Predictive Maintenance for High-Temperature Fan Motors
Plant Name: Advanced material science manufacturer
Industry: Heat treatment
Product(s): Advanced and specialty materials
Heat treatment processes use ovens or industrial furnaces to alter the molecular structure and physical properties of materials, such as those in advanced composites and metals. To ensure that the most complicated materials meet strict specifications, “heat-treat” processes are performed according to highly specialized recipes—and the process cannot be interrupted.
In the U.S., an advanced material science company uses several industrial furnaces to heat treat products such as large aircraft parts and brakes, which are composed of advanced composites and metals. Motors on top of the furnaces operate fans inside them to circulate the heated air in the chamber and ensure a uniform temperature according to the product recipe.
Maintaining the reliable performance of a furnace fan allows operators to avoid wasting large batches, which sometimes require days of heat-treat processing.
Challenges arise from the vulnerability of the fans to unpredictable failures. Typical root causes are increasing vibration in motor bearings and running the fans at the fringes of their specified operating ranges. Heat-treat operators can track temperature and vibration either by handheld monitoring devices or via sensors. Both methods provide early anomaly detection that enables operators to address equipment issues before they interrupt the process or otherwise impact the batch quality.
Their locations on top of the furnaces can also make monitoring fan operations difficult. At the U.S. advanced materials company, the fans sit atop four-story-high furnaces, which prevent monitoring with traditional, portable handheld devices.
Other challenges for heat-treat operators include the ability to efficiently maintain records of temperature and vibration data, determine trends in the data, and accurately predict problems before they arise.
Recently, the U.S. advanced materials company recognized the need for a method to monitor the furnace circulation fans throughout the facility. The procurement team selected Yokogawa’s Sushi XS770A Wireless Vibration Sensor, an industrial IoT solution. After a quick plug-and-play sensor installation, the Sushi Sensor will enable the customer to remotely determine if temperature or vibration pose a risk to any of the fans—located four stories up—and address issues before a failure occurs or effective temperature control is compromised.
The FM-approved Sushi Sensors measure vibration (velocity and acceleration) along the X, Y, and Z axes, generate a three-axis composite, and monitor the fan surface temperatures. Yokogawa factory-provisioned all the sensors before shipping them to the customer and integrated them into the GA10 data logging application software. This complete solution enables the process to completely realize the benefits of IoT technology.
Easily programmable Sushi Sensors will transmit data to the GA10 software, which uses artificial intelligence (AI) to learn the characteristics of normal and expected operating conditions. The GA10 software can trigger alarms and send warnings when operations trend outside of a normal range. The information is automatically entered into an on-premise database that allows vibration trends to be viewed over time. Other companies using this solution have opted to store the data, instead, in the Cloud.
In addition to displaying trends, the GA10 software delivers a health score that is based on the vibration and temperature measurements made by the Sushi Sensors. The customer team will be able to act on that health score to investigate anomalies and determine the best actions to avoid risks to the heat-treat process.
Yokogawa can provide a full-scale implementation of heat-treat processes including solution design, factory provisioning of instruments, commissioning, and end-to-end support for the complete lifecycle of a furnace.
- Plug-and-play installation, factory provisioning of certificates, and simple commissioning provide significant reductions in costs, implementation time, and risks.
- Flexible solution with easy-to-add sensors simplifies changes and system expansions.
- Continuous remote monitoring of instruments and predictive analysis reduce risks of failure and improve scheduled maintenance.
In the iron and steel industry, it is crucial to improve the quality of not only products but also manufacturing and operation technologies, as well as to address environmental and energy-efficiency issues. Yokogawa helps customers to create the ideal plant and evolves with them for mutual growth.
Mining operations produces valuable minerals or geological materials from the Earth. Economical recovery often requires high throughput and high availability of the process with low operation costs, and stringent safety and environmental regulations.
This product acts as a battery-powered wireless vibration sensor and it is suitable for Industrial IoT (IIoT) applications. Wireless Vibration Sensor measures vibration along the X, Y, and Z axes in addition to monitoring the surface temperature.
Sushi Sensor is a wireless solution for Industrial IoT (IIoT). It has excellent environmental resistance, and adapt LoRaWAN, a wide area wireless communication method that realizes power saving and long-distance communication.