Asset Saves

Vibration levels were increasing at the pump drive-end bearing, indicating a potential lubrication issue or developing bearing defect.

The CME recommended greasing the pump bearings and monitoring for any changes in vibration levels to determine if lubrication would improve the condition.

After greasing the pump bearings, acceleration levels decreased by approximately 40%, confirming lubrication as the primary issue. Vibration stabilized following the correction, and the alert was resolved.

After startup, the pump showed elevated vibration at turning speed, reaching approximately 1.5 in/sec. This pattern is commonly associated with structural looseness, particularly at the pump hold-down bolts.

The CME recommended inspecting the pump mounting hardware and verifying that all hold-down bolts were properly secured.

Inspection confirmed that two hold-down bolts were loose. After tightening, vibration levels decreased significantly from 1.5 in/sec to 0.5 in/sec, confirming looseness as the root cause. The issue was resolved.

An increasing axial vibration trend was observed, with motor turning speed as the primary contributing frequency. The rise appeared to correlate with process changes and startup conditions following maintenance work.

The CME placed the asset on watch to monitor for continued progression. It was recommended to maintain normal PM intervals and, if the condition worsened, verify hot sheave alignment and inspect belt tension and condition.

The fan had previously been secured and PM'd, including belt re-tensioning and sheave alignment. After process conditions stabilized, vibration levels improved and remained steady. The asset was returned to normal monitoring status and marked resolved.

Possible outer race fault frequencies were identified in the vibration data, indicating a developing issue with the motor bearing rolling element races. The affected component has an estimated one-month lead time, and an unplanned failure would require repeated machine shutdowns to manage scrap while waiting on parts.

The CME recommended inspecting the motor bearings and applying lubrication if needed, along with confirming completion so the data could be reviewed for improvement. Proactive attention was advised to avoid unplanned downtime while parts would be on order if the condition progressed.

The sensor location was verified, the motor bearings were lubricated, and the motor was inspected with no additional issues found. Early identification and corrective action helped reduce the risk of extended unplanned downtime, avoiding an estimated 90 hours of disruption and approximately $360,000 in potential production losses.

Oil analysis revealed severe contamination and wear. Iron particle count was 785 (target 25 or less), with a high PQ index indicating significant ferrous debris. Viscosity measured at 265 cSt versus the expected 320 cSt for AGMA 6 oil. Water content had doubled since the previous sample, and changes in the additive package indicated the lubricant was not consistent with prior oil used.

The CME recommended verifying the correct lubricant was in use and performing a hot oil flush to remove contamination and wear metals. If flushing was not feasible, a full oil change was advised along with installing a filtration system using a 7-micron beta 1000 filter.

The customer replaced the oil with the correct specification. This action restored proper lubrication conditions and prevented an estimated 336 hours of unplanned downtime.

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.

Vibration levels increased to approximately 2.0 in/sec, with a pattern indicating imbalance, likely due to buildup on the fan.

The CME recommended cleaning the fan during the next available outage to remove any buildup contributing to the imbalance.

The fan was shut down and cleaned. Following cleaning, vibration levels returned to normal, confirming buildup as the root cause. The issue was resolved.

High vibration was observed at crusher speed on the motor, indicating potential sheave misalignment or incorrect belt tension.

The CME recommended inspecting sheave alignment and verifying proper belt tension. Cleaning the crusher was also suggested to rule out buildup contributing to the condition.

Customer replaced the motor, belts, and sheaves. During installation proper alignment and belt tension was achieved.

Following pump replacement, vibration data showed significant improvement, confirming a prior developing issue. Inspection of the removed pump revealed severe bearing wear and pitting, validating the condition detected in the data.

The CME recommended replacing the pump bearings and rotating the motor by hand during repair to check for any signs of motor bearing roughness.

The pump was replaced, resulting in immediate improvement in vibration levels. Early detection and action prevented a potential catastrophic failure. If the pump had failed unexpectedly, it would have caused a full production shutdown. With a 14-week replacement lead time and continuous operation, this equated to 2,352 hours of potential downtime. Using conservative production estimates, the total potential impact was calculated at approximately $5.8M. After applying conservative adjustments, the avoided impact was estimated at approximately $1.6M and 784 hours of unplanned downtime.

A temperature spike was observed on the gearbox, increasing from approximately 140°F to 180°F. The rapid rise indicated a developing mechanical issue, potentially related to bearing condition or inadequate cooling.

The CME recommended immediate inspection of the gearbox and associated components to determine the cause of the temperature increase and prevent further damage.

Following the alert, the team inspected the unit and identified significant bearing wear and pitting. Corrective action was taken before failure occurred. If the Gas Contactor Mixer had failed unexpectedly, it would have resulted in a full production shutdown. With an estimated 4-week lead time for replacement and continuous operation, this would have equated to approximately 672 hours of unplanned downtime and an estimated $1.65M in lost production.

