Problem: Belt Frequency Vibration
Machine: Vacuum Pump
Solution: VibePro Vibration Monitoring
Executive Summary
This case study showcases the significant cost savings achieved through the proactive use of VibePro’s 24/7 permanent monitoring system featuring permanent mounted tri-axial vibration and temperature sensors on a key piece of equipment – a 75 hp vacuum pump. Through detailed vibration analysis, the system not only identified a persistent issue but also guided the maintenance team to a solution that prevented potential production downtime and equipment failure, leading to substantial cost avoidance.
Initial Observations
The issue began with the vacuum pump exhibiting belt frequency vibrations that persisted despite initial maintenance efforts to tension and track the belt. Scheduled preventative maintenance revealed worn sheaves, and though they were replaced along with the belt, the vibration issues continued. A deeper investigation uncovered the root cause: a “breathing” concrete pad, visibly moving up and down, which undermined all attempts to correctly tension the belt.
 Crack In Concrete Base Pad |
 Close Up of Hair Line Crack |
Onsite Analysis
Utilizing VibePro 24/7’s tri-axial vibration and temperature sensors, the maintenance team conducted a comprehensive analysis. Despite replacing the belt and attempting to adjust tension, the problem persisted until the discovery of the cracked and unstable concrete base pad. This foundational issue had rendered previous maintenance efforts ineffective, highlighting the importance of thorough diagnostics.
Corrective Action
The recommended solution was to replace the concrete base pad during a scheduled December outage, a strategy that not only addressed the immediate vibration issue but also ensured the longevity and reliability of the vacuum pump. Continuous monitoring was advised to prevent future occurrences.
Cost Saving Analysis
Had the issue led to a belt failure, the immediate solution would have involved 6 hours of labor for belt replacement and shaft alignment, costing $475 in labor and $500 in parts. However, the potential for production risk and quality issues with the boards, leading to waste or scrap product, was a significant concern. By addressing the problem proactively, we avoided approximately $3,168 in labor costs (assuming an 80-hour unplanned maintenance event) and $6,200 in parts, totaling an estimated savings of $8,393 by opting for planned maintenance over an unplanned emergency fix.
Future Focused Solutions
This case highlights the vital role of continuous monitoring in identifying hidden issues that can lead to significant production challenges. By integrating VibePro’s 24/7 monitoring into their maintenance strategy, companies can not only ensure the operational efficiency of their equipment but also significantly reduce maintenance costs through proactive interventions.