Equipment Health Management

Importance of Equipment and Risk Assessment for Failure Mode

Importance of Equipment and Risk Assessment for Failure Mode

In a production line, there are all kinds of machines for different tasks. With the technical assistance from H & H Orient Inc., machines are managed by levels according to their importance in production. Through failure mode and effect analysis (FMEA), possible online failures and malfunctions caused by machines can be systematically predicted. Main reasons for these phenomena can be analyzed, and influences of modes can be assessed to find out priority. Prevention measures are made by discussing with customers beforehand to come up with response strategies and follow-up measures, so that risk or uncertainty of production or high maintenance costs can be reduced.

Risk assessment process

  • Collecting information Collecting information of equipment on production lines with numbers and specifications of machines
  • Listing types of equipment failure modes
    • Levels of equipment importance
    • Summarizing equipment maintenance part lists, prices, and deadlines
  • Cost assessment Assessing time required for equipment maintenance and costs such as production loss
  • Risk assessment reportDetermining equipment importance and submitting risk assessment report for failures
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Asset Health Condition Analysis

Through advanced patented technology and electric monitoring equipment, H & H Orient Inc. provides all kinds of mechanisms to check asset health conditions, in order to meet demands from all industries with different production equipment. You don’t need to carry a lot of checking tools running back and forth between the production line and the office painstakingly. All you need to do is to press a button on the screen while sitting on your chair comfortably. Then through the network integrated with the system, all the important health data related to the production machine are shown on the screen to be read and analyzed.

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Initial setup for monitoring technologies/ Advance setup for warning values

Through advanced patented technology and electric monitoring equipment, H & H Orient Inc. provides all kinds of mechanisms to check asset health conditions, in order to meet demands from all industries with different production equipment. You don’t need to carry a lot of checking tools running back and forth between the production line and the office painstakingly. All you need to do is to press a button on the screen while sitting on your chair comfortably. Then through the network integrated with the system, all the important health data related to the production machine are shown on the screen to be read and analyzed.

Process of warning value set up

  • Confirming vibration standardsConfirming vibration standards according to the ISO standards
  • Measuring vibration valuesMeasuring vibration values for shock waves and vibration
  • Continuously recordingContinuously recording measurable data
  • Judging equipment conditionsJudging if equipment is in good conditions
    • YesSetting up warning value range for equipment monitoring
    • No Maintaining equipment and re-measuring
Manual point check/ Online condition monitoring system planning

Manual point check/ Online condition monitoring system planning

To efficiently implement equipment condition monitoring, detailed in-advance planning and setup are required, in order to achieve the effectiveness of reasonable control of equipment maintenance costs. With years of field experience with devotion to the equipment monitoring field and delicate equipment, H & H Orient Inc. helps customers to accurately analyze importance of equipment and judge its risk, designing a reliable and reasonably efficient equipment condition monitoring system.


Manual point check/ Online monitoring and diagnosing system planning

  • Risk assessment reportDeciding equipment importance and submitting a risk assessment report
  • Choosing a methodChoosing between Manual point check or online monitoring and diagnosing
    • Manual point check
      Confirming number of machines / manpower requirement for manual point check
      Setting up equipment point check schedule
      Purchasing devices for manual point check
    • Online condition monitoring
      Confirming equipment specification and requirement for condition monitoring
      Performing online condition monitoring system planning and proposal
      Implementing condition monitoring and testing
  • Equipment condition monitoring
Equipment condition monitoring
High reliability
Accessibility
Practiclity
Criticality
Repeatability

Equipment condition monitoring

The concept of planned condition monitoring is simple. All maintenance staffs actually know the real reasons of equipment malfunction. To solve equipment malfunction problems, what they really need is: to be clearly told the information generated in the initial stage when the equipment shows abnormality and the seriousness of the abnormality. You can not buy an instrument with a reasonable price and expect it to find all the problems. On the contrary, you should set up goals (which abnormalities require correction measures) and determining monitoring methods applied. Thus, with a reasonable price, you can obtain reliable data of equipment conditions in a short time. With professional technology and a talented team, H & H Orient Inc. offers you the most stable and reliable solution for equipment condition monitoring .

