Process Fan Refurbishment in Recycling Plant Restores Reliability and Minimises Downtime
A leading recycling and waste management company was experiencing excessive vibration from a critical process fan, resulting in premature bearing wear, increased maintenance requirements and a growing risk of unplanned downtime. The site needed a solution that would restore reliability while keeping production running.
Janet English recognised that a more comprehensive engineering solution was needed. Working alongside a specialist engineering partner, she coordinated a full investigation to identify the root cause while ensuring the plant remained operational.
To minimise disruption, the existing fan motor was removed and replaced with a temporary replacement unit, allowing production to continue while the original equipment underwent a detailed assessment.
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The Challenge
The site reported excessive vibration from a critical process fan, leading to accelerated bearing wear, increased maintenance costs and concerns over long-term equipment reliability and an increased risk of unplanned production downtime.
The Solution
Engineers carried out a full strip-down, inspection and refurbishment programme to identify the root cause of the vibration and restore reliable fan operation. This involved:
- Removing the fan ducting to safely access the fan assembly.
- Removal of the inlet cone and fan impeller.
- Original drive motor was removed from the fan assembly and replaced with a temporary replacement unit to maintain plant operation.
The fan impeller was thoroughly cleaned before being refitted to the replacement motor. Engineers completed all necessary mechanical assembly, alignment and electrical reconnection, ensuring the system was correctly configured. Rotation checks were conducted to verify proper operation, and dynamic balancing was performed to significantly reduce vibration levels. Once complete, the inlet cone and ducting were reinstalled, and final commissioning and operational testing were carried out before returning the fan to service.
At the same time, the original motor was returned to the workshop for a full inspection and overhaul.
The Results
Following installation of the temporary replacement motor, the fan was successfully commissioned and tested. Vibration analysis confirmed the equipment was operating within acceptable limits, delivering stable and reliable performance.
Workshop inspection confirmed excessive wear within the motor drive-end bearing, which had developed over prolonged service and was identified as the primary cause of the vibration experienced by the fan assembly.
The original motor was then fully refurbished, including:
- Replacement of bearings and all associated consumable components.
- Refurbishment of the motor windings.
- Comprehensive workshop testing and vibration analysis.
The refurbished motor successfully passed all performance tests, with vibration levels restored to within acceptable operating limits. Once complete, it was returned to the customer as a fully serviceable spare motor, providing additional resilience and reducing risk of future downtime.
The Outcome
The project successfully eliminated excessive fan vibration, restoring stable and reliable operation of the equipment. By addressing the root cause rather than simply treating the symptoms, the solution reduced bearing wear and ongoing maintenance costs. The use of a temporary replacement motor ensured that production disruption was kept to a minimum throughout the process. In addition, the customer now benefits from a fully refurbished spare motor, improving maintenance planning and enhancing overall plant resilience to breakdowns.
By combining technical expertise with careful project coordination, ACORN delivered a solution that restored equipment reliability while helping the customer maintain production throughout the refurbishment. Get in touch with your local branch for more information about services and solutions ACORN can provide.
