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CASE STUDY Vibration Spike Caught Before Chipper Failure at an Alberta Sawmill

Pulp and Paper Motor Sensor
INDUSTRY

Pulp and Paper

EQUIPMENT TYPE
Motor
FAILURE MODE
Lubrication
IMPACT
$422K saved 
96 hours of downtime avoided 
19 days from initial alert to verified resolution
THE CHALLENGE

The facility’s chipper is essential to continuous wood processing operations. If it fails, production across the entire line stops. Waites detected a concerning rise in vibration levels on the non-drive end bearing. Without intervention, the facility faced a four-day outage, potentially delaying outbound shipments, incurring expensive contractor repairs, and significantly disrupting revenue and labor planning.

PROBLEM IDENTIFIED

Waites’ certified vibration analysts quickly identified a lubrication issue after sensors showed abnormal vibration patterns. Increased RMS acceleration and high peak-to-peak spikes indicated a potential bearing defect or insufficient lubrication. Impacting spikes on both the non-drive and drive ends further confirmed the urgency.

pulp-paper-motor-before-1

RMS acceleration trends clearly showed a concerning rise in vibration levels on the chipper's non-drive end bearing, with acceleration reaching 1.3861 g.

pulp-paper-motor-before-2

Peak-to-peak vibration data highlighted a sharp increase to 30.14 g, providing clear evidence of the severity and urgency of the bearing issue on the chipper’s non-drive end.

pulp-paper-motor-after

Time waveform analysis of the chipper bearing drive end identified multiple clear impact spikes, reinforcing the diagnosis of bearing issues or insufficient lubrication.

QUICK RESOLUTION

Over the weekend, the maintenance team opened the housing, inspected the bearing, and repacked it with grease. Follow-up readings showed stable RMS and Pk-Pk levels, confirming the issue had been resolved. The sensor mount was also double-checked and secured.

$ 422,000
COST SAVINGS
96 Hours
DOWNTIME AVOIDED
19 Days
ALERT TO RESOLUTION

RAPID RESULTS

Thanks to Waites’ proactive monitoring, the bearing fault was resolved early, ensuring uninterrupted production and keeping the chipper fully operational. Acting swiftly prevented significant disruption. 

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