Predictive Maintenance and other Reliability Services
Predictive Maintenance Services
Predictive Maintenance Services are very important for companies dealing with heavy and intricate machinery. By taking advantage of predictive maintenance, you can avoid many headaches knowing that you made a long-term commitment of protecting your investments. In addition, budgeting becomes manageable: maintenance and repairs should be a number that can be estimated far more accurately than a company who doesn’t take advantage of predictive maintenance.
There are numerous reasons why you should regularly perform predictive maintenance services including:
- Improving the general maintenance level of your system this way that leads to enhanced productivity of the plant. Employing this technique on a regular basis will ensure that you improve the reliability of your system by a very huge percentage. This is due to the fact that any potential eventualities have been addressed adequately.
- Helps plant owners reduce costs usually used for replacements. Many components become faulty because the problems were not detected in due time, thus were not addressed properly.
- These services also improve overall safety and quality of work that is being produced.
- Having a specialist on-site presents an opportunity to catch other problems that ordinarily would escape notice.
Many issues that normally cause failures in most system usually start small and eventually end up huge because no measure was taken to curb them. Companies providing predictive maintenance services usually provide you with the required necessary solutions.
Other monitoring services usually include thermography, oil analysis, vibration, motor current, ultrasonic, and alignment. These services are offered as soon as the predictive tests reveal that they need to be done. Knowing immediately the results of a test that spotlights a specific problem is a significant advantage because you’ll be able to make an educated decision regarding the next step.
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.
Motor Current Signature Analysis
Roll Roundness Profile Analysis
By measuring the relative motion between press rolls and detecting irregularities, roll roundness profile analysis helps ensure that your products achieve a consistent quality.
Quantifying the decibel levels in noisy work areas ensures that accurate safety measures can be taken to protect your employees’ hearing.
Ultrasound air surveys detect leaks in pressure and vacuum systems, detect electrical arcing, and inspect for bearing failure.
Root Cause Bearing Failure Analysis
Our Reliability Team provides root cause bearing failure analysis services to help our clients discover the reason(s) for the failure of their equipment.
This partial list represents some of the problems that can be identified:
- Cage Damage – Cage damage has many causes, including excessive speed, vibration, blockage, and wear
- Contamination – Denting of rolling elements and raceways
- Electric Arcing – Electric arcing is caused by electric current flowing through bearings and breaking at the surface that lies between the races and rolling elements. High temperatures occur at the corresponding points, producing pits on the raceway, as well as rolling elements
- False Brinelling – Elliptical wear marks in an axial direction at each ball position with a bright finish and sharp demarcation that are often surrounded by a ring of brown debris
- Fatigue Failure – Often referred to as spalling, fatigue failure is indicated by the fracture of running surfaces and eventual removal of small, discrete particles of matter from the inner ring, outer ring, or rolling elements. Spalling is ongoing and once initiated, will spread with continued operation. It is always accompanied by a noticeable increase in vibration
- Lubrication Failure – Discolored rolling elements (blue/brown) and rolling element tracks. Excessive wear of rolling elements, rings, and cages follow, resulting in overheating and catastrophic failure
- Misalignment – A wear path that does not run properly parallel to the raceway edges on the raceway of the non-rotating ring
- Path Patterns – Inspecting the wear path pattern found inside a dismantled bearing clarifies the bearing’s operating conditions. Analyzing and comparing conventional and abnormal wear paths provide a complete picture of how that bearing performed under conditions where it worked
Operating Detection Shape Analysis, otherwise known as ODS, is used to visualize the vibrating pattern of a moving piece of equipment that is influenced by the operating forces of that equipment.
ODS analysis utilizes a well-equipped analyzer and a software package to record the dynamic behavior of a piece of equipment and its mechanical structure.
ODS displays the magnified vibrating pattern of the machine in real-time operating conditions. The vibration and phase measurements are taken on hundreds of points and in various directions on the machines. The vibration pattern can be shown in various 3D formats. ODS is a very powerful technique for solving forced vibration problems. It makes it far better than the modal analysis system that is only helpful in analyzing the innate resonant character of the structure.
ODS analysis displays the exaggerated movement of a structure that is the result of the forces working on that structure, both internally and externally.
Why use This Advanced Technique?
- You can observe and analyze the exaggerated dynamic behavior of your machinery
- Helps pinpoint problems in any kind of rotating equipment, associated bases, or frames
- Your machines do not need to be taken off-line, minimizing lost production time