This case study explores the application of a wireless condition-based monitoring system in detecting and resolving an issue with exhaust fan installation in a large industrial paint oven. The main objective of the case study is to demonstrate the effectiveness of the wireless monitoring system in identifying equipment issues, preventing potential failures, and improving overall operational efficiency. The key findings emphasize the importance of monitoring critical equipment, even when it is newly installed, to ensure optimal performance and mitigate risks.
Background and Context:
A customer recently had a new multi-stage paint oven installed in their facility. They wanted to have the supply and exhaust fans monitored to protect their investment from start up to prevent any unexpected downtime and increase production time.
The wireless Vibration monitoring system featured multiple dual-axis sensors that measured velocity, acceleration, and temperature. These sensors transmitted data to a controller every 10 minutes, which was then sent to a secure website for further analysis and trend monitoring.
A custom system was designed to monitor the bearing locations of the exhaust and supply fans and motors. Sensors were placed at each bearing location, secured magnetically, and configured to transmit data to the controller. The monitoring team ensured the controller received data from all sensor points at each bearing location.
Results and Outcomes:
After analyzing the trending data and identifying excessively high temperatures, it was determined that the oven manufacturer had installed the exhaust fans in the wrong direction. Instead of expelling hot air from the oven, the fans pushed it back in, significantly shortening equipment life. Armed with this information, the customer was able to have the oven manufacturer rectify the issue at their expense. As a result, the customer experienced reduced equipment failures and energy consumption.
Lessons Learned and Best Practices:
This case study demonstrates the importance of monitoring critical equipment, even when it is newly installed and professionally set up. Organizations facing similar challenges should prioritize thorough equipment inspections and partner with experienced monitoring solution providers to ensure optimal performance. Moreover, the case study highlights the value of continuous monitoring and proactive maintenance in preventing issues from escalating and ensuring equipment longevity.
The wireless condition-based monitoring system was crucial in detecting the incorrect installation of exhaust fans in the industrial paint oven. By identifying the issue and enabling its prompt resolution, the system helped the customer avoid further equipment failures, reduce energy consumption, and maintain product quality and safety. The case study highlights the potential of wireless monitoring technology to optimize performance and prevent equipment failures across various industries.