p dc engineering b

PreDiCon SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

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PDC Engineering 23-25 Windermere Road

Blackpool FY4 2BX Tel (01253) 400541 Fax: (01253) 400552

email: [email protected]

SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

TRAINING

SYSTEM AUDITS

SYSTEM SETUP

REMOTE ANALYSIS

VIA MODEM

CONTRACT MEASUREMENT,

ANALYSIS &

REPORTING

ON LINE & OFF-LINE

MONITORING

TRAINING IN VIBRATION ANALYSIS,

THERMOGRAPHY & OTHER

TECHNIQUES

NEEDS ANALYSIS

AIR LEAK SURVEYS FOR

CLIMATE CHANGE LEVY

DISCOUNT SCHEME

AWARD WINNING

SYSTEMS

CONSULTANCY & TROUBLE

SHOOTING

PDC Engineering SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

PDC Engineering. Contract services for Predictive MaintenancePDC Engineering has implemented PdM solutions for many industries encompassing many PdM vendor solutions. We have installed and operated systems of all sizes with PDC Engineering installed systems winning joint first and first runner up in the last independent PdM awards. All PdM services are performed by engineers with experience in implementing multiple vendor and technology solutions. PDC Engineering is not tied to any particular vendor and can give completely independent advice. Outside of the vendors themselves we have setup more off-line vibration, on-line vibration and thermographic systems from many different vendors in a variety of applications than anyone we know. This has provided us with a sound grasp of what makes PdM work in industry

PdM feasibility studies Our engineers have the expertise to identify whether PdM will work effectively for your plant, focused on your particular equipment and program goals. We will recommend the best fit solution for your needs and help you and train you in how to best implement it.

On-Line Remote Vibration Analysis If your capital expenditure will not allow you to purchase an on-line monitoring system, let us install a system and we will interrogate the system remotely on a daily basis. All data is transferred via internet and we report back to you immediately we find an exception condition. We also provide a full report every month giving you an overview of all monitored equipment.

Existing system audits If you are an existing system user and are not achieving the goals intended there may be a reason. We have the experience to find the causes and get you back on track.

Thermographic Surveys Our qualified technicians and engineers can carry out a thermographic survey of your plant. The survey is carried out on equipment that you nominate and we will tell you the condition as determined by the infra-red signature.

On Site Vibration Analysis Surveys If you are an existing PdM user but lack the experience for detailed data analysis, let us do it for you. Either you collect the data and modem it to PDC Engineering for analysis or we will send in one of our engineers to take the readings for you. We do the analysis and send you results.

Air Leak Detection Surveys The Climate Change Levy is charging businesses an extra 15% on top of their energy bills. Reduce your energy bill significantly by reducing the amount of compressed air being wasted through leaks. Air leaking through a hole 1/8 on a 75psi system that is in use throughout the year will cost over 1000. Reduce the waste get an air leak detection survey.

Phone: (01253) 400541 Fax (01253) 400552 UK E-Mail: [email protected]


PDC Engineering. Data Collection & Reporting Vibration analysis can be very difficult to analyze. Why not get the experts to carry out all of the work for you and present you with a simple set of results and recommendations after every visit? Our engineers are the best in the business and we will ensure that the reports give you good, practical advice.

After each visit for off-line or every day for on-line remote, you will receive a verbal report immediately if anything is dangerously close to failure. For off line systems you will then get a fax or e-mail report within 2 working days and a complete written report mailed to you within one week. On-line remote monitoring systems will provide a same day verbal and e-mail report and a full condition analysis every month.

Vibration Analysis The written reports for vibration analysis include not only a copy of the plot but also, more importantly, recommendations for repair. Reports are stored in a database for easy data retrieval and custom report generation. A cost analysis module is available if required.

Typical Vibration Analysis Report

Thermography The thermographic reports include the thermal image as well as a digitally stored visual image. A further report may be generated if required after the repair work is carried out. Reports may be custom designed at no extra charge.

