How Predictive Maintenance In Spartakus APM Saved Over $171k

In today’s industrial environment, predictive maintenance plays a crucial role for businesses aiming to reduce maintenance costs. This case study highlights how a pulp and paper facility leveraged cross-referenced oil and vibration analysis within Spartakus APM to save $171,840 by preventing unnecessary repairs and avoiding unplanned shutdown.

Let’s explore the details.

The Warning Signs: Increased Vibration Levels on the Refiner

During a routine bi-weekly inspection, a Laurentide Controls technician noticed a sudden and significant increase in vibration levels on one of the plant’s refiners.

These vibrations corresponded to twice the rotation frequency of the rolling elements and matched a ball spin frequency (BSF) pattern, signaling a potential ball defect in the bearing.

Given the risk of unplanned downtime, the team made the proactive decision to schedule a bearing cartridge replacement. To confirm the root cause of the vibrations, the reliability team dispatched the lubrication team to collect an oil sample from the refiner’s hydraulic system. The results revealed water contamination in the lubricating oil, a critical finding that prompted immediate changes in the corrective action.

The Solution: Predictive Maintenance Technologies Cross-Referenced in Spartakus APM

With insights from Spartakus APM (Asset Performance Management), Laurentide quickly generated a detailed report outlining the issue. While increased vibration was initially flagged as a symptom, the cross-referencing capabilities of Spartakus APM revealed that vibration itself was not the root cause. Instead, the analysis identified water contamination in the lubricating oil as the underlying issue driving the abnormal vibrations.

Replacing the bearing cartridge might have temporarily masked the vibration symptoms, but it would not have addressed the contamination in the lubrication system, leaving the equipment at risk for future damage. By leveraging Spartakus APM, the team prioritized a targeted approach: performing a system flush and an oil change to eliminate the water contamination entirely.

These corrective measures restored the lubrication system to optimal condition. Once the water contamination was resolved, vibration levels decreased significantly and returned to normal operating ranges, confirming the success of the intervention.

By focusing on the true root cause rather than opting for a temporary fix, the team not only resolved the immediate issue but also reinforced the equipment’s durability and operational reliability for the future.

Results: $171,000 Saved Through Early Intervention

By leveraging predictive maintenance and acting on the data, the plant avoided:

  • Labor Costs: The issue would have required mobilizing multiple workers for at least two full days. At an estimated cost of $50 per hour, the total labor cost would have been around $3,840.
  • Part Replacement: The bearing cartridge, valued at $168,000, would have required urgent ordering and replacement.
  • Extended Downtime: Without timely action, water contamination would have accelerated bearing degradation, potentially leading to an unplanned shutdown of the refiner. Avoiding this scenario not only prevented disruption but also allowed the plant to avoid additional losses tied to production downtime.

Overall, these preventive measures saved the company an estimated $171,000, including labor, materials, and lost production costs.

Spartakus APM as the Enabler for better Predictive Maintenance

The success of this intervention highlights the power of predictive maintenance tools in addition with Spartakus APM. By training its teams in the use of oil analysis with vibration analysis in Spartakus APM, Laurentide equipped its staff with a comprehensive view of asset health and analysis reports. This proactive approach allowed the team to:

  • Monitor asset health and performance.
  • Detect potential issues before they escalated.
  • Cross-reference different technologies.

The ability to act quickly and decisively not only reduced costs but also boosted the plant’s confidence in its maintenance strategy. 

Conclusion: Predictive Maintenance as a Strategic Advantage

Informed decision-making and proactive monitoring are essential for modern industries aiming to stay competitive. The $171,000 saved in this case study showcases how PdM, powered by advanced tools like Spartakus APM, can transform maintenance and reliability operations. By identifying issues early and addressing them efficiently, companies can not only avoid unnecessary expenses but also ensure long-term reliability and success.