The ability of specialists to identify and fix breakdowns before key production systems fail can be considered a sign of effective maintenance and repair. The most common tool for managing these risks is Vibration Analysis (VA).
Diagnostics of this parameter allows you to compare deviations with common types of failures, identifying problem equipment at an early stage of wear. The most accurate and useful analytics for the prevention of downtime is possible when vibration is considered in conjunction with other indicators:
– temperature of support bearings and moving parts;
– pressure in hydraulic and oil systems;
– structural and chemical composition of lubricants;
– the intensity of the load and the mode of operation of the equipment.
An integrated approach to vibration analytics and high-quality interpretation of diagnostic results help to make an objective forecast of the technical condition of assets.
The intensity and nature of vibration changes each time the components of the rotary equipment wear out and approach the end of their life. Analyzing this unique identifier is the key to categorizing failures and the first step towards creating an effective downtime prevention strategy.
Based on the results of the analysis, a qualified specialist can predict the causes of many failures:
– displacement and misalignment of components;
– loosening of bolts and fasteners;
– wear of the support bearing;
– eccentricity of the air gap between the rotor and the starter;
– problems with impellers;
– mechanical defects of gears;
– damage to the rotor rods;
– shaft deformation;
– short circuit in the starter winding;
– violations of the technological process;
– power supply problems.
To increase the efficiency of vibration analysis, sensors help to capture the full frequency spectrum and duration along three axes at the same time. And in order to interpret the results of such studies as accurately as possible, it is worth using advanced methods of combined diagnostics.
One of them in his study described Mohamed Wahba, Clobbi World’s MENA Region Representative, Experienced Reliability Manager and Master of Business Administration. He determined the relationship between the unique signature of the induction motor current, the vibration map and the prediction of the technical condition of the moving parts of the rotor.
The MCSA (Motor Current Signature Analysis) method is used for diagnostics in hard-to-reach places and hazardous conditions. For more familiar scenarios, this technique is also useful. It allows you to accurately assess the technical condition of rotary equipment without stopping production.
From analytics to practical solutions
Vibration analysis is a time-tested diagnostic technique that has earned a positive reputation among both reactive and predictive service aficionados.
Let’s consider the benefits for each of the two strategies.
Reactive Maintenance is focused on operating equipment to failure. In this case, vibration analysis allows you to determine the optimal load level to ensure high performance. It also helps to identify the problem node at the earliest stage of failure. This significantly reduces downtime and saves money as you only repair and replace parts that are worn out.
Predictive Maintenance focuses on reliability and problem prevention. By taking advantage of vibration analysis, you can accurately predict the condition of your equipment, create a cost-effective and efficient maintenance plan, and extend the life of your assets. If an enterprise wants to increase control of business processes, strives for stability and is ready to invest in digital technologies – when building a service strategy, it is worth paying attention to vibration analysis.
An experienced service technician can interpret vibration diagnostics results. But if we are talking about effective monitoring of the state and accurate prediction of failures, the trend analysis should be done by artificial intelligence (AI).
A person is physically incapable of comparing hundreds of qualitative and quantitative measurements with all possible failure scenarios in a short time. And if we are talking about a large number of assets, a complex production cycle or geographically disparate facilities, then one cannot do without intelligent solutions.
SmartEAM has tools to optimize maintenance. Our IT solutions take vibration and other operational data into account to determine the Health Index. It is the variable that is automatically used to build the optimal maintenance plan – cost-effective, flexible and efficient.
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