Acoustics monitoring prevents downtime
September 1st 2007

By carrying out regular condition monitoring checks on critical rotating plant and machinery, Corus Northern Engineering Services (CNES) has helped a limestone quarry in Cumbria maintain its output, efficiency and profitability. CNES' condition monitoring team has been working closely with Cumbria-based Shapfell Lime Quarry for more than 12 years now, providing monthly patrol monitoring at the site, using a range of condition monitoring equipment and techniques, including handheld acoustic monitoring devices and vibration monitoring systems.

On a recent patrol monitoring visit, an engineer from CNES discovered unusually high readings on the primary crusher at the site, which raised concerns. Through further investigation using acoustic and vibration analysis systems, the CNES engineer discovered that the unusual noise levels and irregular readings were related to a fault on one of the primary crusher's main bearings, which had been running for more than 30 years. Significant wear and damage were found on the inner raceway of the bearing.

By analysing the results, CNES was able to advise Shapfell's maintenance team when it should plan to replace the bearing.

Shapfell's maintenance engineers were mobilised and the bearing replacement took place at a scheduled plant shutdown period, without causing any major disruption to the crushing process.

"The bearing was replaced within one week during a shutdown period, so there were no disruptions to production," says Ian Taylor, business development engineer plant condition monitoring at CNES. "For this particular site we used handheld acoustic monitoring meters."

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