Background
Timely pump maintenance in a Food & Beverage plant Eastway has proudly served for over a decade, saves the company €78,000 with the Eastway Safeguard® system. Positioned strategically on critical assets, the Eastway Safeguard® system was implemented in 2018 to maximize output by minimizing unplanned downtime. This innovative solution has empowered the company with data-backed insights into the health and efficiency of their critical assets, ushering in a new era of technology-driven asset management. Additionally, Eastway offers a suite of services in this company that complement the innovative Eastway Safeguard® system. These services include on-site vibration analysis to detect mechanical issues, electrical thermography inspections to prevent electrical faults, and steam trap and ultrasonic leakage inspections to optimize efficiency and reduce energy wastage.
Case description
In January 2023, an increase in vibration values were detected at the jet blender pump observed at both the pump’s inlet and outlet test points. These readings were concerning because of the acceleration and velocity values and promoted Eastway to recommend timely pump maintenance. Figure 1 provides a detailed look into the unsettling velocity trend at the pump’s inlet test point from January to April 2023. Similarly, Figure 2 showcases the corresponding acceleration pattern over that same timeframe.
Figure 1. Velocity trend at Jet Blender Pump’s IN test point: Jan-April 2023
Figure 2. Acceleration trend at Jet Blender Pump’s IN test point: Jan-April 2023
Recommended Action
Further analysis of the vibration data was conducted by Eastway’s remote monitoring team. This comprehensive analysis included the examination and comparison of vibration FFT spectra (Fast Fourier Transform), enveloped spectra, and time waveform signatures. Figure 3 presents distinct signatures corresponding to running rpm, harmonics, noise symptoms and non-synchronous frequencies. The graph revealed a noticeable increase in non-synchronous frequency amplitudes, pointing to potential issues related to flow and wear.
Figure 3. Acc FFT of Jet Blender Pump’s OUT test point, recorded in April 2023
Considering the data analysis, Eastway recommended a timely pump maintenance inspection of the pump internal components. Emphasis was placed on assessing the rotor axial clearances because of the indications of potential wear and increased clearance within the pump bearings.
Action taken
Following Eastway’s recommendations the pump was replaced in May 2023. The results were immediately evident. The post-replacement data depicted a significant reduction in vibration values, falling well within the acceptable range. Figure 4 specifically shows a marked difference between the two months: the May readings (denoted in blue as “After”) clearly contrast the April data (highlighted in grey as “Before”), underscoring the marked improvement post-intervention.
Figure 4. Acc FFT comparison for Jet Blender Pump’s IN test point: April 2023 (Before) vs. May 2023 (After)
Results
After the maintenance operation, Eastway’s recommendations led to optimal vibration levels. At this stage, no additional actions are deemed necessary, highlighting the value of proactive monitoring and timely interventions. The early detection, underscored by the Eastway Safeguard® system, was instrumental in efficient resource planning and preparation, optimizing repair times and ensuring that production schedules remained unhindered. This case not only highlighted the importance of predictive monitoring but also confirmed the efficiency and foresight embedded in Eastway’s approach.
Table 1 illustrates the importance of having 24/7 monitoring service in place to detect failures for this case of pump wear, allowing corrections to be carried out before costly system failures occur.
Table 1. Estimated cost savings