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設備故障診斷

Diagnosis of equipment malfunction

In order to achieve high-level production efficiency, highly-accurate and efficient methods should be applied to monitoring a system to find out potential abnormal conditions or reasons of malfunctions to further save additional product costs and reduce production loses which can be avoided. This way, abnormal risk factors in product lines can be efficiently controlled to maintain high reliability of equipment.

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Reducing production loss and waste on extra costs

  • Diagnosing equipment malfunction
  • Confirming equipment abnormal condition
  • Reading data of equipment monitored
  • Finding out factors of abnormality
  • Confirming when parts will be delivered and deciding schedule and manpower for machine shut down
  • Maintaining equipment
設備安裝與校正

Equipment installation and adjustment

Balance of equipment operation
You can find out the balance status of your equipment using the machine condition testing meter.

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Equipment shaft adjustment
Incorrect shaft alignment may cause over-vibration of equipment. Power is wasted and shaft and shaft-coupling may be damaged. The result is increasing equipment operation costs, reducing efficiency, and loss of profits. H & H Orient Inc. offers laser alignment meter and stainless steel spacer to solve this type of problems.

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Bearing monitoring
SPM is the short for shock pulse method. It’s a patented technology. Equipment can be efficiently monitored by rolling bearings signals. Since this method was developed in 1969, many people have been trying to improve it. Nowadays, it has already become a method used in the world for monitoring equipment.
  • Difference between shock wave and vibration Difference between shock wave and vibration At the moment a metal ball hits a metal stick, a pressure wave travels through both materials (figure 1 on the right). This wave may easily disappear in a second. When the wave crest hits the shock wave sensor, dampened oscillation of the reference quality of the sensor is caused. The amplitude of the wave crest is a function of impact speed. In the next stage after the impact, both objects start to vibrate (figure 2 on the right). The frequency of vibration is a function of the mass and shape of the hitting object.
  • Shock wave signal handling Shock wave signal handling The shock wave sensor can sense not only shock waves of large amplitudes, but also weak shock waves. When resonance frequency is 32k Hz, there is a reaction. When the frequency of vibration is lower than 32k Hz , It will be filtered.
    The first grid represents the sensor. The one under it is the synthetic wave from vibration signal of machine and shock wave of resonance frequency. The second grid shows what when current passes through the filter, a series of 32kHz shock values pass the filter as well. Their amplitude is defined according to their shock wave energy.
    The transient values are transformed into analogical electric pulse. The last grid shows the bearing shock wave signals after transformation, which are combined with fast and continues strong and weak electric pulses.
  • Types of shock waves Types of shock waves The sensor signals after filtering reflect the pressure change of the bearing interface. When the oil film of the bearing is thick, shock wave values are low without obvious wave crests. When the oil film reduces, shock wave values increase. However, there are still no obvious wave crests. In case of damage, strong shock waves are created, showing irregular intervals.
  • Measuring operation status Measuring operation status The shock wave meter uses dBsv (shock value) as scales. Shock wave signals are measured in two levels. When the micro processor assesses signals, the number of the bearing (ISO number) and the rolling speed (RPM and bearing diameter) must be provided.
    Any damage on the surface of the bearing may cause stronger shock waves and significantly change characteristics between strong and weak shock waves. This way, shock wave values can be immediately transformed to the corresponding oil film thickness or value of surface damage.
  • SPM spectrum The pattern of shock waves created by a damaged bearing is usually similar to the frequency caused when a bead goes through a track. For example, the pattern of the shock waves created by damaged gear wheels is different. If there is interference in the source of shock waves, types of shock waves created may vary.
  • Measuring signals The resonance frequency of the SPM shock wave sensor which measures signals is 32 kHz, which is the frequency of the best carrier wave. The type of the output signals is the same as that of the linear modulating signals. The only difference is that the SPM sensor’s frequency and amplitude are precisely adjusted. Therefore, when receiving signals, it is not necessary to worry about precision or to adjust resonance frequency of equipment.
