Resources for condition monitoring

The Value of Reliability as a Service

2013-05-01T09:32:08-05:00

The success of condition-based maintenance programs depends on the ability to drive collaboration among users and experts, and distribute results to decision-makers while having a dependable infrastructure to ensure security, reliability and flexibility. Cloud-based business infrastructures like software as a service (SaaS) can play a significant role, making it easier to share information and support a stable, actionable and sustainable program.

While cloud computing is sweeping through enterprises for just about every application, condition monitoring and predictive maintenance (PdM) is no different. In fact, the PdM industry potentially stands to gain more from the cloud revolution than most any other industry. To date, PdM systems have been primarily isolated to individual laptop and desktop computers. PdM was completely left behind in the client-server boom of the 1990s. By moving to the cloud, PdM systems are gaining the advantages associated with the cloud, including cost sa

SKF Unveils Intelligent Bearing Technology

2013-04-09T09:23:33-05:00

SKF recently launched SKF Insight, an intelligent bearing technology that enables bearings to communicate their operating conditions continuously with internally powered sensors and data-acquisition electronics.

"These innovations are set to revolutionize condition monitoring for bearings, especially in critical machinery and technically challenging applications," says Tom Johnstone, SKF president and CEO. "SKF Insight technology will make condition monitoring more widely available, especially in applications where it was previously impossible or impractical. With our integrated diagnostic technology, our customers can get even better control over the life cycle of their machinery, leading to lower total costs with higher reliability and machinery uptime."

Previously, condition-monitoring techniques could only monitor damage after it had occurred. Now, by sensing directly on the bearing, SKF is able to monitor the damage from the first microscopic eff

UE Systems to Host Ultrasound World

2013-02-14T13:27:49-06:00

UE Systems Inc. will present the ninth-annual Ultrasound World "Top Gun" Conference in Clearwater Beach, Fla., from May 6 to May 10, 2013.

South Carolina senator and former Alcoa executive Paul Campbell is returning as keynote speaker.

"Based on his enthusiastic reception at Ultrasound World VII, Senator Campbell is guaranteed to energize, motivate and inspire attendees as they prepare for five days of cutting-edge education and professional advancement," said Doug Waetjen, the program organizer.

The conference program will consist of presentations from industry leaders and interactive workshops that will focus on the latest trends in ultrasound best practices in condition-based monitoring and reliability programs. The conference will also feature exhibitions introducing attendees to the newest and best advancements in the industry along with post-conference courses for specialized software.

"This is a great venue for

SPM Instrument Introduces New Condition Monitoring Device

2012-12-21T10:25:10-06:00

SPM Instrument recently introduced its next generation of handheld measuring devices, the Leonova Diamond. The portable, heavy-duty instrument is designed for condition measurement in rough industrial surroundings. It is the first portable device to offer the SPM HD measuring technique for condition monitoring of rolling element bearings.

The instrument also boasts sophisticated vibration analysis capabilities, with an excellent signal-to-noise ratio and razor-sharp spectrums even where signals are weak and low in energy content. The wide frequency range, covering from 0 to 40 KHz, enables measurement where absolute position is vital.

For machinery with journal bearings, the Leonova Diamond reliably measures dynamic and centerline movement of the shaft. Multi-channel measurement enables

Ludeca Introduces Wireless Condition-Monitoring System

2012-09-11T09:29:59-05:00

Ludeca recently introduced a new wireless condition-monitoring system for machine components that is designed to optimize the availability of plant equipment, improve equipment reliability and reduce unwanted maintenance costs.

The Vibconnect RF wireless system measures machine vibration, bearing condition and temperature, and transmits the relevant data to the bridge where it is evaluated. The system not only monitors the condition of roller bearings and other rotating components, but also detects damage caused by cavitation.

The Vibconnect bridge acts as the central receiver, processing the data from the sensor units and transmitting it through the operator's network for visualization and archiving. For the evaluation of received data, the system includes a ran

Parker Acquires Kittiwake Developments

2012-07-24T10:24:35-05:00

Parker Hannifin Corporation recently announced that it has acquired Kittiwake Developments Limited based in Littlehampton, England.

Kittiwake Developments is a manufacturer of condition monitoring technology including wear debris sensors, oil testing and analysis instrumentation, and acoustic, vibration and gas emissions monitoring sensors. The company’s products are used alongside filtration technology in the commercial marine, oil and gas, power generation and defense markets.

Kittiwake Developments, which has annual sales of approximately $20 million and employs 95 people, will be integrated into Parker's Filtration Group.

"Kittiwake Developments will allow us to extend our position in diagnostic products and reinforce our ability to offer our customers complete health monitoring solution for their filtration systems," said Peter Popoff, president of Parker's Filtration Gro

Azima DLI Establishes New PdM Standard

2012-07-17T11:01:09-05:00

Azima DLI recently announced a new category within the predictive maintenance (PdM) industry — Reliability as a Service (RaaS). According to the company, RaaS is a new standard for delivery of highly efficient, cost-effective machine condition monitoring programs.

In conjunction with the new standard, the company launched its TRIO CA6 with RaaS, a cloud-based vibration data collector and machine condition analyzer. The new data collector comes with a cloud-computing solution that provides access to the latest PdM analysis technologies and collaboration tools. It features locally installed ExpertALERT analysis software, cloud-based ExpertALERT analysis software web application and cloud-provided WATCHMAN Reliability Portal, as well as hosted data storage and replication services, mentored PdM training, and professional analytical expertise.

With a solid-state hard drive, sunlight-readable touch screen and Wi-Fi access, the CA6 can automatically connect with de

IMI Launches Vibration Monitoring System

2012-07-05T10:10:11-05:00

IMI Sensors recently introduced the new Echo wireless vibration monitoring system, which is designed to allow users to monitor the health of critical machinery more frequently and safely than walk-around systems while helping to reduce downtime and inefficiency.

Requiring no gateways, mesh or repeaters, the system uses extended range radio frequency (ERRF) technology to transmit long distances in typical plant environments. It transmits at only 0.75 milliwatts effective radiated power (ERP) in the unlicensed 900 megahertz band and does not interfere with other wireless communications such as Wi-Fi.

The system consists of wireless vibration sensors, a junction box, a receiver and monitoring software. Each wireless vibration sensor can be programmed to transmit data at a pre-determined inte

Ludeca Unveils New Balancing Device

2012-07-03T08:50:35-05:00

Ludeca Inc. recently unveiled a new portable measurement tool to help users balance plant equipment in difficult situations. The VibXpert II Balancer is a lightweight device used for field balancing of rotating machinery in one or two planes.

The balancer is designed to make balancing simple with its intuitive and easy-to-use graphical interface, which leads the user through the balancing procedure step by step. Its large color display facilitates the presentation and interpretation of the balancing data. A variety of balancing methods can be selected, and built-in ISO tolerances alert users when the equipment is within specification.

In addition to its balancing capabilities, the VibXpert II Balancer features vibration analysis capabilities to support the diagnosis of u

Mobius Awarded Accreditation

2012-06-28T09:39:16-05:00

Mobius Institute has announced that its board of certification has been awarded accreditation by International Accreditation Foundation (IAF) member JAS-ANZ, in accordance with ISO/IEC 17024 and ISO 18436-1, to provide vibration analysis certification per ISO 18436-2.

The Mobius Institute Board of Certification (MIBoC) is an independent entity within the Mobius Institute organization that is directed to ensure Mobius and its authorized training centers deliver training and certification that meet or exceed the requirements defined by ISO 18436-1 and 18436-2 standards.

Through an extensive audit and review process by Joint Accreditation System of Australia and New Zealand (JAS-ANZ), MIBoC was awarded accreditation. Accreditation awarded by an IAF member organization, under the IAF Multilateral Recognition Arrangement (MLA), ensures mutual recognition of accredited certification between signatories to the MLA and are recognized worldwide based on their equivalent accredita

SKF, Fibria Sign Maintenance Contract

2012-06-19T10:26:13-05:00

SKF has announced a five-year contract with Brazilian pulp and paper company Fibria. The contract is one of the largest SKF has received for its Integrated Maintenance Solutions.

As part of the contract, SKF will supply bearings, predictive and lubrication services, training, engineering, condition monitoring, operator driven reliability (ODR) and maintenance products.

"We have worked with Fibria for around 12 years and have developed a partnership that has helped them reduce costs and increase productivity by better managing their assets," says Vartan Vartanian, president of SKF’s industrial market, regional sales and service. "This contract renews our partnership and extends the scope for the two existing plants and adds the mill at Tres Lagoas."

