The Catch
An overlooked valve caught before it became a crisis
HanPHI detected a steady rise in lubricating oil temperatures across two pulverizers at a 560-MW thermal power plant. Both machines showed abnormal readings, with one pulverizer’s lubricating oil temperature climbing from 36.5°C to 52.8°C, and its oil tank rising from 41.9°C to 50.4°C.
The second pulverizer followed the same pattern. Together, the signals drove the system’s HanPHI health index down to 72.7%, a clear flag for action.
Detected Anomalies: Lubricating Oil Temperatures
Pulverizer A: Oil Temperature
52.8°C
↑ from 36.5°C
Pulverizer A: Oil Tank Temperature
50.4°C
↑ from 41.9°C
Combined Health Index
72.7%
↓ below normal patterns
Pulverizers Affected
2 of 2
Both units flagged
What Happened
A maintenance error caught in time
1. Detection
HanPHI identified rising lubricating oil temperatures across both pulverizers and triggered early warning notifications in real time.
2. Alert
The centralized monitoring and diagnostics center (CMD) immediately notified the site team of the abnormal temperature readings.
3. Root cause
After recent pulverizer maintenance, the site had temporarily closed the cooler outlet valve to raise temperatures rapidly and then failed to reopen it once the oil reached the target temperature.
4. Resolution
The site immediately corrected the valve position after receiving the early warning. The issue was resolved before it could escalate into a full pulverizer trip.
Outcome: With HanPHI’s early warning, a pulverizer trip caused by operator error was prevented, saving the plant an easy $50,000 in unplanned downtime and repair costs.
About HanPHI
HanPHI is a machine learning-based plant health intelligence platform that detects potential and hidden equipment failures before they escalate into costly downtime. Using advanced pattern recognition and real-time analytics, it gives plant operators the lead time they need to act.
Compares live data against predicted values to generate a continuous health score from 0–100% across every system and sensor.
Immediately surfaces the cause of potential failures, equipment degradations, and operational errors so teams can act fast.
Visualizes normal plant operation data to help operators quickly pinpoint where and why equipment anomalies occur.
Monitors assets regardless of equipment manufacturer, type, or complexity — across individual plants or entire fleets.
Quickly identifies normal operating behavior by analyzing historical equipment data with no complex configuration required.
Builds a secure operating environment through unidirectional networks and encryption, protecting critical infrastructure.
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