  • Input data All mode identifications require precise bearing information and accurate rolling speed measures. Finding a line or a mode of a line in the spectrum is merely a mathematical procedure. Rolling speed is one factor while abnormal frequency is another. Abnormal bearing frequency is defined by linking ISO bearing numbers to the CondmasterPro bearing catalog.
  • Assessment In CondmasterPro, bearing frequency mode can be set in advance. After related symptoms of bearings are linked to measure points, when a user clicks on its name, a light spot will indicate the corresponding bearing mode. You may also add other symptoms according to your needs, such as the gear mesh mode. When bearing symptoms are clearly found in the spectrum, it is proved that the signals received are from the bearing.
總量振動量測法Vibration SeverityTo monitor general equipment problems such as unbalance, insufficient structure strength, loose parts, etc., vibration severity is a very effective method. Not much information needs to be input when adopting this method. It’s easy to use. The standard for assessment is the international industrial standard ISO 10816. The unit for vibration RMS speed is mm/s or inch/s.
Most of industrial machines belong to one of the three vibration levels below: Level 2: Medium machines, on general mounts, 15-75kW
Level 3: Large machines, on firm mounts, 75-300kW
Level 4: Large machines, on flexible mounts,>300kW
Vibration AnalysisEvaluated vibration analysis method (EVAM) is a combination of several existing measuring technologies and statistical methods. It offers comprehensive information of equipment conditions. This method is best applied to large-scale cost-efficient industrial equipment condition monitoring:
  • Quick setup menu on measuring points for guidance
  • Easy data collection with protable data collector or online equipment
  • Automatic condition assessment
  • Vibration time records and analysis The three operational stages of EVAM®:1. Vibration time records and analysis EVAM® makes up for the differences between the vibration severity (the method suggested by ISO) and the traditional spectrum analysis (users must be strictly trained). Original data are used when applying this method. It offers more information than the ISO method without investing a lot of technology and time.
    The automatic data processing provides at most 9 parameters (including whirling force, impulsive wave, and friction) for detailed images of the vibration force on the equipment.
  • Vibration spectrum analysis2. Vibration spectrum analysis Spectrum analysis is one of the functions of EVAM®. It is used for monitoring a lot of specific equipment abnormality. EVAM® uses FFT to calculate spectrum for every measuring point. To setup every measurement, users can pick a specific mechanical problem , such as unbalance, bad alignment, malfunction of motor and gear box, bearing damage, etc., from the failure symptom list of pre-defined program.
    Therefore, must time spent on searching in the spectrum to find related information can be saved. Signs for malfunctions are automatically marked on the spectrum with individual parameters. This way, failure trend with a specific machine can be analyzed or you may use the software to conduct assessment directly.
  • Assessment of specific condition of a machine3. Assessment of specific condition of a machine A set of vibration values obtained when equipment is running normally as the baseline data. The median and standard deviation of these values are compared with monitored parameters. The conditions are shown in three colors including green, yellow, and red. Users do not need to study any details to obtain a clear condition report covers all condition parameters and equipment malfunction parameters previously selected by users.
    EVAM® can be used on a protable data collector. It has functions such as SPM bearing monitoring, ISO vibration degree monitoring, and other measuring and continuously measuring functions. SPM also provides an online monitoring unit with frequency range up to 20000 Hz.
Balancing You may use a protable Leonova high-level machine analysis device or a T30 machine status detector to adjust balance of equipment. Here we only briefly address the equipment balancing function of Leonova. For more detailed information, please contact your local SPM agency or reference the user manual.
平衡校正手持式儀器資訊
  • Single-side balancing with 4 measurements Vibration severity of rotor can be obtained (mm/s RMS) by one measurement without test weight. Then test weight is added at 0°, 120°, and 240° for calculation of weight and position for balancing.