The performance-based contract includes jointly defined indicators that are aligned to Fibria's business strategies. These include indicators connected to the operational stability, inc

Saving Time and Money with Condition Monitoring

2012-05-18T09:19:28-05:00

A recent acoustic emission (AE) study identified a potential critical bearing failure that became a planned preventive action for a leading food manufacturer. This also avoided considerable cost and unplanned downtime.

The acoustic emission equipment and the main tool used during the planned inspection routes were manufactured by Holroyd Instruments. This example will show the value of this type of equipment in avoiding a major unplanned event that could have had massive cost consequences for the business. Collateral damage to the associated equipment would have proved very costly, and the lead time to rebuild could have caused extensive downtime that would have meant disgruntled customers not being able to rely on stock availability.

The story began in April 2010 when some initial elevated readings were noted at two node points on a large step-down transfer gearbox that were sampled on a seven-day routine. The distress readings were elevated and triggered the alarm leve

Spectronics Unveils New Ultrasonic Diagnostic Tool

2012-04-03T09:01:12-05:00

Spectronics Corporation recently introduced a new ultrasonic diagnostic tool that converts and amplifies inaudible ultrasonic sound into audible “natural” sound. The MDE-2000 Marksman II allows a technician to “hear” even the smallest compressed air, natural gas, propane tank, vacuum, steam and other pressurized leaks before they lead to major breakdowns.

The tool uses a two-tiered approach to ensure accurate diagnosis. The receiver converts inaudible ultrasonic sound into audible sound using heterodyne circuitry. The unique Sound Signature Technology then fine-tunes the audible sound into the natural sound emitted by the leak itself.

A 5-LED signal intensity indicator and audible alarm pinpoint the exact source of the problem. An Internal Noise Contr

LumaSense Introduces Dissolved-Gas Analysis Monitors

2012-03-29T10:48:46-05:00

LumaSense Technologies Inc. has introduced a new line of dissolved-gas analysis (DGA) monitors that allow electric utilities to more effectively reduce outages caused by faulty load tap changers (LTCs) and transformers.

The new SmartDGA platform uses non-dispersive infrared (NDIR) gas-sensing technology and features a unique hardware design that reduces installation time. It is designed to help utilities achieve widespread condition monitoring across generation, transmission and distribution assets at a cost significantly less than traditional DGA monitors.

The first monitor in the new line, the SmartDGA Gauge, will be the industry's first dedicated online gas monitor for LTCs. It requires no carrier gas, no frequent calibrations and can be retrofitted to LTCs to provide asset condition status.

"We believe a smart grid begins with an optimized supply network in the utility grid," said Vivek Joshi, LumaSense CEO. “This means having reliable

Mobius Introduces Machine-balancing Training Software

2012-03-13T08:39:35-05:00

Mobius Institute has announced the release of iLearnBalancing, a computer-based training product that teaches maintenance professionals how to perform in-place dynamic balancing of industrial machines. The training is delivered by DVD or through the Web via the iLearn-online learning portal and is run on a personal computer.

The software is designed to provide complete understanding of the different types of unbalance, including static, couple and dynamic unbalance, as well as what is needed to correct them. It also offers ways to ensure that you are not chasing the wrong solution during the balance process, how to tell if a machine is truly out of balance and whether there’s another fault condition with similar symptoms.

As part of Mobius Institute’s iLearnInteractive product line, iLearnBalancing features extensive 3-D animations and simulators to make the subject more interesting and understandable. The interactive course is fully narrated, making i

What You Should Do Before a Plant Closure

2012-03-09T08:45:06-06:00

It’s happened … the announcement that a major portion of your facility is being closed for the foreseeable future. What do you do next?

Accept the news that your plant is facing an impending plant shutdown. It is not necessarily a “knockout” for the plant or your career. Remember, in the often uneven battleground called the global marketplace, just about anything can happen. Be ready to get up and start fighting again.
Designate responsibility to an individual for writing a list of possible scenarios. The individual should have enough clout to implement the chosen strategy, if necessary.
Go to the top of the company and request that sufficient funds be made available to execute the initial shutdown and preservation strategy.
Choose the right type of long-term equipment caretakers. Those selected are often security or ex-supervisory types rather than experienced operator/craftsmen with intimate knowledge

People Make the Difference in Maintenance and Reliability Improvement

2012-03-05T10:27:27-06:00

Many people may have gravitated to the maintenance and reliability industry because of the desire to work with machinery. I was trained in engineering and understand how machines operate and work. Machines behave in logical ways. They all follow the mechanical and electrical laws of nature. Engineers are immersed in those laws in their years of schooling. People in the maintenance field thrive on knowing that machinery works and behaves in logical ways.

In a previous article for Reliable Plant, I pointed out the thought similarities between an organization’s safety improvement effort and a maintenance and reliability improvement effort. The idea that zero injuries are possible is a key concept for any safety effort to gain momentum, but how does a plant or an organization really improve safety results?

What I have experienced over the past 30 years is a continual and steady safety improvement effort. In the early years, much of the emphasis was on identifi

Kittiwake Launches MHC Bearing Checker

2012-03-01T09:51:23-06:00

Kittiwake recently announced the launch of its MHC Bearing Checker, a small handheld device that can provide instant indication of machinery condition. The acoustic emission-based instrument is designed as a cost-effective solution to monitoring an unlimited number of machines on a periodic basis.

Based on the detection of high-frequency activity that is naturally generated by deterioration in rotating machinery, the MHC Bearing Checker’s Distress parameter removes the need for machine-specific interpretations. If the Distress parameter is greater than 10, the user knows there is a problem and can instigate further checks. A decibel level is also provided, giving an indication of the overall noise of the bearing, which increases with the rotation speed as well as with degradation of the bearing or inadequate lubrication.

Each measurement takes approximately 10 seconds and requires no setup, previous history or knowledge of machine design det

Acoustic Emission: The Next Generation of Vibration Techniques

2012-02-22T09:21:15-06:00

History, experience and familiarity count for a lot where conditioning monitoring is concerned, but that doesn’t negate the need for change, innovation and the advancement of tried, tested and trusted techniques. The late Steve Jobs commented: “Innovation is the ability to see change as an opportunity, not a threat.” Condition monitoring (CM) is transforming rapidly and so too must the mindset of CM practitioners and users. It’s not good enough to simply disregard a disruptive technology in an effort to protect the “old guard.” When combating downtime, there’s no place for historical sentiment.

Steadily disrupting traditional vibration techniques is acoustic emission (AE). AE technology spawned from the aviation industry where vibration analysis simply couldn’t be easily applied, short of a suicidal maintenance technician hanging off the wings. AE technique is based on frequencies much higher than are monitored in the repetitive, sync

Using Orbits for Condition Monitoring

2012-02-03T08:32:41-06:00

Orbits have historically been used to measure relative shaft movement within a journal-type bearing. The shape of the orbit told the analyst how the shaft was behaving within the bearing as well as the probable cause of the movement. This was accomplished using proximity probes usually mounted through the bearings with a 90-degree separation and a tip clearance set to around 0.050 inches. With today’s modern analyzers, it is possible to also collect an orbit using case-mounted velocity probes or accelerometers to see how the machine housing is moving. Another way of putting it would be the orbit represents the absolute path in space that the machine housing moves through (see Figure 1).

Ultrasound World VIII to be Held in Florida

2012-01-26T08:46:59-06:00

Ultrasound World, a forum for ultrasound technology, has been scheduled for May 14-17, 2012, at the Clearwater Hilton in Clearwater Beach, Fla. Entering its eighth year, Ultrasound World has grown into one of the top conferences for reliability and energy conservation. This year’s program will feature presentations and short courses by users of ultrasound technology and will cover a wide range of topics for condition monitoring and energy conservation.

Among the presentations offered include “No More Equipment Failures! Can You Say That?” by Todd Fraser of Procter and Gamble, who will describe how his department dramatically reduced bearing failure incidents using ultrasound technology. The short course “Clean, Green and Reliable” will explain how equipment reliability delivers low-cost, energy-efficient assets at plants around the world. Other important topics, such as effective energy conservation practices and detecting and a

Answering Common Maintenance Planning Questions

2012-01-09T09:07:39-06:00

At a recent conference, a number of questions came up that were never properly answered, so I thought I would try to address some of these. The questions involved getting maintenance planners to focus on planning, getting them focused on future work and allowing time to plan.

First, let’s look at roles. The planner should be strategic and focused on future work (i.e., next week and beyond). The supervisor, team leader or lead person should be tactical or focused on today and this week. If parts are needed this week, it’s not the planner but the supervisor who should be dealing with it. The same goes for emergencies; we can’t plan and schedule them, so they should not normally involve planners.

