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Can Vibration Unbalance Affect the Function of Electric Motors?................ 2 Digital Thermography: See it Before it Burns You........................................... 3 Giving your equipment the finger. Wait, what?................................................ 5 Laser Shaft Alignment: Cornerstone of Predictive Maintenance.................. 6 Maintenance Tips to Cut Costs and not Quality............................................... 7 PdM: Programs Saving Money & Headaches................................................... 8 Reliability: Layered like an Onion.....................................................................10 Shaft Alignment: Why you need to stay in line..............................................12 Predictive Maintenance Services from L&S Electric.....................................15
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Coupling Imbalance
When there is an improper arrangement of key and couplings on the frame, or there is some problem with alignment and mounting capabilities of the machine, this sort of imbalance is likely to occur. This condition may even include the usage of an oversized coupling. This may lead to bending of shaft, extreme imbalance, and rubbing of seals. If this imbalance goes beyond limits, it may result in catastrophic failure of shaft.
Thermal Imbalance
Rotor movement produces high temperatures, and when there is too much heating in an improper manner, the shaft may bend and the equipment alignment may be disturbed. This affects the rotor placement.
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L&S Electric > Blog > Predictive Maintenance Programs > Digital Thermography: See it Before it Burns
Use of digital thermography is one of the most effectively used techniques in monitoring equipment and machinery internal conditions in industrial field. This technique is used in proper verification of and measurement of the temperature of objects surfaces. With a precise and dependable conclusion it can be determined if there is high surface temperature in machinery or equipment surfaces. High surface temperature can lead to heat emission that can cause precious loss of energy. With the proper application of digital thermography technique it will be easier to create a reliable and precise output that allows the specialists to effectively evaluate back up and data software.
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L&S Electric > Blog > Predictive Maintenance Programs > Giving your equipment the finger. Wait, what?
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Predictive Maintenance
Laser Shaft Alignment: Cornerstone Laser Shaft Alignment: Cornerstone of Predictive of Predictive Maintenance Maintenance
Posted on September 30, 2013 by David Manney Laser shaft alignment is a way of measuring misalignment between two or more shafts and is the industry standard for predictive maintenance and machinery alignment. The manufacturing industry today uses laser shaft alignment heavily because machinery alignment is a costeffective solution whenever critical functions are at risk. When a driver like an electric motor or a turbine is coupled to a pump, a generator, or any other piece of equipment, it is essential that all the shafts are accurately aligned. Any misalignment between them increases stress on the shafts and will almost certainly result in excessive wear and premature failure of the equipment. This can be exceedingly costly. When your equipment is down, is profitability being sacrificed for shortsighted or outdated policies? These days, who can afford that? Typical causes of misalignment range from initial fabrication to operational vibration, overheated components, bearing issues, the high-energy usage, load imbalance and rotor bar problems. In addition, older, low-resolution, dial indicator technology cannot measure accurately enough for todays specifications and applications. Dial technology is also subject to reading errors, ratedependent hysteresis and sticky dials. In contrast, laser alignment systems make shaft alignment faster, easier and more accurate than dial technology as they eliminate the sag and thermal changes inherent in dial indicators. In order to keep your machinery operating at the lowest cost and highest yield, you have, no doubt, implemented a routine maintenance schedule. Maintenance can be broken down into four levels: 1. 2. 3. 4. Reactive (aka run-to-failure) Basic preventive maintenance and routine inspections Combination predictive/preventive maintenance methodologies Incorporating a computer maintenance management system (CMMS) with laser shaft alignment, vibration analysis, infrared thermography, etc., and predictive and preventive maintenance methodologies Laser Shaft Alignment Testing completed by L&S Electric
L&S Electric > Blog > Predictive Maintenance Programs > Laser Shaft Alignment: Cornerstone of
Laser shaft alignment is a natural fit with CMMS because it does all the calculations and graphically prompts you through each step of the alignment process. It collects reliable information regarding the condition of a machine that might otherwise go undetected until the machine runs to failure. Researchers estimate that as much as 50% of the damage to rotating machinery directly relates to misalignment. Therefore correcting this problem is critical to production. However, these are not the only reasons. Laser shaft alignment can dramatically reduce your operating costs through: Earlier identification of problems, enabling proactive maintenance Lower overall cost of doing business through exceptional reduction in machine failures Lower labor costs as a result of fewer emergency repairs Production optimization by maximizing uptime Increased quality of production and extended useful lifecycles via significant reduction in mechanical vibration Consistently accurate, error-free measurements to 0.0001 (2.54 ), with reports generated directly from the instrument in conformity with current ISO requirements Quantifiable energy savings In summation, laser shaft alignment is the cornerstone of predictive maintenance. Maintaining manufacturing machinery using laser shaft alignment is no longer an option; it is a must if you expect to remain competitive in todays economy. As a matter of policy, laser shaft alignment should be an absolute necessity before your machinery is put in service.
