
    Atten2 RSMK [Rugged Smart Monitoring Kit]_OA
    RSMK: High-speed version for test benches and labs.
    OilCMS: Offline suitcase for particle analysis.
    Atten2 OilHealth Probe
    OilHealth Probe: Monitors fluid degradation.
    Atten2 OilMoisture_2_OA
    OilMoisture: Measures water content in PPM.
    Atten2 OilHealth Max
    OilHealth Probe MAX & OilStreak: Advanced degradation and moisture monitoring via bypass installation.

  • Discovering Hidden Air Leaks with Acoustic Imaging

    Explore the FLIR Application Story showing how acoustic imaging helps manufacturers uncover hidden compressed-air losses and improve plant performance.

    In this FLIR application story, you’ll see how acoustic imaging technology helps manufacturers uncover hidden compressed-air losses and improve overall plant performance. For the full story and deeper insights, click the link to read the complete article on compressed-air leaks in automotive manufacturing.

    Modern acoustic imaging tools like the FLIR Si-Series are changing how manufacturers detect leaks. They help teams quickly spot issues and plan repairs more effectively, without disrupting production.

    Read the Full Article

    Article Highlights:

    • Automotive plants use large amounts of compressed air, making hidden leaks common.
    • Undetected leaks raise energy costs, reduce efficiency, and strain compressors.
    • Noise and complex pneumatic systems make traditional leak detection difficult.
    • Acoustic imaging cameras, like the FLIR Si124-LD Plus, quickly locate even tiny leaks.
    • They work during normal operations and require minimal training.
    • Built-in analytics estimate leak size, energy loss, and cost impact.
    • Early leak detection saves energy, reduces emissions, and boosts productivity.

    Key Takeaway:

    Proactively using acoustic imaging, for example with the FLIR Si-Series of cameras — to find and fix hidden compressed-air leaks in automotive plants helps companies avoid waste, cut energy and maintenance costs, ensure reliable production pressure, and improve productivity and competitiveness.

    View our Acoustic Imaging Range:

    FLIR Si2x-LD
    FLIR Si12x-Pro
    FLIR Si2-PD