Vibration

Vibration

Operating Deflection Shape (ODS) analysis

Operating Deflection Shape (ODS) analysis is a highly detailed motion study to determine root cause(s) of complex vibration issues of a machine and as needed, its accompanying foundation, platform, piping, ductwork etc. Interviews with customer and preliminary testing and will determine the size and scope of the ODS model for optimum results.
 
An ODS scale model of the test subject is created in the ODS software. Hundreds of frequency, amplitude, and phase measurements are recorded to animate the model with true in-service data.
 
The model is animated at all applicable frequencies around a full 3D view for motion analysis and videos of important findings are recorded to accompany a full written report of findings and recommended solutions.

On-Line AMS 6500 prediction and protection

For some rotating assets, and the processes associated with them, periodic route-based data collection is insufficient to indicate asset health. Online condition monitoring provides the frequency and types of data necessary to stay on top of developing issues during normal operations and to respond quickly to sudden changes during transient conditions. Emerson’s AMS 6500 Machinery Health Monitor is a versatile, scalable system that can be deployed in a variety of configurations to deliver online condition monitoring exactly as needed for the application.
 
The AMS 6500 Prediction rack mounted multi-channel machinery health monitor and analyzer help troubleshoot your entire machine or group of machines. It offers optional transient analysis for turbo machinery startup, coast down, and production state monitoring. Monitor and record all channels continuously and simultaneously for hours, days, or weeks – unattended.
 
AMS Suite integration saves time and facilitates multi-technology integration. PeakVue™ technology can be added for early identification of bearing wear in paper machines, rolling mills, complex gearboxes, and rolling element bearing machines. The CSI 6500 Machinery Health Expert has all the capabilities of the CSI 2140 Machinery Health Analyzer. Portable vibration analyzers are the cornerstone of a successful predictive maintenance program. However, some anomalies, like root-cause investigations and machine train evaluations, can surpass the capabilities of even the most sophisticated 4-channel portable data collector. For example, turbo machinery start-ups, coast downs and production state monitoring require multi-channel, simultaneous recording, vibration monitoring, and real-time feedback to capture rapidly changing events across an entire machine train. For balance of plant critical machines, multi-channel monitoring solution with journal bearing, rolling element bearing, and gearbox monitoring technology is necessary for root cause analysis and to determine if the machine will survive to the next outage.

AMS Machinery Manager

Early detection can prevent unplanned shutdowns
Increase equipment availability and lower costs through comprehensive monitoring of the health of your mechanical equipment. AMS Suite: Machinery Health Manager predictive maintenance software allows you to instantly review the condition of critical mechanical equipment and make this critical information readily available to key decision-makers in your facility. You’ll have troubleshooting, analysis, diagnosis, and reporting tools right at your fingertips. Use the predictive diagnostic power of AMS Machinery Manager to detect asset problems and determine root cause before they cause production interruptions.
 
Get more life out of your mechanical assets

  • Prioritize maintenance action based on machine condition and criticality. Shift from reactive and preventive to predictive and proactive maintenance.
  • Ensure accurate diagnosis and identify root cause of reoccurring problems by employing multiple technologies to detect all mechanical asset failure symptoms.
  • Improve communication and planning by broadening the view of asset health across multiple users. Promote corporate-wide deployment and increase team effectiveness.
  • Integrate asset information through AMS Suite: Asset Portal to drive increased asset reliability and performance across the plant.

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Ultrasonic Inspection

Ultrasonic Testing Services can be used in any industry. Typical applications include:

Leak Detection:

Ultrasound leak detection covers a wide range of leaks: pressure or vacuum and any gas.

One of the more popular applications for ultrasound is compressed air leak surveys. Technicians are able to analyze and report on cost reduction due to wasted energy.

A major advantage to ultrasound leak inspection is that as a high frequency, short wave signal, ultrasound emissions tend to be localized around the leak site. By scanning an area with an ultrasound instrument, a Technician will follow the sound of the leak to the loudest point. Once identified, the leak amplitude can be noted and recorded for reporting a cost analysis and environmental impact.

How Ultrasonic Leak Detection Works.

During a leak, a fluid (liquid or gas) moves from a high pressure to a low pressure. As it passes through the leak site, a turbulent flow is generated. This turbulence has strong ultrasonic components which are heard through headphones and seen as intensity increments or decibels on the instrument’s display panel. It can be generally noted that the larger the leak, the greater the ultrasound level.