Harmonics of 9.32x running speed with 1x sidebands were detected, indicating a potential bearing defect. This occurred shortly after a recent bearing replacement, with continued vibration on the ODE side. Resolution: The full wheel assembly was replaced, and vibration levels have since decreased.

The CME recommended planning to replace the ODE bearing again, as the DE bearing vibration dropped after replacement, suggesting the issue may be isolated to the ODE.

The full wheel assembly was replaced, and vibration levels have since decreased.

The fan bearings showed impacts at 4.5x turning speed with harmonics, and the FFT displayed a haystack pattern (broadband noise), suggesting a lubrication issue.

The AssetWatch Condition Monitoring Engineer recommended greasing the bearing to see if vibration levels would decrease.

The customer lubricated the bearings, which reduced and stabilized vibration levels. The trend will continue to be monitored.

A concerning vibration signature developed at the shoe press bearing. Multiples of 9.46 Hz with 1X sidebands indicated severe looseness or a rapidly developing bearing defect.

The AssetWatch Condition Monitoring Engineer recommended an immediate inspection of the roll and bearings as soon as the process allowed.​

The site found the outer race of the bearing in pieces. Both the roll and bearings were replaced, which stabilized vibration levels.

The bearing showed an upward velocity trend across all asset sensors, with multiple harmonics of turning speed present in the waveform and spectrum—signs consistent with looseness.​

The AssetWatch Condition Monitoring Engineer recommended a field inspection to check for abnormal conditions, as well as inspecting for excessive wear, damage, lubrication issues, and any loose or broken structural components.​

After installing new refiner plates, vibration levels dropped significantly and returned to normal. This action helped prevent potential bearing damage and unplanned downtime.

An increase in acceleration vibration was observed, with light impacting around outer race fault frequencies (~7.15X turning speed).​

The AssetWatch Condition Monitoring Engineer recommended lubricating the bearing to see if it reduced noise and vibration.​

The bearing was lubricated, which improved vibration levels until it could be replaced. Bearing replacement resolved the issue and avoided unplanned downtime.

Multiple 5X running speed harmonics were detected on the pump, indicating a vane pass issue. This suggested potential impeller wear or damage.​

The CME recommended inspecting the pump impeller for wear or damage and analyzing process data (flow/pressure) for recent changes. Any flow restrictions or incorrect valve positions should also be checked.​

The impeller and stuffing box were replaced due to two failed vanes. Losing this pump would have shut down the depitchers, ultimately halting the entire TO refinery.

Increased vibration amplitudes at 1X, 2X, and 3X RPM were detected at the gearbox input, indicating possible coupling wear or looseness. The increase was observed in two data points. Further inspection confirmed the coupling needed replacement.

The CME recommended replacing the coupling at the next available downtime and checking the alignment to prevent further wear or misalignment issues.​

The coupling was replaced and the equipment was restarted that night.

The fan opposite drive end bearing was showing harmonic frequencies in the spectrum, indicating that excessive clearances could be developing in the fit areas of the bearing.

The CME recommended inspecting the bearing locking collar for looseness.

The customer found that the fan bearing was loose on the taper and replaced the bearing, reducing acceleration levels drastically. During inspection, a bent fan blade was also discovered and scheduled for replacement during planned downtime.

Rising motor vibration revealed a worn coupling in this roll application. Early detection enabled timely replacement, reducing vibration, preventing failure, and avoiding 6 hours of unplanned downtime while saving $439,200.

The CME recommended taking apart the coupling for inspection. While apart, a lift test should be performed on the motor shaft to check for excess bearing play.​

Upon inspection, the motor side of the coupling was found to be stripped, with the teeth completely worn down. The coupling was replaced, resulting in a noticeable drop in vibration levels.

A sharp increase in velocity and acceleration was detected on the bearing. Vibration patterns suggested a bearing fault.​

The CME recommended inspecting the bearing ASAP by looking, listening, and feeling for abnormalities. The auto-lube system should also be checked for proper function.​

The bearing was replaced during an outage, resulting in a significant reduction in vibration levels.

High motor and blower turning speeds suggested possible structural looseness or resonance.​

The CME recommended checking for loose bolts, broken welds, and cracks. If looseness was found, alignment and belt tension should also be checked.​

Preventive maintenance was performed, including greasing bearings, checking belt tension, and tightening loose bolts.

Both blower bearings overheated, exceeding 200°F, with high vibration levels. The DE bearing was the worst. Balancing might be needed if issues persisted.​

The CME recommended inspecting and lubricating bearings, checking belts and pulleys, testing for bearing clearance issues, and inspecting mounting bolts.​

Bearings were lubricated, air filters replaced, and mounting bolts checked. The issue was resolved, preventing a major failure.

A significant increase in RMS acceleration and impacts at ~760 CPM indicated a likely inner race defect on the intermediate shaft bearing.​

The CME recommended an oil analysis, along with planning for gearbox replacement. Vibration trends were monitored for changes.​

The gearbox was replaced during an outage. Acceleration readings dropped from 25 g’s Pk-Pk to under 5 g’s.