The planning group should be a separate group. The planners should have craft skills; often, they are some of your best craftspeople. However, if you have your planners attending the production meeting where the last 24 hours are reviewed, shame on you. How can th

Defining the Role of a Maintenance Planner

2012-01-03T08:46:09-06:00

Organizations should have a clear work description of what a planner’s role is. The role may vary between organizations, mainly due to plant size. Some organizations have combined planners/supervisors. Some have dedicated planners for shutdowns/turnarounds. Many have people with a planner’s title but no planning.

So how do we figure out a planner’s role? The first step is to decide if you (as a plant) want to have planning. In my opinion, it would be a huge mistake to decide against planning, but if you do, you might as well get rid of planners and/or the role of planning. Most of us will decide we should have planning.

We can’t figure out a clear role unless we first have a clear, agreed-upon workflow that describes in which order we are going to pass on information, to whom and who is responsible. Therefore, the first step is to design clear, agreed-upon workflows (business processes) for our daily work, shutdown work, etc. Once we have the work

How to Achieve Effective Maintenance Planning

2011-12-27T09:21:25-06:00

As Sisyphus well knew, pushing things up mountains is difficult, and the uphill struggle from the reactive to the proactive maintenance world is often a frustrating “three steps forward, two steps back” process. That’s a major reason why so many slide back into the familiar, ugly, day-to-day, survival morass at the bottom.

One of those steps on the way up is where preventive maintenance inspections are getting done, we’re finding things that need to be fixed and we’re fixing them. However, we’re still not getting that much better. We’re constantly fixing the same things over and over.

The famous quote, “Those who ignore history are doomed to repeat it,” remains as true as always.

Granted, the “find it, fix it and move on” mode is a big step up from the “fix it when it breaks” mode, but it doesn’t look or feel like great improvement, so many get discouraged and tend to look for

Maintenance Planning and Scheduling for Success

2011-12-19T10:23:24-06:00

While on a recent flight to Atlanta, I was leafing through a maintenance book when the person across the aisle struck up a conversation. Turns out, he worked as a veteran maintenance supervisor in a large mill where he has worked for the last two years. He spoke about how things were bad from a reactive standpoint and had gotten worse after the mill downsized. As part of the downsizing effort, they had removed some key players and replaced them with some not-so-key players. We talked about how their maintenance planning and scheduling activities were progressing, to which he was disappointed in the progress they had achieved.

It turns out that he had two maintenance planners/schedulers with a span of control of about 1:25, yet he was still doing a tremendous amount of planning and scheduling himself. He commented that the span of 1:25 fell within the best practices guidelines. In addition, he mentioned from previous training that he learned that a planner should be able to plan thr

Using Dynamic Electric Motor Monitoring to Identify Mechanical Issues

2011-12-14T08:50:54-06:00

Dynamic electric motor testing is often called on-line testing because it requires the motor to be running and generally assumes the motor is in its natural environment. Dynamic testing involves the connection of voltage probes and current transformers. Connecting dynamic test equipment is safe, quick and non-intrusive. Data is acquired and results are displayed in a summary format. The collected data is compared to the user-entered nameplate information and is presented in a pass/fail format with both current test data and trending logs displayed after each successive test.

The Need for Motor Testing

Every reliability technician knows that costs associated with motor failures can be devastating to any business operation. Finding that a motor is operating with conditions that create excessive heat or stress is a guide to the technician to make changes in the motor’s operation and to monitor its insulation. Knowing that a motor is in imminent dang

Discipline and Diligence Are Key for Root Cause Analysis

2011-12-12T09:31:43-06:00

OK, so now you have put up these fancy (or so you think fancy) check sheets and charts for standard work, expecting the improvements to happen. Things go well for the first couple of days or weeks – if you are lucky. Everyone is abuzz with this focus of action, but then it begins to degrade. What is happening?

Diligence and discipline of execution are important underlying details of root cause analysis. The new methods are oftentimes person dependent rather than process dependent. So, we find that the owner maintaining this new system goes on vacation, and the team finds itself quickly back where they started – frustrated and not knowing where to head next. These new methods fall to the side and are sometimes even removed in shame.

The important aspect of this improvement process is applying consistent performance through discipline. The team members must be able to apply the techniques in order to achieve the performance levels and results expected.

New Testing Methods Can Benefit Mechanical Systems

2011-12-07T15:45:59-06:00

Experimental modal analysis (EMA) and operating deflection shape (ODS) analysis are new techniques used to animate the dynamic response of mechanical systems. An EMA provides mode shapes associated with natural frequencies of a mechanical system. An ODS offers an animation of the deformation characteristics of a vibrating mechanical system during operation.

The animations can be extremely helpful in defining areas of structural weakness or identifying areas of mechanical “looseness.” In cases of resonant excitation, the animation techniques can be used to evaluate the potential benefit of structural and/or mechanical modifications.

Experimental Modal Testing

Excitation of a natural frequency, referred to as resonance, is one of the most common reasons for excessive vibration of machines and supporting structures and foundations. In some cases, the source of the dynamic force that excites the resonance can be identified and removed. However,

5 Keys to Maintain Equipment Reliability

2011-12-05T08:55:44-06:00

There is so much similarity in all that we do within the maintenance planning and scheduling world that compares to other separate and distinct functions. Let me explain. Borrowing from root cause analysis process methods, I trust you are familiar with Ishikawa diagrams (also called fishbone diagrams or cause-and-effect diagrams). These diagrams are one method that is used for product design, quality defect avoidance or variation, or to identify factors that lead to some event, hence the use in root cause analysis.

The categories typically include:

Man (people)
Methods: How the process is performed and the specific requirements to perform the tasks, including time estimates
Machines: Any equipment, tools, etc., needed to do the job
Materials: Consumables, parts required
Measurements: Data generated from the process

All of these items combine together to create some output or event. In

Using Thermography to Uncover Hidden Problems

2011-11-30T11:10:19-06:00

Thermography can be used to identify and analyze thermal anomalies for the purposes of condition monitoring of machines. These thermal anomalies are usually caused by such mechanisms as operation, improper lubrication, misalignment, worn components or mechanical loading anomalies.

Infrared thermography is based on measuring the distribution of radiant thermal energy (heat) emitted from a target surface and converting this to a surface temperature map or thermogram. Thermal energy is present with the operation of all machines. It can be in the form of friction losses within machines, energy losses within machines, as a characteristic of the process media or any combination thereof. As a result, temperature can be a key parameter for monitoring the performance of machines, the condition of machines and the diagnostics of machine problems. Temperature is also one of the key causes and symptoms of lubricant degradation and loss of lubrication function within a machine.

Infra

Implementing Solutions to Root Causes

2011-11-28T08:53:16-06:00

Root cause analysis and root cause failure analysis are commonly used terms, but I have always felt that they are somewhat misguided.

First, there is not really such a thing as a “root cause” to a problem. If you try to find a definition for “root cause,” you will discover a mix of homegrown attempts, but all of them are general or unclear in nature. Here is an example: “A root cause is an initiating cause of a causal chain which leads to an outcome or effect of interest.” Aside from being wrong, it is quite a bunch of incomprehensive verbiage.

The problem with definitions such as these is that in the real world it is never possible to prove a single event that solely initiates a whole chain of other events. That is because there are always other events before the so-called “root cause event.” This may seem like semantics, but for problem-solvers, it is important to keep in mind that there never is a silver-bullet answer.

Identifying Mechanical Faults with Motor Current Signature Analysis

2011-11-23T08:39:41-06:00

Motor current signature analysis (MCSA) has proven to be a highly valuable predictive maintenance tool. Although it is a relatively young, rarely utilized technology, it is rapidly gaining acceptance in industry today. Mechanical faults related to belts, couplers, alignment and more are easily found through the use of a demodulated current spectrum.

MCSA is simply the process by which motor current readings are recorded and analyzed in the frequency domain. It has been around since 1985 and proven itself well over the years in locating rotor faults and air gap problems in motors.

The motor current signature is recorded in a time domain format. The current is represented in a graph form with the amplitude shown on the “Y” axis and the time on the “X” axis. The result is a typical current sinewave shown in Figure 1.

In order to analyze the data, a Fast Fourier Transform (FFT) is

3 Common Excuses for Not Performing Root Cause Analysis

2011-11-21T11:18:09-06:00

Most people know what is good for them. We know it is better to eat vegetables than cookies and chips. We know it is healthier to exercise than watch TV. How come the cookies and chips are flying off shelves while the veggies whither? How come the average person spends 20-some hours in front of the TV while we struggle to get one single hour of exercise in a week? The answer is that we don’t do what is best for us. We more often do what we feel like and what is easy.

The same logic applies to plants and mills. For example, most everyone agrees that we should fix the root causes of problems rather than the symptoms. However, most of us don’t fix the root causes of problems. We keep repairing breakdowns and patching problems with temporary solutions year in and year out. How come? There are a million excuses, but none of those make any sense if we look at what is best for a company over time. Let’s look at the most common excuses.