Mechanical Inspection:

Ultrasonic inspection of mechanical equipment has many advantages. It provides early warning of bearing failure, detects lack of lubrication, prevents over lubrication and can be used on all bearing speeds (high, medium and low). In addition, since ultrasound is a high frequency, short wave signal, it is possible to filter out stray, confusing background noises and focus on the specific test point.

Ultrasonic Mechanical Inspection can be used to monitor bearing faults (all speeds), lack of lubrication, prevent over lubrication, compressors, pumps (cavitation), motors, gears/gear boxes, hydraulic systems, fans, couplings, and many others.

Ultrasonic condition analysis is straightforward. The technician can observe sound levels while simultaneously listening to the sound quality, perform data logging, data analysis, trending, trend reports, and spectral analysis through specialized software.

How Ultrasound Bearing and Mechanical Inspection Works

Mechanical movements produce a wide spectrum of sound. One of the major contributors to excessive stress in machinery is friction. Ultrasound instruments detect friction. By focusing on a narrow band of high frequencies, the instrument detects subtle changes in amplitude and sound quality produced by operating equipment. It then heterodynes these normally undetectable sounds down into the audible range where they are heard through headphones and observed on a display panel for trending, comparison, and analysis.

Thermography

Mechanical Thermography

In the world of mechanical systems heat will most of the time point to impending trouble caused by excessive electrical resistance, lubrication failure, worn components, and other common problems.  These problems can lead to expensive or even catastrophic failures and trying locate the underlying problem can be time-consuming, and manual inspection can be costly.   Because thermography is non-contact and nondestructive the need for a costly shutdown or manual inspection can be eliminated sustaining normal production until a root cause is identified.  This allows us to test production under normal loads and operating conditions in real time ultimately leading to a better understanding of how our machinery if functioning.  In only a matter of hours thousands of points can be collected, inspected, and cataloged allowing a case history to be built for each component of concern. 

Electrical Thermography

Electrical system failures are frequently preceded by a considerable period of increased heat in the faulty components of the system. If the increase in the component heat is detected in time, repairs can be performed before a failure occurs. Infrared thermography is the primary tool tool that can identify areas of abnormality.

What faults can be detected?

Infrared thermography can detect several conditions that may undermine the operational efficiency of your systems. These include overloads, loose connections, inductive heating, open circuits, harmonics, unbalanced loads and defective equipment.

Safety

With the high speed at which complex industrial processes run, sudden failure may create hazardous conditions. This could include flying debris that may hurt your workers. By detecting electrical problems in good time, the tool helps to avoid fires caused by overloaded circuits or faulty wiring.

Cost Savings

Inspections using infrared thermography will help in detecting problems and allow for repairs. This will mean fewer downtimes and interruptions in production which will lead to increased productivity, and significant financial savings.

Quality

Product quality is dependent on a processes that runs reliably and consistently. When you can deal with electrical problems before failure occurs your systems can operate optimally. This will greatly simplify your delivery quality products.

Lower insurance premiums

With reduced losses and improved your cash flow you will pay lower premiums for commercial insurance coverage that protects against interruptions.

Infrared thermography allows you to perform inspections without interruptions to your process during the inspection as the inspection can be done while systems are running. This will also help to improve your profits.

Balancing

Field balancing is a technique used to balance a rotating part in place without removing the part from the machine. The advantages of field balancing are apparent, in that time can be saved by not removing the rotating part from the machine and sending it to a shop for balancing.

Imbalance occurs when a shaft’s center of mass does not rotate at the center of rotation.  This results in a heavy spot on the rotor. This heavy spot produces a centrifugal force that forces the rotor to rotate off center and causes a high vibration amplitude at 1x the rotor speed in spectral and time waveform vibration data.

Some of the causes of rotor imbalance can be from eccentricity, improper key length, stress relief distortion, thermal distortion, corrosion or uneven wear, deposit buildup, asymmetrical design, assembly errors, and rotor damage.

For more information please watch the below video that further describes what imbalance is and the methods used to correct it.

Process Optimization

Gain the process insight to optimize every point.

Your job is a balancing act. Downtime and off-spec product reduce your throughput, while challenges like energy inefficiencies, regulatory compliance and facility safety eat into your bottom line. At the same time, an aging workforce is retiring and taking its industry experience with it, leaving you with increasingly less-experienced personnel who must tackle new challenges and ever-changing regulations. To stay competitive, you have to address these constantly fluctuating priorities.

