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Multiple assets runtime extended by vibration-based timely bearing lubrication

By:

SKYLER

The Challenge

Detecting bearing fault frequencies and identifying trend increases is relatively straightforward with Skyler. However, for predictive maintenance programs to be truly effective, these detections must translate into actionable insights.
For example, a rise in acceleration Pk-Pk values can trigger targeted (bearing re-greasing. This intervention can extend the remaining useful life of the bearings by several months, preventing failures that would have occurred otherwise.

The Case

Three examples are presented below, each demonstrating
how bearing remaining useful life was extended through either fresh grease application or bearing oil replacement:

  • 1
    Oil-lubricated Bedeschi crusher

    150 HP motor
  • 2
    Grease-lubricated dust collector fan

    Pillow-block bearing
  • 3
    Grease-lubricated 200HP motor

    Driving a screw pump

What We Detected

Vibration Evidence

Vibration trends (RMS & Pk-Pk) revealed lubrication issues across all cases.

Pattern

High-frequency “haystacks” in the spectrum indicated impact exciting bearing natural frequencies and BPFO fault harmonics.

Potential Consequences

Without intervention, damage accelerates, and re-lubrication may no longer prevent sudden failure.

Patterns

High frequency haystack, BPFO harmonics, irregular high impacting in the time wave

Our Recommendations

  • 1
    Re-grease:

    Re-grease the bearings or replace the lubricating oil. Inspect the grease or oil for signs of contamination or overheating.
  • 2
    Re-assess:

    Re-assess damage levels afterward to determine if any permanent damage occurred
  • 3
    Repeat:

    Repeat the process as needed—Skyler will detect any recurring issues and generate subsequent reports.

The Result?

For all three cases, acceleration trends decreased after re-greasing or oil replacement. Bearing remaining useful life was extended, and premature parts replacement and unplanned downtime were avoided.

  • 1
    Dust Collector Fan Bearings

    First trend increase detected in March 2024. Lifetime was extended by 19 months through targeted re-greasing whenever trends rose, executed diligently by the maintenance team (June 2024 & February 2025).

    Bearing damage reached an advanced stage in October 2025 and is scheduled for exchange during the next outage. Savings: $59k in unplanned downtime, $6k in replacement parts.
  • 2
    FK Pump Motor (Grease-Lubricated)

    Additional re-greasing recommended twice outside regular intervals (November 2024 & November 2025), each time reducing vibration trends. Motor remains fully operational. Savings: $6.5k in unplanned downtime, $42k in replacement parts.
  • 3
    Motor for Bedeschi crusher (Oil-Lubricated)

    Oil flush and replacement recommended twice outside regular intervals (August 2024 & September 2025), each time reducing vibration trends. Motor remains fully operational. Savings: $25k inreplacement parts.

Impacting in FK pump motor due to under lubrication before (blue) and after the re-greasing (yellow).

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