Asset type
Agitator & mixer monitoring
SAM4 monitors chemical reactors, blending vessels, and mixing tanks from the motor control cabinet — detecting bearing degradation, seal failure indicators, imbalance, and gearbox issues without opening the vessel or entering the process area.
At a glance
- Monitoring method
- Electrical Signature Analysis (ESA)
- Sensor location
- Motor control cabinet (MCC)
- Voltage range
- Low and medium voltage
- Drive type
- DOL, soft starter, VFD
- Equipment types
- Reactor agitators, blenders, top-entry mixers, side-entry mixers
- Faults detected
- 4 fault types
- Typical lead time
- 3–10 weeks before failure
Why monitor agitators and mixers
Inside a sealed vessel — invisible to inspection, critical to production
Agitators operate inside sealed, pressurised, or hazardous vessels. Physical inspection requires vessel isolation, draining, and confined space entry. Most agitators run without any condition monitoring — failures are discovered only when product quality drops or the seal leaks.
typical cost of an unplanned agitator failure — including vessel isolation, cleaning, repair, and production loss.
average downtime for an agitator failure in a chemical plant, including vessel decontamination and recommissioning.
of agitators in a typical chemical plant have continuous condition monitoring before SAM4.
What SAM4 detects on agitators and mixers
Four fault types from one sensor location
| Fault type | What's happening | How SAM4 detects it | Typical lead time | Confidence |
|---|---|---|---|---|
| Bearing degradation | Motor bearing and gearbox bearing wear, lubrication breakdown | Characteristic bearing fault frequencies in the motor current spectrum | 4–12 weeks | Full |
| Seal wear | Mechanical seal degradation leading to leakage risk, shaft wear | Progressive load profile change as friction characteristics shift | 3–8 weeks | Full |
| Imbalance | Product buildup on impeller blades, erosion, or damaged impeller | 1× running speed component increase in the current spectrum | 2–8 weeks | Full |
| Gearbox faults | Gear tooth wear, bearing degradation within the gearbox assembly | Gear mesh frequencies and bearing fault frequencies in current spectrum | 3–10 weeks | Full |
Detection capability depends on drive topology, sampling rate, load variation, and operating conditions. See ESA detection constraints.
Installation on agitators and mixers
30 minutes. No access to the vessel required.
Open the motor control cabinet
SAM4 installs at the MCC — the same panel your electricians already access. No confined space entry, no scaffolding, no process shutdown.
Clip sensor onto motor supply cables
Current and voltage sensors clip directly onto the existing cabling. No wiring changes. No interruption to the asset's operation.
Connect and commission
The SAM4 gateway connects via cellular (4G/LTE) — no dependency on your IT network. Monitoring starts immediately. First diagnostic results within 48 hours.
Where agitators and mixers are monitored
Industries using SAM4 on agitators and mixers
See SAM4 monitoring agitators and mixers
A 30-minute demo shows SAM4 running on agitators and mixers like yours — with real fault data and real diagnostics from chemical process operations.