Categories
Industry News News

Screen Monitoring with Waites Wireless – Iron Ore Mine WA

An iron ore mining client in Western Australia was experiencing repeated failures on their vibrating exciters. These failures had resulted in production losses and were a health and safety hazard.

The site strategy for monitoring the screens was to use vibration analysis. To do so, the clients historically used hard-wired industrial piezoelectric accelerometers. A condition monitoring technician would then routinely (monthly or greater) manually collect vibration data onto a portable device and review the signals for signs and faults.

The original solution:

Increased frequency of the vibration analysis survey to weekly in order to provide earlier detection.

Whilst the vibration data collection and analysis method is proven to detect faults, there are three problems that make this method ineffective or unreliable for screen exciters.

1. The cable of the hard-wired sensors often fatigues due to the harsh environment (oscillating screen) which meant vibration data could not be collected.

2. A bearing can go from ‘normal’ to ‘severe’ condition within days. When failures do occur, they are normally catastrophic destroying shafts, gears, weights and exciter cases. Given the nature of the rate of deterioration, even a fault detected early on in its failure mode, a routine survey would need a very high frequency of measurements to provide an accurate report of the assets’ health to operations/maintenance.

 3. Weekly inspections are demanding on vital condition monitoring human resources.

All of the above problems meant a labour intensive, seven-day inspection routine was unsatisfactory for plant reliability and personnel safety.

With the above challenges being a constant source of concern, the client engaged GVS Reliability Products and installed the Waites Wireless online condition monitoring system. This overcame the challenges of collecting higher frequency, important asset health data, was a cable free solution and did not require a technician to walk around and manually collect the data.

To the customer, this meant overcoming all three challenges listed above.

The below case study highlights the versatility of moving to wireless technology, which ultimately proved its worth in detecting both the initial fault and the rapidness of the failure, preventing significant secondary damage and reducing down-time.

Case Study

The Waites Wireless SM1-1150 motes were installed one on each exciter across a few screens to monitor and detect the signs of early bearing faults. Exciter temperatures, acceleration and velocity levels were trended and time waveform and FFT data were captured and stored in the cloud for ease of access and analysis. The Waites Wireless ‘ImpactVUE’ feature was also utilised for the early bearing fault and impact detection ability.

The trends of the exciters (see below – Figure 2), show the steady operation with acceleration levels for over three months. Over this period the alarm sets were tailor-made to suit the machine and its operating condition at the site.

A few months after an outage in December, the trend of the drive-end exciter can be seen slowly increasing (see below – Figure 3). In early February, the hourly acceleration readings on the screen exciter began to spike breaching alarm levels. At the triggering of the ‘caution’ alarm, Waites Wireless automatically sent notifications to the Condition Monitoring team.

The triggering of the ‘caution’ alarm gave the onsite Condition Monitoring Team the chance to inspect the asset, diagnose the issue and provide early notice to the Operation Team of the fault and machine condition. 

The Waites Wireless ‘ImpactVUE’ FFT shows (see below – Figure 4) the inner race fault frequencies clearly defined.

The site team used their onsite data collector which clearly showed similar data to the Waites Wireless platform (see below – Figure 5). 

Shortly after this data was collected, the vibration amplitudes dramatically increased, and the decision was made to shut the screen and plant down (see below- Figure 6).

By neutralizing the threat, secondary damage to other components was avoided, greatly reducing the costs of the rebuild/repair. While the failure was fast moving, Waites Wireless provided sufficient time for maintenance to be organised with necessary parts, prior to the shut-down. By giving time for maintenance to be organised and ready, Waites reduced the overall downtime and the financial impact to the company of this impending failure.

Two days later, another completely different screen monitored by Waites Wireless hardware, sent their condition monitoring team alarms that indicated similar signs of rapid failure while the other screen was under maintenance. The trend increased dramatically on the 4th of February (see below – Figure 7). 

The Waites Wireless condition monitoring system was able to prevent catastrophic secondary damage on two screens in quick succession. This success story is achieved for the customer by the intelligent use of Waites Wireless high frequency data sampling intervals and a good practical alarm set configuration.

Reach out to your local GVS Reliability Products representative via sales@gvsensors.com.au for more information on how to easily monitor your own vibrating screens (and other rotating equipment) with the Waites Wireless condition monitoring hardware.

