In smelting plants, charge pipes are essential for supplying furnaces with the raw materials required for metal or substance production. During the smelting process, various gases are generated, which are not desirable in the furnace or pipes due to the chemical reactions occurring during production. To prevent this, charge pipe fans are installed to ensure adequate airflow, preventing unwanted gases from accumulating on the furnace surface or backing up into the pipes.

But what happens if one of these fans breaks down?

Challenge

If a charge pipe fan fails due to a gas blowout, production is likely to be halted. The resulting downtime can be extremely costly. Additionally, the fan needs to be replaced, factoring in the cost of parts, inventory, lead times, and the maintenance work required.

Fan maintenance is typically planned based on the assumption that the fan will run until failure. However, using failure as the trigger for maintenance makes it difficult to predict when the fan will need attention. Variations in operating conditions and slight differences in fan components (such as the electric motor, bearings, impeller, and housing) can significantly influence the fan’s lifespan in unpredictable ways.

While preventive or calendar-based maintenance could be more effective in some cases, it may result in replacing the fan while it still has useful life left, leading to unnecessary inventory, excess stock, and additional maintenance work. Though the cost of these fan components may not seem significant in the overall picture, it adds up over time, contributing to unnecessary expenses that could be avoided.

Solution

Using Neuron Vibration sensors, you can effectively monitor the condition of the charge pipe fans and predict when maintenance or replacement is required, based on real-time data.

For example, a rise in vibration levels is a clear indicator that inspection is necessary. By monitoring vibration, you can identify potential issues early and determine whether the fan needs to be replaced, allowing maintenance to be planned according to the actual condition of the fan rather than relying on scheduled checks.

This approach helps avoid the risk of fan failure and prevents unnecessary fan replacements that could occur under a fixed maintenance schedule.

By taking a proactive approach, you can reduce unplanned downtime and enhance overall production uptime. These fans play a crucial role in the production process, where energy-intensive reactions and extreme temperatures are common. Therefore, it’s essential to maintain safety and process control, including proper maintenance of charge pipe fans.

Monitoring these fans not only increases safety by providing vital information about key equipment, but it also reduces the need for manual inspections and repairs, making the workers’ tasks easier and more efficient.