Speaker A
Okay, folks, um, thank you very much for coming along. Uh, we're going to talk in this short half an hour session on condition monitoring and very importantly, discuss condition improvement.
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Speaker A
Um, as a subset of that.
Speaker A
Um, my name's Dean Whittle, I work for a company called Reliability Maintenance Solutions.
Speaker A
Um, I'm a training manager for RMS.
Speaker A
So, hopefully this information we're going to convey today will be clear, concise.
Speaker A
And hopefully very visual to to make it understandable.
Speaker A
Um, there's a lot to go through, so.
Speaker A
Here we go.
Speaker A
Okay, so we have this.
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Um, opportunity, um, in front of us.
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To monitor and understand the health of our assets.
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Obviously, a key aspect of that is to improve availability.
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And indeed, um, reduce downtime.
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So all the blue things are good things.
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And all the red things are not so good.
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Things we want to actually improve.
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So, you know, less downtime.
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More availability.
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So increase capacity.
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So we're not going to dwell on these too long, but just key points here.
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Things that we're looking to actually improve.
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Um, less planned downtime.
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You know, if we don't need to take planned downtime, let's not do it.
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Let's measure on condition.
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The benefit is, um, less costs.
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Reduced waste.
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So there's a number of benefits that if we focus on these key areas in red.
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That will glean and gain aspects of the blue areas in, as you see above.
Speaker A
I guess shareholders are kept happy.
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Regulators, statutory requirements on assets, you know, we're complying with conformity by measuring condition.
Speaker A
And equally, maybe our employees are happy as well.
Speaker A
But the key point is, how are we going to actually achieve this?
Speaker A
How are we going to improve condition and and understand the condition of our assets?
Speaker A
Well, the key aspects here are management of assets.
Speaker A
Management of people via the use of condition monitoring.
Speaker A
So we're going to use condition monitoring methods, but equally, not just focus only on measuring condition.
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But equally as important, measure, um, focus on condition improvement.
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So we're looking to improve the condition.
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Not just measure, um, the condition and wait for something to degrade.
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Let's improve the condition.
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But as we work through, we'll see that.
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So we kind of got this really, really focused responsibility.
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With many, many complex machine types.
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That we want to understand the condition.
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Um, you know, if if we don't understand the condition, those machines will eventually run to some point and then fail.
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So measuring condition will allow us to understand the health.
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And you know, the responsibility we've got is these machines are very complex.
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You know, they're delivering a very important function to the business.
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So it's not just the asset here, a compressor.
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It's the individual parts of that compressor.
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You know, the fact that the bearing we're going to use is correctly lubricated.
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It's fit for purpose.
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It's got the right clearances.
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And it's installed properly.
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And it's a quality bearing.
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We buy that.
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We buy quality.
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We buy reliability.
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Equally, the gears, the same applies.
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You know, obviously the gears need to come together, need to mesh properly.
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The right lubrication needs to be used.
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Um, and obviously our gears need to be aligned, etcetera, etcetera, etcetera.
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So we won't dwell too much more on that.
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So, condition monitoring, we're going to, um, minimize the risk of failure.
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By understanding the condition.
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Via early fault detection.
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Okay, so we're going to measure machines.
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Um, obviously failure will happen.
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But it can be avoided.
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I think that's the message.
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We can avoid failure by understanding condition.
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So equipment gives us warnings.
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It talks to us.
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It doesn't speak English, it doesn't speak Scots, but what it does speak is signals.
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As we'll see in a moment.
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You know, it speaks vibration, maybe it speaks sounds, ultrasonics and so on.
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There's a number of things we can use.
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So the principle, the basis of what condition monitoring is.
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We've got an asset here that runs for a duration of time.
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We, we trend, we track, we monitor, we choose the right measurements.
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And it runs defect-free.
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Happy days.
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Good asset.
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No problem at all.
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But then at some point, and quite soon after a defect is initiated, we have the potential for failure.
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Maybe here it's rather exaggerated, maybe that time is maybe a little bit shorter than that.
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Generally speaking.
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And from that point forward, we're going to see a degradation in the asset health.
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Okay, so we're we're moving more and more closer and closer to actual functional failure here.
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And there's a journey we take where vibration and oil analysis and ultrasonics.
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Um, you know, and and infrared thermography can be used to measure the condition.
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And understand at different stages of failure where we are on this kind of P to F interval.
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Point of detection through to point of of of failure.
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Of the asset itself.
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Um, you know, arguably if we can see things much, much, much, much sooner here, for example.
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The planning time we've got in green is great.