Typical Thermographic Report



PDC Engineering. Infra Red Thermography As an object gets hotter, it emits more radiation in the infrared part of the electromagnetic spectrum. With a device that could measure infrared radiation you could indirectly measure the temperature of an object. We call this device an infrared camera and we call the science of its use Infrared Thermography. PDC Engineering has the best cameras available with a reporting system second to none. Thermographic techniques can be used to detect a host of different problems. Our engineers are all qualified in the use of thermographic cameras and have extensive experience in the various applications.

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Electrical Defects

Switch room and bus surveys are quick and extremely effective. One section of blown bus can put your factory out of operation for a full day. Compare that cost to a single day for one of our engineers with an infra red camera at a cost of 300 (or 55 p.h. for smaller jobs) including a comprehensive written report.



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Mechanical Defects

Bearings with lubrication problems, dry push rods or screws, slipping belts, bad compressor valves, insulation defects, bad steam traps - the list goes on and on. If the defect causes a temperature change, we can see it and tell you about it.

Spot Welding Problems

We have a wealth of experience in detecting problems in secondary weld cables, transformers, and weld guns. This image shows a weld tip with a cooling water connection that is too short causing overheating of the weld tip - resulting in bad welds.

Building Structural Surveys

Concrete structures are vulnerable to internal delamination and debonding of render coatings or other surface finishes. This may be a result of corrosion of the internal reinforcing bars or may have been a result of the original pour due to poor compaction. Thermography can detect the areas of delamination or debonding by measuring the heat transfer.

Wall Insulation & Flat Roof Surveys

Use thermography to detect excessive heat loss or external draughts. Avoid the huge expense of a complete roof repair by using thermography to pinpoint the areas where repairs are necessary.

Underground Pipe Leak Detection

The traditional method for locating leaks is to isolate one section of the system at a time until the general area of the leak is identified and then dig several trial holes on a hit and miss basis. Using thermography, any leak or defective insulation will cause a slight increase in the temperature of the ground above the leak enabling quick accurate location..


SUPPLYING AFFORDABLE COMPLETE SOLUTIONS PDC Engineering

PDC Engineering. Predictive Maintenance Consultancy & Trouble- Shooting In many cases it is difficult for the maintenance or production engineer to identify the cause of a fault. Very often the cause can be traced back to a structural natural frequency coinciding with a machine operating speed or other forcing function. Using advanced techniques and equipment, our engineers have the knowledge and experience to help identify the causes of such problems and recommend realistic solutions. We have identified several case histories from our files and include these as examples.

Vibration Analysis Vibration influence on a load cell

We were called in to investigate a problem that a client of ours was having with a load cell on a copper smelter. The problem was variations in the poured weight of the copper and the engineer in charge had a suspicion that environmental vibration could be playing a role. There is a load cell under each spoon, which accurately measures the weight of the copper during the pour process so that the finished product is at an exact weight. Variations in the weight appeared to occur randomly so our engineer set out to determine any causal link between vibration and load cell output. The time trace showed that vibration was measurable at the load cell. The surprise was that this vibration was caused not only by the pour process but also by exterior influences such as the movement of the overhead cranes and fork-lift trucks. The time trace below shows the filter-out vibration over one full operating cycle.

The next stage was to identify the vibration source. An FFT spectrum of the floor showed a

dominant frequency at about 7 Hz. This was shown to be the natural frequency of the floor and was excited by all of the external forces named above. The spectrum analyzer was then connected to the voltage output of the load cell. Interestingly, the load cell output also showed a frequency at about 7 Hz. It was now obvious that the vibration in the floor was directly affecting the load cell output. The intermittent nature of the problem was due to the random impacting from external influences and the fact that the controller samples twice during each process pour. The answer was to first put a notch filter in the load cell output to remove the problem frequency and secondly to install vibration isolators under the load cell feet. The long term solution is to grout under the floor to remove the vibration completely.

