Case Study: Learn how DALOG’s machine protection assistant increased lifetime and avoided downtime for one of our clients, a plant in North America

In today's highly competitive industrial landscape, equipment reliability is essential for maintaining profitability and minimizing operational disruptions. Machine monitoring systems have become indispensable, especially in sectors like manufacturing and materials processing, where even a brief downtime can result in significant costs.

DALOG’s real-time equipment monitoring has proven effective in extending machine lifetime and reducing unexpected downtimes for numerous clients. This case study illustrates how DALOG supported a North American client in identifying and resolving equipment issues in a complex plant environment.

First of all, we needed to assess the situation, in order to come up with a solution. In order to do that, we monitored 21 critical machines in various operational areas of the client’s facility, including pyro processing, raw grinding, and finish grinding. The setup included 68 wireless acceleration sensors and five DAMASTA projects involving hardwired sensors. DALOG’s goal was to optimize machine conditions, increase the overall efficiency of the equipment, and avoid costly downtimes.

Example of In-Scope Machine - Finish Mill 2 – First Gear Stage and Oil Condition

Challenge

At the onset of monitoring, DALOG’s system identified developing issues related to the gearbox’s first gear stage. The spectrum analysis revealed the presence of bearing and gear-related frequencies that indicated suboptimal lubrication. Additionally, the envelope trends of multiple acceleration sensors, beginning in October/November 2023, showed progressively increasing values. This issue, if left unresolved, could have led to significant wear and unplanned downtime.

Solution

The plant performed a gearbox inspection, which revealed ongoing wear at the bearings and
gears of the first gear stage. An oil analysis pointed to a contaminated lubricant. DALOG advised the installation of an external filtration system to address oil contamination in the lubrication unit. Vibration sensors were used to monitor the gearbox's performance and ensure stabilization post-filtration.

Outcome

Regular monitoring and filtration resulted in stabilization of wear trends and prevented further deterioration. The gearbox now operates under improved conditions, with regular borescope inspections and oil sampling as part of the maintenance routine.

Technical data

• Machines monitored: Finish Mill 2
• Number of sensors: Multiple acceleration sensors for vibration and envelope trends
• Area covered: Gearbox + Motor + Lubrication

Result

Avoided consequence of fast deterioration of gearbox condition and equipment downtime due to
early gearbox failure.

1 Early stages of failure detected by DALOG system due to metal-to-metal contacts caused by insufficient lubrication.

2 Picture of finish mill during installation of the system; all HSE measures strictly observed.

By leveraging advanced monitoring systems and proactive maintenance strategies, the client’s plant successfully extended the lifetime of critical components, reduced downtime, and maintained operational efficiency. As industrial environments continue to demand higher productivity and lower maintenance costs, systems like DALOG's are paving the way for more resilient and sustainable plant operations.

Are you interested in implementing an effective predictive maintenance strategy for your own company?

Contact us and we will discuss more on your needs and the potential solutions.