Asset Saves

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.

Turning speed vibrations on the motor DE increased significantly, with noticeable impacts at 1X turning speed in the time waveform. This suggested a possible coupling or bearing clearance issue.​

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​