1. “There is no t

How to Implement an Effective Chain-wear Monitoring Program

2011-11-16T09:34:54-06:00

Chain-wear monitoring has been a part of equipment reliability programs since the first link was forged. It is such an integral part of an organization’s reliability program that it has become part of industry slang as in the phrase, “A chain is only as strong as its weakest link.”

Chains are a part of almost every industrial process. They are found in a plant’s material-handling transportation system, key components in the operation of hoists and cranes, or as a part of the connection that controls a safety stop device.

Regardless of its function, the failure of any component that makes up a chain is costly to the owner, if not disastrous. Even though we would all agree that a chain failure is undesirable, modern industry’s chain-wear monitoring has remained varied in its approach and frequency.

Typically, chain reliability inspections are applied through a periodic inspection sampling procedure or replacement schedule. Visual in

Why Execution is Key for Business Strategies

2011-11-14T10:54:15-06:00

Business strategies developed by companies are often useless. A business strategy is basically a plan for what the company should focus on in the future. It is a promise and guideline to steer a company in the right direction. It’s not too different from your personal New Year’s resolution.

Most people’s New Year’s resolutions include things such as losing weight, exercising more, drinking less and improving their marriage in some form. The universal formula for change in any personal-improvement book or business book is to:

Understand what to do
Understand how to do it
Execute

Let us compare a business strategy with our beloved New Year’s resolution. We know what the problem is, right? We are fat, unhappy, stressed, whatever. We usually know how to improve (drink less, exercise, spend time with the wife), but we fail to execute.

The hard truth is that we try a little. We s

6 Techniques to Error-proof Your Plant

2011-11-10T08:59:05-06:00

When faced with the task of improving plant efficiency, the average plant manager breaks the task down by the five or six existing "departmental silos." Each silo leader subdivides responsibility, repeating the mistake, and passes it on to individuals. As a result, we see young, intelligent engineers overwhelmed by the task handed to them of "get out there and improve maintenance." The situation is not so bad for the less intelligent or those who have become automatons; they just keep repeating what has gone on forever and collect another paycheck.

What the plant manager needs is a better way to visualize his situation, a method that will allow him to develop a new strategy. The following insights are based on work done at MIT and by many other professors in "human error" at international centers of learning. The "Error Pyramid" is unique, but the remaining techniques and technologies have been established for 15 years or more.

Why Vibration Troubleshooting Instruments are Inadequate for PdM

2011-11-07T09:51:41-06:00

This video explains the difference between troubleshooting instrumentation and the types of instruments and software that are used to implement predictive maintenance programs. Often providers of troubleshooting instruments confuse the industrial market as to the differences between their capabilities and true condition monitoring.

TPI Unveils Vibration Analyzer with RFID

2011-10-31T16:59:46-05:00

Test Products International (TPI) recently introduced a new line of condition-based monitoring instruments designed to help prevent serious safety events, decrease equipment downtime and reduce operation costs.

The Ultra is a handheld vibration analyzer that indicates problems such as imbalance, misalignment and bearing defects. With built-in RFID to identify measurement points, the Ultra offers a high-resolution spectrum and user-selectable demodulation filters.

The included C-Trend software makes it easy to store, analyze and report data for predictive maintenance. Color-coded alarms highlight problems, while trend lines show potential problems before they happen. Optional networking software is available.

For more information, visit www.tes

National Instruments Introduces New Vibration Measurement Software

2011-10-24T11:15:44-05:00

National Instruments recently announced the latest version of its NI Sound and Vibration Measurement Suite software, which provides a comprehensive collection of analysis and signal processing tools for noise, vibration and harshness (NVH) testing, machine condition monitoring (MCM) and audio test applications. Engineers can use the suite as stand-alone software or combine it with NI hardware and NI LabVIEW system design software to simplify test system development and control. With its new vibration data-logging functionality and other enhancements, the Sound and Vibration Measurement Suite 2011 helps engineers to more easily customize and automate any MCM or NVH test or monitoring application.

"The NI Sound and Vibration Measurement Suite is an integral part of our MCM applications," said professor Jay Lee, director of the National Science Foundation's Industry/University Cooperative Research Center for Intelligent Maintenance Systems at the University of Cincinnati

Quick Guide to PM Development and Execution

2011-09-19T09:18:41-05:00

In many organizations, groups are often trying to chase the latest buzzwords of the day and yet have never established the foundation required to support those efforts. PM development and execution are classic examples. For this discussion, when I refer to PMs, I am talking about both preventive maintenance and condition-based maintenance tasks. This is by no means an exhaustive explanation of all of the considerations necessary for a comprehensive PM program. It is intended as a rough guide to foster continued discussion into the topic.

Stop doing non-value added PMs or task steps within the PM. We can never seem to find time to update or correct the PM tasks or frequencies but can always find time to continue doing the wrong work (go figure! ).
Assuming that you already have a PM program in place, start with the equipment where you are bleeding or hemorrhaging the most. This is often not your most critical assets.
Identify the failu

Using Ultrasound for Condition Monitoring

2011-09-12T08:19:52-05:00

In the past decade, the capabilities of many condition-based assessment tools, sometimes called predictive technologies, have significantly expanded. The hardware has become more compact, more rugged and much easier to use. The companion software applications have become more powerful with exponentially increasing capabilities. Additionally, the software tools have become more mainstream with much less reliance on proprietary protocol and programming. This situation has led to expanded use of these sophisticated tools to monitor and assess equipment health. We have seen vibration analysis, oil analysis, infrared, motor circuit analysis and many other non-destructive tools become very popular. Many organizations now stress their use as a prominent part of the maintenance and reliability programs.

As Reliability Centered Maintenance (RCM) theory points out, it is important for an organization to use multiple predictive technologies in a program. The type and how much of each predicti

How to Create Detailed Inspection and Detection Strategies

2011-09-06T09:45:08-05:00

Detailed inspections require the right type of person with the right mind-set, attitude and training. Most mills/mines/plants have some type of inspection program, but unfortunately the inspections are often ineffective.

There may be many reasons why inspections often aren’t effective, but one reason is that inspections are not done detailed enough to find problems. Many inspectors simply walk by equipment, making sure it wasn’t stolen last night, and if they are in a good mood, they may make sure it hums.

Let’s look at a few examples.

Example 1: A typical pump and motor coupling configuration in a paper mill

This plant has an inspection system in place,

Justifying a Predictive Maintenance Program

2011-08-29T16:18:53-05:00

“How do I quantify my PdM finds? Where do I go to establish my credibility?”

Grow a thick skin, fast. You have to develop some way of bringing some sense to the finds you have made in your predictive maintenance program.

Now that trust has been established and your routes are being executed, you wonder if the work you are doing is worthwhile. Are there any finds to report on to show you are doing a good job? How do you quantify the finds that have been reported and put a dollar sign to the finds to prove the system is working to the benefit of the company or department? How do you show that you are saving money and that the trust you have been afforded is well founded?

Nobody teaches us how to do this. It is one of the most difficult processes you have to establish in your PdM program, but it’s essential to justify your program’s existence. My way of quantifying a good find is simply to use a delay avoidance process. I take the cost per

How to Implement Modern Condition Monitoring Systems

2011-08-22T13:36:13-05:00

To be more competitive, efficient and cost-effective, more and more companies are implementing automation and remote condition monitoring systems, sensors, alarms, PLCs, accelerometers, human-machine interface panels, etc. Now many are implementing wireless networks to monitor equipment globally at remote monitoring systems.

These modern systems are truly technological marvels and amaze even the most jaded technophiles. But we must be careful because the solutions we implement today are going to lead to the problems we must grapple with tomorrow.

Back 15 years ago when I first got active in the maintenance management industry, managers did not know what was going on in their business because they did not have any reports other than manual entries. Then we implemented a CMMS system, and they did not know what was going on in their business because they had more than 600 reports and over 200 computer-generated graphs.

Now forensic engineers, those who research m

Let Risk and Your Equipment Determine Your Maintenance Strategy

2011-08-11T14:38:02-05:00

When I attend conferences and workshops and read articles on maintenance and reliability, more and more I hear people touting that preventive maintenance is more costly and not the right approach. When we talk about preventive maintenance, we are primarily talking about time-based inspections, but it can include overhauls/rebuilds as well. But before we take statements like these as the gospel and apply them carte blanche to all of our equipment, we need to understand the basis for that reasoning and when to apply it.

