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Kappa X Discovers Significant Fan Problem, Prompting Essential Maintenance


The client required a robust and precise solution to monitor machine vibration at a food production factory to ensure machine longevity and minimise costly downtime. By analysing the complex and detailed data from Kappa X, our groundbreaking system enabled the maintenance team to identify a critical imbalance issue with a fan, evident during machine restarts. Due to our system's invaluable data, they could make an informed decision to inspect the fan for potential issues or damage, prompting further investigation.




Machinery and Operations

Our client operates a food production factory equipped with a power plant that uses critical gas fans. These fans require consistent condition monitoring and vibration analysis. For each critical gas fan, a 250kW direct drive fan operates at a running speed of 1485 RPM. The reliability of these fans is crucial for maintaining optimal production processes, and any disruptions can lead to significant costs, unwelcome downtime and operational challenges.



Machine on a food production site


Implementation

Sensoteq Kappa X wireless sensors were installed on each fan to monitor their condition. These sensors provide tri-axial vibration and temperature readings at three-minute intervals, delivering comprehensive data and allowing in-depth analysis. The data is transmitted to the Sensoteq Analytix HMI Software. On this occasion, the software was installed in the control room, allowing site administrators to continuously monitor the fans' condition. Our intuitive system simplifies the data analysis process, allowing users to access and interpret crucial machine readings. Furthermore, the system will notify key personnel when the critical alarm threshold is exceeded and essential maintenance is required. This proactive approach ensures the maintenance team can promptly detect potential issues.



Sensoteq HMI screen in access on-site


The Problem

Before this shutdown, the fan operated at a steady velocity of approximately 4mm/sec RMS. However, upon restarting, the fan’s velocity levels surged dramatically to approximately 23mm/sec RMS. This significant increase from the previous levels raised the warning alarm, alerting the maintenance team. A potentially costly issue had been raised, requiring proactive investigation.



Sensoteq Analytix software


The spectrum data below showed a high velocity reading of 12mm/sec RMS indicating a potential machine imbalance. Such imbalances can result from several factors, including worn or misaligned components, uneven weight distribution, or improper assembly. Due to the complex readings from our advanced sensors, the site made the informed decision to inspect the fan impeller for signs of damage or dirt buildup which could have been affecting machine performance.



Sensoteq Analytix software


The Solution

During the inspection, the maintenance team discovered substantial dirt deposits had accumulated on the impeller and casing. The fan was thoroughly cleaned, removing all excess debris to improve machine performance and efficiency. The likely root cause of the issue was a significant piece of dirt dislodging during the start-up of the fan. This debris became trapped in the impeller, causing it to shift out of position and become unbalanced.






The Result

Before cleaning, the fan's velocity levels had surged to over 30 mm/sec RMS, highlighting the urgent need for maintenance. Following the cleaning, the levels were reduced to 1mm/sec indicating that excessive debris accumulation was the issue. An investigation was planned to understand the machine’s significant dirt buildup, despite being classed as a clean fan. Due to our cutting-edge sensing technology, the client received detailed vibration data. These readings were pivotal to the client as they analysed the increasing problems, carried out crucial maintenance and opened an investigation that would ultimately improve the site’s operations and efficiency.


Sensoteq Analytix software

Overall, this proactive approach not only resolved the immediate issue but also led to improvements in the site’s overall operations. The problems with this machine highlighted the value of continuously monitoring equipment to ensure efficient performance. With Sensoteq sensors and our Analytix software, you can receive detailed insights leading to precise and timely interventions, radically reducing your costs and downtime. Contact us today and learn how you can enhance your maintenance strategy and improve your operational efficiency.


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