Skip to main content

Making Maintenance Smarter via Remote Monitoring and Digital Tools

By Dan Phillips.

WHAT TRENDS HAVE YOU OBSERVED OVER THE PAST YEAR?

Especially with personnel working remotely, we’ve seen an increase in companies connecting and tracking equipment with sensors and other Internet of Things (IoT) hardware and software to enhance their preventative maintenance capabilities. The coupling industry is catching up with the rest of the world in terms of the data revolution. But even there, demand has exploded in terms of end-user interest in how couplings are designed and selected, how they are manufactured, how they operate, how they are maintained, and how they are serviced.

CAN YOU GIVE AN EXAMPLE?

Just like you and I track our orders from Amazon and get regular updates during the process, customers are looking for the same easily accessible live data for couplings. The procurement team needs quick access to product information to make purchases. Project managers are looking at Gantt charts to understand more about the process and status while couplings are being designed and manufactured. Installation and maintenance teams need access to manuals and service experts. The Regal Kop-Flex team is building a complete digital customer experience (DCX) to support these goals.

WHAT ADJUSTMENTS IS REGAL MAKING IN RESPONSE?

We have embraced smart manufacturing via Perceptiv monitoring and diagnostics. Our team utilizes remote monitoring for some customer critical equipment, providing real-time alerts and monthly performance reports. Integrating all a facility’s mechanical components is possible, and we are evaluating the cost benefits and overall ROI of doing so. For some, having their critical equipment monitored is enough, while others want to integrate our components into their existing smart ecosystem.

For example, we have been gathering data from couplings that allow plant operators to make better maintenance decisions by monitoring performance trends with the Kop-Flex Powerlign torque monitoring system. It allows users to minimize emissions and fuel costs by tracking performance trends in connected equipment. This system can be purchased new with couplings or retrofitted to existing Kop-Flex or other brand couplings.

Our Perceptiv intelligence group uses an array of torque monitoring solutions for online monitoring, predictive maintenance, and failure analysis. This includes the use of augmented reality tools. Additionally, there is definitely a trend to have spares for all critical equipment. It minimizes downtime if you have a spare coupling to hand instead of having one shipped. Some customers send the main coupling back to our Kop-Flex team for recertification.

WHAT NEW PRODUCTS OR SERVICES ARE YOU OFFERING?

Regal continues to expand Perceptiv on-site and remote monitoring and diagnostics to help our customers install and monitor equipment 24/7 or as needed. These tools save money by diagnosing potential problems before they happen. Examples include torque monitoring, vibration observation, and motor current signal analysis.

A Regal technician installing Perceptiv remote monitoring technology

The Regal Tag-It Program powered by Perceptiv intelligence is an asset management platform to view details on mechanical and electrical assets in operation and reduce redundant or obsolete inventory. The program creates a path for continuous facility improvement by enabling faster maintenance and simplifying the MRO procurement process. In addition, users can easily add Perceptiv wireless monitoring to keep an eye on critical equipment. This 24/7 monitoring technology will help customers to increase equipment reliability and maximize production. The combination of hardware, software, and “humanware” provides a new way for users to interact with Regal products and their equipment. All of this helps customers to harness the power of IoT in their facilities.

WHAT IS YOUR RECERTIFICATION PROGRAM?

We expanded our coupling recertification program to repair, rebuild, and recertify couplings removed from service to API 671 standards. This allows our customers to have a lower-cost recertification coupling available for future planned outages or emergencies. Customers can recertify their disc, diaphragm, and gear couplings for up to 50% savings from the cost of a new item. Ship the used/worn coupling to one of Regal’s worldwide repair facilities, where they will be disassembled and undergo a non-invasive cleaning. Evaluation determines the material integrity and flexible elements, then we remove and replace any hardware, if necessary. They are then reassembled and rebalanced in accordance with API 671 or original OEM specifications. After a final inspection, they are returned to the customer within 4 weeks.

We also offer a Max-C resilient coupling that provides damping for applications with shock loading or cyclic torques. The Max-C can be mated to disc or diaphragm couplings to tune the drive train. They are frequently used on synchronous and variable frequency drive motors.

Dan Phillips, Technical Director, Monitoring and Diagnostics, Regal, discusses couplings, the Internet of Things, remote monitoring, diagnostics, and smarter maintenance practices.

 

Source: Turbomachinery Magazine, July/August 2021.