From the Reliability-Centered Maintenance side, we know that we can’t apply the single bathtub curve to all equipment failures. We recognize that six separate failure curves exist, and greater than 80 percent of all failures occur outside the infant mortality or end-of-life wear-out zones, meaning the failures are totally random in nature. No doubt that condition-based monitoring using various tools like vibration or temperature monitoring is better and a less c

An Effective PM Program Requires a Solid Foundation

2011-08-01T14:43:58-05:00

From previous surveys and depending on the audience responding, either everyone (upward of 90 percent) or a minority (less than 40 percent) has an effective preventive maintenance (PM) program. With the range so broad, let’s dig a little deeper to determine what it takes to have an effective PM program. For the purposes of this article, I also am including condition-based monitoring activities such as inspection.

What is the strategic and business case for your PM activities? Why are you doing the PM activities, and how did you come to choose those activities? Did you just pull them from the equipment manual? What value is the program providing you? No, I’m not talking about the “perceived” value. What is the measured value that you can prove to your partners? If they stop operating the equipment to give you a window to do PM activities (condition-based inspections and so forth, not necessarily component replacement activities), what do they get in return?

Tango Mobile Offers Equipment History Documentation Through Smart Phone or Tablet Technology

2011-06-17T14:26:38-05:00

Bringing convenience and mobility to industrial maintenance, 24/7 Systems, Inc. now offers Tango™ Mobile. Tango™ software on a smart phone allows plant personnel and managers to retrieve information about plant equipment stored through Tango™ Reliability Information Management.

One problem with asset information is that the asset and its reliability information are located in distant areas. To look up or enter asset information, technicians must leave the asset and go to the computer inan office to access the information.

Tango™ QR codes can be installed on equipment by plant personnel, contractors or repair vendors.

Quickly scan a QR code with Tango™ Mobile and instantly view the following information:

Condition Monitoring History
Equipment Repair History
Equipment Design Details
Linked Documents

Oil analysis provider unveils new services

2011-04-25T15:02:37-05:00

Abanaki Releases New Edition of Oil Skimmer Facts Handbook

2011-04-12T13:38:22-05:00

Using iPad application for vibration analysis

2011-01-19T13:49:44-06:00

PdMA tip: Swirl effect is useful tool for detecting broken rotor bars

2011-01-18T08:57:28-06:00

A useful spectral tool for detecting broken rotor bars is the swirl effect, which occurs just below the 5th harmonic of line frequency (300 Hz on a 60 Hz line frequency).

Global machine condition monitoring equipment market to reach $2.1B by 2015

2011-01-18T08:54:22-06:00

Growth in the world machine condition monitoring equipment market has long been driven by capital investments in industries such as chemicals, petrochemicals, pulp & paper, metals, and heavy equipment manufacturing, among others. Condition monitoring has gained importance, over the years, as companies critically focused on asset utilization and productivity. The need for eliminating catastrophic breakdowns and unnecessary maintenance costs in production processes has and will continue to drive the adoption of condition monitoring solutions across several industries.

How Solutia uses the Optalign Smart shaft alignment system

2011-01-17T16:07:56-06:00

A sales engineer at Ludeca Inc. introduces the Optalign Smart shaft alignment system. He then speaks with Nihal Raval, a maintenance reliability engineer from Solutia Inc., about how Optalign Smart helped him.

Animation explaining laser shaft alignment

2011-01-14T08:55:56-06:00

Up to 50 percent of the damage to rotating machinery is directly related to misalignment! So just see the advantages of laser shaft alignment and increase your machine availability, productivity and machine lifetime

How to laser align rotating shafts

2011-01-14T08:50:23-06:00

This video shows how to laser shaft align rotating shafts as quickly as possible with Fixturlaser's "True Position Sensing", available on the Fixturlaser XA and the Fixturlaser GO. Laser shaft alignment with Fixturlaser's dual laser, dual sensor design means the system tracks the shafts' true positions, allowing alignments to often be completed with just one set of measurements and adjustments. The XA and GO laser shaft alignment tools are available in the United States from VibrAlign Inc.

Wireless condition monitoring for rotating equipment

2011-01-06T15:59:36-06:00

Ron Kittle, a senior product analyst for the Timken Company, talks about the StatusCheck wireless condition monitoring system.

GE acquires remote monitoring and diagnostics firm SmartSignal

2011-01-06T13:44:45-06:00

GE Intelligent Platforms on January 6 announced that it has completed the acquisition of SmartSignal, a privately held, analytics software company based in Lisle, Ill. SmartSignal specializes in providing remote monitoring and diagnostics solutions to the Power Generation, Oil & Gas and other industrial sectors. SmartSignal is a leading provider of predictive diagnostic software and monitoring services used to anticipate, prevent, and avoid equipment failure. The company has more than 40 product and technology patents, and has won more than 25 awards for product excellence.

Guohua wind turbines choose SKF for remote monitoring

2011-01-03T07:32:58-06:00

When the fourth-biggest wind farm operator in China increases its installed capacity by 50 percent within one year, that indicates a company that knows its business. And one of the business aspects that all wind farm operators need to take care of is “turbine reliability” – keeping the turbines turning as much as possible and keeping maintenance activities down to a minimum. Reduced or controlled maintenance is always a valuable contribution to bottom-line profitability, but when you’ve got 2,000 megawatts of installed capacity, the target by end 2010 for Guohua Energy Investment Company, based in Beijing, China, then you are talking about huge amounts of money.

GE notes its favorite monitoring and maintenance apps of 2010

2010-12-29T12:39:32-06:00

GE has been in the app fast lane — from consumer-friendly apps such as healthymagination’s Morsel, which helps people chip away at unhealthy habits, to GE Lighting’s Mood Cam app, which let’s you snap a picture of a room and see how different lighting styles might look to CNBC Real-Time, the only free app that offers real-time stock quotes from the NYSE and NASDAQ before, during, and after market hours. (The professional version gives real-time information and analytics on over 100 international markets.) But three that particularly caught our eye this year are the ones that most people might not at first think of when it comes to apps — as they’re for planes, trains and electric utilities.

PdM software innovations lead to improved operating margins

2010-12-28T16:57:45-06:00

The capability of today's predictive software provides immediate answers, not merely data. By proactively using predictive maintenance, one automobile manufacturing plant realized savings of up to $112,000.

Optimize wireless condition monitoring with Essential Insight.mesh

2010-12-22T07:00:59-06:00

Wireless condition monitoring is a key factor in plant health and safety, however; battery powered monitoring devices require maintenance and put limitations on data collection. Essential Insight.mesh 1.1, the latest version of the Bently Nevada product line’s wireless condition monitoring solution, has external power flexibility eliminating the need for batteries and associated maintenance. The external power also allows for the selection of more frequent data collection, meeting a broader range of applications, and it is the world’s first electromagnetic vibration energy harvester powering a sensor mesh network. This offering along with flexible mounting options provides easier installation that best meets specific application deployment needs with more flexibility than previous solutions.

How a printing plant uses infrared thermography to detect issues

2010-12-20T07:47:19-06:00

This video shows how a printing plant utilizes infrared thermography cameras to detect issues on press equipment.

When troubleshooting equipment, first impressions are important

2010-12-16T09:17:27-06:00

When troubleshooting a machinery problem, whether for an unusual vibration problem or a component failure such as a bearing or seal, first impressions from the initial machinery inspection are very important. Any troubleshooting exercise should begin with a thorough investigation of machine history - process, design, operation, maintenance, and all available machine details. These first impressions are necessary to make sure the troubleshooting team is fully armed with important data and minimize the chances of a misdiagnosis.

The importance of non-destructive testing and condition monitoring

2010-12-16T09:08:06-06:00

The British Institute of NDT is the professional institute for all those engaged in non-destructive testing and condition monitoring. It is concerned with the education and training of its members, and the advancement of the science and practice of the subject.

Vibration analysis at an AkzoNobel plant

2010-12-15T07:45:10-06:00

Structural vibration monitoring of wind turbines

2010-12-15T07:43:03-06:00

This video explores the subject of structural vibration monitoring of wind turbines.

How the Oglethorpe Power Plant uses vibration analysis

2010-12-15T07:40:20-06:00

This video shows how the Oglethorpe Power Plant in Georgia uses vibration analysis.

Progress Energy targets uptime, costs with infrared cameras

2010-12-15T07:38:03-06:00

See how FLIR's P640 infrared camera is used by Progress Energy, a power transmission company, for predictive and preventative maintenance to ensure constant supply.

Orlando to play host to 2011 infrared thermography conference

2010-12-15T07:35:57-06:00

Organized by the Infraspection Institute, IR/INFO is the most important conference of the year for infrared thermographers. This year, the infrared conference will be held at the Disney Boardwalk Conference Center in Orlando, Fla. For infomation, visit www.irinfo.org.

