Case Studies

Petrochemistry: Monitoring the magnetic clutch of a boiler fan

clutch fan

Any wireless network vibration system must take into account its own safety. Although temperature and vibration data of are generally not considered sensitive, it is not acceptable to allow this information to be accessed by anyone. The fear of loss or data piracy when we use a wireless system is always present in our minds. Based on a 128 bit AES encryption and the IEEE 802.15.4 communication protocol, the I-care wireless sensor system offers the most recognized security standards with incredible levels of quality vibration data. We must also consider that the Wi-care Wireless Vibration system is completely independent and does not interact in any way with other wired or wireless systems

The following case study represents a typical remote analysis application of a boiler fan. 

Food industry: Monitoring a fan imbalance

food fan

Condition monitoring technology has been used in the industry for a long time to improve maintenance and production, by reducing unplanned shutdowns. One of the parameters followed in current programs is vibration according to its direct relevance to the condition of rotating machinery. The Wi-care wireless system allows your vibration data to be analyzed at distance and at any time. Beyond the measurement system, the use of remoteanalysis allows the establishment of a strong condition based maintenance partnership. The availability of an expert in vibration diagnosis without additional travel costs efficiently reduces the predictive maintenance budget. Decreasing very expensive diagnostic expertise allows the redistribution of budget within the condition based program on a broader set of machines. We generally consider that 1/3 of the final invoice is made up of travel expenses. Using the Wi-care wireless system coupled with the I-CARE condition monitoring remote diagnosis team, offers a chance to cut these travel costs. At a time when many maintenance budgets are being decreased, via the use of Wi-care, we allow expenses to be redirected to where they are most justified.

 The following case study represents a typical remote analysis application of a fan in the food industry. The monitoring was performed in a very effective way for the customer and analyst in order to detect and protect the fan from an excessive imbalance.

Monitoring of typical pumps and aerator in a water treatment plant

IMG 2737l

 The wireless vibration network of Wi-care system consists of the communication between three components; the transmitter, the range extender and the receiver. The transmitter is fixed on the machine and transmits the vibration and the temperature data at the measurement point. The second element of the Wi-care wireless network is the range extender, its function is to transmit vibration and temperature data over long distances to the receiver. The third part of the communication path is the receiver/gateway which automatically and continuously organizes the network. The web platform allows you to access all data including vibration spectrum, analysis and recommendations reports, you can also manage data collection parameters like periodic time interval, on demand acquisition, alarm/alert level acquisition or even the spectrum parameters without physical interaction

The following case study describes a remote analysis of 3 typical equipment inside a water treatment process. Wi-care wireless network is monitoring over distances temperature and spectral vibration of an aerator, an underground centrifugal pump and a vertical effluent pump

Vibration surveillance: Oil rig – Power generator


The Wi-care™ system is the latest wireless condition monitoring system from I-Care. The system has been designed to detect measure and analyze the root causes of excessive levels of vibration and temperature. The Wi-care system is a cost-effective tool used to report any vibration or temperature deviation in a short time. I-CARE team of engineers using the data from Wi-care is able to give you a condition monitoring remote diagnosis at any time 24 hours a day/7 days a week. Exceeding an alarm level automatically induces the collection of the vibration spectrum and the recording of temperature data. The analyst can then easily make an appropriate remote diagnosis. Go for wireless, save money, save installation costs and time!

 The following case study describes and explains a typical remote analysis application of an internal bearing friction detection/trending. Case study is done on a power generator dedicated to oil rigs.

Detecting sudden bearing failure occuring in 8 hours

pump refinery brg1

Nowadays each person linked one way or another to maintenance has to be confronted to contradicting objectives:

1. Decrease maintenance costs

   2. Increase equipment availability

In order to meet this challenge, an efficient work schedule is required. Only predictive maintenance allows avoiding unnecessary interventions and their related costs. This schedule requires detecting emerging defects, and therefore more advanced technologies are needed. In order to schedule maintenance actions, an equipment monitoring schedule should be set up. Thanks to actual technical developments like Wi-care wireless vibration and temperature system, bearing defects on classic equipment can be detected with certainty until 6 months before it reaches a risk level of shutdown.