  • Single-side balancing with 2 measurementsDuring the first measurement, no test weight is required, and vibration severity of rotor can be obtained. Then, test weight is added to calculate weight and position for balancing. To apply this method, vibration measurement with time synchronization is required (pulses are triggered by a SPM rotation speed meter or a nearby switch) to find the phase angle between two measurements.
  • Double-side balancingDouble-side balancing is like single-side balancing, with the difference being the former measuring vibration amplitude and weight adjustment using a double-side method. Measurements are made by moving vibration sensor or connecting two sensors. No matter which method you choose, the result of balancing can be calculated in the final stage. If necessary, you may also export data for further analysis.
    Leonova guides you to balance your equipment step by step. You may modify rotation direction and change parameters to be measured, for example, replacing speed with acceleration or displacement. Besides RMS values, the spectrum also shows unbalanced vibrations. At least 4 samples are needed for two measurements.
  • Alternative solutions offered by Leonova for adjustment of unbalanced equipment: 
    • Test weight: Proper test weight can be obtained after inputting rotor diameter, weight, and RPM value.
    • Adding weight separately: Adjusted masses for the two points are obtained after inputting number of division for rotor.
    • Reducing weight: Holes are drilled according to diameters and depths of different materials.
    • Replacement along the diameter: Weigh is re-calculated after inputting distance change along the diameter.
    • Transforming angles into lengths: Unit of measured circumference of roger is changed from angle to length.
    • Retained test weight: Adjusted mass is calculated using retained test weight.
    • Total weight: All adjusted masses of rotor are replaced with one single balancing weight.
Shaft Alignment
Shaft alignment is an optional function of Leonova™ Infinity (advanced machine analysis meter) which is fast and easy to use.
  • Laser shaft alignment device Laser shaft alignment deviceLineLazer laser shaft alignment device includes a detector/transmitter, a stand, chains, rods, cables, and a measuring tape, which are all placed in one suitcase. This device can be widely used for compressors, gear boxes, generators, pumps, etc.
    The detector can detect locations and receive signals from a large range. No small adjustments are needed. Thermo displacement value can be entered by users. In addition, the precise inclinometer can continuously and automatically detect rotation angles of the detector/transmitter as long as rotation is less than half encirclement. The unit of measurement is 1/100 mm or 1/1000 inch.
  • 高階機械分析 Leonova advanced machine analyzerThe design ideal of the Leonova advanced machine analyzer is to simplify graphic display and interactions with users, so that measurement results can be easily understood. Users may read operational instruction on the screen while using the alignment function. All the alignment records are stored in the collector for filing and printing. Measurement program
    • (Automatic or manual) adjustment for horizontal equipment
    • Adjustment for vertical equipment with protrudent edges
    • Softfoot measurement
    • Thermo displacement compensation
    • Leg position locking function
    • Shaft alignment collector
CLOSE

Diagnosis of equipment malfunction

設備故障診斷

Early fault detection and evaluated data for condition based maintenance is our main business. SPM covers every aspect, from handheld instruments and permanently installed warning devices to large scale online monitoring systems controlled by our own software.

Portable instruments The SPM range of handheld instruments includes equipment for shock pulse measurement, vibration severity measurement and vibration spectrum analysis. Several instruments are multifunctional.
Continuous monitoring A permanently installed continuous condition monitoring device is ideal for the surveillance of individual machines and unmanned plant equipment in remote locations. It has no operating costs but will trigger an alarm and/or shut down circuit whenever a programmed limit value is exceeded.
Machine alignment Poor alignment is the most common cause of excessive vibration in machines causing waste of energy and damage to bearings and couplings. This in turn increases your running costs and reduces the effectiveness of your machines, a negative impact on company profitability. SPM provides laser alignment and precut shims.
Maintenance tools SPM offers a range of small, inexpensive and handy maintenance tools.
Accessories Transducers and wireless measuring point tags.
Software SPM has developed a comprehensive software package for efficient condition monitoring of industrial machines.
Training The SPM Academy trains executives, supervisors, production personnel and maintenance personnel who are involved in different ways in mechanical condition monitoring.