Exhaust Fan (3 star)
Problem: We detected excessive fan speed vibration and harmonics on all measurement locations. We recommended first checking the motor and fan bearings for any looseness/lack of rigidity and the belts/sheaves for wear and proper alignment. We also recommended cleaning/balancing the fan.
Solution: We were informed the fan base was rebuilt and the fan was balanced. As a result, we detected a significant improvement in fan speed vibration and harmonics on the motor and fan bearings. Horizontal vibration on the outboard motor bearing is 79% lower than the last measurements (see trend below).
Financial Impact
- Downtime Avoided: Even a single 8-hour outage could cost $100,000+ in lost production.
- Repair Costs Avoided: Bearing/motor replacement can run $50,000–$250,000.
- Energy Savings: Balancing and alignment typically improve efficiency by 3–5%.
Return on Investment
- ROI: >500%, with potential upside exceeding 1000% depending on avoided production losses
Stand 14 Main Drive (3 star)
Problem: Vibration measurements were taken on the primary gearbox input and output bearings and the input roll housing bearing. We detected a significant increase in harmonic vibration at the outer race defect frequency of the roll housing output shafts SKF N222 bearings. The vibration is evident on the primary gearbox, but is much higher on the roll housing input bearing. This represented a change in vibration patterns, and vibration levels on the roll housing input bearing were higher than we’ve see in the past. We recommended inspecting the roll housing output shaft bearings for damage especially the SKF N222 bearings.
Solution: Customer responded to the report findings right away and found the bad bearings that were identified on the report. They replaced the bearings and were running the next morning.
ROI: If the SKF N222 failed catastrophically, it could have damaged the gearbox or roll housing. A catastrophic failure could have meant 2–5 days of downtime for repairs. With the benefits of our system, they saved close to $1 million. This catch ultimately gave them huge savings with 10-25x ROI with this finding alone.
Line Stands (1 star) CMAS detection
Problem: A peak vibration was detected on the external gearbox. We detected an increase in high-frequency harmonic vibration at multiples on the output shaft speed since when producing 5.5 mm and 6.6 mm rods, accompanied with elevated wideband noise floor. Though the vibration decreases when producing 16 mm rods, we recommended checking the output bearing for adequate lubrication, unusual noise and elevated temperatures.
Solution: Customer checked the bearings, and there was damage being produced. This resulted in significant savings.
ROI: This finding avoided needing a gearbox replacement and not having 2-3 days of downtime. With this catch alone, the customer received around 5x ROI.