SMART CONTROLS
Modern tooling takes maintenance to the next level
Over the past decade, new technology has made a massive diff erence to the maintenance service off ered to refrigeration end-users by
leading refrigeration engineering companies. John Simpson, Star Refrigeration regional manager - South East explains.
T
echnology has enabled refrigeration engineering to move way beyond traditional planned, preventative maintenance programmes. Progressive maintenance providers today deliver a more proactive and predictive service, thanks to modern tooling and smart engineering technology.
High tech modern tooling including electronic gauges and diagnostic devices, are now an essential feature in the refrigeration engineer’s toolbox. Combined with the development of remote monitoring technology, modern tooling has revolutionised plant maintenance for the benefi t of customers and service providers alike. Modern engineering tools and techniques are now
central to plant maintenance programmes, which are designed to support and protect each customer’s key business asset. Maintenance activities are focused on plant reliability, boosting effi ciency, reducing running costs and maximising the operational life of the plant.
The technology behind modern tooling has evolved signifi cantly in the last fi ve years. Maintenance companies have invested in sophisticated technology that allows engineers to
24 July 2021 •
www.acr-news.com
undertake simple yet valuable diagnostic tests in reduced time scales on planned customer site visits. From oil analysis and laboratory testing, through to laser alignment, maintenance engineers can now provide a highly specialised service to help customers reduce operational costs and minimise plant downtime. Where specialist testing by a third party service provider was previously commissioned and undertaken annually, modern tooling techniques allow diagnostic services to be conducted on a more regular basis by fi eld engineers. This enables maintenance companies to gather key operational data, which can be quickly analysed and actioned to improve plant performance and reliability. Only a few years ago, refrigeration engineers were
spending many hours a day on site taking plant readings and logging analogue data. Maintenance reports and spreadsheets were completed during site visits, then inputted or uploaded to computer servers back at branch offi ces. Modern tooling technology has recently advanced
in leaps and bounds. Field engineers are working smarter and faster during site visits, thanks to electronic test equipment and digital analytical devices. These high tech modern tools can relay vital information direct from plant and equipment, transmitting data straight to a smart phone app. For example, a task that once took an engineer
45 minutes to undertake on site and required follow up admin at branch, can now be fully completed in only a couple of minutes. This is thanks to a range of simple-to-use electronic instruments linked to transducers, sensors and probes, which accurately measure and record the required plant data and record the information direct to an app on the engineer’s mobile phone.
Vibration Analysis Conducting vibration analysis is a process that monitors the levels and patterns of vibration signals and determines the dynamic load within a component. Utilising vibration analysis on an open drive compressor pack arrangement provides an
early indication of component wear and allows trend data to be captured. Due to the arrangement of the compressor and drive motor, any wear or developing fault in either part has the potential to cause issues and damage to both components. Early diagnosis of a problem is pivotal to reducing risk and downtime for the plant. Analysis is generally conducted by using a range
of sensors to measure vibration levels when the plant is running at specifi c capacity intervals. The movement/dynamic parameters are then compared, giving an indication of component condition and wear levels. Vibration analysis used to be a service that was only conducted by a specialist contractor on either a quarterly, six-monthly or annual basis. Now maintenance engineers have the necessary equipment available to take a number of basic readings on regular site visits, by installing a range of sensors and probes on the compressor/drive motor. Measurements are transmitted directly to an online app on the engineer’s mobile phone. This data can be reviewed and analysed off -site, either by in-house engineering experts or a specialist company, to see whether the data recorded falls within or outside the recommended parameters.
Motion Amplifi cation The latest development in vibration analysis technology, motion amplifi cation involves putting a series of video cameras around the plant. These cameras record super slow video and when played back/analysed, engineers can determine anomalies/ excessive movement on the plant. This incredible technology takes vibration analysis to a whole new level, with tell-tale signs of component wear now captured exceptionally early.
Thermographic Scans Thermographic scans are conducted to identify areas of heat within plant and equipment through non- destructive testing. These scans can help to identify issues with electrical wiring, which if not identifi ed and investigated could lead to catastrophic panel fi res, equipment faults and plant failure. No longer the remit of specialist fi rms, thermographic scans are now being conducted by in-house maintenance engineers. Thermographic scanning devices can be connected to a refrigeration engineer’s mobile phone. Photos and videos of the
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