Maintworld Issue3 2016

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CONDITION MONITORING Major bearing manufacturers tell us that between 50 and 80 percent of all premature bearing failures are cause by lubrication issues. Choosing the Right Diagnostic Tools The human brain is amazing. How many times have you opened a drawer that’s full of all sorts of things and picked out the one thing that you opened the drawer to find? THOMAS J. MURPHY C. ENG, Corporate Training Manager, SDT International,, tom@sdt.be WE DO THIS frequently and think little of it. How much more difficult would that search be if you did not know what the object that you wanted to find actually looked like? Unfortunately, this happens a lot in the world of condition monitoring. Companies go to great lengths, and considerable expense, to purchase the “right” equipment or select the “right” contractor but then put almost no effort into the most important part of the preparation – to identify what failures look like. In the reliability world, this preparatory stage is called Failure Mode and Effect Analysis. Having all the right tools and not knowing what to look for will yield minimal success – all that new high technology will end up on a shelf in a couple of years’ time and quite possibly there will be a stigma attached along the lines of “we tried that and it doesn’t work”. Failure Mode and Effect Analysis (FMEA) FMEA is like a formal, structured, version of Murphy’s Law. • What system defects are possible? • How likely are they? • How significant are they? • How can we design them out? • How can we mitigate their effect on the system reliability? • Is it cheaper and easier to run to failure? • How can we identify their presence? Condition monitoring is all about this last question, how to develop a structured measurement approach that goes looking for the onset of a particular failure mode. Included in this strategy is the realisation that not all failures are trendable – some failures, a leak is a good example, are binary. A leak exists or it doesn’t, it is binary. What would you be measuring on a pipe fitting that would predict that it is going to work loose? My first manager in my professional career was an old Navy man who taught me that “to fail to prepare is to prepare to fail” and that is as true in the application of condition monitoring as anywhere else. To correctly deploy a monitoring tool, first know what to look for and then choose how to find it. Choose? Yes, in many cases there are multiple tools that can find a problem. Realising that brings a refreshing freedom: if some of your team prefer to use one tool over another and both will find the problem, give your 16 maintworld 3/<strong>2016</strong>
CONDITION MONITORING team the freedom to use whatever they enjoy using or are most comfortable using. The result? Inspection routines are completed, problems are found, your expensive tools are used and reliability increases. What Can I Do with IR, Vib and US? Infrared cameras measure Infrared radiation from which they compute temperature. IR cameras provide a full-field real-time display that allows the user to see thermal patterns and distributions far more quickly than can be achieved using a single point temperature device. Vibration is a measurement of one of three things: acceleration (force), velocity (momentum or energy) or displacement depending upon the frequency range and the application. Phase measurement is a critical part of vibration measurement that is often overlooked. The use of phase allows a vibration instrument to perform balancing, operating deflection shape and modal testing. Ultrasound instruments measure sound at frequencies beyond human hearing, for example in the frequency range between 36 and 40kHz. Ultrasound is particularly good at detecting three parameters: friction, impacting and turbulence. There are eight application pillars of this type of ultrasound equipment: • Compressed gas leaks (air, CO2, Nitrogen, Argon, etc.) • Steam leaks and steam traps • Valves • Hydraulics • Electrical (LV, MV and HV) • Tightness • On-condition lubrication • Rotating machinery condition Clearly, from this list, ultrasound offers tremendous value for money in terms of problem coverage. Crossover Applications It is not uncommon to come across these crossover applications where multiple tools are available but a purist will insist that “this is the right way to find this problem”. Right way? There is no right way. If there is a problem and it can be found, surely that is the primary concern, not compliance with some unwritten norm that says “thou shalt use …… to find this problem”. FMEA IS LIKE A FORMAL, STRUCTURED, VERSION OF MURPHY’S LAW. Coupling misalignment is a typical example of a crossover application. It is possible to take vibration measurements to deduce that there is coupling misalignment. If there is line of sight of the coupling (something which is quite rare these days) it is possible to identify that the coupling is warming up, which is going to be caused by the periodic friction generated by the misalignment. Discover the hidden treasure in Maintenance Discover the hidden treasure in Maintenance There is value hidden in every maintenance organization. All companies have the potential to further improve, either by reducing costs, improve safety, work on the lifetime extension of machinery or by smart maintenance solutions that improves uptime. The question is where maintenance managers should be looking to fi nd these areas of improvement and where they need to start. You will fi nd the answer to this question at Mainnovation. With Value Driven Maintenance ® and the matching tools like the VDM Control Panel, the Process Map and our benchmark data base myVDM.com, we will help you to discover the hidden treasure in your company. Do you want to discover the hidden treasure in your maintenance organization? Go to www.mainnovation.com CONTROLLING MAINTENANCE, CREATING VALUE.
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Page 3 and 4: FLEXIBLE PROGRAMS Tailor a program
Page 5 and 6: IN THIS ISSUE 3/2016 24 Researchers
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Page 9 and 10: The Industrial Interoperability Sta
Page 11 and 12: INDUSTRIAL INTERNET IIoT Industry 4
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Maintworld Issue3 2016

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