Equipment Type
Fan
Equipment Name
Main Draft Fan
Faults
Rotor misalignment, Rotor Unbalance
Early Detection of Main Draft Fan Rotor Misalignment
How Wisper Ensured Continuous Operation at a Steel Factory
Metallurgical
Introduction
This case study demonstrates how an AI-powered condition monitoring solution detected an early-stage rotor misalignment fault in a critical main draft fan system at a steel factory, allowing maintenance teams to take timely action and avoid unplanned downtime. The main draft fan is a key component for the factory's continuous production.
Equipment Overview
The main draft fan is essential supporting equipment for the sintering system. Its primary function is to draw air through the flue, creating a negative pressure that ensures the solid materials in the sinter mixture fully combust to supply energy for the sintering process. Additionally, it exhausts the various gases produced during sintering through the flue, where they are purified by the electrostatic precipitator before being discharged through the chimney.
The Challenge
Preventing unplanned downtime for critical equipment in a steel production environment is difficult due to:
High-Consequence Failure: Unexpected failure of the main draft fan can immediately halt the sintering process, leading to significant production loss.
Complex Root Causes: Misalignment and subsequent unbalance can be caused by various factors, making accurate root cause identification challenging without advanced monitoring.
Continuous Operation Necessity: As a central component in the sintering system, the fan must maintain continuous, stable operation to ensure the factory's operational continuity.
Wisper Solution
Wisper CMS continuously monitored the health status of the main draft fan.
On January 12, 2024, Wisper detected abnormal characteristics at the fan's input end. The anomaly was identified and diagnosed as rotor misalignment, with possible causes being poor coupling alignment or worn bearings. A diagnostic report was immediately generated and triggered, alerting the site to monitor the equipment status and score changes.
Following the intervention, the equipment returned to a healthy range—validating the accuracy of the diagnosis issued by Wisper CMS.
The outcome
In this case, the dynamic balancing effectively resolved the issue and restored proper operating condition.
Minimized Downtime: Maintenance was planned and executed before a catastrophic failure could occur, enabling data-driven decisions that significantly reduced risk and improved operational efficiency.
Accurate Fault Diagnosis: The diagnosis of a rotor issue was fully consistent with on-site inspection results, which found an unbalanced problem, confirming the system's high level of accuracy and dependability.
