How Spartakus APM, Oil & Vibration Analysis Saved $200K

Operating in the challenging climate of Northern Quebec, mining facilities rely heavily on the uninterrupted performance of critical equipment. Gear reducers, devices that decrease motor speed while increasing torque, are integral to many mining operations. By changing the motor’s speed and torque, the reducer helps pumps work at the right levels. This is important for heavy tasks, like moving large amounts of slurry or debris in mining.

In this case study, we explore how the implementation of a condition-based maintenance program combined with Spartakus APM helped identify and resolve a gear reducer issue before it escalated into a catastrophic failure. The combination of oil and vibration analysis program, combined with Spartakus APM, not only mitigated risks but also saved significant costs for the operation.

Early Sign of Potential Failur

Electrical motor and pump used in a mining facility.

The first anomalie emerged in August 2022, when the vibration analysis tool flagged a minor increase in gear mesh frequency. The vibration analysis equipment detected the analyzed vibration in the gearbox of the coarse screen pump #1. At the time, the increase was minimal and deemed non-critical, requiring no immediate action. However, the situation changed in May 2024 when vibration analysis detected an unexpected and significant increase in gear mesh frequency, along with dense modulation at 1x the slow shaft speed.

In this context, dense modulation at 1x the slow shaft speed refers to a vibration pattern in the vibration signal where the amplitude of the gear mesh frequency fluctuates significantly at a frequency range equal to the rotational speed of the slow shaft.

This modulation typically indicates that the vibration energy from the gear mesh is being influenced by a problem related to the slow shaft, such as misalignment, imbalance, looseness, or wear. The “dense” aspect suggests that these fluctuations are frequent and pronounced, making the signal more complex and potentially pointing to a more severe or developing issue in the system.

This alarming development signaled a serious issue within the gear reducer, raising concerns about its potential impact on operations. If left unaddressed, the problem could have led to a total failure of the equipment, causing unplanned downtime, increased repair costs, and disruption to production schedules.

Problem Evolution

As the months progressed, the issue became more pronounced:

June 2024: Used oil analysis revealed signs of ferrous and metallic wear particles, indicating ongoing internal degradation of the gear reducer. Notably, this occurred despite a recent oil change conducted in May 2024. The rapid increase in iron concentration within the oil suggested that wear was accelerating.

Dashboard from a report showing Oil analysis with data on aluminum, copper, iron, etc.

December 2024: A final diagnosis confirmed the presence of a gear fault involving two broken teeth on the output shaft gear. This structural failure was identified as the root cause of the ongoing issues. To prevent a complete breakdown, the maintenance team made the decision to replace the gear reducer.

Approach and Actions Taken

The successful resolution of this issue was made possible through a condition monitoring vibration analysis, oil & grease analysis and a proactive approach:

Condition-Based Monitoring with Spartakus APM

Elementary vibration analysis and an oil analysis program were combined and cross-referenced within Spartakus APM to monitor the anomalies over time, enabling more comprehensive insights and accurate troubleshooting. Spartakus APM provided actionable insights, enabling the team to identify the underlying cause of the issue and monitor the health of the gear reducer. For instance, the oil analysis laboratory captured critical data points before and after the oil change, highlighting the ongoing wear despite initial mitigation efforts.

Vibration analysis from Spartakus APM report.

Targeted Interventions:

In May 2024, a proactive oil change was performed to address contamination and reduce wear, improving the operating conditions of the gear reducer.

By the end of December 2024, after continued monitoring and diagnosis, the team executed a proactive replacement of the gear reducer. This action ensured the issue was resolved before a catastrophic failure occurred.

Results and Benefits

Spartakus APM identified potential critical failures through oil and vibration analysis, delivering significant benefits:

Cost Avoidance:

The total cost of a complete failure was estimated at $400,000, including repair expenses and operational downtime. By intervening early and replacing the gear reducer before failure, the company saved approximately $200,000.

Improved Equipment Reliability:

The replacement of the gear reducer, combined with fresh oil, resulted in a significant stabilization of vibration levels. Furthermore, the elimination of ferrous contamination marked a clear improvement in the health of the equipment.

Conclusion

This case study shows the importance of a condition-based monitoring approach, enabled through Spartakus APM, in ensuring equipment reliability and optimizing maintenance costs. By leveraging tools such as Spartakus APM, oil analysis kit and vibration analysis software, the team was able to detect and address the issue early, avoiding a potentially catastrophic failure.

The success of this intervention underscores the value of proactive maintenance strategies in mining operations, particularly in harsh environments where vibration testing is necessary. Moving forward, regular post-replacement monitoring is recommended to ensure the long-term performance of the new gear reducer and maintain optimal operational efficiency in all electric motors and rotating equipment