Reliability Success Stories
Quick and Effective Action on a Fan Problem in the Food Industry
| Challenge | Sporadic abnormal noise at a critical fan without direct measurable deviations. |
| Solution | Rapid implementation of continuous monitoring with MSF–2 sensors and targeted inspection of mechanical components. |
| Industry | Food production |
| Result | Minimal production loss and the prevention of unplanned downtime. |
The Challenge
The first remote analysis of the available measurement data found no abnormalities that could explain the abnormal noise. On advice, we immediately carried out a new measurement, which also showed no abnormalities. The operator also reported that the sound was not audible during the measurement. We advised the client to carry out inspections with increased frequency and, if possible, to take a measurement as soon as the noise was detected again.
The next morning, the abnormal sounds were heard again. Unfortunately, the noise disappeared again before vibration measurements could be made. Given the criticality of the fan and the difficulty of repairs, the customer decided to have an AVT Reliability service engineer come to the site.
Introduction
In the food industry, mission–critical machines are essential for uninterrupted production. One evening one of our customers in this sector heard an abnormal noise from a crucial fan. This ventilator was already included in a condition monitoring program through Machine Sentry®, with regular measurements every three weeks. Due to the unexpected noises, AVT Reliability was called in for emergency support. This case study describes how our approach led to a rapid diagnosis and minimisation of production loss.
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Our Approach
Once on-site, our engineer equipped the setup with multiple MSF–2 (Machine Sentry Fixed) sensors, programmed for a batch collection mode. This setup collected over 4,000 data points, including vibrations and temperatures, within an hour. This allowed us to quickly gain insight into any temporary changes in the condition of the fan. The challenge was that the sound was only sporadically perceptible and always disappeared quickly. However, thanks to the continuous data collection, we were able to establish a correlation between the perceived noise and changes in vibration data. An onsite analysis revealed that the problem may have been related to the V–belts and pulleys of the fan.
The Solution
A targeted inspection of the V–belts and pulleys showed that the strings, despite being only three months old, slipped in the pulleys under specific load. As an ad–hoc solution, the V–belts were replaced immediately, with a scheduled maintenance moment before the replacement of the pulleys. A control measurement after the repair showed that the vibration levels were back within acceptable limits and the abnormal noise was no longer perceptible.
Follow Up
Thanks to our fast and targeted approach, the customer was able to avoid an unplanned downtime, which could have caused potentially major consequential damage. The inspection and replacement of the V–belts took less than two hours, causing only minimal disruption to the production process
Why AVT Reliability?
This case demonstrates how the combination of advanced condition monitoring tools such as Machine Sentry and our technical expertise helps customers respond quickly and effectively to complex challenges. Our goal is always to minimize downtime and costs, while maximising the reliability of critical equipment. Are you curious about how we can support your organisation? Then contact us!
