Condition Monitoring/Predictive Maintenance

The new BS40 structure-borne sound sensor offers reliability and precision

Challenge

„What led to this condition? “ is one the most common questions asked by clients during the inspection of failed or damaged bearings. Although rolling bearings are among the most invaluable components in most of machines, it is pretty common the case that companies are lacking of effective bearing inspection practices. Monitoring for changes (trending) is conducted to reliably detect deterioration in critical assets condition. This must be done using robust characteristic values. If the alarm threshold is exceeded, an action must follow, which then requires a detailed analysis. In order to identify a fault or damage pattern and to reveal the causes, special evaluations of raw data are made. Simple characteristic values are not sufficient for this purpose. For machinery with rotating shafts, the focus lays in monitoring the rolling bearings. As interface between shaft and foundation of the machine, they have to absorb the resulting forces. This implies that faults and damage in design and operation have a particularly strong impact on rolling bearings. This is exactly what makes them suitable measuring points.

BS40: Innovative and reliable solution

The new BS40 structure-borne sound sensor was developed and manufactured by SONOTEC to help companies worldwide to take a better care of their bearings. This handy and robust sensor is ideally suited for condition monitoring of rotating machinery parts. It convinces with a laser-welded stainless-steel housing. The ¼”-28 UNF threaded bolt allows maximum flexibility in mounting. The BS40 can be used with magnets for flat or curved surfaces or can also be screwed to adhesive pads with an internal thread. Thus, a high reproducibility can be achieved. The optimized sensor characteristic in the range from 10 to 65 kHz ensures a nearly linear frequency response. A downward extension of the ultrasonic frequency range to < 1 kHz also provides more flexibility for machine diagnostics. The sensor contains a piezocomposite material developed by SONOTEC which helps to overcome the disadvantages of many market solutions. A more reliable assessment of bearings becomes possible.

SONAPHONE & LevelMeter App: Intuitive hardware and software

With the intuitive LevelMeter App, the digital ultrasonic testing device SONAPHONE® enables broadband measurements and characteristic value determination. Due to its high sampling rate of 256 kS/s, signals up to 128 kHz can be analyzed. Up to this limit, characteristic values can be calculated and audio signals can be generated based on the filter settings. The device offers two methods for transforming the ultrasonic signals into the audible frequency range. The heterodyne method is used when a narrow-band transformation (bandwidth 4 kHz) is realized, while the vocoder method is suitable for a broadband transformation. The live signal is shown as time wave form, level graph and spectrogram.

 

Excellence in condition monitoring program

A great and powerful combination of the SONAPHONE®, the intuitive LevelMeter App, the broadband BS40 sensor and the software for the management of predictive maintenance tasks DataSuite helps to achieve excellence in an ultrasound condition monitoring program. This holistic ultrasonic solution helps the maintenance team to ensure that manufacturing processes in the industrial facility are running smoothly. Lubrication decisions can be made based on the acoustic feedback of bearings. Furthermore, companies are able to act in advance when bearings replacements become imminent as an early intervention can help to omit significant issues. It is now easy to recognize bearing damage early and optimize their lubrication with ultrasonic testing devices developed and manufactured in Germany.    

To learn how SONOTEC can help you, please visit www.sonotec.eu

    

 

 

”This case study describes the process of using the correct condition monitoring technique to monitor Rotating Biological Contactor (RBC) main bearings at 1RPM”

Severn Trent Water Asset Care Team were tasked with finding a reliable condition monitoring solution to monitor the main bearings of these RBC’s as when they fail they have huge consequences to the business. These RBC’s are usually located in remote sites and are difficult to keep track of with each area maintenance team having planned inspections but no real idea of condition.

SPM HD is proven to be the ideal condition monitoring solution for monitoring the lubrication decrease and early signs of damage on these bearings, other techniques such as ultrasound or Vibration Analysis could not detect these problems during previous trials. Due to SPM Technology proving itself Severn Trent Water decided to start with purchasing a Leonova Emerald initially then after presenting to the Directors they decided to invest in the same portable instruments for every area in waste water for Severn Trent. 38 Leonova Emerald instruments.

Rotating Biological Contactors (RBC) are an essential part of the water industry in remote areas. The RBC process allows the wastewater to come in contact with a biological film in order to remove pollutants in the wastewater before discharge of the treated wastewater to the environment. 

 

Fig.1 A remote site with 2 RBC enclosures

Each RBC consists of a main bearing at either end of the main shaft. One side of the RBC has a Motor/Gearbox. The speed of the main bearings are fixed usually between 1.8rpm and 0.9rpm depending on the size of the RBC. The length from one main bearing to the other also varies depending on the type of RBC installed.

