Improve Productivity and Safety

What is Condition Monitoring?

Condition monitoring is a non-intrusive method for finding faults before breakdown:

  • Involves the monitoring of a parameter, such as vibration or temperature.
  • Identifies a change which indicates that a failure is developing.
  • If left, a more significant failure or breakdown will occur.
  • Predictive maintenance allows actions to be taken to prevent a breakdown and avoid the consequences of failure, such as economic damage and loss of productivity.
  • A mix of techniques provides complementary data for analysis that helps determine a more informed recommended remedial action.
  • Condition monitoring includes techniques such as vibration analysis, thermographic imaging, oil analysis and acoustic measurement.

What challenges do you face?

If your organisation faces any of the following challenges then our condition monitoring service will benefit you:

  • Productivity losses.
  • Asset performance shortfalls.
  • Poor reliability culture and behaviours.
  • Run-to-failure regime – not finding degradation and dealing with it before breakdown.
  • Unable to complete your preventive maintenance programme.
  • Threat to your brand reputation from productivity issues.
  • Not getting value-add from your current CBM provider.
  • Your in-house team needs assistance with reliability skill-sets, knowledge and experience.
  • Compliance shortfalls with electrical safety.
  • Energy losses.

CBM Benefits

Our approach allows you to benefit from a condition-based monitoring regime that fully exploits the detection of degradation and reduces breakdowns:

  • Condition based monitoring is non-intrusive, as tasks are conducted with the machines ‘running’.
  • Conditions that shorten normal lifespan are addressed before they develop into a major failure.
  • Condition monitoring techniques detect degradation earlier than ‘old-school’ inspection-based maintenance regimes.
  • CBM allows maintenance to be ‘leaned’.
  • A CBM programme results in improved utilisation and effectiveness of your engineering resource.
  • You will achieve better asset performance and improved productivity with critical breakdowns being avoided.
  • Planned remedial tasks cost less than the cost of a reactive repair.
  • A condition monitoring programme, that involves your engineering team, will lead to an improved reliability culture.

Condition Monitoring Services

Vibration analysis is the process of measuring the vibrations of a machine’s moving parts, those under stress and the machine as a whole. Collecting and analysing the data, taking into account previous results, provides the earliest detection of developing problems.

Suitable sensors and equipment are available for use in hazardous areas. There are 3-levels of vibration analysis available depending on the criticality and access arrangements of individual equipment:

      • Manual data collection: Our condition monitoring engineer collects the relevant CBM data from the agreed assets with a routine visit to the site each month.
      • Remote monitoring: Bluetooth rechargeable sensors are provided and installed on equipment with ‘high criticality’ and access restrictions, which make manual data collection impracticable. Remote sensors are also able to capture data from intermittent running equipment or equipment which require higher frequency monitoring than manual data collection allows.
      • Continuous monitoring: This can be provided for assets which have been identified as ‘high criticality’, with a high failure impact and which are prone to suffer from failures which have a short PF interval. Continuous systems are scoped, priced and installed on a case-by-case basis and provide automated alarm notifications with periodic subject-matter-expert analysis.

The infrared radiation emitted by a machine, under normal operating conditions, can be measured and analysed in order to gain information relating to its condition. Routine monitoring will identify changes in infrared emissions which may be associated with physical changes to a component within a machine.

Thermographic imaging is used in a condition monitoring programme to help identify abnormalities in plant and machinery, by identifying any temperature rise as a result of component failure. For example, a hot spot on a machine casing may indicate a bearing that is about to fail.

Thermography is used to detect both mechanical and electrical faults. Electrical thermography is used to diagnose faults in electrical systems and determine if electrical systems and electrical panels are operating as normal, in order to reduce risks and breakdowns.

Acoustic analysis and vibration analysis are often used in combination to detect multiple failure modes that may be missed when only using one technique. It is particularly effective on slower rotating equipment.

Additionally, acoustics analysis or ultrasonic inspection is a condition monitoring technique used to monitor lubrication in greased bearings. It detects failure conditions such as over-greasing and under-greasing.

We use ultrasonic testing to conduct compressed air and steam trap surveys.

Oil condition monitoring involves conducting physical and chemical tests on an oil sample to determine the condition of the lubricant, the level of contaminants in the oil and the health of the machine. Sample kits and guidance on sample collection are provided and oil analysis data from a partner laboratory is captured within our cloud-based portal to provide an audit trail, support trend analysis and allow reporting.

Analysis identifies trends over the life of a machine which helps to determine and monitor the condition of an asset. This can help extend equipment life and eliminate costly repairs.

Motion Amplification detects movement, then amplifies it to a level visible with the naked eye, which improves the understanding of the components and influences forming the motion.

This condition monitoring technique is used to diagnose vibration issues such as misalignment, imbalance and looseness. Other issues such as structural cracks, resonance and soft foot are also diagnosed. Motion amplification is also used for structural movement such as platforms, pipework and equipment plinths.

An electrical panel thermal survey is a key component of your electrical compliance strategy and improves electrical safety in your factory.

Thermography is a non-contact technique that detects heat energy produced by electrical components under operational conditions; utilising the fact that developing faults result in elevated temperatures. It is a reliable indication that a fault may be found in the electrical system if a hot spot is detected.

Thermal imaging surveys are conducted whilst the electrical system is under normal load and this ensures there is no production downtime.

Electrical panel thermal surveys are the most-effective, predictive maintenance technique for identifying defects such as loose connections, over-loaded cables and faulty electrical equipment. It is safe, quick and cost-effective.

A visual condition-check of the panel is also conducted by our condition monitoring engineer at the same time and this provides an opportunity for engineering compliance issues to be spotted and reported.

Generating compressed air can be responsible for as much as 30% of your energy consumption and a significant amount of this energy can be wasted through leaks in the system. An air leak survey is the easiest way to save energy from your compressed air system.

Acoustic air leak detection allows our condition monitoring engineers to evaluate the condition of a sealed or pressurised system. An air leak survey enables remedial actions to be planned and executed to repair leaks.

Each leak identified is tagged, ranked and presented as individual report sheets including photographs for ease of identification. The report sheets can be printed and attached to corrective work orders. All leaks are quantified and costed, allowing you to determine the cost-saving once the corrective actions are complete. It is common for the cost-saving to be greater than the cost of the survey.

Steam system inefficiencies result in wasted energy, faulty product runs, environmental pollution and production loss. A major influence in system efficiency is properly functioning steam traps. Traps that ‘fail open’ result in a loss of steam and its energy. Traps that ‘fail closed’ can significantly reduce heating capacity, resulting in product contamination, corrosion, or damage to the steam heating equipment.

Acoustic inspection is ideally suited for on-line steam system inspection. Ultrasound is a short-wave signal that is very localised. This enables our condition monitoring engineers to listen to the translated ultrasound signal produced by trap operation and evaluate the condition of individual traps. Leaks can be readily heard, blockage recognised and ‘blow-by’ clearly detected.

Want to know more? Talk to our team

If you would like to increase productivity through non-intrusive maintenance with our condition-based monitoring service, please submit your details and a member of our CBM team will be in touch.

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