To achieve your goals, your facility must consistently produce at optimal throughput levels. Excessive maintenance, unscheduled outages and process variability all impact production throughput. The Rosemount 3051S Series of Instrumentation provides accurate and reliable measurements every time so you can reduce maintenance, outages, process variability, and achieve faster startups. The Rosemount 3051S also helps reduce maintenance and anticipate problems that might cause an unscheduled shutdown or slowdown by providing added process and equipment insight. It is easy to install and maintain correctly so your people can install it right the first time, and in less time, so it stays right over time.

Contact us to discuss how we can optimize your operation to increase productivity and profitability.

 

Condition Monitoring:

Condition monitoring is the main tenant to condition-based maintenance, which is performing maintenance after one or more predictive indicators identify that the equipment’s performance is deteriorating or it is going to fail. It is the process of monitoring certain parameters of rotating equipment like vibration and temperature to identify one or more developing faults. In addition, we believe that being comfortable knowing that “all is good” with your equipment is equally important and allows for scheduling production with confidence. Reliability_Solutions_Inspect-Monitor-Correct_10-30-2018

More than just data collection

It sounds simple – routine monitoring of your rotating equipment results in data necessary for deriving information about the condition of your equipment; however, if the data isn’t accurate, your analysis won’t be either. If you can’t acquire data in a timely manner, you will miss early warnings of developing problems. Emerson’s condition monitoring solutions are specific to the application and criticality of your machines, and deliver data you can count on for accurate diagnosis of machinery condition. In any event, Insight to how your equipment is currently operating and how it might be operating in the future allows for scheduling production with confidence or scheduling maintenance to support your production goals.

PeakVue: Are you looking for an early detection edge?

Emerson’s PeakVue™ technology provides an edge by providing predictive diagnostic knowledge for rolling element bearings. Traditionally, analysis of vibration data required specialized training and tools to extract any information from the data. Emerson’s PeakVue™ technology cuts through the complexity of machinery analysis to provide a simple, reliable indication of equipment health via a single trend. PeakVue™ filters out traditional vibration signals to focus on impacting, a much better indicator of overall asset health on any type of rolling element bearing machine.

Our Offerings:

A key strategy to improving reliability is to monitor the condition of production assets in your plant. We offer a variety of condition indicator technologies in conjunction with our principals, specific to the nature and criticality of those assets. These include portable handheld and asset management solutions, wireless transmitters, online continuous monitoring systems that can include protection capabilities, machinery health sensors, prediction software, mobile apps, oil analysis technologies, and services to support the gathering and interpreting the data, as well as correction services for balancing and alignment, mechanical seal installation, on-line vibration prediction and protection project services.

Advanced Visualization and Mobility:

AMS ARES™ is Emerson’s software platform that allows asset based data analytics and alarms for plant assets like rotating equipment as well as valves and transmitters to keep key stake holders up to date about the health of their assets in real-time.

AMS Machinery Manager can integrate with multiple predictive diagnostic technologies to monitor different types of mechanical assets and identify unique failure symptoms. The modular technology applications incorporate diagnostic and reporting sources into a common database for analysis of machinery health across the entire plant.

Through this integration, you gain a comprehensive view of each monitored machine and more accurate diagnosis of developing problems. Correlation from multiple technologies allows you to identify and fix the root cause of issues once.

Plantweb™ Advisor Suite are applications that provide visual indications of the health, performance, and energy of operating equipment, to allow your plant to run reliably, efficiently, and optimized.

Plantweb™ Health Advisor
This solution analyzes the combination of process and equipment data to report overall asset health for essential assets like pumps, blowers, cooling towers and heat exchangers.

Plantweb™ Performance Advisor helps you to run your process more efficiently, track operating performance against targets, schedule maintenance activities, and determine the root cause of production asset inefficiencies. When your maintenance and operations staff are alerted to degrading asset performance, critical production decisions can be made to mitigate outages and improve your bottom line.

Plantweb™ Energy Advisor is a real-time Energy Management Information System (EMIS) that automates the process of mapping and managing energy consumption, across a site, as it is being consumed. Real-time alerts, dashboards and emails notify decision-makers when energy consumption is greater than expected so that actions c be taken to drive down energy costs.