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L&S Electric > Blog > Predictive Maintenance Programs > Maintenance Tips to Cut Costs and not
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L&S Electric > Blog > Predictive Maintenance Programs > PdM: Programs Saving Money & Headaches
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maintenance based on a direct relationship between an asset and operating conditions. PdM provides a high return on investment (ROI) by virtually eliminating catastrophic failure. When you know which equipment needs maintenance and why, PdM replaces unscheduled maintenance stops without shutting down most of the equipment, thus increasing operational uptime. If the equipment shut down is scheduled, PdM offers a quicker turnaround as well as Lockout/Tagout protocols, ensuring that machines are properly shut off and not restarted prior to the completion of service. Other advantages include: Extended equipment lifetime Lower impact on the environment Optimized spare parts handling An effective PdM program uses non-destructive testing, such as:
Thermographic Analysis
Infrared (IR) light and analysis provides the widest, non-invasive range of applications, from high to low-speed equipment and can be effective for spotting both mechanical and electrical
Lubricant Analysis
Lubricant analysis extends machine and oil life. There are two categories of lubricant analysis, Used Oil Analysis and Wear Particle Analysis: Used Oil Analysis determines the condition and quality of the lubricant and its suitability for continued use; Wear Particle Analysis determines the mechanical condition of lubricated machine components, allowing you to detect and identify the composition of solid material present and evaluate particle type, size, concentration, distribution, and morphology.
Vibration Analysis
Vibration analysis is most effective on high-speed rotating equipment. Vibration analysis easily diagnoses pending equipment failures as well as lubrication needs. According to ISA Automation Week, 25 years of documented savings show a 20:1 benefit-to-cost ratio for vibration analysis programs. In conclusion, the advantages of a PdM program are manifold and should be an integral part of any serious maintenance program. The US Department of Energy (DOE) estimates an 8%12% cost savings over preventive maintenance. In fact, according to the DOE, the following average savings are typical within industrial settings: Up to 1000% ROI 70%75% reduction in equipment breakdowns 35%45% reduction in process downtime 25%30% reduction in maintenance costs, including parts and labor 20%25% increase in production
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L&S Electric > Blog > Predictive Maintenance Programs > Reliability: layered like an onion
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similar results under consistent conditions. Reliability: layered like an onion In the world of rotating apparatus, depending upon your motor, gearbox, Posted August 9, 2013 by David blower, on etc, isnt simply important, itsManney vital. Reliability is blog, something that produces Writing at his Jim Cahill spotlights an similar results under consistent conditions. industrial energy team and their focus on
Posted on August 9, 2013 by David Manney L&S Electric > Blog > Predictive Maintenance Programs > Reliability: layered like an onion Reliability is something that produces
In the in world of rotating apparatus, reliability our process world: depending upon your motor, gearbox, Having reliable process manufacturing blower, etc, isnt simply important, its vital. operations begins with reliable Writing at his blog, Jim spotlights an components and Cahill reliable control industrial energy team and their changing focus on strategies to handle reliability in our process world: conditions. Emersons Jennifer Sandstrom, a senior industrial energy consultant, highlights the role of consultants Having reliable process manufacturing in unpeeling the many aspects of designing and maintaining reliable operations. operations begins with reliable components strategies conditions. and to reliable handle Emersons control changing Jennifer
Sandstrom, a senior industrial energy consultant, highlights the role of consultants in unpeeling the many aspects of designing and maintaining reliable operations. Reliability is something (equipment, software, etc) that produces similar results under consistent conditions. Well, thats easily said and easily understood but if you, and if youre reading this blog you probably do, live in a process world, the conditions are consistently dynamic meaning similar results could be quite a challenge! Reliability is something (equipment, software, etc) that produces similar Well, And, speaking of results similar, under similar consistent in the wayconditions. that a Timex is thats said and easily understood but if you, and similar easily to a Rolex? After all they are both time pieces that if monitor the passage of youre reading this blog you do, live in a process time but the connoisseur of probably chronometry or horology may beg to differ about world, the and conditions dynamic meaning similarities results. are One consistently of the challenges then in delivering reliability is to similar results could be quite a challenge! understand the context and for us that means the client, his pain and his process.
