Background
This case study describes enhancing operational efficiency by identifying deterioration in a critical centrifugal pump as detected using the Eastway Safeguard® System. Discovering this through our early warning system, significantly minimized unplanned downtime and enhanced operational efficiency in a global pharmaceutical company. The phased installation of the Eastway Safeguard® online monitoring system commenced in 2020 and continues to date, covering critical and non-critical production and facilities equipment. Eastway has been providing a range of condition monitoring services to this client since 2012. Collaboration between the reliability team and Eastway’s remote monitoring team has ensured swift decision-making and proactive maintenance interventions.
Case description
In December 2023, the Eastway Safeguard® System detected a significant increase in acceleration (g’ RMS) vibration values from both the motor non-drive end and motor drive end of a critical centrifugal pump. Figures 1 and 2 illustrate the unexpected rise in acceleration values from the motor non-drive end and motor drive end test points. Alerts were automatically sent to site key personnel and the Eastway team, initiating further analysis.
Figure 1. Centrifugal pump – motor non-drive end acceleration (g’ RMS) trend from October 2023 to January 2024.
Figure 2. Centrifugal pump – motor drive end acceleration (g’ RMS) trend from October 2023 to January 2024.
Recommended Action
Based on the increased acceleration (g’ RMS) and intermittent knocking noise from the pump, along with non-synchronous peaks, it suggested deterioration of the motor bearings and the pump volute. Furthermore, the amplitudes of these frequencies were noted to intensify over time. Due to the critical nature of the equipment and its role in the company’s production line, the Eastway team recommended an inspection of the motor bearings and pump internal components for any signs of wear during the next downtime. A spare pump set was ordered and stocked in the workshop.
Action taken
Following Eastway’s recommendations, the production and maintenance teams scheduled a maintenance intervention for the centrifugal pump at the end of January 2024. The pump was replaced with the spare, and upon inspection, the motor bearings were found to be deteriorated, showing clear signs of wear and stress. After the pump replacement, vibration measurements indicated significant improvements, with vibration trend levels returning to acceptable limits and noise levels came down. Refer to Figure 3 for the motor non-drive end test point, which shows the decrease in acceleration (g’ RMS) vibration values.
Figure 3. Centrifugal pump – motor non-drive end acceleration (g’ RMS) trend from October 2023 to March 2024.
Results
This case confirms the benefits of using the Eastway Safeguard® System by demonstrating the measurable value of enhancing operational efficiency through the early identification of deterioration in a critical centrifugal pump. Close collaboration between the reliability team and Eastway ensured effective monitoring and timely intervention, leading to successful pump replacement within a scheduled downtime window.
Table 1 below summarizes the importance of having predictive maintenance in place to detect failures. In this case, motor bearings deterioration was detected before it progressed to a critical level, allowing corrections to be carried out before costly system failures occurred, thus maintaining operational continuity.
Table 1. Estimated cost savings