Categories
Industry News News

Iron ore mining and Motion Amplification®

Rio Tinto Yandicoogina (iron ore mine in West Australia’ Pilbara region) recently completed training for their latest acquisition; Motion Amplification®.

Rio Tinto own an integrated portfolio of iron ore assets: a world-class, integrated network of 17 mines, four independent port terminals, a rail network spanning nearly 2,000 kilometres and related infrastructure – all designed to respond rapidly to changes in demand. Rio Tinto are one of the world’s leading producers and exporters of iron ore.

Rio Tinto’s world-class Predictive Maintenance program informs maintenance and operations of asset health and increases overall plant reliability. Therefore, Motion Amplification® is a perfect technology to enhance that success.

Motion Amplification® deliverables:

  • Visualisation of the root cause of unacceptable vibration detected via routine and online Predictive Maintenance (PdM) programs
  • Through visualisation, transition to root cause problem solving and defect elimination
  • Perfect tool for screening assets, fault finding, commissioning new assets, and pre/post repairs or retrofits
  • Communication between technical and non-technical personnel and original equipment manufacturers, enhancing the decision-making process

The training was well received with one participant saying ‘Great video Andrew – Thanks again on behalf of the team’. The Motion Amplification® training is Certified by RDI Technologies Inc.

Motion Amplification® – Visualise, Measure, Troubleshoot, Correct.

Reliability You Can See and Trust.

Visit www.opticalmotion.com.au to learn more about the sensor of the future.

Categories
Industry News News

SDT Ultrasound saves production losses by inspecting vital steam delivery system

Since 1999, Adam De Gioia has been a fitter and turner working in a range of different industries from water/wastewater, pharmaceutical, hydraulics, food manufacturing, mining and oil & gas.

Starting his own company; ‘Final Drive Engineering Services’ in 2014, Adam soon partnered with a respected OEM of hydraulic components. It was here that he developed a passion for steam delivery systems and quickly became the ‘go to guy’ for repair work.

In recent years, he has been contracting to a well-known food manufacturing facility where he carries out offline maintenance. Over time he witnessed the degradation of their steam system which resulted in issues in the *CIP (clean-in-place) system.

Adam quoted – ‘Unfortunately, it’s kind of ‘Out of sight, Out of mind’, and only repaired when completely failed’.

To paint a picture, there are approx. 30 steam traps of differing types around the site. They are all critical in terms of pasteurizer and CIP performance. If one trap was to fail, multiple lines and holding tanks would be disrupted and production would cease until repairs were carried out.

Steam Trap with cloudy sight check
Steam Trap with no sight check. How do you know it's working?

Seeing the cost of production losses mounting on his customer, Adam knew he’d have to take a proactive approach.

Online research yielded numerous hits on steam system protection hardware using the SDT Ultrasound range. A meeting was organised with GVS rep Peter Haines at GVS HQ in Newcastle. In 1 hour they covered the basics of ultrasound, how Ultrasound inspection has numerous applications and finished with a focus on Steam Traps.

Adam recognized the benefits, purchased the SDT ULTRAChecker and put it to work the very next night.

Here are Adam’s words about his first experience with SDT’s equipment;

‘The 1st trap I tested had a very cloudy sight check. Using the audio and Histogram (bar graph) feature (on the ULTRAChecker) I quickly determined that it had failed. The 2nd trap had no sight glass on the check valve, and again through the earmuffs, the constant sound indicated yet another failed trap. 2 from 2.

‘The Engineering team are excited by the results. We can now identify steam issues and get on top of it early.’

ULTRAChecker used on functioning Steam Trap. The Histogram (bar graph) shows the fluctuation of when it is open and closed. Simple.

BUT Adam didn’t stop there.

Seeing how effective using a precision Ultrasound inspection device was, he turned to other areas of the plant.

He then went on to identify issues with:

  • condensate return pump
  • auto blow down on one of the boilers
  • hydraulic circuits
  • air leaks on the trucks air system.

In future, Adam will also aim to participate in ‘Live Online Level One’ (LOLO) Ultrasound course to further expand his knowledge and monitor other areas of plant.