time but DeltaV the connoisseur chronometry or include!) horology all may beg to differ about devices, hardware, of etc. (too many to with documentation to similarities and results. One of the challenges then in delivering reliability is to prove and certify mean time between failures (MTBF) and other key performance understand the context and for usdefine that means the client, his pain and his process. indicators (KPIs) and metrics that reliability.
And, speaking oflongstanding similar, similar in the wayin that Timex of is reliable technology Emerson has a background the a supply similar to a Rolex? After all they are both time pieces that monitor the passage of Fisher valves or regulators, Rosemount and Rosemount Analytical measurement
Emerson has a longstanding background in the supply of reliable technology Fisher valves or regulators, Rosemount and Rosemount Analytical measurement devices, DeltaV hardware, etc. (too many to include!) all with documentation to prove and certify mean time between failures (MTBF) and other key performance indicators (KPIs) and metrics that define reliability.
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L&S Electric > Blog > Predictive Maintenance Programs > Shaft Alignment: Why You Need to Stay In
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Shaft Alignment: Why you The Green in Precision Shaft Alignment need to stay in line
Precision Alignment of electric motors coupled to pumps, compressors, gearboxes, blowers, etc.; contribute to savings in the consumption of electricity. Since all fossil power plant generated electricity causes carbon emissions, reduced electricity
Between-Failure, thus money for hazardous liquids saving and that means OPTALIGN First Laser Alignment parts and the increasing basically entire production. chemical industry as well as refineries have experienced Tool leaking seals. Hazardous liquids contaminate the environment. Only well aligned All industries using pumps to transport pumps guarantee that mechanical seals perform to perfection and that means avoidance of leakage, another area where Better Alignments help the GREEN movement.Every leaking seal or stuffing box in Water and Water Treatment plants is a waste of scarce resources. Only good alignment of motor-driven pumps will avoid leakage. Shaft/Coupling alignment contributes in more than one way towards great savings and a GREENER ENVIRONMENT.
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Vibration Analysis and Special Analyses Programs With complete Predictive Maintenance Programs that are customized to your specic needs, we can diagnose defects in rotating equipment in their early stages before catastrophic failure or unscheduled downtime occurs. Laser Vibrometer Readings Experienced L&S technicians use advanced laser technology to detect problems in hard to reach areas. We are able to gather accurate data from as far away as 660 feet, reducing the number of inaccessible bearings. Operation Deflection Shape Studies While a machine is operating, our equipment creates a 3-D animation of the structural movements, allowing us to accurately detect potential stress in rotating and driven equipment, bases, and motor frames.
Motor Current Signature Analysis Detecting rotor problems in AC induction motors can prevent unscheduled downtime before valuable production time is lost. Roll Roundness Profile Analysis By measuring the relative motion between press rolls and detecting irregularities, roll roundness prole analysis helps ensure that your products achieve a consistent quality. Sound Level Analysis Quantifying the decibel levels in noisy work areas ensures that accurate safety measures can be taken to protect your employees hearing. Ultrasonic Air Surveys Ultrasound air surveys detect leaks in pressure and vacuum systems, detect electrical arcing, and inspect for bearing failure.
Semi-Annual Semi-Annual As Required As Required As Required Semi-Annual As Required As Required As Required As Required As Required As Required As Required Quarterly Monthly As Required
Notes:
All 3600 RPM motors should be checked yearly to assure a longer life. Vibration Analysis findings determine when this may be required. All of L&S Electrics services come with detailed formal reports and historical trending for true Preventative and Predictive Maintenance Programs. These services also interface with our Motor Repair Shops for fast networking on problem solving. Networking and modems are available for faster response to problem containment issues.
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