NEW bench­mark for pump and mo­tor pre­dic­tive main­te­nance

DEMM Engineering & Manufacturing - - MAINTENANCE MATTERS -

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.”

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