One of Indonesia’s leading consumer packaging paper manufacturers operated large-scale machinery at its facility, including high-speed paper machines, pulpers, and massive air handling units consisting of fans and blowers. The facility relied on periodic checkups and manual readings, which meant that during unplanned downtime due to a fault in a primary motor or a fan assembly, the plant incurred significant losses in productivity and maintenance costs.

Objective

PROBLEM

The plant relied on high capacity motors coupled with gearboxes and fans. The paper plant faced several issues like:

  • Unpredictable Failures: The reactive approach to maintenance meant that bearing failures were often only identified after the failure occurred and the damage was caused.
  • Operational Safety Risks: Manual vibration monitoring in high-temperature or restricted areas posed significant safety risks to operators.
  • Production Vulnerability: Critical fan and blower assemblies are essential for the drying process; their failure halted the entire production line.
Solution

SOLUTION

To transition from a reactive to toward condition-based maintenance (CBM) approach, the paper plant installed a continuous vibration monitoring system that consisted of:

  • Precision Sensing: Piezoelectric accelerometers were permanently installed on bearing housings to capture high-accuracy mechanical data.
  • Forbes Marshall VibTrans Dual Channel Transmitter: This dual-channel transmitter converts sensor signals into 4-20mA real-time data for immediate visibility.
    • Integrates seamlessly with existing plant PLC/DCS for automated alerting.
    • Digital displays provide local operators with an instant “pulse” on machine health (mm/s).
  • Protection: Stainless steel armored cables and weather-protected panels ensure signal integrity in harsh mill environments.
Benefit

BENEFITS

The installation of Forbes Marshall’s continuous vibration monitoring system delivered measurable impacts on plant operations:

  • Proactive Asset Management: Early detection of bearing wear allows for repairs during scheduled maintenance, eliminating mid-shift breakdowns.
  • Enhanced Safety Standards: Automated readings remove the need for personnel to interact with dangerous, rotating machinery.
  • Reduced Maintenance Costs: Preventing secondary damage to shafts and gearboxes significantly lowers the total cost of ownership for critical assets.