The following case study describes and explains a real case of remote bearing fault detection. The continuous surveillance was set up in a very effective way for the customer and analyst allowing us to detect in time this sudden high bearing faulanalyst 

Tracking gear Mesh Frequency - gearbox Cement plant


Wi-care case study gearbox -1

Since the 90’s there has been no huge revolution in the technical aspect of vibration monitoring, the fundamentals of a spectrum analysis job itself are still the same. For last decades, the evolution revolution has taken place in the way the technology is applied. Today, the revolution is to partially reduce the human intervention and dematerialize the analysis/managing software. Wi-care system now offers the possibility to suppress manual data collection while focusing the human resources on the highest value task, the data analysis.

The following case study describes and explains a typical remote analysis application of a gear mesh fault detection and tracking. The continuous surveillance was set up in a very effective way for the customer and analyst 

Prevention of a sealing failure on a centrifugal pump in Brewery


Wi-care case study Brewery- pict1

The entire vibration market within the Conditional Maintenance industry is moving towards wireless monitoring networks. For decades, our industry has been equipped with continuous vibration and temperature monitoring systems. The successful installations around the world are actively involved in the provision of rotating machinery health data and resulting maintenance decisions. The new trend is to remove some of the annoyances related to these wired systems by replacing them with wireless networks. A fundamental innovation of the Wi-care system is to be able to connect to your old vibration sensors, remove their cables and turn them into wireless vibration sensors in just a few minutes.

The following case study represents a typical remote analysis application of a centrifugal pump. This pump is related to a washer in the Brewery. The fault was detected in a very effective way for the customer and analyst.


Ball spin frequency and friction: centrifugal pump in chemical plant

pict1There is no benefit of having a wireless vibration sensor if it isn’t part of a network. They are several advantages to create a wireless network, such as reliability of data transmission, easy and cost effective system upgrading, movable sensors. Currently, creating a large network will always offer more possibilities to relay the data from one measurement point to the receiver. Basically, the bigger and the more dense the network is, the more reliable the data transmission. From the beginning of your vibration program, it is important to think about the wireless vibration network extension. The solution developed in the Wi-care system is based on a receiver connected on the internet and able to manage up to 144 transmitters, each transmitter sending vibration and temperature data. In order to reach long distance data transfer and remote locations, the Wi-care involves a range extender in its network.

The following case study describes and explains a typical remote analysis detection of a ball spin frequency and friction on a centrifugal pump in chemical plant.

Outer race defect detection and monitoring on a crusher bearing: cement plant


thumb wi-care case study cement- crusher-bearing1With very few operations, Wi-care can turn your current online vibration system into a wireless permanent online vibration analysis. You may already have a wired vibration system installed on your critical assets but you are aware that over the time the system is less and less effective due to malfunctions, wire damages, losses. You can connect the Wi-care transmitter to almost all your vibration sensors to get the added values of the wireless vibration. The Wi-care system provides an innovative web platform access using either QR code reading (via a smartphone), the touchscreen gateway option, or any modern web access. This would apply whether you are an inspector looking for onsite instant value and trend (QR code); an operator in the control room tracking any malfunction alarm (touchscreen) or a reliability engineer reading online vibration analysis data and reports from an office via the web platform. The I-care remote diagnostics team or the global reliability manager can check reliability KPI and machinery health, even when away from the office.

The following case study describes and explains a typical remote analysis application of bearing defect detection on a crusher. The detection and continuous surveillance was set up in a very effective way for the customer and analyst.


Distributors wanted

You like our wireless system; you believe your customers will be also enthusiastic.  I invite you to join our team to develop your activity via the Wi-care system.
Join the I-CARE growing network by answering our research for durable sales partnership over Europe, Africa, Asia and USA.
Send me an email at
Nicolas Bleret, I-care, Belgium
Business Development director