Infrared cameras provide benefits for utility companies

2010-12-15T07:33:29-06:00

This video shows FLIR cameras in the field and why infrared thermal imaging has become a key tool for predictive maintenance programs for utility firms everywhere.

FLIR unveils i5 thermal imaging camera

2010-12-08T12:45:35-06:00

This video provides an introduction to the i5 Thermal Imaging Camera from FLIR Systems, a tool for predictive maintenance and problem spotting.

Machinery Health Monitor combines vibration and temperature monitoring

2010-12-08T10:34:27-06:00

Emerson Process Management announces the addition of a unique temperature module for the CSI 6500 Machinery Health Monitor. The new A6630 temperature module complements the vibration monitoring capabilities already available in the CSI 6500 and delivers critical bearing temperature measurements. The A6630 module accepts RTD and thermocouple signals directly, reducing the installation cost and complexity of temperature monitoring.

The 5 biggest risks to effective asset management

2010-12-06T14:36:23-06:00

Asset management is an integrated approach to optimizing the life cycle of your assets, beginning at conceptual design, through to usage, decommissioning and disposal. By acknowledging and paying attention to the five primary risks to effective asset management, you can put in place plans to mitigate the effects these might have on their program.

NRC inspectors watch maintenance, safety practices at Three Mile Island

2010-12-06T13:08:22-06:00

Resident inspectors with the U.S. Nuclear Regulatory Commission are stationed at Three Mile Island nuclear power plant to protect public safety and to be independent watchdogs over the plant's hundreds of employees and the actions they take every day. This incloudes all maintenance work (including machinery lubrication). There are inspectors stationed at all commercial nuclear facilities in the U.S. View the article at http://articles.lancasteronline.com/local/4/321494.

The history behind the OPTALIGN laser shaft alignment system

2010-12-06T08:41:46-06:00

Learn more about PRUEFTECHNIK, a leader in laser alignment technology, and its OPTALIGN laser shaft alignment system.

SKF device enables machine condition diagnosis

2010-11-29T12:58:06-06:00

The new SKF Microlog Advisor Pro gives maintenance, service and quality inspection technicians on-the-spot and easy to understand machine condition diagnosis. This stand-alone device does not rely on prior measurement data, and does not require advanced predictive maintenance software. As a result, users immediately benefit from a proactive maintenance approach without the need for vibration expertise, or prior setup of an advanced PdM route-based system. And with the ability to choose from a range of application modules, the SKF Microlog Advisor Pro delivers the functionality of several maintenance tools in one handheld device.

How a Nucor mill benefits from condition monitoring

2010-11-23T12:38:26-06:00

This article describes the justification, development, application and benefits of an integrated condition monitoring and diagnostics solution. Specific case studies at a Nucor Steel plant are presented along with discussions of deployment issues and barriers that have been overcome.

Programs help Harrison Steel improve energy efficiency

2010-11-23T11:49:34-06:00

Industrial companies that are interested in reducing energy consumption and the associated costs should examine the results that Harrison Steel has realized by partnering with both the DOE Save Energy Now and EPA Energy Star programs.

Wireless technology helps boost production, cut costs at Tecpetrol

2010-11-22T10:38:58-06:00

Emerson Process Management’s Smart Wireless technology, based on the IEC 62591 (WirelessHART) standard, is enabling Tecpetrol to boost production while reducing maintenance and operations costs at natural gas compression and delivery facilities in Argentina.

Bearing failure investigation and explanation

2010-11-08T14:01:20-06:00

In this video, Lee explains what's wrong with several bearings and why they've failed. He also shows some new bearings for comparison and gives some preventative maintenance tips.

Using vibration analysis to test for bearing wear

2010-11-04T09:47:51-05:00

This article discusses an example of an outer race-bearing defect on a 1,250-ton air-conditioning chiller. The defect was detected using off-the-shelf portable vibration analysis hardware and software. The article discusses methods used to diagnose and trend the bearing defect using vibration spectra as an indicator of the bearing condition. The diagnostic methods covered are universally applicable to other types of machines (pumps, fans, gears) with rolling contact bearings.

Diagnosing a boiler pump motor with an ultrasound detector

2010-11-04T08:52:54-05:00

In this video, a maintenance technician uses the UL101, an ultrasound detector, to diagnose a thrust and non-thrust bearing in an injector boiler pump motor. He places the UL101 on the grease fitting and adjusts the UL101's gain to the lowest possible setting. Lowering the gain setting will isolate the ultrasound to only the bearing being tested. Maintenance teams use the UL101, ultrasound detector, for quick troubleshooting on mechanical components.

Case study: Diagnosing a low-speed gearbox problem

2010-11-02T10:28:22-05:00

This article explores the diagnosis of a suspected gearbox problem in a large plant connected with the paper industry. The lubricating oil in the gearbox was regularly subjected to analysis, and the last report stated that there were iron particles in the oil. The maintenance supervisor sought to determine the source of the oil contamination, and it was suspected that the metal was coming from one or more of the gears. The problem then became to identify the faulty gear (if any), so as to allow the maintenance effort to proceed without delay.

Using iPad technology in vibration analysis applications

2010-11-02T08:16:20-05:00

Thomas Hoenig, president of GTI Spindle Technology Inc., discusses how Apple's new iPad technology is changing the face of vibration analysis in manufacturing. Presented as part of Cutting Tool Engineering's Fast Track Seminar series hosted during IMTS 2010, Hoenig's seminar includes a brief demonstration of the iPad at work.

Thermal imaging for electrical and mechanical maintenance

2010-11-02T08:12:48-05:00

CBM and RCM help to maximize safety, uptime at YICT

2010-11-01T08:34:15-05:00

Being one of the biggest single container terminals in the world brings certain expectations from the operators and customers alike. Professionalism, reliability and efficiency are three of the most important and, coupled with a high regard for safety, are major focus areas for the Yantian International Container Terminal (YICT), in Shenzhen, southern China.

Tutorial on Macro Sensors LVDT Signal Conditioner

2010-10-27T09:46:58-05:00

Learn how to connect, install and calibrate the EAZY-CAL MME-1000 Mini-Module LVDT Signal Conditioner from Macro Sensors in this informative video tutorial.

Fluke creates online glossary of vibration terms

2010-10-26T10:29:44-05:00

Fluke Corporation has made available at its Web site a glossary of the key vibration terms that those involved in equipment maintenance and vibration diagnosis may encounter when evaluating machine vibration.

Testing tip: Armature defects on DC motors

2010-10-26T09:25:40-05:00

Current analysis of DC motors can provide health assessment of the DC armature while the motor is running. Armature-related anomalies can include commutator bar defects, riser defects (very common) and shorted turns or coils in the armature circuit. The fundamental analysis of these anomalies starts with understanding that the bar, riser or winding with a fault passes under and out of the carbon brush face at a rate of the shaft speed times the number of brushes passed in a rotation. This causes a modulation of the DC armature current. A DC motor turning at 2,000 rpm with four brush holders has a brush passing frequency of 8,000 rpm, or 133.33 Hz. Trending of the brush passing frequency amplitude is highly recommended for early identification of developing armature circuit anomalies.

Overview of a condition-based monitoring system

2010-10-26T08:23:42-05:00

This video provides an overview of the Infor Hansen CBM (condition-based monitoring) solution.

In today's global recession, you have to do more with less than ever before. Every dollar counts, every minute matters. Infor Hansen CBM connects your operational technology (automation devices and alarms) with information technology (Infor Hansen Asset Management System).

Infor Hansen CBM includes a "Virtual Employee" with every copy. His responsibility is to monitor your organization's equipment 24/7/365 and listen for any anomalies or early warning of problems, capture run-time hours and cycle counts, manage preventive maintenance intervals and predict equipment failures before they happen.

Vibration analysis and PdM with RFID tags

2010-10-26T08:20:20-05:00

This video outlines how maintenance technicians can perform vibration analysis and predictive maintenance with RFID tags.

Methods to ensure sanitary practices in pet food plants

2010-10-22T09:58:46-05:00

Until recently, contamination in the production of pet food products had not been considered an issue of concern to pet food manufacturers. With recent outbreaks of salmonella in human beings that were traced back to dog food, producers of pet foods have been re-examining their manufacturing processes. Every aspect of such facilities – from product movement through the plant, contamination from outside sources, to equipment design – require rethinking in light of FDA regulation, sanitary practices and Good Manufacturing Processes.

Prolonged bearing life through effective grease lubrication

2010-10-21T16:55:55-05:00

Grease lubrication knowledge is vital for a bearing company. SKF is putting its knowledge of this area into creating new products and services that contribute to sustainability, energy efficiency and extended bearing life.