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We've got a lot of planning time.
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The the risks, the safety incidences, the the cost of any incident here is very small.
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But the longer that defect's left unattended to, then maybe here ultrasound starts to wake up and tell us a story.
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The bearing in the machine's maybe starting to show signs of distress.
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Then we see some vibration behavior starting to wake up.
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But you notice now that planning time is starting to reduce.
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The amount of time to failure is now reducing.
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And the risks and the costs will grow as time propagates through to functional failure.
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Obviously, here we may have more heat.
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You know, the risks are increasing, the costs are increasing, etcetera, etcetera, etcetera.
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Through to, you know, the the bearing is virtually collapsed and it's rattling around.
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And there's no contact now between the race before it actually functionally fails itself fully.
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And our risks, our costs are very high.
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And unfortunately, we're at no time whatsoever now to plan any action.
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So, these these, sorry, these warning signs.
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What are these warning signs?
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We talk about.
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The warning signs.
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We can use, um, for example, vibration.
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A very quick snippet of vibration here.
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If we take the sound of vibration, maybe just from the motor as a whole.
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You can hear that sound of the motor running away.
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Or maybe the pump.
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Is that coming through?
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The sound?
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It's a bit faint, maybe.
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Thank you very much.
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Cool.
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So that, you know, that's that's the entire sound of the pump as a whole.
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But but individually, the pump blading.
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May produce this sound.
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So that's a completely different sound to the pump vibration as a whole.
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Maybe the bearing in the pump.
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Has a defect.
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So that's a high pitch sound.
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So collectively with vibration, we're able to understand each different heartbeat.
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And understand which part of the machine is causing these sounds that we can ought to be here now.
Speaker A
But what's responsible for this increasing signals and increasing vibration?
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I mean, collectively as a whole.
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With a good running pump, if we measure the pump head.
Speaker A
Anyone got any idea what the sound might be like?
Speaker A
No.
Speaker A
Let's let's maybe hear it.
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Maybe this is a good sound, maybe it's a bad sound.
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Anyway.
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So.
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Maybe our machine doesn't really sound like that.
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But still.
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Anyway.
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But the key point is, with vibration, we're able to home in inside the machine.
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We're like, we're like seeing through the machine by measuring the vibration on the bearings.
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Measuring its heartbeat here with a vibration system.
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To understand which component in the machine is degrading.
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Okay, that's the key point there.
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We can see the bearing failing, we can see the coupling, the blades, the heartbeats.
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Of all of those different components is different.
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Um, equally, we could look at measuring.
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Uh, relative temperatures here with a thermal imaging camera.
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So here I can scan with this camera and look at different phases through this supply.
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Um, obviously, we have a a a hot spot, sorry, there on the yellow phase.
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Equally there on the yellow phase.
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And I can read the uh spot temperature.
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We have to be aware of some um influencing factors that could affect the values we see.
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But it's very, very clear technology that, you know, we can see hot or indeed cold spots.
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If appropriate to the asset we're measuring.
Speaker A
With our vibration systems, we can use motor current signature.
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Motor motor circuit analysis to understand the condition of the rotor.
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The stator and the actual insulation inside the machine.
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Um, equally with oil analysis, we've got oil wear particle analysis.
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We can measure the health of the oil.
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We can know the oil condition.
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We can know whether we've got machine wear developing from inside elements that are breaking down.
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And indeed, whether we've got external contaminants getting into the into the oil.
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Because it's a very critical path that the lubricant is kept clean.
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Obviously.
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So, you know, taking a bearing as a very good example, obviously it will have a certain heartbeat as it rotates around the system.
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But what's a critical path here to stop it entering a failure mode potentially is to maintain that lubrication film.
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You know, that lubrication film is like one micron.
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One micron of of size, so it's critically important that we get that lubrication film right.
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The right grease goes in, the right volume of grease at the right interval.
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Um, obviously we get debris in our oil, um, or our grease.
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You know, we might have a five micron particle here.
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That's going to propagate and cause damage to the actual component.
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The race of the bearing and equally metal particles would, you know, detect themselves.
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And arguably with an oil sample, we might see that.
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But the bottom line is.
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The same applies to gears, you know, a damage to a gear.
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A a tooth chips, that's going to erode away the teeth.
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They're going to propagate into more and more damage.
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We can use ultrasound.
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This is very high frequency analysis, um, or or stress wave analysis.
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As we sometimes refer to ourselves.
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To listen to the sound of the bearing.
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Okay, we can listen to that lubrication film, we can listen to the actual bearing.
