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Proud distributor for Agate Technologies – Portable Vibration Shakers and Calibrators

GVS Reliability Products are now the Australian distributor for Agate Technologies – Portable Vibration Shakers and Calibrators.

Each model offers a variety of different features and functionality, so you can choose the one that best meets your testing and vibration monitoring needs. All shakers are battery powered and can be used in any setting—from in the field to the laboratory where you can verify condition monitoring sensors, systems, cabling, and connectors.

AT-2030 Basic adjustable-frequency amplitude shaker.

AT-2035 Adds the ability to calculate transducer output sensitivity.

AT-2040 Includes more enhanced shaker features, including a sensor simulation feature and advanced support for 4-20mA sensors and proximity probes.

AT-2050 calibrator includes support for piezoresistive, variable capacitance, and MEMS type sensors

Further information for each model can be found here or you can download the ‘Specification & Feature Comparison’ document below.

 

For enquiries please email sales@gvsensors.com.au or phone 02 4925 2701.

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Complementary Technology – Misalignment

Visualise, Measure, Troubleshoot and Correct machinery misalignment with Motion Amplification® and Easy Laser® Reliability Products from GVS.

 

Motion Amplification® and Easy-Laser® are fantastic complementary tools for visualising misalignment, measuring thermal growth, and correcting misalignment making Proactive (Precision) Reliability Maintenance even more achievable.

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Easier than ever to measure flatness and straightness

Now presenting Easy-Laser® XT20 and XT22, the most user-friendly precision laser transmitters ever designed! 
 

One of the most important things during a machine installation is to ensure the flatness of the base. With the new XT20 and XT22 we have facilitated handling, which makes for faster measurements and fewer fault sources. More reliable machine installation, put simply. 

Both transmitters can be used for flatness and straightness measurement. In addition, the XT22 can direct the laser beam at 90 degrees to the laser plane, which means you can solve virtually all types of geometric measurement jobs. The area of use therefore does not stop at measuring the flatness of bases. The XT22 also has a higher technical specification for straightness thanks to fiber laser technology, and can take measurements at distances up to 40 m. The XT20 can take measurements at distances up to 20 m, but is also IP55 rated water and dust proof.    

New technology improves reliability  

We have installed electronic precision levels in the XT transmitters. This gives the advantage of faster feedback when levelling and less risk of errors during calibration, because all users see the same angular value (compared with reading spirit levels).   

The laser transmitters are wirelessly connected to the XT Alignment app. In this way, the user can be guided during calibration and the measurement procedure. In the event of temperature changes, vibrations or impacts that can affect the measurement result negatively, the app gives a warning during measurement. Data about the transmitter and measurement environment can be downloaded together with the report. This all provides greater reliability and traceability for your measurement jobs.  

Functions for easier use  

The rotating head is completely stable and retains its position during measurement. At the same time, with the new fine turning mechanism it is easy to set the pointing direction of the laser beam to hit the detector, even at distances up to 40 m. We guarantee that this will be very much appreciated by users out in the field. All operation is also managed without the need to lock/unlock rotation, which facilitates use considerably.    

Just like Easy-Laser’s previous laser transmitter, the new XT20/XT22 can be installed and positioned in many different ways: with integrated super magnets, on rods to be height adjustable, on stands and magnetic feet etc. We know that this is an important factor in practice to combat all those situations the user faces in reality.   

A rechargeable Li-Ion battery gives long operating times, up to 30 hours. If necessary, the transmitter can also be run directly off the mains.  

Developed for use with the XT Alignment app  

The XT20 and XT22 are used with the programs Values, Basic flatness and Straightness (new) in the XT Alignment app.   

The laser transmitters can be purchased separately (as a kit with charger and fixture) but are also included in complete systems, such as the XT770 GEO. The XT70-M unit can be used as a detector. They can also be used with E series detectors. Note, however, that the XT Alignment app is required to calibrate the electronic levels, and other things in the design of the XT transmitters differ from previous products. Therefore, always ask us first if you plan to replace an older transmitter.   

