Nanoprecise Detects Boiler Fan Motor Needing Repair for Pharmaceutical Giant
Executive Summary
Nanoprecise partnered with a global pharmaceutical manufacturer at one of its European facilities to monitor and maintain the health of critical equipment in contrast media production (an injectable diagnostic agent). Given the facility’s central role in the global supply chain, the company cannot afford production interruptions.
To strengthen asset reliability, the facility deployed Nanaoprecise’s solution, across key rotating assets — including chiller pumps, boiler fans, agitators, ID fans, and effluent pumps.
Using vibration analysis, the system detected an imbalance fault on a boiler fan motor. Early detection prevented a potential site capacity reduction of 25%, which could have delayed up to 250,000 doses per week.
The result: Minimized downtime, extended equipment life, optimized maintenance scheduling, and reliable delivery of life-saving products.
Pharmaceutical Customer Profile
A leading global pharmaceutical manufacturer producing contrast media for diagnostic imaging. The facility operates under strict reliability and quality standards, where continuous uptime is essential to meet global demand.
The site’s boiler fan motors play a vital role in maintaining the steam supply that supports downstream production. Even minor equipment faults can ripple through operations, reducing throughput and impacting patient care worldwide.
The Challenge
The facility’s Boiler Fan provides the forced draft airflow required for efficient combustion in the boiler room. Its motor, mounted in a horizontally hung configuration and suspended from the housing, offers a compact design but is more susceptible to vibration and structural resonance.
Although a backup boiler exists, it can only sustain 75% of the full site’s capacity, making the primary fan’s performance mission-critical for uninterrupted production. The boiler fan’s motors operate under variable loads and speeds, and without continuous condition monitoring, subtle faults (such as imbalance or misalignment) can go unnoticed until they escalate into critical failures.
A potential failure could:
- Delay up to 250,000 doses per week
- Reduce site capacity by 25%
- Require emergency repairs with higher contractor costs and safety risks
The facility needed a proactive solution to monitor motor health and prevent production interruptions.
Solution Deployed
Nanoprecise implemented it’s Energy-Centric Predictive Maintenance solution, providing real-time insights into equipment condition. Key features included:
- Wireless sensors with 6-in-1 machine condition monitoring (including temperature and humidity monitoring)
- Real-time vibration and FFT analytics for imbalance detection
- Automated fault alerts for timely maintenance action
- Cloud-based dashboard for visibility.
- Post-maintenance diagnostics for structural and alignment issues
Within six months, the system detected an abnomal vibration on the boiler fan motor’s X-axis, triggering early intervention. What began as a suspected imbalance fault evolved into a multi-phase diagnostic process that revealed the true root cause: structural resonance.
Assets Monitored
- Chiller Pumps
- Boiler Fans
- Agitators
- ID Fans
- Effluent Pumps
4-Phase Diagnostic & Remediation Process
Nanoprecise’s solution enabled a structured investigation that resolved the boiler fan issue efficiently:
Phase 1: Detection of Abnormal Vibration
- Routine monitoring identified a progressive rise in X-axis vibration amplitudes.
- Spectral analysis revealed a pronounced 1× RPM peak not present in baseline data.
- Early warning suggested a potential rotor imbalance, shaft misalignment, or looseness.
clearly visible on the X-axis (highlighted in green), indicating an imbalance condition
Phase 2: Motor Replacement
- The team replaced the original motor with a heavier 11 kW VFD-driven unit.
- Persistent vibrations indicated the motor itself was not the source of the fault, ruling out common mechanical issues such as bearing wear or rotor eccentricity.
Phase 3: Resonance Diagnosis
- A provisional support stand was installed to test structural stiffness.
- Dispersion plots revealed resonance bands at 2100 RPM and 2400 RPM across multiple axes.
- These findings confirmed the fault was due to structural resonance, not motor imbalance.
Phase 4: Stabilization & Optimization
- The support structure was properly anchored and tightened, increasing rigidity.
- Post-adjustment readings showed stable, predictable vibration patterns.
- Broad resonance effects were eliminated, leaving only a narrow, manageable peak, ensuring long-term reliable operation.
Key Takeaways:
- What appeared as a motor imbalance was actually a mounting and structural resonance issue.
- A system-level, data-driven approach was critical for identifying and correcting the true root cause.
- Early detection with Nanoprecise allowed for planned maintenance, avoided emergency repairs, and extended equipment life.
Outcomes & Impact
Avoided Production Losses: Early detection converted a potential emergency into a planned intervention, preventing a 25% site capacity reduction and ensuring uninterrupted delivery of up to 250,000 doses per week.
Increase in Remaining Useful Life: Timely maintenance reduced stress on the motor, extending its useful life and preventing secondary damage.
Optimized Maintenance & Labor: Planned intervention avoided the high costs and safety risks associated with emergency repairs, enabling more efficient scheduling of labor and resources.
Increased Visibility: Real-time condition monitoring provided the maintenance team with actionable insights and a longer planning horizon for operational decisions.
Reduced Need for Contractor & Contractor Expenses: By reducing unplanned downtime, the company didn’t need to call in a costly contractor for emergency repairs and kept it inhouse.
Increased Safety: With a longer planning horizon, the company reduced the safety risks associated with rushed emergency repairs.
Conclusion
Nanoprecise’s Energy-Centric Predictive Maintenance solution gave this pharmaceutical leader the visibility and reliability needed to protect critical production. By enabling early detection of imbalance and structural issues, Nanoprecise helped the facility avoid costly downtime, optimize equipment performance, and ensure uninterrupted delivery of life-saving contrast media.
Even minor mechanical faults in high-stakes pharmaceutical production can have cascading effects. With Nanoprecise, maintenance teams can predict failures, take targeted corrective actions, and safeguard critical operations with confidence.