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Um, sound that it's making audibly through a through a monitoring device.
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An ultrasonic device, for example.
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Here, we've lost lubrication film.
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Metal to metal contacts increasing.
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Our decibel level will will go up.
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Um, less prolonged, that's only going to cause further damage.
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So it's important, we've put some grease in now, we feel it's appropriate to put grease into the bearing.
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To reestablish the lubrication film.
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So we can understand if the grease we're putting in is having an impact on the bearing.
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But equally, we check it some moments later, maybe an hour later.
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To make sure it's still running sweet and sound.
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And our lubrication film has returned.
Speaker A
Okay, so, um, how are we going to apply these programs properly?
Speaker A
Um, it's all very well having high technology, uh, vibration systems or ultrasonic systems, etcetera, cameras.
Speaker A
But how are we going to go about using them in the right way, in the right application?
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With the right kind of settings?
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That's that's very important.
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I think arguably often overlooked, the words mentioned so often, but, you know, it's very important that we focus our asset on critical assets.
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We understand the consequences of failure of assets.
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The likelihood of failure.
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And then we can start thinking about the appropriate method of maintenance to maintain this asset.
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Understanding its failure modes.
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The failure rates.
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The P to F interval, how long or how short could that be for each failure mode?
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And the detectability.
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Now and only now really can we start to say to choose the right type of technology.
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Okay, it's very important we understand the failure modes.
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And we apply the right technology or technologies to monitor the health of that asset.
Speaker A
That's very important.
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It's not rocket science.
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It's something that can be done in a very fluent, clear way.
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And the knowledge is on plant already.
Speaker A
But is there more we can do?
Speaker A
We can monitor condition, we can measure the health of the bearing.
Speaker A
We can understand the lubrication film.
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But is there more we can do?
Speaker A
We can eliminate root causes of failures in the beginning.
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Not just focus on monitoring a bearing that eventually is going to fail anyway.
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With condition monitoring, I'm not going to make it better.
Speaker A
Just because I condition monitor it, it's still going to fail.
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Unless I do something about what the condition monitoring guy is telling me to do.
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I replace the bearing.
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So, you know, it's it's it's critical here.
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We're not just focusing on monitoring.
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We're focusing on condition improvement.
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So if we can kind of wind this story back and this guy here.
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You know, if we take him back to to this point in time where, you know, we had this area where.
Speaker A
Machine's running perfectly, quality of product it produces is great.
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No health conditions whatsoever.
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It's running sweet and sound.
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Happy days.
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So let's let's focus on improving condition.
Speaker A
And just bear with me a second.
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Let's take that just to the extreme end.
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For this to work, I think.
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There we go.
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Here we go.
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So we're going to wind back that P to F interval.
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Pull it back into this defect-free zone.
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And then expect and continue to run not weeks, days, maybe months, but years.
Speaker A
Yeah.
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Years of running reliability from an asset because we're taking care of it.
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We're focusing on causes of failure.
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Not just monitoring failure with condition monitoring.
Speaker A
Is that's basically what the goal of condition monitoring is?
Speaker A
Is to detect, monitor, trend and track.
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Degradation.
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This is going to improve reliability.
Speaker A
By doing focused root cause analysis.
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At some point in years in the future, sure enough, failure could then redevelop.
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But we condition monitoring still to see that story.
Speaker A
Okay.
Speaker A
So, you know, root cause.
Speaker A
What what's this all about?
Speaker A
I mean, the number of machines that I see, pumps that cost 50, 100,000 pound installed.
Speaker A
On very flimsy structural configurations, the base plates eroded away.
Speaker A
The concrete, you know, the base, the support for the machine is not good before you even put it in.
Speaker A
That's a bad start to begin with.
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But we've got a story here where we've got bearings and couplings that we need to align properly.
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We need to actually make sure the bearing's fit for purpose.
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Um, if the bearing is right for its application, and indeed the lubrication is correct.
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Don't just pick up the nearest grease gun.
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Put the right grease in in in the machine, in the bearing.
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Align the two bearings.
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The bearings need to be aligned properly.
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The shaft needs to be aligned.
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The machine needs to be balanced properly.
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The air should circulate freely through the system.
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No restrictions.
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If not, that's going to cause forces back on the machine.
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Cause more stress.
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So if we take this example here, this fan's trying to show kind of an imbalance story.
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That's going to cause a a a radial force on the bearing.
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So this bearing, in a way, it's it's contained within the bearing housing.
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It wants to do this.
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This is the motion the bearing's trying to actually take.
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But it's constrained by the bearing housing.
