Optime is a wireless condition monitoring and automatic lubrication solution.
The site benefits from the early detection of failures, as the Optime app provides information on the condition of the pump and monitors the lubrication of the motor.
WEIG, an accredited, owner-operated group of companies in the international paper and cardboard industry, employs 1,800 people at locations in Europe and South America. Its portfolio comprises a closed value-added cycle, from wastepaper recycling to the production and marketing of paper as well as cardboard and cardboard products such as folding boxes and plasterboard.
The WEIG Group were looking for a predictive condition monitoring solution for the maintenance of a centrifugal pump at its cardboard plant in Mayen. An unplanned shutdown of this pump would bring the entire production line to a standstill. To prevent this, WEIG chose the Optime CM predictive condition monitoring solution from Schaeffler’s Optime Ecosystem.
Optime CM is a wireless condition monitoring solution that is said to give the maintenance team greater transparency due to the digital service provided by the Optime app. The Optime C1 lubricator from the Ecosystem was also used. After a few months in use, the solution prevented an unplanned shutdown of the centrifugal pump.
The machines in WEIG‘s cardboard division operate around the clock, seven days a week. Gypsum plasterboard and folding boxboard are produced mainly from waste paper. The machines in the line are exposed to high speeds, extreme humidity and high operating temperatures, including the centrifugal pump. In continuous operation, this pump mixes pulp with water to form a paper fibre pulp which it then conveys onwards. The pump rotates continuously so that a certain quantity can be constantly supplied. If it fails, the entire production process is stopped.
Oliver Schmitt, maintenance expert at WEIG explained why the maintenance team were looking for a predictive monitoring solution: “The pump is often at risk from cavitation. Due to the high flow velocity in the suction line, the pressure can fall below the vapour pressure and vapour bubbles form. When the liquid flow reaches the impeller of the pump, the negative pressure changes to positive pressure. In the worst case, the vapour bubbles can implode.”
As this streaming pump had not yet been monitored, the maintenance department was looking for a predictive condition monitoring solution.
Schaeffler’s Optime Ecosystem is a solution that combines its Optime CMS (with the sensor variants Optime 3, Optime 5, and Optime 5 Ex) for wireless condition monitoring, and its intelligent, interconnected lubricator Optime C1 for automatic lubrication.
With Optime C1, all users need to do to get the latest status of their lubrication points is to check the app from wherever they are located. The app tells them which lubrication points are insufficiently supplied with grease and which cartridges need to be refilled or replaced.
After around three months of using the Optime sensors, the maintenance team received warning messages. An increased level of background noise was recorded on the motor, bearing damage and cavitation was detected on the pump. The maintenance team confirmed the unusual behaviour of both units.
Insufficient lubrication turned out to be the cause of the motor noise. After installing an Optime C1 lubricator, the controlled lubrication reduced the characteristic values of the motor bearing to normal values.
The increased characteristic values on the pump indicated bearing damage. An analysis of the measurement data showed damage to the inner ring of the A-side bearing. This damage could be confirmed on the dismantled bearing.
Since these corrective maintenance measures were performed, there have been no further rolling bearing defect frequencies and the characteristic values have remained below the alarm thresholds.
If the centrifugal pump fails unexpectedly, the entire production process comes to a standstill for six to eight hours. Production workers are then unable to carry out their work. Assuming that production stands still for six hours and the damage is serious, high costs can be incurred.
Oliver Schmitt, master professional, vibration analyst, WEIG Karton stated: “Within a very short period of time, Optime CM has become a reliable partner of our maintenance department. One look at the Optime app is enough to know how our machines are doing. I am delighted with the simple installation, easy handling and all-round service from Schaeffler. Our future plans: to install more sensors and lubrication systems from the Optime Ecosystem.”
The Optime Ecosystem consists of many elements that work together to reduce downtime. It starts with the Optime user interface, which provides an overview of all machines and lubrication points. The mobile app allows users to access information independent of location.
This is made possible by the Optime Cloud & Analytics. With unlimited processing power and capacity, huge amounts of data can be processed that users can edit. This data comes from the Optime vibration sensors and intelligent lubricators via the Optime gateway: a standalone device that is claimed to make secure cloud connectivity and IT integration easy.
The automatic and self-healing Optime mesh network connects all Optime devices with each other. The mesh network enables large-scale installations. This means that machines can be monitored from any location with Optime CM condition monitoring and machine lubrication can be simplified with OPTIME C1.