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Technology in predictive maintenance is growing fast, and so is Condition Monitoring which is one of the its most important activities. In particular, the wireless sensors in Condition Monitoring came to change completely the way we used to see machinery reliability.
What is Condition Monitoring? What do we need to learn about modern technologies applied in it? Well, I am a Vibration Analysis technology developer and I invite you to take some time to read this few tips I have written for you.
Condition monitoring is the process of periodically measuring one or more parameters in machinery to identify significant changes that usually indicate failures in process. It is an essential part of predictive maintenance, thus, allowing to plan maintenance actions focused on avoiding failures and their consequences.
Therefore, condition monitoring provides enough information to address actions towards components that require attention.
Continuous condition monitoring is usually applied to rotating machinery such as fans, compressors, pumps and combustion engines etc.
There are several techniques applied in condition monitoring but in importance we can enumerate the following:
In Erbessd Instruments we created enough options of condition monitoring systems for you. Starting from low cost equipment with large capacities, to integral systems with multiple automatic parameters such as our Phantom® vibration and condition monitoring system.
Digivibe M30 Condition Monitoring System is an advanced and portable system designed to analyze machinery vibrations individually. It is capable of plotting spectra in the field with up to 1,638,400 lines of resolution. Additionally, Digivibe M30 is able to perform dynamic balancing on site for 1 and 2 planes.
The Wiser 3X triaxial accelerometer also has the Wiser Vibe and Digivibe application compatibility for Condition Monitoring. It is the latest generation of wireless accelerometers, capable of sending 4 vibration channels in real time for X, Y and Z axes as well as an additional reference channel for phase comparison. In addition to being ultra-portable, Wiser 3X incorporates start and stop functionality in the same power button, to save valuable time during data collection.
Permanent Condition Monitoring System – Phantom ERP-V22 is a set of wireless sensors designed for permanent mounting. Featuring Vibration, Amperage, Temperature, and RPM. Phantom records vibration FFT from 3 axes simultaneously X, Y and Z. In addition, it includes a battery with duration of 2 to 5 years that can be changed at the end of its useful life.
The criticality index of a system is often used to determine the type of condition monitoring that needs to be applied to a system. Hence, critical Index takes in account the following factors:
Criticality index, therefore, divide the machines into 3 categories:
Savings due to production downtime reduction: The most significant savings arising from predictive maintenance are due to the significant reduction in production downtime.
The savings arising from downtime reduction can be calculated through the number of hours of downtime multiplied by the added value per hour for the process.
Cost of downtime = Downtime X $ Value per hour of process
Savings in maintenance costs: Additionally, Savings in maintenance are due to the reduction in man-hours to carry out repairs + savings due to the reduction of unnecessary replacements. This is calculated as follows:
$ Savings in Hours = (Man Hours invested in Major Maintenance – Man Hours for minor maintenance) X $ weighted Hour / Man
Condition Monitoring Costs: The costs of condition monitoring systems depend on the chosen system which can be Permanent or Portable. Of course, Permanent systems require more investment if the number of machines is large. On the contrary, Portable systems are cheaper, although, they require a specialist to measure each machine periodically.
The main goal of machinery condition monitoring is to reduce its wear and tear by extending the lifetime of all its components. Either through the reduction of vibration or by improving its temperature conditions, the machine will have a lighter work and therefore several benefits.
Electric power consumption: Making a mathematical correlation between vibration and energy is very difficult. Even more because of the wide variety of machines that exist in a company. However, a study conducted by The Journal of Industrial Technology* proved that a given machine can consume twice as much current only because of its vibration. Of course, this study was made in motor that can increase its vibration in proportions that a big machine is unable to do. Nevertheless, the study does prove a realistic relationship between power consumption and vibration.
Safety and health: The reduction of vibration is closely related to the reduction of noise from a machine and therefore reduces the impact on the health of the staff in charge. Prevalence of conditions such as retinal detachment and hearing loss induced by noise can be reduced by applying a correct condition monitoring.
Environmental and Economic Impact. The ecological footprint left by predictive maintenance is considerably greater than that of predictive maintenance, because in the first one, the idea is to replace critical parts as well as lubricating whether it is needed or not. These actions are intended to avoid stoppages, although they are not always necessary.