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But at the end of the day, the forces are still in the machine.
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And those forces will cause additional stress.
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Additional forces on that bearing.
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Reducing its life.
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So, what's the solution?
Speaker A
Root cause, quality, balance your machines to a tolerance that's precision.
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And maintain that.
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Reduces the forces.
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Quality align the machine, etcetera, etcetera, etcetera.
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So obviously, a machine could be misaligned, maybe it wouldn't visually move that much.
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But if you bolted that machine down and it's misaligned.
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Those forces go to the bearings.
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Those forces go to the shaft seals that cost thousands of pounds.
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Premature failure of rotating component assets due to a very fundamental, simple thing to do.
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Align the machine.
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It's not rocket science at all.
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So maybe the the two shafts are misaligned angularly.
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That's going to put stress and load on the raceways of that bearing.
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Maybe the bearing's cocked on the shaft itself.
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Not common, maybe, but if the shaft is worn, that could be cocked.
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It's cocked in the outer race, so the bearing could be cocked over in the outer race.
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That's going to induce extra stress, extra forces in that bearing.
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Common today.
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Variable speed drives.
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Variable speed drives.
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Can induce the potential of what we call EDMs, um, their discharges.
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Basically, spark erosion through the bearings.
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That's a common failure mode on a variable speed drive.
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Root cause fix.
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Potentially, earth the machine properly.
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As a simple, simple solution.
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Or majority bearings today in that situation will be insulated.
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So they insulate the bearings to stop the currents flowing through the bearing.
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Okay.
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Okay.
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So we've got a standby machine.
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It must be perfect when we want to use it.
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It's perfect.
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Well, maybe not.
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The pump beside this machine is vibrating.
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That transmits vibration to the standby machine here.
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What results?
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Static indentations.
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We call it false brinelling.
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So the machine's not rotating and it puts distinct wear marks on that machine.
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We start the machine up three months later because we want to do something on the other pump.
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And we've got a problem straight away.
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So not good situations.
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We need to eliminate that as a root cause.
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We're back to this lubrication film again.
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I I you know, I keep kind of talking about it, but it's it's a very, very critical path.
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It's absolutely essential it's maintained.
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We've now lost lubrication film.
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What's going to result?
Speaker A
Stress, increased friction.
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If we're measuring ultrasonics, we're measuring vibrations, they will deteriorate.
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But arguably, unless we do something about it, it's still going to fail.
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So we need to establish that lubrication film.
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And make sure it's it's correct.
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It's a very critical path in a bearing.
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Okay.
Speaker A
So we we we can use all this technology.
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We can monitor condition.
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And, you know, with vibration, we can see these shock waves, you know, we've got a repetition here.
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Shock, shock, shock.
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And we can clearly measure those and we can say with vibration.
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It's the inner race, it's the outer race, whatever.
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But one thing we cannot do.
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Is make the machine more reliable.
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What makes it more reliable is getting to the root cause.
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Just because I condition monitor it, it doesn't make it better.
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It doesn't make it better.
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Getting to the root cause, putting the root causes to bed is what makes it better.
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Improve condition.
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Underline again, improve condition.
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So condition monitoring is great.
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But hopefully the story we we we are conveying here is we need to go beyond that.
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We're not just focusing on monitoring bearing faults, we're looking at improving reliability of an asset.
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We've got all this technology, but we need to focus on improving reliability.
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Okay, so we need to go beyond standard maintenance practices.
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Standard condition monitoring is the message.
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We want to improve reliability.
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It starts before the machine is ever put in position.
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At the design stage.
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The manufacturing stage.
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The procurement stage.
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The shipping stage.
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The installation stage.
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Let's look at that journey.
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So we've got this machine.
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It's precious.
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It's a precious machine, it's worth a lot of money.
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It's critical to production.
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And we must maintain the reliability of this asset.
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So before it's ever even installed, the journey starts.
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But what we're going to do here is create a force field.
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Okay, so we've got this kind of force field around the machine to protect it.
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And we're going to stop the unreliable suppliers coming into this force field.
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We're going to stop cheap spares.
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We buy cheap bearings, we buy cheap seals, we buy cheap.
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Do we buy reliability?
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Possibly not.
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The way the machine's transported before it's going to be installed is critical.
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So we've got to make sure that's that's fit for purpose.
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The transportation methods.
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It's contractors that are used.
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You know, we we've got to get these things right.
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Because if not, we're buying problems before it's even installed.
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Not good.
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Poor design, obviously, design stage.
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We need to make sure it's fit for purpose.
