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Powering the Process℠ is a podcast for engineers, plant managers, and operations leaders focused on industrial systems, plant optimization, and manufacturing efficiency. Hosted by ProcessBarron experts, each episode delivers practical insights on material handling, air and gas systems, industrial equipment, and reducing downtime.
00:00:02:06 – 00:00:33:19
Jen Little:
This podcast is brought to you by ProcessBarron. Handle Everything Better.
Welcome to Powering the Process—the podcast focused on the real work behind industrial manufacturing. Each week, your host, Jen Little, digs into the systems, equipment, and strategies that keep plants running efficiently. From everyday operational challenges to emerging engineering solutions, we’re here to share practical insights to help you keep your process moving.
00:00:33:22 – 00:00:36:11
Jen Little:
Let’s get started.
Introduction
00:00:36:13 – 00:01:07:16
Jen Little:
Have you ever wondered what it takes to keep massive industrial systems running every day? It’s not just engineering—it’s boots on the ground, hands-on expertise, and quick thinking under pressure. Today, we’re going behind the scenes with the frontline problem solvers who step in when critical equipment needs repair, upgrades, or emergency fixes—from power plants to paper mills.
00:01:07:18 – 00:01:35:06
Jen Little:
They work in challenging environments to keep operations moving and downtime to a minimum. In this episode, you’ll hear real stories from the field—what it’s like to troubleshoot under tight deadlines, the tools and skills that make the difference, and how our technicians help industries avoid costly shutdowns.
00:01:35:08 – 00:01:47:14
Jen Little:
So let’s go. Today’s guest is Roy Hollis, head of our Service Tech Group, with 48 years of experience at ProcessBarron. Roy, thank you for joining us.
00:01:47:17 – 00:01:52:00
Roy Hollis:
Thank you for having me. I’m glad to be here.
Fan Imbalance & Diagnostics
00:01:54:20 – 00:02:00:20
Jen Little:
Roy, what are the most common causes of imbalance in an industrial fan?
00:02:00:22 – 00:03:54:28
Roy Hollis:
We need to start by looking at fan applications. Some fans handle hot, dirty, abrasive gases, while others handle clean, ambient air. Fans like ID fans, overfire air fans, and FD fans operate in harsh environments where uneven wear can increase residual imbalance. If that wear isn’t controlled, debris can accumulate more easily and make the imbalance worse.
On clean-air fans—PA fans or SA fans—you typically only need to check balance at installation or after shipment issues. These fans are usually what we call “sleepers.” But over time, fatigue can cause cracking, or foreign objects can strike the fan, which increases imbalance. If a clean-air fan suddenly shows rising imbalance, that’s a red flag and needs immediate inspection.
Support issues can also simulate imbalance. Deteriorated foundations, looseness, or weak supports will amplify vibration, so diagnosis has to be done carefully.
On-Site Troubleshooting Process
00:04:42:05 – 00:05:29:27
Jen Little:
When you first arrive on-site to diagnose a fan problem, what’s the first thing you do?
Roy Hollis:
First, I meet with the customer and listen to their concerns. I review trend data, vibration history, and operational data. If it points to imbalance, once lockout/tagout is complete, I inspect the fan for buildup, debris, impact damage, or defects.
If nothing stands out internally, I inspect the supports—checking for loose bolts, bad grout, cracked piers, or foundation issues. Then I collect phase and amplitude data, primarily in the horizontal axis, since that’s the path of least resistance. Once the data checks out, I proceed with the balance procedure.
Evolution of Tools & Technology
00:06:54:08 – 00:09:22:23
Roy Hollis:
Thirty-five years ago, balance machines were little more than a box, a strobe light, and cables. Data wasn’t stored—you wrote everything down, often in terrible conditions. Today’s balance analyzers store data, calculate corrections automatically, and allow full vibration, spectral, and waveform analysis.
With one analyzer, I can balance a fan, assess foundation health, check bearings, evaluate couplings, perform motor analysis, and even conduct natural frequency testing. Today’s technology allows us to solve virtually any fan-related problem efficiently and accurately.
Memorable Field Story
00:10:45:29 – 00:13:47:14
Roy Hollis:
One job that stands out was at a paper mill in the Pacific Northwest. The boiler was down, the entire mill was shut down, and I had an audience—literally lawn chairs set up watching me work. After inspecting and collecting data, I applied correction weights, reduced vibration, and brought the fan back online. When it stabilized, the crowd applauded. Twelve hours later, it was running smoothly, and the customer was thrilled.
Life of a Field Service Technician
00:13:57:29 – 00:16:32:09
Roy Hollis:
A service technician is always on call. Even when in the office, you’re prepared to leave at a moment’s notice. In the field, the work can range from balancing and root cause analysis to bearing failures, support analysis, grout inspections, and full system evaluations. Every day is different.
Training & Preparation
00:18:31:20 – 00:22:54:05
Roy Hollis:
We train constantly. Our training center includes bearing simulators, coupling fault simulators, and a full-size fan system that allows us to recreate real-world problems. For new technicians, safety comes first. Green hires spend years developing skills under senior technicians. It takes about ten years to become fully seasoned, but after six months, many can handle basic balancing on their own.
Building Customer Trust
00:24:33:25 – 00:25:54:24
Roy Hollis:
Trust starts with listening. I don’t oversell, and I never speak negatively about competitors. I deliver what I promise and remain available 24/7. The customer has to know I’m there to help—nothing more, nothing less.
Advice to New Technicians & Operators
00:29:39:06 – 00:31:57:09
Roy Hollis:
For technicians: integrity, discipline, and a willingness to keep learning are non-negotiable. If you think you know it all, you’re done.
For operators: inspect critical equipment annually and use continuous monitoring. Wireless vibration and temperature sensors provide constant visibility and prevent catastrophic failures before they happen.
Digital Fan Guardian
00:33:22:01 – 00:35:11:03
Roy Hollis:
Digital Fan Guardian uses wireless sensors to monitor vibration, temperature, balance, alignment, and bearing health. When an alarm is triggered, data is sent to the cloud and reviewed immediately by a technician. This technology prevents failures that could shut down production for weeks or months.
Closing Thoughts
00:35:27:29 – 00:36:31:04
Roy Hollis:
Everything I have is because of ProcessBarron. The people, the customers, the experiences—I wouldn’t change a thing. Working with this company has been one of the most rewarding experiences of my life.
00:36:31:06 – 00:36:54:25
Jen Little:
Thank you, Roy. Your story, your experience, and your impact mean a great deal to all of us.