The Challenge
Client provides water and sewerage services to the ACT region. A critical component of their wastewater management is two furnaces used to treat biosolids. To ensure proper ventilation and efficient combustion, induced draft (ID) fans are employed. For operational security, these ID fans must be reliable, closely monitored, and subject to preventative maintenance.
Initially, sensors were installed on the ID fans to monitor overall vibration levels. However, there were instances where increasing vibration levels required adjustments to operating speeds or in-depth inspections to determine the cause.
To enhance monitoring capabilities, VibCloud’s route-based solution was implemented to provide condition monitoring data and analytical insights. This system successfully identified issues such as bearing deterioration, lubrication problems, and unbalanced operation.
Given the complexity of the fans, which operate at variable speeds and loads, route-based monitoring alone was insufficient for a robust predictive maintenance approach. The solution needed to provide a comprehensive understanding of the fans' condition, detect problems early, and identify issues under specific operating conditions.
The Solution
To address these issues, the client implemented VibCloudOnline to complement the existing route-based system. This advanced intelligent monitoring solution is designed to track and analyse vibration changes and trends, even amid complex variable speed and load operations.
The system involved installing tri-axial vibration and temperature online sensors that enable automated, real-time monitoring of all operational states of the ID fans. With a high sampling rate, robust system processing, and integrated smart analysis and visualisation, the solution provides comprehensive early detection and analysis capabilities for common failure modes of ID fans, despite operational complexity.
The system was operational after a two-hour installation of sensors and a gateway, allowing the reliability team to monitor the ID fans from anywhere, at any time.
The Results
- Identify and avoid operating conditions: Prevent increased vibration levels, such as resonance amplification.
- Detect and address potential bearing issues: Optimise lubrication schedules and prevent failures.
- Prevent dust build-up: Reduce the risk of damage and unplanned downtime.
- Assess bearing deterioration proactively: Allow for planned replacements and minimise disruptions.
Expanding the Approach
The early success of VibCloud Online led our client to expand its use to other critical assets within the plant, such as centrifuges and pumps. This demonstrates the versatility and effectiveness of the solution in enhancing overall plant reliability and operational efficiency.
