Cane Knife Motor Vibration Monitoring: A Case Study on Preventing Major Machinery Failure
In this case study, we examine how Engineering Dynamics Services (EDS) prevented a major machinery failure through our monthly comprehensive vibration monitoring and predictive maintenance service. The scenario unfolded at a client’s industrial plant, where a critical piece of equipment was at risk of an unexpected breakdown. By deploying advanced vibration analysis, EDS not only identified early signs of bearing damage but also provided timely recommendations that ultimately saved the client from costly downtime and repairs.
The monitoring process employed a state of the art FFT Analyser with software to capture precise vibration data from the machinery.
Initial analysis uncovered unusually high bearing frequencies in the number 2 Cane Knife Motor. Specifically, the non-drive end (NDE) bearing’s outer race and the drive end (DE) bearing’s inner race showed signs of damage. EDS promptly informed the client and advised lubrication as an immediate remedy.
Subsequent surveys revealed no improvement despite lubrication efforts. EDS then recommended planning for bearing replacement. However, due to production demands, the machine had to remain operational. EDS increased monitoring frequency to closely track the bearings’ condition.
When the machine was finally taken offline for repairs two and a half months later, inspection confirmed significant damage to both NDE and DE bearings, validating EDS’s earlier analysis and recommendations.
The timely identification of these defects by EDS’s monitoring programme prevented what could have been a major and expensive machine failure. This case underscores the value of investing in a Condition Monitoring programme, highlighting its role in maintaining machinery health and avoiding costly downtime and repairs. The client’s investment in this programme proved prudent, ensuring continued productivity and preventing severe operational disruptions.
The monitoring process employed a state of the art FFT Analyser with software to capture precise vibration data from the machinery.
Initial analysis uncovered unusually high bearing frequencies in the number 2 Cane Knife Motor. Specifically, the non-drive end (NDE) bearing’s outer race and the drive end (DE) bearing’s inner race showed signs of damage. EDS promptly informed the client and advised lubrication as an immediate remedy.
Subsequent surveys revealed no improvement despite lubrication efforts. EDS then recommended planning for bearing replacement. However, due to production demands, the machine had to remain operational. EDS increased monitoring frequency to closely track the bearings’ condition.
When the machine was finally taken offline for repairs two and a half months later, inspection confirmed significant damage to both NDE and DE bearings, validating EDS’s earlier analysis and recommendations.
The timely identification of these defects by EDS’s monitoring programme prevented what could have been a major and expensive machine failure. This case underscores the value of investing in a Condition Monitoring programme, highlighting its role in maintaining machinery health and avoiding costly downtime and repairs. The client’s investment in this programme proved prudent, ensuring continued productivity and preventing severe operational disruptions.
Plot 1
Plot 2
Motor NDE Bearing NSK 6326 C3
Motor DE Bearing FAG NU326E
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