NEW benchmark for pump and motor predictive maintenance

SCHAEFFLER IS introducing advanced new condition monitoring technologies to Australasia that the company says are setting new benchmarks for predictive maintenance of rotating equipment such as pumps, fans and electric motors.

The new globally proven technologies, including the latest evolutions of Schaeffler’s SmartQB and SmartCheck condition monitoring systems were featured at this year’s Hannover Messe exhibition along with a whole host of digitalisation and cloud- based technologies that harness the advantages of industry 4.0.

Applications for which this technology applies include bulk handling and conveyor applications, mining and energy; building, construction and access equipment installations, such as forklifts and logistics; food and beverage and agribusiness processes, including paper and packaging; manufacturing, metals and process engineering, transport and industrial motor and transmission applications, including pumping and HVAC installations and utilities including electricity, water and waste water.

“These technologies are at the forefront of predictive maintenance and condition monitoring globally. Schaeffler has had successes with major companies overseas as well as in Australia, and our team will be closely looking at which new technologies being displayed at Hannover Messe this year can be implemented in Australia, to enhance the reliability of predictive maintenance programmes locally,” said Mark Ciechanowicz, Manager – Industrial Services, Schaeffler Australia.

CASE STUDY 1: PUMPS WITH AUTONOMOUS MONITORING AND LUBRICATION FOR PERLENBACH WATER SUPPLY ASSOCIATION.

The Perlenbach Water Supply Association, which supplies fresh drinking water to roughly 50,000 residents in seven municipalities of Germany’s Eifel region every day, uses a combination of Schaeffler’s SmartQB condition monitoring system and Concept8 lubricator to ensure fault-free and reliable operation of their pumps, and to identify any issues as early as possible, to avoid major problems and downtime.

The preconfigured SmartQB condition monitoring system detects irregularities in electric motors, pumps, fans, and their rolling bearings, and reports potential fault causes in a plain text message after they have been identified. The integration of the system, which was developed in partnership with Mitsubishi Electric, into the control room visualisation means that Perlenbach’s maintenance personnel are informed of incipient damage at an early stage and can immediately initiate maintenance measures and procure any replacement parts that might be needed.

Schaeffler’s Concept8 ensures requirement- oriented lubrication of bearings, to avoid insufficient lubrication or overlubrication, and resulting damage.

“Conventional systems for machine monitoring are costly and complicated. In contrast, the SmartQB is so easy to use that our employees did not require any specific knowledge of vibration diagnosis and were able to get started right away,” said Joachim Dankwardt, deputy manager of the water procurement/treatment department, Perlenbach Water Supply Association.

CASE STUDY 2: ELECTRIC MOTORS REPORT THEIR CONDITION TO THE CLOUD FOR SPIT ELECTRICAL MECHANICS

Dutch industrial service company SPIT Electrical Mechanics employs Schaeffler’s expertise for the maintenance of its customers’ machines. The company is transitioning from regular offline measurements to continuous online measurements by using Schaeffler’s SmartCheck condition monitoring system, which will reduce outlay and costs for SPIT.

Connecting to the Schaeffler cloud allows SPIT to access the many years of bearing and vibration analysis expertise of Schaeffler’s engineers in the form of digital services. The“Condition Analyzer” digital service, for example, delivers automated diagnoses of the machines’ condition, offers in- depth analyses, and generates plain text messages.

Schaeffler’s solution reliably prevents mechanical failure of electric motors. For the service company, the partnership with Schaeffler means that it can make fewer on-site visits to the customer and can plan maintenance work further in advance and consequently increase the machines’ efficiency and availability.

“SPIT and Schaeffler are the perfect partners when it comes to cloudbased condition monitoring, and Schaeffler offers the right products to enable us to make further developments. Schaeffler’s additional expertise creates genuine added value for our customers,” said Mark Ent, Managing Director of SPIT.

LOCAL APPLICATIONS

Global examples such as Perlenbach and SPIT show the advantages of well-implemented condition monitoring solutions and how they can improve predictive maintenance programmes and reduce the Total Cost of Ownership ( TCO) of rotating equipment such as pumps, fans and electric motors, says Ciechanowicz.

“In Australia, companies are typically operating in even harsher conditions than those present overseas, due to higher average temperatures and extreme weather conditions. It’s even more important under these arduous conditions to accurately measure the condition of important rotating equipment and identify and issues as early as possible,” he said.

“Condition monitoring technologies should be seen as an investment. While there are upfront costs involved, these costs are dwarfed by the costs involved if something breaks down, including repair or replacement, lost production and downtime.

“We’ve had local examples where a condition monitoring system has identified and helped prevent a major component from breaking down – a main generator or rotor on a wind turbine, for example – and the total savings could pay for the condition monitoring technology for the entire wind farm of 100 or more turbines.”