The time waveform is showing amplitudes of over 60gs pk-pk. The correlated waveform shows severe modulating impacts, as well as harmonic peaks in the FFT. This indicates that there is a bearing fault present in the motor bearing.​

The CME noted that lubricating the bearing may lower the vibration levels, but at these amplitudes, there is likely permanent damage to the bearing. After lubricating the bearing, the CME did not see enough improvement and recommended swapping out the motor.

The motor was changed and vibration amplitudes returned to normal. The customer noted that 10,000 units were saved at $80 per unit, which resulted in $800,000 in cost savings. The customer also cited 24 hours of downtime was avoided, "It saved a day because we could plan the motor change around production. We didn't lose a batch of paint."​

There was elevated vibration related to the gear mesh. The CME recommended taking an oil sample to check for wear metals. The Lubrication CME reviewed the oil analysis report and noted wear metals, particle count, and water content were all high.

Both CMEs collaborated with the customer on a plan to inspect the gearbox, check the oil level and then change the oil.

The customer found the input seal was leaking and there was very little oil in the gearbox. The seals were replaced and the oil was changed. The customer avoided replacing the gearbox and noted a savings of $50k.

The oil report analysis identified improper viscosity across multiple compressors​.

The CME collaborated with the customer to verify what lubricant was supposed to be used and recommended an oil change to the desired viscosity​.

The customer identified the lubricant as EP 320 and changed the oil, noting that they saved $5,000/unit on 5 units.

The lubricant is dirty and showing extreme wear. The number of iron particles is 785 and should be 25 or less. The lubricant is listed as an AGMA 6 which should have a viscosity of 320 but it measures 265 cSt. There is a high PQ index indicating large amounts of ferrous materials being removed. The amount of water has tripled since the last sample. The additive package has changed significantly indicating this is not the same lubricant previously tested.​

CME asked customer to verify the lubricant and recommended a hot oil flush to remove the large amount of wear metals and refill with the correct lubricant. If that is not possible, the lubricant should be changed and a filtration system should be attached and filter with a 7 micron beta 1,000 filter.​

The customer changed the correct oil and 336 hours of downtime were prevented.​

There were high-frequency peaks with harmonics in the upper-frequency range of the motor ODE. There was also high SCR firing frequency peak at 21,560 CPM. This could indicate an issue with the brushes.

The CME suggested blowing brush dust out of the motor, checking brushes and springs for proper wear and tension, and inspecting the armature for any issues.

The customer cleaned and lubricated the motor and replaced the brushes, which saved 12 hours of downtime and $38,000.

The vibration data points indicated rotating looseness and the fan ODE side had a high 2x in the axial position. 2x running speed is an indication of an alignment issue.

The CME recommended checking the bearings and alignment at the next available downtime.​

The customer changed out both DE and ODE bearings, which avoided a failure and 64 hours of downtime.

There was high frequency haystacking that indicates a possible lack of good lubrication.

The CME recommended greasing both motor bearings.

The customer greased the bearings and avoided having to replace the motor.

RMS acceleration readings suddenly spiked on both of the compressor ODE monitoring points. There was an extreme degree of high-frequency harmonics, which could indicate thrust bearing wear.

The CME advised the customer to inspect the compressor for signs of thrust bearing wear and plan for the replacement of the thrust bearings. It was also recommended that If vibration readings continued to climb over the next several days, the compressor would need to be shut down to avoid more extensive damage.

The male thrust bearing on the ODE side of the compressor was replaced. Post-replacement, vibration readings returned to the normal range. The customer noted that they saved $150,000 and avoided a shutdown.

High vibration at crusher speed was detected on the motor, indicating possible sheave misalignment and/or incorrect belt tension.​

The CME recommended inspecting the sheaves for proper alignment and ensuring proper belt tension​.

The customer replaced the motor, belts, and sheaves, which saved 24 hours of downtime and $240k.

Condition monitoring engineer observes vibration on agitator ODE, issues maintenance recommendation

Sheaves and belt replaced, but condition monitoring engineer calls out worsening sheave misalignment

The sheave pulley bore was found to be too big, and the ODE bearing was hot. Replaced taper lock and bearings. Issue resolved, $150k saved.​

Condition monitoring engineer observes increased amplitude in rotor bar activity with turning speed sidebands, indicating electrical issue​

Condition monitoring engineer issues maintenance recommendations to check all electrical connections and measurements, scan with a thermal gun, and replace the motor if not an external issue.​

Motor replaced before failure, customer calls out $250k save​

AI alerts condition monitoring engineer; observes harmonics 1x turning speed and >50 g’s pk-pk at turning speed, indicating excessive looseness.​

Condition monitoring engineer issues maintenance recommendation for to perform lift check on Fan ODE​

Excessive wear damage was found (0.025” overall) on the housing and bearing; both replaced, avoiding catastrophic failure ​

AI observes +60°F rapid change on motor ODE​

Condition monitoring engineer issues maintenance recommendation

Motor cooling fan sudden failure was detected and repaired​