What are the vibrations of your industrial asset?
Capture them 24 X 7 and read on for the answers
Vibrations are unique signatures usually captured in series, with the signal’s amplitude (y-axis) depicted over time (x-axis). The back and forth movements of individual components of the industrial equipment combine to form a complex time waveform showing overall vibration. In its simplest form, vibration is repetitive motion of equipment or a structure and can occur in numerous forms. Various types of vibration (e.g. free vibration, forced vibration, flow-induced vibration, random vibration, etc.) can be measured for analysis.
Why monitor vibrations?
80% of the mechanical faults can be detected by vibration monitoring. Change in vibrations is the main reason your product quality and quantity are adversely affected, and your targets are missed. But what exactly is a rise in vibrations? The rise in vibrations is usually a result of an unexpected deviation of the trend. 70% of the deviation occurs due to mechanical faults such as overload, poor lubrication, and/or foundation issues of the equipment. It’s usually harmless unless it impacts the production, equipment and the operator. Typical symptoms of this condition include improper maintenance, incorrect selection and application of lubricant, inaccurate pressure on the assembly line, unconventional machine settings and overloading the equipment to cause voluminous production in lower time.
How are vibrations captured?
Vibrations can be seized with the deployment of a Plug and play sensor near the bearing locations of the mechanical rotating equipment such as motor, pump, blower/fan, gearbox, spindle-bearing, etc. In fact, as many as 36,000 equipment data signals can be monitored within a minute to interpret the health of equipment, with vibration signals being the most vital and common. The vibrations generated by operating equipment can be instantly measured and with its edge-cutting technology, the analysis and insights can be accurately obtained.
Vibration analysis in Vibration monitoring is a vital parameter in reliability-centered maintenance (Predictive Maintenance), and condition monitoring programs. A condition monitoring program is a two-tier program that detects the discrepancy in vibrations (or parameters monitored) and eliminates the root cause of the discrepancy by analyzing the data captured. This analysis can also be used to determine the root cause of a rise in vibrations which subsequently may lead to equipment failure. The key benefits of identifying and mitigating vibration problems include reducing the risk of failure, extending the life of the equipment, and lowering overall maintenance costs.
How long does it take to understand vibrations?
99% of the vibrations captured produce 100% actionable insights instantly that help the Maintenance team and CBM expertise to understand the discrepancy in vibrations. The insights are locally and remotely visible on the dashboard and can also be observed as a change in the visual light indicators on the sensor.
The spectrum of raw data captured and analyzed breaks down into further corrective remedies. For instance,
- An increase in temperature of the motor bearing may suggest the need for lubrication to combat the friction in its winding.
- Increase in Noise/ Acoustics may be indicative of an improper fixing or mounting of the equipment, loosening of the nuts and bolts used to mount the equipment or structural issues.
- An increase in signal energy may pinpoint to overall violation of vibrations, consequently damaging the equipment and risking the plant operations.
What to watch out for?
Check for the alarms and notifications sent by SMS and Emails as a result of the vibrations crossing the standardized threshold limits. On-site inspection of the equipment is mandatory. A remedial step to lubricate the motor winding, clean the fan/blower blades, supervise the equipment settings, tightening the loosened components, etc. can successfully prevent the equipment breakdown.
Infinite Uptime’s Patented, Make in India, Predictive Maintenance solution, suitable for harsh environments and hard to access locations in the plant efficiently monitors triaxial vibrations, temperature, and acoustics of rotating mechanical equipment. The analytical information provided as a spectrum caters to the needs of overhauling the equipment when it is actually required. Further, the insights also help to prioritize in arranging for critical spares, enabling a quick decision of repairs and replacement, studying the equipment history, a detailed investigation of the instance or the duration of the anomaly can act as a guideline for production planning, increasing the MTBF and eliminating secondary damage.