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So once we've kind of got those things right.
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And that starts in the bigger picture, no doubt.
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We've got to say that anything that comes into the plant is then fit for purpose for the asset.
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So that if we need to replenish grease on this machine once every six months.
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That the grease is is the correct grease.
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Not just the the nearest grease gun is picked up and used.
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It's the correct grease and it's not contaminated.
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Because if it's contaminated, we've seen previously what can result.
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We've got to make sure that parts we use from store.
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Stock, they've been stored properly, they're clean.
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Dust, moisture has not contaminated before we put these parts into the machine.
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Poor installation practice.
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We've got to make sure that we actually install our machines properly.
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I cannot overemphasize the point I've made about the base.
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You know, a nice stiff, rigid base with a quality machine bolted onto it.
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That's a good story.
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But how many people focus on putting a quality base in?
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Quite few to be fair.
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Surprising.
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We all think people do, but do they?
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Shocking, to be honest.
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Poor operating practice.
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If you maybe with condition monitoring, you have the potential to install online monitoring.
Speaker A
One one benefit that tends to bring is you see a lot more information coming back more regularly.
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And you can almost say, you know, guys, last night on that ship.
Speaker A
You were not operating that pump properly.
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You know, that pump needs to be.
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Cared for in the way it's used.
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Just like your motor car.
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You know, you don't thrash it down the motorway every every second of the day and come to a grinding halt and so on and so forth.
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Because you know, we're going to take care of the way we use the machine.
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Unnecessary PMs.
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Why do we need to do a PM if we can condition monitor it and it's saying it's fine?
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Is this an appropriate method of monitoring?
Speaker A
We don't necessarily need the PM.
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Intrusive inspections.
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Can they be alleviated by using condition monitoring?
Speaker A
So we use condition monitoring to take away the need to do an intrusive inspection.
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We measure it, trend it, track it while it's online.
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Doing its duty.
Speaker A
So whilst this is kind of a maze of different points.
Speaker A
They are very simple points to be fair.
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And if we get those things right, we've now got the best possible chance.
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Of of a a reliable asset with long life.
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Good reliability figures.
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Obviously, what's important, and I guess what that's what this is for.
Speaker A
We still continue to monitor the health of the asset.
Speaker A
That's still a need, please.
Speaker A
You know, that's still something we need to do.
Speaker A
Um, to continue monitoring.
Speaker A
If we don't do these things right, then basically we're inviting trouble.
Speaker A
Before the machine's ever used.
Speaker A
And arguably, what's going to happen?
Speaker A
The balls are going to get the machine, they're going to make the machine angry.
Speaker A
And failure will will result.
Speaker A
So that's not a desirable situation.
Speaker A
Okay.
Speaker A
Just checking the time here.
Speaker A
So.
Speaker A
Okay.
Speaker A
Um, I'm quite worried about the time I had to be fair.
Speaker A
But it looks like I'm going to finish possibly a moment or so earlier.
Speaker A
So in conclusion.
Speaker A
Breakdowns can be frustrating.
Speaker A
You know, but with condition monitoring, we have the ability to listen.
Speaker A
To see inside the machine and understand condition.
Speaker A
However.
Speaker A
What condition monitoring on its own doesn't do, it doesn't improve reliability.
Speaker A
Improving reliability involves taking a proactive approach.
Speaker A
Looking at root causes of why bearings fail.
Speaker A
Why couplings fail.
Speaker A
Why shaft seals fail.
Speaker A
Etcetera, etcetera, etcetera.
Speaker A
If we get those things right, that's what will increase reliability.
Speaker A
So we're going to focus on condition improvement.
Speaker A
So there is a solution.
Speaker A
We monitor our equipment, we monitor the condition to prevent catastrophic failure.
Speaker A
Um, obviously we get improved safety.
Speaker A
And planning, we, you know, we're in control.
Speaker A
We can plan when we're going to do something.
Speaker A
Because we know the condition.
Speaker A
And equally as important, as I've kind of tried several times to focus on.
Speaker A
We're going to focus on improving the condition.
Speaker A
You know, improve condition, we will increase reliability.
Speaker A
We will get more life out of that asset.
Speaker A
And that's good for everyone, good for the business.
Speaker A
So, I guess at the end of the day, I guess happy days, everyone's happy, and we have a solution to our problem.
Speaker A
Maybe with the correct technology and the correct methods applied.
![[Full Episode]Nothing Else Compares（English-dubbed）#cdr… — Transcript](https://i.ytimg.com/vi/YYJruShKWz8/maxresdefault.jpg)