Easy-Laser have been known for their reliable geometry measurement systems for decades. With the new Generation XT laser transmitters we are taking a step into the future, to a whole new level of reliability, precision and user-friendliness. The XT20 and XT22 are the laser transmitters of the future, in every way.   

Take a look for yourself or visit the XT20/XT22 product page to learn more.

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Create a Compressed Air Leak Management Program with SDT. It’s EASY

Why We Ignore Leaks
Compressed air is a misunderstood utility. As such, it tends to be misused and even abused. Leaks continue to be the biggest problem; often overlooked because they are difficult to detect, don’t smell bad, don’t make a mess on the floor, and rarely stop production.

 

The Real Cost of Leaks
One of your factory’s highest operating expenses is the energy consumed by your compressed air system. Only 25% of the cost of a compressed air system is capital cost and maintenance. The remaining 75% is energy, and as much as 35% of that energy is wasted satisfying leaks.

Additional Impacts
Compressed air leaks create fluctuations in system pressure, which negatively impacts product quality. Compressors work overtime to compensate, leading to early degradation of the asset. Eventually, the compressor system can’t keep up with demand. What can you do? Buy yet another compressor for more capacity? Or optimize the capacity you already have by finding and fixing leaks?

With so much at stake, why are compressed air leaks managed so poorly, and why doesn’t every organization have an air leak management program?

 

Where to Look for Leaks
Every component has the potential to leak, but we can hasten our search by focusing on common failure points. Usual problem areas are branch line connections, automatic drain traps, desiccant filters, regulators, coalescent filter assemblies, quick couplers, valves, hoses, fittings, pneumatic cylinders and thread sealants. Most leaks occur at points of use, so begin your search there.

How to Find Leaks
Locating air leaks in a loud factory floor is next to impossible with a human ear. The best, and easiest, way to find air leaks is using ultrasound. Ultrasound detectors allow you to hear the minute hissing noise produced by leaks, despite the roaring noise of a production area. Ultrasound detectors are portable, easy to use and require little training to get started.

SDT have a range of hand-held devices from the entry level LEAKChecker to the SDT340 which can be used for both airborne & structure-borne applications. And now with the all new  SonaVu acoustic imaging camera you can ‘SEE” the leak in real time making it even easier to scan larger areas.

How to Manage Leaks
It’s not enough to just find leaks. Fixing and documenting savings is a necessary part of the program.

Fortunately SDT have simple and easy to use platforms to track and calculate these costs.

LEAKReporter

A mobile smartphone App available for iOS and Android. LEAKReporter is focused, simple and free. It saves inspectors time and money by documenting leaks in pictures, estimating their cost impact and creating fast comprehensive leak reports. This can be used with the LEAKChecker, SDT200, SDT270 or SDT340.

SonaVu InSights™

Is a web application for creating instant reports of compressed air leak and electrical asset surveys performed with the SonaVu Acoustic Imaging Camera from SDT. Document findings, prioritize repairs, estimate cost impact, eliminate energy waste, and save money with this free application.

Being competitive has never been more important than it is today. Energy costs directly impact your bottom line. There is no easier way to reduce energy waste than to tackle the “low hanging fruit” in your compressed air system.

It doesn’t have to be complicated.

Detect, fix and save money with SDT Ultrasound Solutions.

Author – Tristan Rienstra

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Why RDI’S IRIS M™ Motion Amplification™ is Essential Technology

RDI’s IRIS M™ Motion Amplification™ takes Asset Management and Reliability to another level
Problem

The industrial landscape in Australasia is ultra-competitive with companies always looking for technologies that will propel them to best in class for their industry.

Solution

RDI’s IRIS M™ Motion Amplification™ is one of those ESSENTIAL technologies that will take your Asset Management and Reliability to another level.

