When a machine fails unexpectedly, the unplanned downtime, maintenance deployment, and lost productivity can put a crimp in any industrial operation. In the case of critical assets, the stakes will be especially high. How can such situations be avoided? Condition monitoring technologies hold the key.
Condition monitoring technologies enable early detection of operating abnormalities in rotating equipment. Abnormalities are identified based on measurements of various physical operating parameters, including vibration, temperature, and others. The measurements make it possible to pinpoint problems before they can escalate and make pre-emptive remedial fixes.
The toolbox of condition monitoring technologies has become well stocked with options ranging from basic handheld or stand-alone data collectors to more sophisticated, connected, and networked systems. Some devices and instruments focus on assessing the more significant operating parameters, such as vibration, while highly engineered systems at the other end of the spectrum can be configured to monitor and diagnose many more.
Their capabilities expand with integration into computerized maintenance management systems, the use of specialized software programs, and application modules and accessories targeting specific types of analysis.
Periodic surveillance of machine conditions usually will be sufficient for relatively non-critical assets. But for machines deemed “too critical to fail,” more frequent and/or continuous monitoring will be the order of the day – enabled by on-line condition monitoring systems with either hardwired or wireless sensors.
On-line systems deliver up-to-the-minute information – collecting data 24/7 or over a predetermined data-collection frequency via permanently mounted sensors and then transmitting that data to a host computer running relevant software packages. The mounted sensors and related software uncover issues and ultimately allow for timely analysis and fixes.
Hardwired For Success
In the universe of on-line monitoring solutions using hardwired sensors, SKF Multilog IMx on-line systems illustrate how far the technology has evolved, both in form and function. The series includes units for use in extremely tough industrial environments and is further diversified with other models dedicated for monitoring machinery operating in specified industries and applications.
As an example, the robust and programmable IMx-8 unit exemplifies the power and promise of machine condition monitoring systems. The system runs on an existing LAN or WAN and network with computers, printers, and servers, or over the internet.
The IMx-8 incorporates eight analog signal inputs configurable for use with standard industrial sensors to collect data on vibration, acceleration, velocity, displacement, and temperature, among other parameters. (Other units in the IMx series have been equipped with 16 or 32 analog channels for gathering even more information from more sensors.) Individual warning and alarm levels controlled by machine speed or load can be set for each measurement point.
The system can further connect with cloud services for storing and sharing data and for accessing expert reporting and recommendations from a remote diagnostic services location.
As safeguards for the unit, a built-in auto-diagnosis capability checks all sensors, cabling, and electronics for any faults, signal interruption, shorts, or power failure and then automatically alerts when problems are found.
The compact IMx-8 – no bigger than a paperback novel – fills a big need by fitting easily into smaller spaces and opening opportunities to save cost and make installation easy by utilizing existing instrumentation cabinets. The unit’s smaller footprint also more readily accommodates applications where monitoring instruments may need to be located as closely as possible to the monitored machinery.
As with the 16- and 32-channel IMx units, the 8-channel version serves as a complete system for early fault detection and prevention. The capability to connect with mobile devices and laptops allows for user-friendly configuration and real-time display of machine condition data.
A 4GB internal memory can store a year’s worth of machine data and numerous event captures to promote tracking, trending, and analysis over time.
Going Wireless
For some machine surveillance jobs, especially when only required temporarily, implementing a hardwired system may not be in the cards. Perhaps fixed cabling may not be logistically possible, a permanent system cannot be justified on certain semi-critical or balance-of-plant machines, or costs associated with cabling and installation may get in the way. Fully untethered, wireless systems can overcome such issues.
In addition, the potential of WiFi-enabled monitoring systems can be expanded by facilitating monitoring applications that in the past may have been difficult or impossible, such as temporary installations positioned for troubleshooting or applications involving monitoring from remote locations.
The self-contained and battery-powered SKF Multilog WMx on-line system – a compact, 8-channel, field-mounted monitoring device – exemplifies an ideal technology to broaden 24/7 monitoring coverage, monitor “bad actors,” troubleshoot, supplement walk-around routes, enable remote monitoring, and/or provide “end of life” tracking of failing components, such as bearings. The unit can easily be relocated whenever and wherever needed. The WMx can monitor four channels of vibration, four process inputs, and one tachometer input. Using standard industrial constant current powered sensors, the system collects acceleration, velocity, displacement, temperature, and bearing condition and automatically uploads and stores the data for viewing, alarm evaluation, and analysis using proprietary software.
The system usually will be programmed to wake up and take measurements based on a fixed time interval, or it can be externally activated on demand by a programmable logic controller. Either way, wireless technology expands condition monitoring capabilities where hardwired systems cannot and widens the scope of proactive machine monitoring throughout a plant.
Whether hardwired or wireless, viable machine condition monitoring systems can provide a big assist in performing appropriate inspections, maintenance activities, and fixes at the right time when and where needed, regardless of the calendar. As a result, operations can extend maintenance intervals, consolidate maintenance initiatives, and reduce risks of unplanned downtime.
Enlisting expert support can make a significant contribution toward optimized outcomes. Partnering with an established services provider with experience in the many interrelated aspects of condition monitoring and possessing the appropriate engineering resources and analysis capabilities will help to realize the central mission of keeping critical machinery up and running as intended.
About the Author
Greg Ziegler is Business Development Manager for On-Line Systems at SKF USA Inc. He has more than 30 years of experience with Machinery Protection systems, On-Line Condition Monitoring systems, and sensor technologies for industrial applications. Prior to his current position, he managed the company’s Condition Monitoring product service business, leading a team of engineers for system installations, maintenance, training, and mentoring customers.
Greg can be reached at (610) 220-2667. His email is greg.ziegler@skf.com
For more information, visit www.skf.com.
