The baghouse fan exhibited signs of bearing failure on both the fan and motor sides. Vibration analysis showed peak-to-peak amplitudes exceeding 10 g's, along with random high-frequency content indicating moderate bearing wear due to under-lubrication. Although the asset had previous alerts noted, it was the AI anomaly detection at 3:00 AM on a Saturday that prompted immediate action, preventing a costly failure and production stoppage on the melt deck.
The CME recommended lubricating the motor and further inspecting the fan bearing based on the AI anomaly and vibration data. Given the vibration patterns consistent with wear, bearing replacement was advised during the next available maintenance window.
The motor was lubricated, and the fan bearing was replaced. This quick response, driven by the AI alert, averted a motor failure at a critical point in production, saving the operation from unplanned downtime and product loss due to a lack of spare parts on hand.
