Acoustic Emission Program is one of the oldest techniques in Condition Monitoring Which unfortunately has not been paid to it. One of the techniques that can help to user for Preventive Maintenance is Acoustic Emission.Using this technique, the failures, especially early failures in the rolling bearings can be detected. Whereas, a few months after the start of rolling bearings failure, fault signs of will appear in the vibrational spectrum. acoustic emission technique in two fields, ultrasonic and sonic is done.
Thermography is one of the advanced techniques in equipment diagnostics, especially furnaces, steam generation systems, evaluation of thermal insulation, electrical panels and connections and etc. In this technique thermal images of equipment are shown in colored spectra l diagram using thermovision cameras. In these images, different parts of equipment can be observed in different colors depending on their temperature, so the colors are indicative of a specific part temperature. The performance of this technique in troubleshooting of refractories and thermal insulation is unique.
This technique can help us to identify various defects including:
As already mentioned, vibration analysis is one the most powerful and applicable techniques among condition monitoring techniques. In order to implement vibration analysis program in a productive company, some procedures have to be carried out. To analyze recorded measurements, technical and engineering knowledge is needed.
BASAMAD engineering company is ready to implement vibration analysis program in productive companies and complexes employing experienced CM engineers and utilizing advanced instruments.
The implementation procedure of vibration analysis program is as below:
Condition monitoring is a technique which has grown in various countries during last years. Of course this technique is not used in whole industries. By performing this technique in different companies, unreasonable routines, which impose high expenditures most of the times, are eliminated and predictive maintenance strategy is used instead of preventive or others. Predictive maintenance is based on condition monitoring and diagnostic techniques.
Generally, proper implementing of CM techniques reduces unwanted down times and expenditures significantly. Instead, investing costs for establishing and application CM is very few comparing gained profit.
Preparing CM Schedule in production plants is one of the main activities of BASAMAD.
BASAMAD company establishes this schedule comprising following steps: Documentation; preparing technical documents, data acquisition, fault analysis, reporting.
BASAMAD uses the following techniques for condition monitoring of rotating equipment:
– Vibration Analysis
– Acoustic Emission
– Oil Analysis
– Online Monitoring
– Current signature analysis
Oil Analysis Program
Scheduling & fulfillment of maintenance activities based on conditions is the first and most important stage in proper maintenance before failure. Possible defects & failures of equipment can be distinguished using previously measured data such as vibration, oil, and thermography data. However, maintenance department has opportunity to plan and carry out corrective maintenance or take predictive action before any failure. This will result in significant decrements in maintenance expenditures as well as spare parts.
In mechanical systems which are lubricated with oil and their components are in contact with the oil, oil condition monitoring (OCM) is an effective method in diagnosing mechanical defects. A rotor rotates on a very thin film of oil in the range of micrometers. When this film is lost, metal to metal contact happens which will result in producing high temperature and consequently catastrophic failures. Therefore ensuring the health of the oil is essential. The oil in machines, resembles to blood in bodies, indicates the health characteristics of the machine. Oil analysis gives us valuable information which are used in decision-making for maintenance and operation. In this method, a few amount of lubricant is sampled in special containers and sent to the laboratory. Then a series of predetermined tests are done which will give us valuable information about the condition of the lubricant and the equipment condition as well. This leads to minimizing failures and damages to the equipment, reducing costs, increasing productivity, reliability of machines and quality of products. Oil condition monitoring aims to monitor oil contamination, evaluation of erosion particles and monitoring the quality of oil.
Four main applications of oil analysis in the field of condition monitoring include:
After proper maintenance planning and perfect machinery condition monitoring, some routines are needed for machinery maintenance. Not only proper planning and condition monitoring schedule is enough to achieve less defects and maximum equipment life time and reliability but also appropriate fulfillment of PM routines are also effective for getting closer to goals. To fulfill the PM routines properly, having a good schedule or executing method is necessary. Beside this, using expert engineers & technicians and updated tools as well are necessary. Improper performing of PM routines can impose high expenditures to production plants.
Performing different maintenance routines (A,B,C) on rotating equipment such as compressors, steam turbines, pumps, fans, gearboxes is of the services of BASAMAD engineering company.
BASAMAD also introduce you a CMMS software known as ELITE for maintenance management. This software is written by our specialists and can be adopted for any plant
The high expenditures of energy in advanced countries forces managers to keep their equipment in the best efficiency point. In fact, when equipment works efficiently and in good performance condition, not only improves production efficiency but also its life and reliability will increase.
Monitoring of equipment efficiency, change in the design in order to improve the operating conditions and machinery performance optimization, are of the actions that can be taken to achieve maximum production and efficiency without imposing risk to the equipment. For example, in steam turbines, steam losses and consuming can be lessen by efficiency monitoring, inlet and outlet steam flow , trending inlet and outlet steam pressure and steam temperature. Producing electricity from forced vibrations in rotating machinery is another example of engineering services in the world. By putting piezoelectric plates under the feet or legs of rotating machines, the vibration force which is the result of machinery operation will be converted to electrical energy.
BASAMAD is ready to analyze defected equipment to make changes and increase reliability and efficiency of them.
There are several objectives that have always been taken into consideration by managers, including production continuity, achieving to maximum equipment efficiency, minimizing equipment failures, reducing rework to achieve the maximum benefit and reliability. Maintenance routines scheduling is one of the effective ways to achieve these objectives.
Maintenance routines scheduling needs cooperation of condition monitoring, maintenance, operation and engineering groups, experts, industrial engineers, and scheduling software (CMMS). The software used in maintenance scheduling can be different for each company.
Implementation of maintenance routines scheduling, is based on the equipment technical information, the experimental information, and the condition of each equipment. For this reason, a suitable equipment maintenance routine program is implemented according to environmental and operational conditions of the equipment. It is clear that the period of these maintenance routines can be changed over time.
For instance, there are various sources for bearing relubrication program as one of the maintenance schedules including manufacturer’s documentation, software and standards of bearing manufacturers, preventive maintenance routines in other companies, etc.
By utilizing appropriate method, employing experienced experts and skillful supervisors from one side and using proper tools from the other side play key roles in repair and maintenance activities on rotating equipment. Implementing improper repair activities may result in huge and even irreparable damages in productive companies. For instance, if a vital compressor in an oil company with thousands of dollar daily income encounters a problem, the consequences would be the repair activities expenses, replacement new parts and the lost income of the company.
BASAMAD engineering company has planned to implement repair and maintenance activities in the productive companies and complexes by employing experienced experts and skillful supervisors. Repair and maintenance on compressors, steam turbines, variety of pumps, air coolers and gearboxes are some examples of what BASAMAD engineering company can offer to productive companies and complexes.
Consulting Services in Condition Monitoring, Predictive Maintenance and etc.