GVS love these examples of our ability to supply a solution to a client with a challenging problem.

Thanks very much to Adam for sharing your story of success working with us!

If you’d like to learn how precision Ultrasound inspection will decrease production losses, see this video.

 

The tool used by Adam in the case study is SDTs ‘ULTRAChecker’. It is one of various options in the SDT’s Checker range. See the SDT range of products here.

 

Contact us GVS Reliability Products to learn more about ultrasound, the most diverse monitoring technology on the market.

 

*CLEAN IN PLACE or CIP systems play a critical role in food and beverage manufacturing. They automatically clean, rinse, sanitize pipework ensuring processing components are free of bacteria.

Categories
Industry News News

FLSmidth joins the Motion Amplification® Revolution

FLSmidth has been providing market-leading engineering, equipment and service solutions to the global mining and cement industries for over 140 years. A key to their success has been a focus on improving asset performance and efficiency (from concept through the entire life cycle) so Motion Amplification® was the perfect technology to further enhance that success.

The team recently completed the Certified course by RDI Technologies and are now ready to offer this unique service to their customer base. Photos below.

The new IRIS M™ system will be stationed at FLSmidth’s Pinkenba workshop where it will primarily be used during the factory acceptance testing across a number of product types. It will also be a vital tool for their site services team. From commissioning through to inspections, it will aid with the identification, verification and more importantly ‘VISUALISATION’ of vibration data, aiding with communication between departments and customers alike.

Motion Amplification® – Visualise, Measure, Troubleshoot, Correct. Reliability You Can ‘See’ and Trust.

Visit www.opticalmotion.com.au to learn more about the sensor of the future or contact your local GVS rep today.

Categories
Industry News News

POOR LUBRICATION: What ‘data’ are Lubrication Technicians using to grease?

Stories are great. Humans thrive on stories. Being able to hear and then re-tell stories is what sets humanity apart from other living creatures.

Weird side note: some humans can hear and re-tell the stories of non-living things like; machines!

For example, the below data (sent to us by a customer) would look confusing to most people on the planet. But, in that data lies a story waiting to be told…

This data tells the trained eye that ‘raised acceleration and noise floor in higher frequency spectrum’* was beginning to be a significant problem for this motor DE (drive end) bearing.

But, the conclusion of the story is that… the high frequency acceleration just magically disappeared…

Or is there another story to tell?

Recently, this customer took delivery of 4 x SDT LUBECheckers from GVS.

So, when given the work; grease the bearing, with the aid of the LUBECheckers the lubrication technician was able to leave the asset in an ‘optimal lubricated state’.

This data tells us that; through investment in technology, a machine bearing was clearly saved from further damage

This story is a success story. And this success story comes from 1 x bearing on 1 x electric motor…

This customer works in one of the largest mines in Australia. So, now armed with SDT Ultrasound, they can multiply that success story by how many bearings they have across the facility.

Good news stories make you feel warm and fuzzy… 🙂

Get in touch with GVS to learn how easy it is to use and deploy LUBExpert and LUBEChecker at your facility so you can tell a lot more success stories.

*vibration analysis talk

Categories
Industry News News Uncategorised

The 4 different types of soft foot

Soft foot is a term we often use when we talk about shaft alignment. In fact, you must always perform a soft foot check before the actual alignment work can start; it is an essential part of securing a reliable installation. Let’s go through the different types of soft foot and why they occur.
 

By soft foot, we mean that the machine is not resting evenly on all feet. Another expression you may have heard is machine frame distortion.

Why do we need to check and correct soft foot? Can it be that big a problem if there is a tiny gap underneath one machine foot or a little pile of dirt under another? Well, yes. Because if the machine is not standing perfectly flat on the machine base, you can (and most likely will) run into problems such as shaft deflection, increased vibrations, bearing failure – and, in the end, machine breakdown. And that will be a lot more expensive than fixing the soft foot problem in the first place! Luckily, all Easy-Laser shaft alignment systems come with a program for soft foot check that tells you which feet you need to adjust and how much.

There are four types of soft foot which all have one thing in common: one or more feet are not resting firmly on the machine base. And there are different reasons for that. So, let’s take a look.