Machine Operator Vibration Induced Sickness

One client called us in to identify the cause of excessive vibration at the operator station. The vibration was causing the operator to feel nauseous at particular machine speeds. The subject machine was an extruder used in the manufacture of insulation for electrical cables. Noise and vibration frequency domain readings showed that the main frequency of concern was at 300 Hz. The amplitude at this frequency was extremely severe at specific speeds of the extruder but became innocuous (although always measurable) at other speeds. Operating the machine over a wide speed range, our engineer saw two main frequencies of vibration caused by the DC motor electrical drive (constant at 300 Hz) and the frequency of the main drive gears which changed with the speed. When the speed was such that the gear meshing vibration coincided with the DC drive vibration, amplitudes were measured in excess of 75 mm/s RMS. The cause of the problem was two-fold. There was an SCR fault on the motor drive and one gear wheel had been incorrectly machined to give an inaccurate tooth profile. The SCR was repaired and the gear wheel renewed. The machine now operates satisfactorily and at low noise and vibration levels.

Thermography

Induction heating of a weld robot wrist

This data was captured during a routine check of the secondary circuit weld cables on a spot welding robot at an automotive fabricating plant. High temperatures were noted at the robot wrist at 28C (50F) above ambient. PDC Engineering was asked to find the cause of the over-heating. The initial avenue of research was to look for a mechanical source of heat at the wrist. The advanced analytical capabilities of the thermal imaging software indicated that the source was internal rather than external. The wrist bearings were ruled out as a source as the bearings were not in the same place as the source. It was then noticed that that the weld secondary circuit jumper cables were unusually routed on either side of the wrist. It became apparent that the very high currents (>15kA) in the secondary circuit were developing high magnetic fields resulting in induction heating of the wrist. The jumper cables were re-routed and the problem disappeared.


SUPPLYING AFFORDABLE COMPLETE SOLUTIONS PDC Engineering

PDC Engineering. Predictive Maintenance Training for Industry PDC Engineering. has developed a modular approach to training PdM technology users, aimed at developing an effective PdM program. We focus not only on the technology and how to interpret data, but we also provide help in program set up and tracking your PdM goals.

Courses can be tailor made to suit your individual requirements and are held either at our comprehensive training facility or at your plant.

Training courses start from as little as 140 per student.

Modules I. PdM Management 1 day

a. Maintenance strategies b. Project management c. Choosing the right technologies d. Integration into maintenance e. Procedures f. Reporting

II. Basic Vibration Analysis 2 day a. Frequency -v- time domain b. How the FFT works c. Examples of basic defects d. Transducers e. Accelerometer mounting f. Measurement parameters

III. Advanced Vibration Analysis 2 day a. Resonance b. Dynamic range c. Frequency calculations d. Effects of windowing e. Amplitude demodulation f. Phase g. Fault analysis h. Single plane balancing i. ODS

IV. Two Channel Analysis 1 day a. File capture of vibration data b. Variable speed machines c. Triggering d. Measurement parameters e. Capture and display options f. Two-channel functions g. Impact testing

V. Industrial Thermography 2 days a. Infra red theory b. Qualitative thermography c. Radiometric thermography d. Fault analysis e. PdM integration

VI. Passive Ultra Sound in PdM 1 day a. Ultra sound theory b. Detecting leaks c. Electrical applications d. Mechanical applications e. Integration into spectrum analyzers

VII. Potential Failure Analysis 1 day a. Identifying potential failures b. Determination of applicable technologies c. Definition of suitable measurement parameters

Specialized training courses IIX. PdM on Rolling Element Bearings 1 day

a. Bearing construction b. Elastohydrodynamic lubrication c. stages of bearing failure d. Failure modes e. Fault frequency generation f. Vibration examples of common defects g. Tribology

IX. PdM on AC & DC Motor 1 day a. AC motor construction b. Failure modes c. Generation of electrical frequencies d. Vibration examples of common defects e. Motor current analysis f. DC motor construction g. Failure modes h. DC drives i. Vibration examples of common defects j. Thermography

X. PdM on Pumps 1 day a. Centrifugal pumps - theory of operation b. Centrifugal pump construction c. Positive displacement pumps construction d. Failure modes e. Vibration examples of common defects f. Performance analysis

XI. PdM on Fans 1 day a. Theory of operation b. Failure modes c. Vibration examples of common defects d. Performance analysis e. Adjusting bedplate resonance

XII. PdM on Large Stamping Presses 2 day a. Press construction b. Failure modes c. Specific monitoring problems d. Sensors & installation e. Defining vibration measurements f. Using advanced vibration techniques

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