Client: Bio-pharmaceutical manufacturing plant
Industry: Medical drug manufacturing
Issue: Structural failure in an industrial freezer compressor unit
Background
A bio-pharmaceutical manufacturing facility encountered a critical failure in one of its freezer compressor units due to a crack in the piping system. This failure introduced significant operational risks, including temperature fluctuations, potential drug contamination, and equipment malfunctions, jeopardizing the safe storage and preservation of pharmaceuticals after production. Although the damaged piping was replaced, the facility management remained concerned about a possible recurrence of the issue. They sought a long-term preventive solution to mitigate future risks, leading them to engage Vibtech Genesis for a thorough investigation and resolution.
Root Cause Analysis
Vibtech engineers conducted a comprehensive assessment of the compressor unit, focusing on identifying vibration sources and their extent throughout the system. Despite the replacement of the piping, significant vibration levels persisted, indicating deeper structural issues. Using Dynamic Visual Analysis (DVA), an advanced industrial camera technology that amplifies and visualizes subtle machinery vibrations, our team conducted a detailed evaluation. Video recordings were captured at 16 strategic points around the compressor unit, allowing our engineers to precisely identify the source of the vibrations. Our analysis suggested that the root cause of the excessive vibrations was instability in the foundation beneath the compressor unit.
(Watch one of the crucial video recording captured by the DVA below that suggested foundation instability)
Solution and Recommendation
To validate the findings, our engineers conducted a test using a car screw jack to temporarily stabilize the foundation. This intervention resulted in a significant reduction in vibration levels, confirming the hypothesis that foundation instability was the root cause of the issue. Subsequent DVA recordings further confirmed the improved stability and reduced vibration after the temporary stabilization. (Watch video recording below)
While the screw jack provided short-term relief, our engineers recommended our client to commence immediate repairs to the foundation plate to ensure the long-term stability of the compressor unit. This permanent solution would effectively address the root cause, securing the unit’s structural integrity and preventing future operational risks that could impact the pharmaceutical manufacturing process.
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