1.    Parallel soft foot

Parallel soft foot (sometimes also referred to as rocking soft foot) means that not all four feet are on the same plane. Think of a wobbly table at a restaurant, where you can rock it back and forth. In this case, the laser system software will show high readings (>0,05 mm) for soft foot at opposite corners. With a feeler gauge, you can determine which foot or feet you need to shim and how much. 

There are three possible reasons for parallel soft foot:

  • The leg is too short.
  • The base plate or mounting pads are not coplanar.
  • Missing shims under one or more feet.

To correct parallel soft foot, you add enough shims to remove the rocking effect (use as few as possible, and no more than four shims!).

2.    Bent foot / outside angled soft foot:

This is a common type of soft foot that occurs when the foot’s bottom is at an angle relative to the base. In this case, the laser system will show a high soft foot reading at three or four feet. The foot with the highest soft foot reading will show a tapered air gap from one corner of the foot to another. 

There can be several reasons for this condition, for example:

  • The machinery has been dropped or roughly handled.
  • The base plates are bent or poorly machined.
  • There’s a severe vertical angular misalignment.
  • The feet are welded.
  • Foundation settling has occurred.

The best way to correct this problem is to re-machine the feet, the base, or both. If this is not possible, step-shimming is an option (although you should try to avoid it).

3.    Squishy foot:

Squishy foot is sometimes also known as spring foot. With squishy foot, the feeler gauge won’t detect any gap underneath the foot. Instead, the problem is usually that the space between foot and base is filled with too many shims from a previous attempt to fix soft foot. There may also be a build-up of other unwanted material such as dirt or rust under the foot.  

Reasons for squishy soft foot may be:

  • Dirt, grease, paint, or rust between the foot and the base.
  • Too many shims (remember, you should not use more than four shims per foot).
  • Bent shims.
  • Shims with burrs or thread marks.

To get rid of this problem you need to thoroughly clean the area around and underneath the foot, and replace old shims with new, crush-resistant ones.

Here you can read more about shimming best practices.

4.    Induced soft foot:

Induced soft foot is caused by external forces that affect the machine frame, and it can be hard to detect. The laser system will indicate more than one soft foot, usually on the same side or the same end of the machine. The feeler gauge will find a gap, usually parallel or nearly parallel.

Some possible causes of induced soft foot are:

  • Coupling or pipe stress.
  • Overhung machines.
  • Belts or chain loads on pulleys and gears.
  • The flex conduit is excessively rigid.
  • Structural bracing is attached to the machine.
  • The jacking bolts are inadvertently left tight.

To correct induced soft foot, you need to remove the external forces that cause the problem. This may require more than one soft foot check since these forces can occur anytime during the shaft alignment process.

One step closer to trouble-free operation

Like we said in the beginning of this article: to correct soft foot is essential. No machine is designed to work under stress or with a high level of vibration, which are consequences of soft foot. So, make sure all feet are placed firmly on the ground (or base, in this case) and you have created the best possible conditions for perfect shaft alignment and trouble-free operation!

Categories
GVS News Industry News News Uncategorised

LUBExpert Case Study: 70% of bearings are still OVER lubricated

Bearings need grease, however… 

It’s a common misconception that if a little grease is good then a lot means better. WRONG!

Too much grease will overheat a bearing causing separation of the oil from its thickener and will begin to run out of the bearing. This can set off a chain reaction resulting in lack of lubrication & hardening of the thickener which left unchecked will cause major issues.

Many studies have shown that only 33% of the open space within a bearing needs to be filled to achieve optimum friction reduction. 

33%? How do you that?

ALS Global (Australia’s largest condition monitoring service provider) conducted an independent study over an 18 month period using the LUBExpert. The device was used across a large volume of grease lubricated bearings which were historically replenished using fixed calculated / time based rates.

Find out why ALS now choose the LUBExpert as their preferred method of lubrication. Download the full case study below.

 

How are you lubricating your bearings?

 

Save Time. Save Grease. Save Bearings. Use LUBExpert and ‘Grease Bearings Right’.

Categories
GVS News Industry News News

GVS Reliability Products & IMVAC 2017

GVS Reliability Products was privileged and excited to exhibit and co-sponsor IMVAC, the all new conference for Vibration Analysts & Condition Monitoring Professionals.