Online Vibration Monitoring:

The AMS 9420 Wireless Vibration Transmitter connects easily to any roller bearing machine that runs at greater than 280 RPM. It delivers vibration information over a highly reliable, self-organizing wireless network for use by operations and maintenance personnel. The AMS 9420 is ideal for vibration monitoring applications, especially in hard-to-reach or cost prohibitive locations and it provides reliability with advanced accuracy for all installations.

AMS 6500 Machinery Health Monitor

For some rotating assets and the processes associated with them, periodic route-based data collection is insufficient to indicate asset health. Online condition monitoring provides the frequency and types of data necessary to stay on top of developing issues during normal operations and to respond quickly to sudden changes during transient conditions.

Emerson’s AMS 6500 Machinery Health Monitor is a versatile, scalable system that can be deployed in a variety of configurations to deliver online condition monitoring exactly as needed for the application, delivering Visibility to Asset Health 24/7.

The AMS 9330 Vibration Transmitter is a continuously operating vibration transmitter that interfaces with existing plant monitoring systems while automatically detecting vibration levels. Once installed, it converts the analog output of an ICP® accelerometer into a 4-20 mA signal, proportional to monitored vibration. Vibration data is available in plant data historians and/or control systems for trending and analysis with other process parameters. With the AMS 9330, you will gain continuous access to real-time data for early detection of developing mechanical issues.

AssetScan Bearing Fault Monitor: Avoids the costs and complexities of traditional condition monitoring solutions:
• No wiring
• Battery powered, cellular enabled in single box
• No connection to IT or control system
• Convenience of magnetic mount
• Alerts available to anyone, anytime via text or email
• Predictive fault monitor pre-processed at the sensor
• Information is easily digestible and actionable

Route Based – Portable Analyzer:

The AMS 2140 is the next generation in a family of industry-leading vibration analyzers and data collectors from Emerson. As with previous models, the AMS 2140 can provide:
• Route vibration collection
• Advanced vibration analysis
• Cross-channel analysis
• Transient analysis
• Dynamic balancing
• Motor monitoring
• ODS modal analysis

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Reliability Services

Reliability Consulting

Novaspects’s distinctive competence lies at the intersections of two skill sets: reliability engineering and data integrity. While the depth of our mastery in each skill set allows us to serve our clients using them independently, the combination of expertise in both areas enables us to advise from a truly unique perspective and to implement on a truly enterprise scale. Novaspects’s accelerators and services seamlessly join reliability engineering and data integrity to enterprise asset management systems projects, greatly expanding value to the client through returns from asset health improvement across the enterprise.

Machinery Reliability (PdM)

Poorly maintained machinery is a significant cause of unplanned downtime and unplanned safety and environmental events. Emerson Automation Solutions coupled with Novaspect local technical expertise use a full breadth of diagnostic tools, support a diverse industry base, and a wide range of machine types.

  • Route Based Services (Vibration, Electric Motor Diagnostics, IR Thermography, Ultrasonic, Oil and Grease)
  • Diagnostics Services (Onsite or Remote Analysis of all technologies)
  • Corrective Services (Balance, Alignment, Root Cause Analysis,.)
  • Reliability and Performance Audits (Plant and/or Individual Equipment)
  • PdM Program Reporting/Tracking (including Data Integration)
  • Electronic Operator Rounds (for Reliability Inspection)
  • Online Condition Monitoring Systems (Wired and Wireless)
  • Remote Asset Monitoring (Wired and Wireless)
  • PdM Program Development (Reliability Based)
  • PdM Program Audit (Gap Assessment)
  • PdM Training Services (On-site, Off-site, Mentoring, Classroom)

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Predictive Technologies

  • Vibration
    • Vibration Route Data Collection and Reporting
    • Modal Analysis
    • Multi-Channel
    • Operational Deflection Shape
    • Reciprocating Equipment Analysis
    • Piping/Structural
    • Motion Amplification Vibration Analysis
    • Online Vibration Monitoring (Application support of 6500, 9420, and 9330)
    • Training and Mentoring for MHM / 2140 /CSI Products
    • Vibration Database Building, Maintenance and Optimization
  • Tribology
    • Oil Sampling and Analysis
  • Motor Testing
    • On-Line (Motor Current Signature Analysis)
    • Off-Line (Motor Circuit Evaluation)
  • Ultrasound
    • Valve Leak Detection (internal)
    • Air/Gas System Leak Surveys

Field Service

  • Seal Service Install/Replace (Seal only, no pump removal and install.)

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