Equipment we protect.
Watsynq is deployed on critical rotating equipment across heavy industry. Here is where it works and what it catches — by equipment type, industry vertical, and failure mode.
Mining & Aggregates
Conveyor drives, crushers, ball mills
Cement Processing
Kiln fans, raw mill drives, cooler fans
Chemical Processing
Pump impellers, agitators, compressors
Where bearing failure is expensive.
We focus on industries where unplanned downtime carries a measurable cost per event — not where it's an inconvenience.
Mining & Aggregates
Failure cost: $200K–$2M per event
Conveyor drives, crusher bearings, ball mill pinion gears. Failure cost per event ranges from $200K to $2M in lost throughput depending on the bottleneck position. Watsynq has caught trunnion bearing defects 38 days before scheduled vibration routes would have flagged them.
Cement & Building Materials
High thermal coupling complexity
Kiln fans, raw mill drives, cooler fans. Thermal coupling between kiln and drive makes bearing failure detection harder in this environment — elevated ambient temperatures compress the normal baseline, making absolute-temperature thresholds unreliable. Watsynq uses rate-of-change metrics instead.
Chemical Processing
Unplanned shutdown consequence is high
Pump impellers, agitator seals, compressor bearings. Hazardous process means unplanned shutdown consequence extends beyond throughput loss — process upsets, material waste, and regulatory compliance events. Early warning is a safety issue, not just a cost issue.
180+ failure modes indexed, by equipment class.
Each equipment type has a dedicated failure mode library: bearing defect frequencies (BPFO, BPFI, BSF, FTF), gear mesh harmonics, impeller vane pass frequencies. The model matches your equipment class before scoring starts — not after the first alert.
Trunnion bearing caught 38 days before scheduled rounds would have seen it.
300-person plant. 12 monitored conveyor drives. Watsynq flagged a trunnion bearing on the 47-metre conveyor at 38 days RUL — inside a scheduled quarterly outage window. The bearing was replaced during planned downtime instead of an emergency scramble.
Prior to Watsynq, the plant ran 4-week vibration rounds. The bearing was in early acoustic emission stage when it was flagged — a stage the vibration route would not have detected for another 4-6 weeks.
Lube-oil trending caught a contamination issue the vibration sensor missed entirely.
8 kiln fan assemblies monitored. Lube-oil particle trending caught a contamination issue on Kiln 3 fan inboard bearing — rising ferrous particle count indicating metal-to-metal contact. Acoustic emission confirmed stage-1 inner race defect 52 days before the scheduled vibration route.
Maintenance rescheduled into the next kiln stop without production impact. Physical inspection confirmed: stage-1 inner race spalling with ferrous particle morphology consistent with contamination-induced abrasive wear — caught well before the BPFI harmonic frequency would have appeared in routine vibration data.
Running similar equipment?
Tell us your equipment type and industry. We will show you a real RUL output from comparable equipment — with failure mode detail.