  

Labels:

Comments

Post a Comment

Popular posts from this blog

Maintenance 4.0 Implementation Handbook (pdf)

WHAT IS MAINTENANCE 4.0? Industry 4.0 is a name given to the current trend of automation and data exchange in industrial technologies. It includes the Industrial Internet of things (IIoT), wireless sensors, cloud computing, artificial intelligence (AI) and machine learning. Industry 4.0 is commonly referred to as the fourth industrial revolution. Maintenance 4.0 is a machine-assisted digital version of all the things we have been doing for the past forty years as humans to ensure our assets deliver value for our organization. Maintenance 4.0 includes a holistic view of sources of data, ways to connect, ways to collect, ways to analyze and recommended actions to take in order to ensure asset function (reliability) and value (asset management) are digitally assisted. For example, traditional Maintenance 1.0 includes sending highly-trained specialists to collect machinery vibration analysis readings on pumps, motors and gearboxes. Maintenance 4.0 includes a wireless vibration sensor conne...
Post a Comment
[Read more...]

Technical questions with answers on gas turbines

By NTS. What is a gas turbine? A gas turbine is an engine that converts the energy from a flow of gas into mechanical energy. How does a gas turbine work? Gas turbines work on the Brayton cycle, which involves compressing air, mixing it with fuel, and igniting the mixture to create a high-temperature, high-pressure gas. This gas expands through a turbine, which generates mechanical energy that can be used to power a variety of machines and equipment. What are the different types of gas turbines? There are three main types of gas turbines: aeroderivative , industrial, and heavy-duty. Aeroderivative gas turbines are used in aviation and small-scale power generation. Industrial gas turbines are used in power generation and other industrial applications. Heavy-duty gas turbines are typically used in large power plants. What are the main components of a gas turbine? The main components of a gas turbine include the compressor, combustion chamb...
Post a Comment
[Read more...]

Top 8 Reasons for Mechanical Seal Failure and How to Prevent Them

Mechanical seals are critical components of pumps, responsible for maintaining a fluid-tight seal between the rotating shaft and the stationary pump housing. However, these seals can fail due to various factors, leading to leakage, reduced pump efficiency, and costly downtime. In this article, we will discuss the top reasons for mechanical seal failure in pumps and how to prevent them. 1-Improper Seal Selection Choosing the wrong mechanical seal can cause it to fail. Consider the following factors that can contribute to seal failure: • Chemical compatibility: All seal components, such as the seal faces and O-rings, must be compatible not only with the process fluid being pumped, but also with non-process fluids used for cleaning, steam, acid, and caustic flushes, etc. • Physical degradation: Using soft seal faces on abrasive liquids will not last. Shear-sensitive liquids, like chocolate, can break down and leave behind solids (such as cocoa powder) and force out liquids (like oil). • S...
Post a Comment
[Read more...]

Why Pump Shafts Often Break at the Keyway Area

By NTS Pump shaft failure can lead to significant downtime and repair costs in industrial plants. One of the most common locations for pump shaft failure is at the keyway area. In this article, we will explore the reasons why pump shafts often break at the keyway and what can be done to prevent such failures. The keyway is a high-stress point (weakest point)  on the shaft, where a key is inserted to transmit torque between the shaft and the pump impeller or coupling. During operation, the keyway experiences cyclic loading that creates a bending moment in the shaft, which is concentrated in the keyway area. Over time, this cyclic loading can cause fatigue failure in the shaft material, leading to a fracture at the keyway. In addition to cyclic loading, other factors can contribute to shaft failure at the keyway. Improper keyway design or installation can lead to stress concentrations or inadequate clearance between the key and keyway . Misalignment or overloading can also cause ex...
Post a Comment
[Read more...]

Pump Shaft Breakage: Case Studies and Solutions

By NTS Pump shaft breakage is a common issue that can cause costly downtime and repairs in various industries. In this article, we will explore several case studies of pump shaft breakage and the solutions implemented to prevent future failures. Case Study 1: Chemical Processing Plant A chemical processing plant experienced repeated pump shaft breakages in their cooling water pumps. Investigation revealed that the pumps were not properly aligned with the motor and had excessive vibration due to the misalignment. This caused the pump shaft to fatigue and break over time. The problem was resolved by realigning the pumps and installing vibration monitoring equipment to detect any future misalignment or excessive vibration. Case Study 2: Wastewater Treatment Plant A wastewater treatment plant had issues with pump shaft breakage in their sludge pumps. The pumps were designed with a straight shaft and lacked a flexible coupling, causing excessive stress and vibration on the pump sha...
Post a Comment
[Read more...]