Prolonged bearing life through effective grease lubrication

2010-10-21T14:03:22-05:00

Smith & Wesson hits the mark with oil conditioning system

2010-10-21T13:36:17-05:00

Firearm manufacturer Smith & Wesson saves more than $48,000 annually and has improved the quality of its recycled oil since employing a new oil conditioning system. The system paid for itself in only two months, both in cost savings and increased convenience.

Infrared thermography and condition monitoring at the zoo

2010-10-21T11:50:10-05:00

Think your workplace is a zoo? Try using predictive maintenance technologies in a real zoo.

Plant ensures reliability with predictive maintenance

2010-10-21T11:45:30-05:00

LCRA's utility operations are full of electronic and moving parts. Making sure all those parts stay in working order is the job of predictive maintenance crews. Heat-sensing cameras and vibration detectors are just of couple of the modern tools the crews use to ensure the power and water stay on. Watch as a crew gives an irrigation pumping plant an end-of-season check-up.

Wilcoxon Web site adds Spanish-language area

2010-10-20T15:13:18-05:00

Meggitt, a leading supplier of quality vibration sensors and sensor networks, has added a Spanish-language page to the www.wilcoxon.com Web site, which focuses on vibration sensors for industrial machinery health monitoring.

Pump vibration testing in the shop

2010-10-15T07:17:46-05:00

A basic principle of machinery vibration analysis is evaluating whether specific vibration amplitudes are excessive. The use of vibration equipment in preventive maintenance involves keeping a vibration history on individual pieces of equipment in a plant, keeping a record of all PM heat and when the unit was greased and what type of grease was used.

Bearing analysis kit provides oil and vibration condition monitoring

2010-10-11T13:36:30-05:00

The SKF Advanced Bearing Analysis Kit now is available, providing all the necessary equipment and consumables for oil and overall machine vibration condition monitoring. The kit is designed to provide fast, accurate results for multiple oil parameters, on-site maintenance decisions and assessment of overall machine condition.

Phase analysis: Making vibration analysis easier

2010-10-05T11:11:06-05:00

There is one diagnostic technique which quickly gets to the source of most vibration problems. It is possibly the most powerful of all vibration diagnostic techniques. It has been around as long as vibration analysis itself yet hasn't gotten a lot of attention, and it's rare to find good information about the subject. What is this technique? It's called phase analysis.

Azima DLI and Fluke team up on vibration technology for better troubleshooting

2010-09-29T08:46:35-05:00

Azima DLI, a provider of predictive machine condition monitoring and analysis services, announced September 29 that its ExpertALERT automated diagnostic system (ADS) technology was selected by Fluke Corporation, a leader in portable electronic test and measurement technology. Fluke chose ExpertALERT’s ADS to power the rapid diagnostic capabilities featured in the Fluke 810 Vibration Tester, its newest, most advanced troubleshooting tool. Now, resource-constrained plants can anticipate machinery problems, address recurring failures and bridge the personnel skills gap required for effective vibration monitoring programs.

PM and oil analysis uncover gearbox issue on wind turbine

2010-09-24T06:52:16-05:00

A preventive maintenance check and subsequent oil analysis uncovered a gearbox issue on a wind turbine. The oil sample discovered metal contaminant.

Emerson delivers wireless first with vibration spectrum for detailed machinery analysis

2010-09-23T11:54:31-05:00

Emerson Process Management, a leader in wireless technology for mainstream process manufacturing, has expanded the capabilities of its CSI 9420 Wireless Vibration Transmitter to deliver more detailed information for machinery analysis. In addition to sending operators direct alerts on high vibration caused by faults like cavitation or bearing defects, the CSI 9420 can now also use Emerson's reliable Smart Wireless network to send high resolution spectra to vibration experts for detailed diagnosis of machinery issues.

Arch Coal recognized for excellence in predictive maintenance

2010-09-22T08:41:39-05:00

Arch Coal Inc. on September 22 announced that its predictive maintenance program has been named as the best overall program among mobile equipment fleets from around the world by an industrial trade magazine.

How infrared thermal imaging is used in the utility industry

2010-09-16T10:04:17-05:00

This video shows your FLIR infrared thermal imaging tools are used in the utility industry.

Using the iPad for vibration analysis

2010-09-15T13:44:29-05:00

GTI Spindle reveals its new vibration analyzer built on the iPad mobile computing platform.

Azima launches WATCHMAN Intensive Care condition monitoring services

2010-09-15T09:49:22-05:00

Azima DLI, a provider of predictive machine condition monitoring and analysis services, on September 15 announced the launch of its WATCHMAN Intensive Care condition monitoring services. The services are enabled by the new Sprite Roamer Intensive Care Unit (ICU), a portable, online monitoring system that can be quickly deployed by plant personnel to machines that are in need of attention by professional condition specialists and comes with 24/7 support.

Testing air brakes with an ultrasound detector

2010-09-08T08:36:50-05:00

A technician uses an ultrasound leak detector to test a truck's air brakes for leaks. CTRL Systems Inc. manufactures the UL101, a handheld ultrasound detector. Applications include leak detection and detecting mechanical failures in bearings, gears, pumps and valves. The UL101 ultrasound detector is used for predictive maintenance, condition-based maintenance, energy savings (leak detection) and for quality control inspections.

Shell mechanical team supervisor comments on compressor reliability at his facility

2010-09-07T13:11:07-05:00

Doug Husen, mechanical team supervisor at Shell, talks with SkillTV's Joel Leonard about compressor reliability at his facility. The interview took place at Noria Corporation's RELIABLE PLANT 2010 conference in Nashville, Tenn.

Vibration analysis is like winning the lottery

2010-08-24T09:39:46-05:00

Life would be so easy and carefree with a crystal ball. And, wouldn't your maintenance job be so much simpler if you could just identify machine damage in time and predict the point at which repairs really become necessary? This article describes how it was possible to keep a damaged bearing running for several months until a scheduled annual outage came around – naturally under close observation.

Researchers develop ultra-high-power energy storage devices

2010-08-18T08:46:19-05:00

Researchers from the U.S. and France report the development of a mirco-supercapacitor with remarkable properties in a paper published on August 15 in Nature Nanotechnology online. These micro-supercapacitors have the potential to power wireless sensor networks, biomedical implants, RFID tags and embedded microsensors, among other devices.

Asset-based condition monitoring software for infrared cameras

2010-08-17T09:55:45-05:00

Condition RED fully integrates your infrared camera and analysis package to form an automated report generation system. Condition RED helps you manage your infrared predictive maintenance program by keeping track of your entire asset inventory in an easy-to-operate powerful database. Create infrared surveys in your own facilities using the power of this unique IR camera and asset management system.

Learn machinery lubrication best practices at RELIABLE PLANT 2010

2010-08-17T08:07:43-05:00

Take home best practices from these lubrication case studies, which will be featured at Noria Corporation's RELIABLE PLANT 2010 conference and exhibition. The event will be held August 31-September 2 in Nashville, Tenn.

That's amore! Italian power plant loves new filter strategy

2010-08-16T20:08:06-05:00

Remote monitoring solution enables Centro Energia Teverola S.p.a. facility to improve its machinery efficiency, plant efficiency and predictive maintenance.

System for non-destructive testing and measurement

2010-08-13T09:19:38-05:00

This video outlines a new low-cost system for non-destructive testing and measurement, including vibration analysis, of materials and components.

Motor categories that must meet NEMA Premium standards

2010-08-10T10:44:56-05:00

Beginning in December 2010 the new Energy Independence and Security Act of 2007 (EISA) government regulations will change motor manufacturers requirements to meet NEMA Premium standards for NEMA and IEC frame sizes on motors less than 600 volts. We will be discussing this new regulation in a five-part series of tips highlighting some of the issues that may impact you. Here is Part 2.

Dynamic movement on a boiler feed pump

2010-08-09T11:17:26-05:00

This video will give you an overview of the dynamic movement on a boiler feed pump and the the benefits of measuring and correcting.

The cost benefits of laser shaft alignment

2010-08-09T11:13:50-05:00

This video will give you an overview of the cost benefits analysis of laser shaft alignment.

An introduction to Extech infrared thermometer

2010-08-06T13:50:26-05:00

This video provides an introduction to the 42509 Color Alert Infrared Thermometer from Extech. This dual-laser IR thermometer has high/low alarms with a visual and audible indicator when the temperature exceeds or goes below the set temperature.

Static and dynamic testing as part of PdM programs

2010-08-04T11:41:38-05:00

Periodic static testing and more aggressive dynamic testing of motors are essential parts of predicting the potential for a motor to continue a safe and successful operation. Tracking and trending the results of electric motor testing on a regular schedule is the most effective method of making intelligent predictions.

