Prevent Unexpected Downtime
Reduce Maintenance Costs
“If this unit was to fail catastrophically, we could be down for days, whereas with this predictive maintenance technology, we knew there was a problem and scheduled four hours of downtime to fix the issue.”
Paper & Packaging
A manufacturer that produces solutions based on wood, paper, and biomass for numerous sectors worldwide was seeing frequent unplanned failures. The equipment failures were often caused by unmonitored motors, pumps, gearboxes, and fans that were subjected to severe stress in harsh environments. Safety and Maintenance Managers were looking for a solution to help reduce downtime while simultaneously improving employee safety.
Schaeffler OPTIME™ was the ideal solution for this application, complete with wireless sensors, a gateway and digital analytics services. OPTIME™ detects problems, issues alarms, and provides information about the possible source of the problem. No expert condition monitoring knowledge is required by employees, because OPTIME™ provides it all. Several hundred machines were able to be monitored at once, delivering automatic analysis to one concise platform.
Food and Beverage
A brewery was having issues identifying the problems with a critical boiler feed water pump. The maintenance manager was inspecting the unit frequently to ensure it continued to operate. If the boiler feed pump failed, it could damage pipes and other equipment, resulting in expensive repairs and lost production. The brewery had limited resources to troubleshoot the issues.
A Perceptiv™ wireless vibration monitoring system was installed to monitor the boiler pump remotely. The system was easy to install: no wires or conduits needed to be attached to the vibration point. Within the first month of monitoring, the data revealed abnormally high vibrations in the boiler feed pump were leading to accelerated motor and pump deterioration. The root cause of the issues was misalignment of the pump head to the motor. This was a relatively new piece of equipment and unlikely to be identified as the source of the problems. The team generated a report based on the findings and provided detailed recommendations to correct the issues.
One of the largest global chemical engineering plants was experiencing extended downtime and expensive production loss due to missed equipment failure cues. Tedious, manual equipment inspections were completed every three months but proved ineffective in avoiding machine malfunctions and maintenance requirements.
ABB Ability™ Smart Sensors were installed on motors across all three of the manufacturing plants. The Smart Sensors proved their worth after only a few days in operation when one detected a higher than normal vibration in a motor on a feed roller. In another instance, a sensor picked up an abnormal temperature increase caused by an absorbent pad stuck on the fan cover. Similarly, a bearing started performing abnormally. It was regreased and the condition improved with a slight increase of levels within the alert range, but was still monitored closely. Two months later, the bearing crossed the alarm zone continuously, and it was replaced during the next scheduled maintenance shutdown before it could cause any problems.