  • IRIS M™ enables Proactive (Precision) Maintenance Reliability activities such as precision commissioning, precision installation and DEFECT ELIMINATION
  • Visualisation of the root cause of unacceptable vibration detected via routine and online PdM programs
  • Through visualisation, transition to root cause problem solving
  • IRIS M™ is the perfect tool for screening assets, fault finding, commissioning new assets, and pre/post repairs or retrofits
  • Communication tool between technical and non-technical personnel, enhancing the decision-making process

Contact sales@gvsensors.com.au to learn more about IRIS M™ Motion Amplification™

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Find the root cause with IRIS M™

Excessive vibration is often at the root of premature machine, structure, foundation, vessel and piping failures frequently leading to serious safety incidents and costly repairs and downtime.

One of the most effective, efficient and safest ways to characterize the root cause of excessive vibration is with RDI Technologies Inc.’s Motion Amplification® technology. The IRIS M™ platform enables the user to visualize, measure, troubleshoot, correct and verify the characteristics of excessive vibration problems.

Find the root cause with IRIS M™.

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

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How to select the right vibration sensor

With so many different types, shapes and sizes to choose from, selecting the right vibration sensors (otherwise known as accelerometers) for your operations can be a challenging task. It is, however, essential. To ensure you specify correctly, there is a number of important factors you need to consider.

Vibration range and sensitivity – The range of vibration varies greatly from operation to operation. You should always specify vibration sensors to measure the maximum vibration range of your specific application. In a standard application (80g range), the sensitivity of a typical vibration sensor is 100mV/g, while in low vibration applications (16g) the sensitivity is 500mV/G.

Vibration frequency – Knowing the frequency span you need to measure is as important as knowing the vibration range. The frequency spans are dictated by the fault frequencies of the fastest-turning component in the machinery being monitored. The frequency span of a slow turning ball mill, for example, will be narrower than that of a high speed fan.

Environmental temperature – After poor and incorrect mounting, the greatest threat to the performance of vibration sensors is the environment. High temperatures can affect the operation of the electronics. However, charge-mode accelerometers are specially designed to work in applications with very high temperatures.

Contact with chemicals or debris – This can reduce the reliability of results and should therefore be considered carefully. To ensure performance and results are unaffected by exposure to chemicals or debris, accelerometers with corrosion and chemical resistant stainless steel bodies should be specified.

Hazardous atmospheres – Hazardous environments are those that contain flammable gasses or vapours, combustible dusts, or ignitable fibres, where even the tiniest spark could cause a fire or explosion. To protect people, machinery and productivity, you need intrinsically safe accelerometers, which are specifically designed for use in hazardous areas. They deliver the same level of performance as their non-intrinsically safe counterparts, but do so by using a lower level of energy.

Immersion in liquid – The average accelerometer isn’t constructed to be waterproof. If your application requires accelerometers to be exposed to liquid, the solution is to specify vibration sensors with integral polyurethane cables. This prevents liquid infiltrating the accelerometer and affecting the electronics – whether the sensor is at minimum sprayed with water or even completely submerged in liquid on a permanent basis.

Exit and profile – The exit and profile of a vibration sensor has minimal impact on performance, but if not considered can become a frustration for those responsible for maintenance. Depending on where the vibration sensor is located, you can choose between a top exit, side exit or low profile connection to allow maintenance engineers easy, safe access.

By taking these factors into consideration you can make the right choice in vibration sensor specification for the requirements of the average application or an industry specific use. If you need further assistance or require advice on special applications, GVS is here to help and can assist you in selecting the ideal vibration sensor. Get in touch today, or view our full range of vibration sensors, cables and accessories. 

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Breaking New Ground With New Software Release

RDI Technologies, Inc. (RDI) just released a new update to its groundbreaking software. Version 3.3, the latest release, enhances a user’s experience for both the Iris M™ and Iris CM™ systems and reaches new markets seeking a solution to preventable and ongoing vibration problems. 

