Predictive Maintenance

 

 

 

 

 

 

Anticipated Value

The value of a predictive maintenance program can be estimated for bearing-related failures by means of calculation worksheet.  This calculation can help to make an informed decision about the merit of installing a predictive maintenance system in your specific context.

 

The critical part of an Online Condition Monitoring System is automated fault identification. This requires systematic data processing leading to reliable fault determination and trending.
TS-2 uses tachometers and gear ratios to accurately and continuously determine all shaft rotational speeds.  This is equally effective on high and low speed machines during steady speed or variable speed operation.  The shaft speed is used to separate the vibration into synchronous and non-synchronous components.

Tensor Systems Predictive Maintenance

The World’s Most Sophisticated Predictive Maintenance Monitor
Finding faults in the early stages allows for planned repairs, eliminating unplanned shutdowns and expensive catastrophes

 

TS-2 software trends overall vibration, synchronous vibration, non-synchronous vibration, spectra, cepstrum, kurtosis, etc. for a complete analysis.  When a trend starts increasing in amplitude, the rate of increase is used to determine the length of time before an alarm level is reached. This is indicative of time to failure.

TS-2 database is designed to store each trend for maximum value for the analyst. Each recently collected sample is retained, but older data is purged to less frequent intervals.  The value of the data is thus maximized, while maintaining a reasonable database size.

 

Why TS-2?
In comparison with other monitoring systems, there are important benefits in the TS-2 monitoring system.

• A complete turnkey system including:
• hardware
• software
• custom database with alarms
• Monthly review of each machine by vibration expert
• Wide range of application:
• High & low speed machines
• mining mills, steel rolling mills, wind turbines etc.
• Range of sensors used:
•  tachometers
• motor load
• accelerometers, velocity sensors, proximity probes
• acoustic emission sensors
• temperature sensors
• 24 bit accuracy to 32 KHz.
• Traffic Light display of machine condition provides intuitive user interface and a simple way to show if there is a problem
• Problems reported immediately via SMS and email

 

 

Features:

• Measure vibration, speed, load, metallic particles and water in oil
• Regular (hourly) monitoring of growing faults
• Recognize and trend individual faults
• Protection (alarm and trip) according to API670, ISO10816 and user defined criteria
• Alarms sent via text message and E-mail
• Intuitive software
• Complete information (Alarms, Trends, Spectra, Cepstrum, Kurtosis, etc.)
• Applicable to slow and variable speed  machines
• Remote monitoring, analysis and support worldwide

 

Automated fault detection:

• shaft related faults (imbalance, misalignment, looseness, bent shaft, etc.)
• bearing faults (determining stage of failure)
• gear faults (determining stage of failure)
• single tooth faults detection for every tooth in a gearbox
• installation faults
• oil contamination (wear debris and water)
• electrical faults

Life Remaining:

• each fault is trended over time
• increase in fault severity is used to determine remaining life of component