CHALLENGE

Issue: Unscheduled shutdowns due to bearing vibration failure result in production losses and increased maintenance costs.

Goals:

• Reduce dust attachment to fan blades and resulting imbalance and vibration
• Extend bearing life and MTBR
• Control corrosion and abrasion

Root Cause: High humidity atmosphere with chlorides corrodes fan blades and accelerates dust attachment, creating fan imbalance

SOLUTION

Preparation:

• Decontaminate to remove chlorides
• Dynamic balancing of fan
• Grit blast to Sa 2.5 with 3 mil angular profile

Application:

1. Apply ARCOR 8507 @ 120 mil (3 mm) to leading edge of vanes
2. Apply ARCOR S20 @ total DFT of 20 mil
3. Fan is statically balanced

Results:

• Shutdowns reduced to 1 per year at cost of $25,000
• Bearing life extended due to reduced vibration

ESTIMATED SAVINGS:

• Shutdowns reduced to 1 per year at cost of $25,000
• Bearing life extended due to reduced vibration
• Annual savings more than 18x repair cost

ROI = 1760%