RDI ’s technology platform turns every pixel of a video camera into a displacement sensor. With patented software processing algorithms, Motion Amplification® enables users to see motion that’s impossible to see with the human eye. Always focused on combining customer feedback with cutting-edge technology, RDI conducted a customer feedback campaign over the summer in order to gain a better understanding of what new features would most benefit its customers. 

“We are excited for what this new release means for our line of Iris products,” said Jeff Hay, CEO of RDI Technologies. “This update includes full historization of data allowing our users to measure, compare, and trend nearly an infinite amount of locations across an asset with the click of a mouse. It’s a huge step for our customers in terms of what they can do with the Iris M and Iris CM.”

RDI’s systems are in use in over 38 different industries – a testament to the flexibility of the system and dynamic ways that users have found to apply the technology. In addition to RDI’s typical robust enhancements to the Iris M, Iris CM users have many new features. 

Key Features in the 3.3 Software Release: 
Iris M
  • Iris M™ Acquisition Assistant™:  It’s now easier than ever to obtain high-quality Motion Amplification® videos! The RDI Acquisition Assistant provides users with a step-by-step interactive guide that helps establish important recording settings such as framerate, lens selection, focus, and brightness. The Assistant also allows users to proactively identify environmental conditions before recording, such as light flicker and camera shake. Let the Acquisition Assistant help you achieve high-quality data.
  • Motion Amplification® – Historical Data Analysis: Iris M users now have the ability to store vibration data concurrent with the recordings captured by the Iris M camera. The spectrum and waveform data can be stored with the associated recording, allowing users to perform comparisons across recordings or measurement locations and display waterfall plots.
IRIS CM™
  • Motion Amplification® – Historical Data Analysis: Iris CM users now have the ability to store connected sensor data concurrent with the recordings captured by RDI camera systems. The spectrum and waveform data can be stored with the associated video recording, allowing users to perform comparisons across recordings or measurement locations and display waterfall plots.
  • Iris CM™ Measurement Historization: Now, users can get even more powerful insight into the dynamics of monitored equipment. With Measurement Historization, Iris CM™ users can define measurements to be stored over time for any connected sensor used to trigger recordings. Measurements include spectrum, waveform, and trend data from the connected sensors and the video-based ROI measurements. The associated captured recordings are also stored and available for further analysis in the Motion Amplification® software in conjunction with the historized data. 
  • Iris CM™ Complex Triggers: Iris CM™ users can now define the very specific criteria required from multiple sensors to determine when recordings are captured. Leveraging Boolean logic, users can, for example, define that both a high level of vibration and a specific change in speed must be met before triggering will occur. Now you can trigger when a specific set of conditions are met.

All users with current licenses are encouraged to download the latest software and enjoy the newest features that this technology offers. RDI continues to pioneer its industry and evolves as the markets and needs of customers change.

 

What is Motion Amplification? Visit www.opticalmotion.com.au or contact GVS today to learn about this cutting edge technology.

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SonaVu Acoustic Imaging Camera identifies vacuum leak within minutes

What is an Acoustic Imaging Camera?

SonaVu™ is an acoustic imaging camera. Using its 112 ultrasound sensors and optical camera, it can detect sources of airborne ultrasound and transmit them into a visual image on its touch screen.

Defects such as compressed air system leaks, compressed gas system leaks, vacuum leaks, the presence of partial discharge on electrical assets, and failed/working steam traps all create turbulence. And when there is turbulent flow present, there is airborne ultrasound. SonaVu™ makes the superhuman hearing capabilities visible to the human eye.

Using an acoustic imaging camera these defects and failure modes can be visualised and pinpointed from up to 50 meters away. And due to the visualisation capabilities of SonaVu™, it’s really easy to use too as demonstrated in the video below.

With minimal device training, maintenance technicians can confidently inspect their assets for defects, long before they cause unexpected downtime. 

SonaVu™ – Bring Condition Monitoring into focus.

