CASE STUDY Predictive Maintenance Helps Paper Mill Avoid Bearing Failure and Production Losses
In pulp, paper, and sawmill operations, equipment reliability is critical for maintaining uninterrupted production. At a facility in Alabama, Waites' sensors identified an increase in vibration levels on the drive-end bearing of a base sheet fan pump - a critical component for smooth paper production. Without swift intervention, bearing failure could halt operations, disrupt production schedules, and result in significant financial impacts.
Waites' analysts observed an upward trend in acceleration vibration data, particularly noting irregular spikes in peak-to-peak vibration amplitude and high-frequency harmonics. Analysis indicated potential bearing defects, lubrication deficiencies, or cavitation issues. A thorough inspection confirmed water contamination within the bearing housing as the primary cause, compromising bearing lubrication and performance.
A notable upward trend culminating in a significant peak-to-peak vibration spike (22 g) clearly indicated serious bearing deterioration due to contamination.
A sharp increase in acceleration vibration further confirmed critical bearing lubrication issues, highlighting the immediate need for intervention.
Promptly responding to Waites' alerts, the maintenance team investigated and discovered water contamination affecting the bearing. The team repaired the water intrusion issue, thoroughly replaced the contaminated oil, and ensured adequate lubrication. Follow-up vibration analyses confirmed the bearing condition had stabilized.