Condition monitoring involves the continuous and on-time monitoring of the various industrial equipment and machineries such as vibration, temperature and sound. It is the more proactive means to preventive maintenance where any possible component defects are identified at an early stage. The most used and effective system is the vibration monitoring system and the vibration equipment that uses a set of tools used to measure one or more parameters in order to identify changes in the behavior of the machinery. In Fact, the main purpose of these systems is to help in scheduling the maintenance activities based on a process called Predictive Analysis.
Vibration-based analysis techniques are widely used for condition-based monitoring and maintenance services. The vibration spectrum is collected for the machinery which consists of rotating or moving assets. There are 2 major areas being looked at: Acceleration and Velocity of the machines. The prime objective of Vibration Analysis is to carefully monitor rotating machinery and detect possible problems and control future machinery failure (if any).
This condition-based monitoring technique involves the examination of various oil samples used in the machinery on a scheduled/ periodic basis. It also involves the identification and separation of solid particles (ferrous and non-ferrous) from the lubricating oils and checking their characteristics like: size, composition, distribution, concentration, etc. Ferrography testing helps to detect the critical stage of the machinery that may result in critical failures. This type of testing is also called as Wear Particle Analysis or Wear Debris Analysis.
One of the most common problems in rotating machinery is shaft misalignment. Misaligned shafts are one of the greatest reasons for plant breakdowns as it increases the pressure on the machinery bearings and affects the movements. The condition-based monitoring for laser shaft alignment helps in identifying the misaligned shafts and fixes it with maximum precision. This significantly helps in reducing wear and tear on the bearings, seals, shafts, and couplings thereby minimizing the operating and maintenance costs.
Temperature is one of the most common indicators of machinery health. Thermography analysis is widely used for preventative maintenance on mechanical equipment through thermal energy. It is a widely used analytical method to identify the temperature differences with faulty machinery, worn out equipment, damaged material components, etc.
Condition monitoring through ultrasound analysis is one of the most reliable method and versatile predictive technology. As a companion to vibration analysis, ultrasound analysis helps with identifying early fault conditions in rotating and non-rotating machinery, especially with slow rotating assets. It helps to record in real-time the sounds of operating equipment and provide early warning indications of failure conditions.
This is the highly effective preventive maintenance method to detect incipient faults in bearings and even adequacy of lubricant. These testing devices uses the advanced technology that can be used to check the lubrication and friction level and monitor a wide range of plant operations. This effective testing method helps to avoid and control many repairs and failures that commonly occur in industrial settings.
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