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Ultrasound Inspection On Rotating Assets

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GVS Reliability Products in conjunction with SDT Ultrasound Solutions is proud to present the below case study, Ultrasound Inspection On Rotating Assets, submitted by Mike Halls.

Mike is Technical Officer of Condition Monitoring at Rio Tinto’s Yarwun alumina refinery where he has held this position for over seven years. Mike has over 20 years working in the condition monitoring field, utilising popular technologies such as VA, Thermography and Oil Analysis. And now Ultrasound for the last 2 years!

Mike’s years of experience have given him a unique perspective on using ‘alternative’ condition monitoring tools such as the SDT 270 PROthe world’s flagship ultrasound inspection device. With the SDT 270 delivering reliable, repeatable and calibrated ultrasound data and, with the power of signal analysis using SDT’s UAS software, Mike has been able to clearly demonstrate that ultrasound inspection should be the technology of choice for certain applications.

When using Ultrasound inspection technology in a harmonious relationship with other condition monitoring inspection devices, plant coverage increases, as does the overall reliability and availability of monitored assets. This then translates into greater production capacity and therefore overall profitability of an enterprise/company.

A portion of this case history was first published in The Industrial Eye: The official journal of the Australian Institute for Non-Destructive Testing – Condition Monitoring Issue – March/April 2017. 
It has since been edited and rectified to give further information regarding the case.

Read on for Mike’s ultrasound inspection success story…

Case History: Mike Halls – Rio Tinto Yarwun – 16-10-2017

Bearing Life Extension using SDT 270 Contact Ultrasound measurement

vaccum pump

Equipment Details

Equipment: P2620Vacuum Pump

Bearings: Tapered Roller Bearings

Pump Speed: 222 RPM

Motor: 630Kw – 6 Poles

Number of Vacuum Pumps on Site: 21

Costs associated with bearing failure

Overhaul cost due to a bearing failure: $120K
Total Replacement cost: $300K
Costs due to lost production or downtime: Currently there is some redundancy (as long as there are not too many other problems…). This may change in the near as further production demands are made on the plant.

History

Previous vacuum pump equipment failure modes and RCA’s have revealed that there has been an increase in bearing internal clearances & cage wear resulting in premature bearing failure. Due to the nature of these machines, vibration spectral analysis only revealed bearing defects in the later stages of the failure mode. Vibration analysis identified advanced propagation of fatigue due to surface cracks and spalling of the bearing raceway surfaces which were already resulting in unsatisfactory equipment performance.

Contributing factors to consider when using a vibration analysis approach are

a) a relatively low operating speed and

b) fluctuating ‘flow related’ vibration

Both of the above plant characteristics have the tendency to mask the early stage, low level amplitude bearing defect fault frequencies which, had they been detectable, would have indicated sub-surface bearing raceway defects and/or lubrication related anomalies. See the vibration analysis plots below as reference.

Vibration Analysis Plots

Below is the vibration Acceleration & PkVue spectral data taken the day after the acoustic vibration route was collected and, prior to any maintenance or lubricant/greasing intervention. Vibration analysis of the spectral plots indicates that the dominant frequencies relate to the vacuum pump pressure pulse fundamental & related harmonics. Neither of the plots indicates incipient bearing anomalies or lubrication related issues.

vibration analysis_1
vibration analysis_2

Challenge

With traditional condition monitoring technologies being limited in their capacity for detection of the early stages of the bearing failure modes, trending of the degradation process was not possible. Without being able to detect and trend the early stages of the failure modes, this left the plant exposed when needing to determine a projected planned maintenance window. So, once the later stage defects were finally identified, the asset was already at a critical crossroad in

a) needing immediate attention or

b) risk plant failure with consequent potential safety hazards or production loses.

Solution: Acoustic Vibration Monitoring Trial

Acoustic Vibration Monitoring or contact Ultrasound, are terms used when an Ultrasound inspection instrument (in this case the SDT 270 PRO), utilises a sensor to contact (touch) a surface to detect attenuated ultrasound signals. Using a sophisticated instrument such as the SDT 270 PRO, the ultrasound signals can then be acquired as either dynamic (for analysis and playback) or static measurements (for trending) and logged in SDT’s proprietary database, Ultra Analysis Suite (UAS).