Measure surface flatness with products from Ludeca

2010-08-02T10:54:03-05:00

Measure surface flatness and level with precision and convenience. Take a look at the new INCLINEO high-precision inclinometer and the new 3D color graphics in the ROTALIGN ULTRA Flatness featuring the LEVALIGN rotating laser.

Increasing wind farm profitability by reducing gearbox maintenance costs

2010-07-29T10:33:03-05:00

As much as 30 percent of wind farm operating and maintenance costs are associated with gearbox maintenance alone. Reducing these costs can help wind farms stay more profitable, efficient, and competitive, bringing clean energy wind farms to the forefront. GE Energy’s Condition-Based Maintenance Solution, including GE Energy’s Bently Nevada ADAPT.wind Software, reduces gearbox maintenance costs and provides wind farms with a greater competitive edge in the energy market.

Maximize your PdM efforts with oil analysis skills training

2010-07-29T09:43:42-05:00

Detecting an air leak with ultrasonic equipment

2010-07-23T08:02:50-05:00

CTRL's ultrasound detector, the UL101, is designed to be a multi-purpose maintenance and diagnostic tool. One of its core applications is leak detection.

Creating a lean but effective oil analysis program

2010-07-21T13:26:24-05:00

Whether it's a budget issue, management buy-in, lack of individuals or just a small company with limited funds, there are ways to establish an effective oil analysis program with minimal startup and operation costs.

Get your Noria training coupon with RELIABLE PLANT conference registration!

2010-07-21T10:51:14-05:00

Another reason to come to Nashville: Your full conference registration includes a coupon for Noria training.

Performing infrared thermography on motors

2010-07-15T15:48:53-05:00

TEGG Services talks about using infrared thermography to perform predictive maintenance on motors.

Datastick announces machine vibration seminar in California July 20-23

2010-07-15T09:08:36-05:00

A four-day Machine Vibration seminar with hands-on practical experience will be held on July 20 through 23 in San Jose, Calif. Attendees can become certified as Level I vibration analysts by taking a test on the last day.

UE launches Ultraprobe 15,000 Touch

2010-07-15T08:56:38-05:00

Using knowledge based on three decades of experience, the engineers at UE Systems have developed an entire ultrasonic condition monitoring laboratory – to fit in the palm of your hand.

Electric motors tip on spectral band alarms

2010-07-07T09:20:32-05:00

When reviewing spectral data rich with peaks from an unknown origin, consider establishing band alarms around these peaks. Properly designed and applied band alarms allow varied severity indications for a range of frequencies. If the application being monitored is operating in an otherwise healthy condition, then an increase of 25 percent, 50 percent and 100 percent from baseline could be used for observe, caution and severe setpoints, respectively.

Owens Corning employee chooses Fluke thermal imaging for PdM

2010-07-07T09:02:01-05:00

Hear what one Owens Corning employee says about how thermal imaging has helped them maintain their equipment, both electrical and mechanical, and why they chose Fluke thermal imagers to get the job done.

Why you need vibration analysis

2010-07-02T15:58:42-05:00

Alan Richardson, president of Preventive Vibration Analysis Corporation, explains the importance and benefits of vibration analysis.

Pet food manufacturer focuses on eliminating failures

2010-07-01T11:28:07-05:00

A phased control system upgrade has helped a Hill's Pet Nutrition plant in Kentucky to minimize its risk, maximize uptime and boost productivity.

Noria lubrication video training sale ends June 30

2010-06-28T08:59:58-05:00

Take advantage of this limited time sale and quickly introduce your entire team to Noria lubrication and oil sampling best practices. Order online or call 800-597-5460 ext. 104.

IEEE members use remote sensing to promote a sustainable future

2010-06-23T08:27:17-05:00

IEEE, the world's largest technical professional association, and its members are applying engineering and technology principles to address issues of global environmental impact, including monitoring natural disasters and tracking man-induced hazards such as forest fires, oil spills and other types of chemical contamination.

Audible, visual and tactile inspections for PdM personnel

2010-06-22T10:35:18-05:00

Data collection is the backbone of any vibration monitoring effort, yet opportunities to gather additional data while at the machine are typically ignored. Is the vibration industry finally beginning to feel the effects of the pure data collector who has not transitioned into the reliability group from the mechanical trades? What about the site operators and craftsman? This article covers basic inspection techniques that can be applied to optimize time spent in the field.

Azima DLI ensures reliability of Panama Canal locks using vibration monitoring

2010-06-21T08:23:48-05:00

Azima DLI, the leader and premier provider of predictive machine condition monitoring and analysis services, announced that its advanced vibration monitoring capabilities will be used by the Panama Canal Authority (ACP) to achieve important equipment reliability and uptime goals associated with the operation of its lock system. The ACP is the autonomous agency of the Government of Panama in charge of managing, operating and maintaining the Panama Canal.

Using infrared thermography for tanks and vessels

2010-06-18T11:56:18-05:00

This presentation discusses how infrared thermography is used for tanks and vessels.

SKF Machine Condition Advisor product wins award

2010-06-18T11:17:19-05:00

Design News recently announced the results of their 2010 “Best Products” awards, with SKF winning the “Golden Mousetrap” award within the Electronics / Test and Measurement category for the new SKF Machine Condition Advisor, a handheld instrument which simplifies machine monitoring and provides early warning of potential failures.

Make sure maintenance work doesn't create process bottlenecks

2010-06-18T09:31:28-05:00

Bottlenecks often occur when the equipment is unable to reliably produce the required output. Potential causes for this may be physical (equipment breaking down often), human (poor work practices) or latent (ineffective planning processes). Maintenance and reliability issues touch on all of these potential causes. This article discusses what aspects of maintenance affect plant output, and then what actions can be taken to mitigate these negative effects.

A sneak peek at the Ultraprobe 15,000 PdM tool

2010-06-11T13:33:33-05:00

An introduction video of the new Ultraprobe 15,000. This this ultrasonic device, predictive maintenance and energy conservation are made easy.

NV Energy installs wireless solution to increase plant reliability

2010-06-10T14:26:26-05:00

Wireless condition monitoring systems have helped to improve overall plant reliability and efficiency at NV Energy's Fort Churchill Operating Station in Yerington, Nev., by extending condition monitoring to a broader array of essential assets that were previously underserved and classified as mid- to low-criticality.

Oil and fuel quality monitoring on power gen equipment

2010-06-10T14:20:44-05:00

Determining oil quality in real time with embedded and portable oil assessment devices operated by mechanic personnel provides the operational flexibility and rapid means of screening oil quality that is key to establishing a real-time condition-based monitoring program.

Download the new SDT ultrasound App for iPhone

2010-06-10T09:07:55-05:00

One of the more perplexing things for new (and old) ultrasound inspectors is what conclusions to draw from their data and trends. The new i-Phone app from SDT North America is designed to make sense of ultrasound trends and baseline increases. For instance, if your baseline is 20dBµV and today's reading is 26dBµV and you want to know what the 6dBµV increase represents, tap it on your iPhone and you'll know the increase is a factor of 2X.

GE launches new Pressure Converter application for iPhone

2010-06-09T13:10:03-05:00

GE Sensing brings pressure unit conversion mobile with the new Pressure Converter, a mobile application for measuring units of pressure in an industrial setting. Available in the Apple Application Store for free, this mobile tool can easily perform 28 different types of pressure calculations. The Pressure Converter is ideal for plant, process and service engineers, site contractors and laboratory technicians in oil & gas, power generation and other industrial settings, where basic conversion may be needed but a computer is not always easily accessible.

Ludeca 'Laser Align' iPhone App now available for download

2010-06-09T11:19:01-05:00

Ludeca Inc., a leading provider of laser alignment and condition monitoring solutions, presents “Laser Align” a free reference tool for shaft alignment of rotating equipment. With this iPhone application, you can access important reference material and learn about key laser shaft alignment concepts.

American Electric Power lauded for work to enhance turbine reliability

2010-06-09T08:38:45-05:00

This video features an interview with Terry Brown from American Electric Power. AEP employees at Michigan's Donald C. Cook nuclear plant received the 2010 Westinghouse Design Vendor Award for their work on turbine reliability. The Top Industry Practice awards were announced May 19 at the Nuclear Energy Assembly in San Francisco.

Timken provides stone-cold solution to Roanoke Concrete plant

2010-06-08T14:10:53-05:00

Roanoke Cement, a Timken customer for more than a decade, lost 30 percent of their production when their roll press went down unexpectedly – causing major operational problems.

Honda engine factory benefits from machine monitoring

2010-06-03T15:46:24-05:00

With on-line monitoring, Honda uses sensors at its engine plant in China to track the condition of spindle bearings 24 hours a day. The sensors provide a signal at any sign of bearing wear or drop in performance outside specified limits.