The event ran at the Gold Coast from September 5th through 7th. IMVAC (International Machine Vibration Analysis Conference) was designed specifically for vibration and condition monitoring professionals. This is a perfect fit for GVS as we strive to inform and arm the reliability professionals with asset health inspection hardware in our corner of the globe. From the amazing IRIS M, Motion Amplification technology, the ground breaking LUBExpert and our industrial vibration sensor range from Hansford Sensors, GVS added great value to the IMVAC community.

GVS supported the hosting of workshops, learning sessions and case studies to the latest technologies featured in the expo. IMVAC provided practical learning in the important aspects of industrial vibration analysis and the complementary condition monitoring technologies (Thermography, Wear Particle, Oil Analysis, Motor Testing, UltrasoundLubrication, Shaft Alignment and Field Testing).

IMVAC helped attendees form new relationships with fellow reliability improvement practitioners, and provided actionable new skills and knowledge that can be taken back to the plant to help attendees deliver even greater value.

One final word, our principal supplier Ultrasound hardware of SDT engaged the esteemed Tom Murphy to join the team at IMVAC to present and discuss the advantages of a sophisticated Ut inspection device and program. From all reports, Toms presentations were a success and many took take the time to talk to Tom while attending the event.

Top Reasons to Attend IMVAC

  • Focused Event
    IMVAC is dedicated to Vibration Analysis, Maintenance and Reliability, and Condition Monitoring Technologies
  • Variety of Content
    Each IMVAC event has 3 keynote presentations and over 50+ top-rated educational presentations from leading industry experts
  • Expand Your Network
    Network with other learning professionals from leading companies around the world including Shell, Dupont, GE, Siemens, Bridgestone, Weyerhaeuser, GM, Johnson Controls, and MillerCoors
  • Learn from Your Peers
    Improve diagnostic knowledge and skills while building relationships with peers who face the same challenges
  • New Technology
    IMVAC has an Exhibit Hall featuring more than 30 exhibitors providing the latest products and solutions
  • Add to Your Library
    The IMVAC Bookstore gives convenient access to the latest Condition Monitoring books (featured at IMVAC Australia and IMVAC USA)

GVS were indeed excited to be involved in the 1st IMVAC conference to be held in Australia.

We are looking forward to an exciting IMVAC 2018!

Categories
GVS News Industry News News

2017 Mainstream Wrap

GVS Reliability Products was proud to support the 2017 Mainstream West and Mainstream East Conferences held during March this year. The Eventful group did a terrific job of running a program that highlighted the critical role Reliability teams play in organisations of all shapes and sizes.

Manning the GVS Reliability Products stand were both Dr. Jeff Hay (CEO and Founder of RDI Technologies) and Chris Hansford (MD and founder of Hansford Sensors). Chris and Jeff were able to interact with professionals from the local Australian market. In addition to adding value to the conference with their years of industry experience, both Jeff and Chris also received invaluable feedback from those in attendance. This will only help improve any future product development for people operating in the harsh Australian environment.

Jeff delivered an ‘IRIS M Motion Amplification technology’ presentation at both the East and West Mainstream events. The paper was very well received and acclaimed by the Mainstream audiences. It was great to get a wide range of questions and feedback from the Mainstream community on how the technology will be applied to their individual reliability and asset health programs. Several feature requests from attendees are being worked on by Jeff and the RDI team as you read this blog post!

GVS Reliability Products would like to personally thank the, conference participants, the Mainstream committee and the support of the other vendors for making such a wonderful conference a reality.

If you would like to learn more about GVS Reliability Products or anything written above, please contact us via this link.

Categories
Industry News News

Motion Amplification. Simple. Visual. Reliability Revolution.

RDI Technologies is fast growing the network of international representatives. GVS Reliability Products and OMT are very happy that RMS Reliability has been appointed as the exclusive UK representative for Motion Amplification. RMS have set up a designated website for Motion Amplification, see www.motionamplification.co.uk

RMS have already been producing numerous videos that prove how effective and useful the Motion Amplification system can be.

In the case of Motion Amplification, seeing really is believing. Click on the two example videos below to see for yourself.

What is Motion Amplification. View on YouTube video below or download the MP4 file.