Just over twelve months ago, an Acoustic Vibration Monitoring strategy was implemented on a trial basis to complement the vibration analysis program on the vacuum pump routes. This was done mainly to assist with lubrication related concerns and incipient bearing defects that vibration analysis was unable to confidently detect. After employing the ultrasound inspection strategy (with the 270), and the data analysed in UAS, a number of lubrication concerns with the vacuum pump bearings were rapidly identified. See figure 1 and 2 below.

Figure 1. Static trend

graph

Figure 2. Dynamic Signal

dynamic-signal_2

Listen to .WAV sound file at this Dropbox link.

Initial Results and Findings

The above Acoustic Vibration Analysis examples indicate a significant upward trend due to elevated ultrasound generated by the bearings. The ultrasound signal and trend indicate metal to metal contact that is identified by an outer race bearing defect. The causes for this are either inadequate lubrication or incipient bearing defect.

As already mentioned above, at these locations vibration analysis showed only high frequency data with a raised noise floor. This could be attributed to the product ‘flow’ and hence masked the true vibration signal. On the contrary (and unlike vibration), the Ultrasound signal is not affected by the ‘flow’ caused by the pump and hence did not mask/conceal the bearing condition data. Due to the clarity of this anomaly, we can call this a ‘text book case’ because in this example, increased readings in ultrasound data related directly to an inadequate bearing lubrication condition.

Due to the findings via the use of the SDT 270 Ultrasound inspection device, the recommended corrective action was; ‘grease the non-drive end bearing and re-evaluate the ultrasound values’.

Upon the recommendations being carried out in a timely manner, further readings were taken with results shown in Figure 3 and 4 below:

Figure 3. Static trend after recommended intervention

Static-Trend_alt

Figure 4. Dynamic signal after recommended intervention

dynamic-signal_alt

Note: the vertical y axis between fig 2 and 4 is different by approx. a factor of 4

Listen to .WAV sound file at this Dropbox link. 

Secondary Results and Findings

The data collected with the SDT 270 post lubrication intervention shown in figure 3 &4 showed drastically reduced static and dynamic ultrasound signals. Hence, the follow up survey indicated that the values had significantly decreased to within the acceptable ultrasound range. Further inspections were then planned to monitor the health of the asset. Through the unique attributes only available through ultrasound inspection with the SDT 270, the plant was protected.

Conclusion

Cost analysis:

Thanks to Ultrasound inspection and the access to complimentary software, a conservative estimate is that the company avoided a $120K+ cost to overhaul the pump due to a bearing failure. A catastrophic failure ($300K +) and potential compromise to personnel safety and plant production, would have seen the cost to the company far in excess of this $120K estimate.

Technology Analysis:

Ultrasound inspection has unique qualities which were instrumental in allowing condition monitoring to gain a true understanding of the health of the asset. For this application, other condition monitoring technologies were only useful once the asset was in the late stage of this particular failure mode exposing the company to high risks.

Furthermore, with the SDT 270’s ability to collect both dynamic and static data for trending and analysis, and the ability to record and analyse this data in the UAS software, the defect was easily identified and corrective actions taken.

Site Analysis and further actions:

Continued use of Ultrasound inspection technology to identify bearing condition will be employed so as to extend the reliability, availability and life expectancy of these important assets.

When using Ultrasound inspection technology in a harmonious relationship with other condition monitoring inspection devices, plant coverage increases as does the overall reliability and availability of monitored assets.

Thank you for reading.
I hope this study proved to be of use to you confirming best practice in technology integration results in determining a higher accuracy in detecting equipment failure modes.

For PDF download please view here Ultrasound-inspection-for-Rotating-assets-case-study-by-Mike-Halls-1.pdf