Implementing good Predictive maintenance actions will not only reduce the environmental impact by avoiding all these wastes but will also have a much lower productive cost.
The condition monitoring process has key aspects to achieve some of the goals in a short period of time. No one knows everything before starting and therefore it is important to take into account the following advices:
Know what you want to measure: It is very important to decide what parameters you want to measure in a machine, as well as what machines you desire to monitor. The most important parameters for condition monitoring are vibration, temperature and current.
Establish a starting point: You probably are not an expert analyst and you don’t need to, either. The first is to establish a starting point. For all you know, your machine is working fine right now, and you want to know when that changes. The starting point will let you know when your machine exceeds the current values. Over time and with the help of information and experience, you will know what are the real limits for each machine.
Periodic verification: None of this will work by itself unless you create a routine of checking the status of your machinery and alarms. Erbessd Instruments created mobile applications, as well as PC and WEB software for you to have a simple way to do it.
Set Alarms: At some point you will see that your vibration or any other parameter changes. Verify your trend graph, evaluate and adjust your alarm values to know how soon they will be overcome again.
It is a system that integrates multiple variables in a single database. It is very easy to install because you only need to stick the base to the machine and screw the sensor. Phantom connects automatically so it is only necessary to configure basic features like name of the machine.
The system will be sending vibration data as well as temperature, Amperage and speed automatically.
Digivibe Vibration Analyzer is a very powerful device based on a tablet. With the capacity of a normal PC and with enough memory to store more than 20 million recordings both in time signal and spectrum Digivibe leads the market in this field with an additional capacity for up to 2 million lines of resolution.
Digivibe is the first choice for non-permanent condition monitoring systems and it makes the process very simple and automated.
Digivibe is ultra-portable and wireless. Additionally, it includes applications for mobile phones in case you want to work more comfortably.
Digivibe is also a device for dynamic balancing on site and in swing benches.
Last but not least, our Wiser 3X Wireless Triaxial Accelerometer is the less expensive device in our range of condition monitoring systems. However, this does not make it less complete. Quite on the contrary! Wiser includes applications for mobile devices to collect data, make routes and review spectra. Additionally, on site balancing is available with the addition of a laser sensor.
Wiser 3X works closely with our EIAnalytic.com database for machinery and bearings.
Wiser Vibe application is a 100% dedicated application for condition monitoring. Additionally, Wiser Vibe is also a data collector. It can work with our Wireless accelerometers or any of our Digivibe GX400 interfaces.
What you can do with Wiser Vibe:
Share Wiser Vibe with customers or colleagues. Wiser Vibe is Free. This way your customers or colleagues can use it as well at no additional cost. Hence, our app will update all end users on the latest events in the database, such as new information uploaded, or high vibration alarms.
Route data collector: Wiser Vibe is also a route data collector. You can use Wiser Vibe for collecting data, as well as for balancing with any of our wireless accelerometers or Digivibe GX400 interfaces. Additionally, it is 100% compatible with Phantom condition monitoring.
Receive Notifications of Alarms: Wiser Vibe warns you 24 hours a day on any abnormal event of the machinery when you use Phantom condition monitoring. In case it is necessary, you can readjust these alarms at any time according to the needs of each machine.
Off-Route analysis: You can do off-route analysis with Wiser Vibe. Save the signals, send them by email, share them with Digivibe or in the cloud.
Scan the code of your machinery: Are you walking through your company and you are curious about the current condition of a machine?
Take your phone and Scan the QR code. Wiser Vibe will give you the latest recorded vibration values, alarms, and spectrum with a single click.
Create machines: Manage your database from your cell phone, add machines, generate new routes, all from the simple access to phone.
Download Wiser Vibe FREE here:
Thierry Erbessd, Mexican entrepreneur who has revolutionized the field of Vibration Analysis and Dynamic Balancing worldwide.
Thierry is a graduate of the National Polytechnic Institute of Mexico and is also a passionate programmer. This way, Thierry is the creator of DigivibeMX software that competes among the best systems for vibration analysis. He is currently the President of the Erbessd Instruments group, a leading company in solutions for industrial maintenance.
ERBESSD INSTRUMENTS manufacturer of Vibration Analysis Equipment and Dynamic Balancing Machines with offices in Mexico and the United States with representatives around the world.