 

Fig.2 Construction of an RBC

 

Small discs with Biological fluid are in close proximity to each other which is called media. As the RBC rotates slowly these discs treat the water which then moves to the next part of the Treatment process.

There are over 500 RBC’s in Severn Trent Water in different locations around the area. They are all in remote sites which are difficult to access. When a main bearing fails they have to plan in the replacement which can take months as the lead time on the bearings is long as well as the installation of cranes and lifting equipment to remove the RBC. 

Severn Trent Water had a number of these catastrophic failures resulting in them deciding to make plans to trial condition monitoring equipment. 

The initial readings on this asset was shown to be high in comparison to all other RBC’s. The below shows the overall SPM HD measurement results. The bearing was checked and repacked with grease showing a decrease in reading up until October

 

 

The overall SPM HD reading derives ultimately from the time signal reading below. This was confirmed that there was large impacts in the pressence of low readings indicating damage.

 

 

 

Corresponding Time signal

On relacement clear score marks could be seen around the shaft and damage was seen around the casing of the bearing and rollers. If this was left without monitoring it would have catastrophically failed.

 

 

Fig.9 Bearing pictures on replacement

After planned replacement the SPM HD readings reduced from alarm state to acceptable levels. The graph below shows the point when the bearing was replaced around the 20th November.

 

 

SPM HD Trend throught measurement lifetime

 

 

Time signal from healthy bearing

 

 

 

 

 

• ABB and Samotics enter a strategic partnership to extend ABB’s asset health monitoring services to harsh and submersible environments

• ABB to acquire 10 percent stake in Samotics, leading provider of electrical signature analysis (ESA) technology for motor-driven industrial equipment
• Joint ambition is to reach next level of condition monitoring by co-developing advanced digital service solutions focused on energy efficiency and operational resilience

ABB and Samotics, a leading provider of ESA technology that is a high-growth scaleup company based in the Netherlands, have entered a strategic long-term partnership to provide enhanced condition monitoring services. The approach will leverage each company’s capabilities to deliver more insight into machine health and energy efficiency. As a first step, ABB will integrate Samotics’ plug-and-play monitoring solution into its digital portfolio. The financial terms of the agreement were not disclosed.

Samotics’ technology is complementary to the well-established ABB Ability™ Condition Monitoring service for powertrains, a sensor-based solution that analyzes the health and performance of rotating equipment. Samotics’ SAM4 technology, based on electrical signature analysis (ESA), will expand ABB’s application of asset health monitoring of motor-driven industrial equipment as it does not rely on mounting sensors in the field. This means that SAM4 can be deployed on machines in harsh and submerged environments.

Adrian Guggisberg, President of ABB Motion Services said: “Our strategy is to build an ecosystem with leading service providers who can contribute to our customers’ overall success. With Samotics, we share the ambition to co-develop digital services that will offer even greater insight across a wider range of applications to help our customers taking better decisions. The partnership will also create even more value from digital service solutions to grow our annual recurring revenues.”

Jasper Hoogeweegen, CEO of Samotics said: “Entering into a strategic partnership with ABB will open doors with potential customers around the world and help us scale our business. At the same time, we share a mindset and commitment to help solve reliability and energy efficiency challenges.”

Ultimately, developing a system that uses both datasets will provide industrial operators with a more detailed view of asset health so that they can make better decisions to optimize maintenance, boost reliability and reduce downtime.

Samotics has established SAM4 as a robust and scalable system. It is already being implemented across the wastewater and water, steel, and chemical sectors and has established a fast-growing base with thousands of assets monitored. 

ABB plans to roll out Samotics technology to customers before the end of 2022 as part of its growing service portfolio for rotating equipment.

ABB (ABBN: SIX Swiss Ex) is a leading global technology company that energizes the transformation of society and industry to achieve a more productive, sustainable future. By connecting software to its electrification, robotics, automation and motion portfolio, ABB pushes the boundaries of technology to drive performance to new levels. With a history of excellence stretching back more than 130 years, ABB’s success is driven by about 105,000 talented employees in over 100 countries. www.abb.com

ABB Technology Ventures (ATV) is the venture capital unit of ABB (NYSE: ABB). ATV looks for breakthrough technology companies aligned with ABB’s goal to write the future of industrial digitalization. Since its formation in 2009, ATV has deployed around $250 million into startups spanning a range of sectors including robotics, industrial IoT, AI/machine learning, energy transition, cybersecurity, electric mobility, smart buildings and distributed energy. For more information, visit www.abb.com/ventures

Samotics is a leading provider of real-time actionable insights to optimize performance and energy efficiency of AC motors and rotating equipment. An expert team of data scientists, software developers and technical specialists has developed an AI-driven platform that supports global industrial companies in reducing energy waste and unplanned downtime. www.samotics.com

Evolution takes time, and it’s not easy to improve what is already great, but we like challenges, and we did it. Adash’s bestselling vibration data collector, the A4900 Vibrio M, has been relaunched with significant improvements.

