Page 11 - Industrial Technology Extra 7th September 2020

detected by SmartCheck and reported via
the customer’s control system, thus
allowing incipient bearing damage to be
detected at an early stage. Monitored
parameters include vibration, temperature,
speed and cavitation.
The local dealer Supplimax, a certified
Schaeffler partner, recommended the
systems and will be providing future on-site
water, air and environmental resources. The service advice. As a result of Schaeffler’s holistic
company’s area of responsibility includes predictive monitoring solution, the customer is
maintaining the operation of pumping stations. In seeing a number of benefits:
order to avoid flooding in its area of responsibility, l Prevention of unplanned downtime of the
the customer built a pumping station. A catch basin pumping station during ongoing operation.
and three propeller pumps in the pumping station l No costs incurred by production stoppages.
ensure that any excess water is pumped out and l No secondary damage to motors and pumps.
diverted accordingly. l Low acquisition costs of the monitoring systems.
Inadequate pump monitoring led to the l Reduced maintenance costs.
unforeseen failure of a bearing. As a result of this, l Increased plant availability.
the pump wheel began to vibrate, causing 5cm of l Greater security due to self-reporting systems.
wear to the pump housing. In order to prevent Working on the basis of just one occurrence of
pump failures due to bearing damage in the future, bearing damage per year, the following savings
the customer sought a condition monitoring solution would be acheived using the monitoring systems:
for the pumping station. As the pumping station is not manned on a
Schaeffler experts recommended installing six permanent basis, remote monitoring provides a
CONCEPT2 automatic lubrication systems for sound alternative method of observing the system.
lubrication of bearings in the motors and pumps. This holistic solution can also be applied and
This solutions permits ongoing and reliable extended to other units in almost any plant.
lubrication of the bearings. CONCEPT2 supplies two www.schaeffler.co.uk
lubrication points independently of each
other and withstands pressures up to 50
ESTIMATED SAVINGS FOR THE CUSTOMER
bar.
Schaeffler also recommended
installing nine SmartCheck condition Annual maintenance expenditure (8 h).................................... €1,000
monitoring devices to monitor the three One-off expenditure for SmartChecks and CONCEPT2.......... €14,000
pump/motor units. Two SmartChecks are Pump damage without monitoring systems........................... €50,000
installed per unit to monitor the upper
and lower motor bearings, plus an With monitoring system
additional SmartCheck on each of the Cost saving following initial occurrence of damage............... €35,000
pump bearings. Any deviations or Cost saving with each subsequent occurrence of damage..... €49,000
changes in vibration behaviour are

September 2020 • INDUSTRIAL TECHNOLOGY EXTRA • p11