In this case study, we present a condition-based maintenance case using the real-time diagnostic COMPACS system.
Pump Monitoring
In the first example, an operator observed a slow increase in the vibration parameter associated with a bearing defect. The COMPACS system issued an “Action Required” alert, with prescriptions “Check Bearing” and “Check Inner Race.” The bearing was slowly deteriorating, and after 27 days, the oil pump was taken out of service for repair. Knowing the actual state of the pump allowed for scheduled maintenance and a switch to a standby machine. Upon inspection, a crack was revealed in the inner race of the rolling bearing.
Bearing Rapid Deterioration
The second example demonstrates a scenario of the bearing rapid deterioration that cannot be prevented by anyone except operators. It shows twelve-hour trends of acceleration and velocity measured on the front bearing of the pump. The system generated an “Unacceptable State” alert when the acceleration increased from 12 to 24 meters per second squared. The COMPACS system prescribed actions to “Check Bearing Lubrication” and “Check Bearing Cage.” At the time of the “Unacceptable State” alert, the vibration velocity parameter remained in the “Acceptable state” for another 18 minutes before rising sharply from 2.7 to 27 millimeters per second. This early diagnosis allowed operators to proactively switch to the standby pump and prevent an emergency shutdown.
Key Takeaways
The COMPACS system’s precise diagnostics and prompt prescriptions increase equipment reliability and availability, reducing operational costs. Equipment monitoring provides a giant shift to paramount reliability and operational excellence.
Benefits of Condition-Based Maintenance Using the COMPACS System
- Early Detection of Defects: The system identifies defects early, allowing for planned maintenance.
- Real-Time Alerts: Real-time alerts help quickly respond to changes in equipment states.
- Reduced Emergency Shutdowns: Timely switching to standby equipment prevents unforeseen downtimes.
- Enhanced Reliability: Regular monitoring and diagnostics ensure reliable equipment operation and extend lifespan.
Utilizing the COMPACS system is not just a step but a crucial leap toward optimizing maintenance processes and increasing the operational efficiency of rotating and static equipment. It empowers maintenance professionals, industrial equipment operators, and Maintenance Managers to make informed decisions and act proactively, enhancing the overall efficiency of maintenance and operations.
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