Supplied in kit format, in a small yet robust protective transport case, with all required components; it’s ideal for operators, engineers, consultants and analysts alike. Fully integrating into the Adash DDS software suite, the device retains its simple 3-button control, standard vibration measurement(s) and outstanding FASIT evaluation tool, enabling auto diagnosis of potential failures and problems which are presented clearly to the user with visual waveforms and traffic light alarms. This allows equipment breakdowns to be avoided by non-professional users.

Plug and play, don’t bother with settings, just measure!

This pocket sized vibration analyser and data collector has been upgraded with a larger TFT display (240x320 pixels) which ensures the screen is always visible, even in direct sunlight. The larger display further enhances the user experience when viewing FFT and time waveforms, improving front line and visual analysis and problem identification.

Replacement of the standard AA battery chamber with Li-Ion battery technology, provides a rechargeable power pack capable of providing 15 hours of continuous operation. The additional comfort of charge indication means there is no requirement for the user to carry replacement batteries or return to the office to recharge, during longer route data collection activity.

The rubber protection bumper case bolsters an already rugged industrial package, improving the overall mechanical protection and integrity, whilst covering the bottom panel has increased the overall ingress protection from duct and moisture, ensuring this device can be utilised in the most aggressive and oppressive environments.

If you want to identify faults, prevent equipment breakdowns and save money, don’t settle for second best, choose Adash and the New Vibrio M……Perfection in it’s best shape!

www.adashuk.com

As part of its AIP+ (Added Value Programme), NSK’s Condition Monitoring Service (CMS) is a method to determine the health of machine components such as bearings while the machine remains operating. Indeed, data from the process can also be used to help determine (or at least narrow down) the causes of form errors when producing parts on grinding machines.

By using the capacity of cloud-based software to combine the real-time and historical data from Fluke Connect™-enabled tools and sensors, Fluke now enables maintenance engineers and managers to monitor a comprehensive picture of equipment health throughout the facility. The introduction of condition monitoring products that wirelessly transmit data from the field, combined with Fluke Connect Condition Monitoring (FCCM) software, has enabled safe, cost-effective maintenance programs. Maintenance teams can remotely detect potential equipment failures and remedy them before they cause costly downtime. Predictive maintenance is now not only simplified, but it is safer and faster.

Spectrum analysis provides a great deal of information about the health of rotating machinery. But you should consider the spectrum as a summary of the vibration within the machine.

RUFTECHNIK expands its intelligent Online Condition Monitoring portfolio with VIBGUARD compact. As intelligent online CMS, the new VIBGUARD compact offers premium asset manufacturers of drivetrains and machines as well as their operators the same performance as its big brother VIBGUARD.

While VIBGUARD features 20 measuring channels, VIBGUARD compact offers 6 measuring channels for continuous monitoring of fast and highly dynamic processes. The system can be easily integrated into the process control environment of the customer using the bidirectional Modbus interface. With focus on rotating equipment, VIBGUARD compact delivers continuous and detailed condition overviews of all relevant machine components in nearly real time.

On the 20th to 22nd of June, Manchester based condition monitoring specialist SPM Instrument UK Ltd. hosted a meeting with the CEO of SPM International and Managing Directors of its fourteen subsidiaries in Europe, USA, Singapore, and India.

The biannual SPM Management meeting is an integral component of the SPM International corporate structure and an important part in setting the course for the further development of the Group and its activities. The meeting is an itinerant event which the different SPM companies take turns organizing. This time, SPM Instrument UK was chosen to host the meeting, held at the Hilton in Manchester and rounded off with a social event at the Lakeside Hotel & Spa in Newby Bridge.

Until 15th September 2016, Fluke is offering significant reductions on the manufacturer’s recommended price of four popular and rugged thermal imaging cameras, the Fluke Ti300, the TiS75, the TiS40 and the TiS20. All models come with Fluke Connect® which provides greater data management and reporting capabilities via the Fluke Connect app. See www.fluke.co.uk/promotions