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Manufacturing
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United Kingdom
Services
Vibration Analysis
Oil Analysis
Remote Monitoring and Data Services
Our partnership with HJ Enthoven & Sons
Overview
We investigated multiple failures on a Drive End (DE) bearing on a Gypsum Plant Booster fan unit. Through further investigation, it was identified that potentially three different types of grease had been put into the bearing.
All grease was removed and replaced with just one type, preventing unexpected bearing failures estimated at £4,555 per failure.
After experiencing two failures in quick succession on a Drive End (DE) bearing, H J Enthoven & Sons contacted us to request an inspection on their Gypsum Plant Booster fan unit.
The Challenge
We used vibration and stresswave analysis to monitor the motor unit and fan bearings, in order to identify bearing issues/defects, insecurity, imbalance and/or misalignment.
Overall, the running speed vibration amplitudes across the unit gave no concerns to indicate any fan imbalance or coupling misalignment.
The Solution
An initial site visit, utilising an Emerson data collector, revealed imbalance in the main attritor rotor. It was evident that the main three tonne rotor was out of balance. No sub synchronous activity was detected, ruling out a structural looseness.
A further visit was required utilising alternative equipment to confirm shaft integrity and to assess resonance.
A verbal recommendation was given at the time to replace all wear plates equally across the plate circumference and inspect the five free-spinning hammers for signs of wear and free movement.
The Result
The initial set of data collected showed concerning levels of stresswave activity for both fan bearings with prominent cage defect frequencies seen at the DE bearing.
Ours engineers suspected the cause of this was that initial packing grease had dispersed from the bearing following several hours of running. Additional grease was added to the unit, however this only temporarily reduced readings.
Figure 1: Solidification on non-drive end bearing.
Oil around the joint between the bearing housing halves of the non-drive end NDE fan bearing was identified, which indicated a potential separation of oil and soap of the grease. Discussions with site engineers identified potentially three different types of grease had been put into the bearing.
At the recommendation of one of our reliability engineers, the bearing housings were opened, and site engineers found solidification of the greases due to incompatible grease properties.
Figure 2: Our reliability engineer collecting vibration data.
All grease was removed and replaced with just one type. Additional lubrication was added after approximately 12 hours of operation (as per manufacturers recommendations) as initial packing grease once again dispersed from the bearing following start up.
The bearing temperature has remained stable and no issues with fan operation have been reported.
Key outcomes
Identified the root cause of the DE bearing failure: incompatible grease properties.
Removed all grease and replaced with just one type.
Bearing temperature has remained stable and no issues with fan operation have been reported.
Estimated cost avoidance of £4,555 per future failure.
Contact us to find out more about Vibration Analysis, Oil Analysis and Remote Monitoring and Data Services.
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