Vibration Monitoring Identifies Critical Bearing Issues on Boiler ID Fan Motor

Engineering Dynamics Services delivers monthly vibration analysis and predictive maintenance to help clients prevent downtime and improve maintenance plans. A case study at one of our industrial plants shows how our services benefit critical equipment such as boiler fans.

Introduction

During our routine vibration check in May, we found a rising vibration trend on both motor bearings of Boiler 1’s ID fan. We advised replacing both bearings if greasing showed no improvement.

Findings

Almost a month later, our readings showed the drive end (DE) bearing was still rough. At the same time, vibration on the non‑drive end (NDE) bearing and fan bearings kept rising. We recommended replacing the DE bearing and checking the NDE bearing’s lubrication. The client also reported that a new motor had been installed.

Recommendations

By the end of July, follow‑up tests showed the fan bearings were in good condition. Meanwhile, the NDE bearing vibration had stabilised based on the latest readings. However, the DE motor bearing vibration continued to rise.

Our vibration analysis and documented trends clearly highlighted the need for timely corrective action on the motor bearings. Thus, we recommended that the client’s maintenance team promptly replace the drive-end (DE) motor bearing and continue monitoring the non-drive-end (NDE) bearing vibration levels.

Fortunately, the client acted swiftly on our recommendation and found that the old DE bearing was cracked, with failure imminent. Replacing the bearing just in time, they averted the high costs associated with repair and production downtime.

Conclusion

The case study highlights the value Engineering Dynamics Services delivers through vibration monitoring and analysis. Tracking vibration trends over time and giving clear, data‑driven advice allowed the customer to plan bearing replacements before a major equipment failure.

Predictive maintenance based on machine reliability data allows for prioritising maintenance activities and optimising spending. Operating equipment until it fails, risks secondary damage, costly unplanned downtime, and health and safety issues. Engineering Dynamic’s services helps customers extend asset life, reduce maintenance costs, and improve overall plant reliability and uptime.

We encourage clients to use our vibration monitoring on critical rotating assets such as fans, motors, pumps, and gearboxes. In turn, the rewards far outweigh the small cost of predictive maintenance combined with our specialised services.

Motor NDE Bearing Horizontal