MACHINE HEALTH MONITORING of the Bucket Elevator at a leading Cement Plant
Background
A bucket elevator plays a vital role in the
cement industry, primarily employed for the vertical transport of
bulk materials such as limestone, clinker,
cement, and various
additives in the cement manufacturing process. Its primary function
is to facilitate the efficient movement and transfer of materials within the cement
plant.
Industry
Cement
Machine
Bucket Elevator
Fault Type
Misalignment & Soft Foot Issue
Our solution enabled the Cement Manufacturer to achieve the following results
www.cimcondigital.com sales@cimcondigital.com
Deployment
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VIBit sensors were mounted on the Cooling
Fan drive end & Fan non-drive end bearing.
• To monitor the machine's health, VIBit
collected triaxial vibration and temperature readings
every 10 seconds and transmitted them to the iEdge 360 cloud via the plant's Wi-Fi and 4G communications.
•
An AI/ML-based
machine anomaly detection and diagnostics
application on the iEdge 360 platform provided real-time machine
health status and enabled early detection of anomalies.
•
The customer success
team set warning limits in collaboration with subject
matter experts, and the VIBit
application notified users of alerts
via email.
•
Machine operators were alerted to an abnormality through various LED statuses
of the VIBit sensor.
Insights
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On the Bucket Elevator, overall vibration on the Motor DE side, RMS velocity
(3-direction) high alerts were detected.
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RMS –Velocity TREND (3 Axis X, Y & Z) (23rd May to 08th June 2023)
Customer Success & Subject
Matter Experts
The customer success
team and subject
matter experts began observing vibration trends, FFT,
and time waveforms as the severity of
risk remained normal until August 17th. However,
on August 19th, vibrations suddenly increased in trend in the horizontal direction
at a critical state.
Observation:
Motor DE
Vibration signatures generated
the dominant peak found at the 2nd running speed harmonic along with synchronous peaks. This indicated Misalignment & Soft Foot
fault.
Recommendations:
Check the alignment between the motor and
gearbox and also inspect
the motor base foot for any soft foot issue as an immediate action.
AI/ML in Action
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The Automated Diagnosis and Recommendations algorithm found Motor DE side Misalignment & Soft Foot issue and recommended a plan to inspect the alignment between
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the motor and gearbox as
an immediate action.
Early
Detection and Maintenance
The customer maintenance team scheduled
maintenance work orders
and inspected the alignment between
motor DE and gearbox I/P DE
side.
Action:
The alignment was performed on both drives at Motor DE &
Gearbox I/P DE side during routine maintenance to prevent unplanned downtime.
Outcome:
Early detection of potential problems allowed
for timely identification and
maintenance, which reduced downtime and
maintenance costs, improved efficiency, productivity, and workplace safety.
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