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Predictive maintenance & condition monitoring


Keeping ahead of the curve


David Manning-Ohren, ERIKS UK & Ireland, explains why a different approach needs to be taken when it comes to condition monitoring in aggressive environments


I


f you are a maintenance manager working within an “aggressive” manufacturing environment, you will


need to adopt a different approach to traditional condition monitoring methods. In order to be effective, condition


monitoring needs to allow a window of opportunity in which corrective or preventative measures can be taken. Equipment that faces intense pressures,


forces or temperatures has a sharper failure curve than equipment that does not. Any issues, therefore, are likely to occur quickly and have more of an impact. For this reason, traditional methods are


unlikely to spot an issue until it is too late, leading to the very downtime and costs that condition monitoring was supposed to prevent. Luckily, technology exists to cope with the


higher demands of an aggressive manufacturing environment. Tools that use live, real-time data acquisition to keep on top of even small machine changes as they occur, for example, are par ticularly effective in aggressive environments. Data acquisition is more useful than periodic


portable monitoring, because it identifies alterations, such as an increase in dust, fluid, or debris, before they become issues. Maintenance managers in aggressive


environments are advised to do the following:


1. DEfInE ‘aggRESSIvE’ What is aggressive in one context might not be in another. Flour on a bakery floor, for example, is not aggressive, but flour in a bearing is.


2. KEEp It clEan Keeping the factory floor as free of contaminants as possible will help to prolong the lifespan of equipment. Dampen down dust with sprays, or use extractor fans to remove it. Actions such as these make the aggressive environment smaller and more manageable.


3. EvalUatE thE lOcatIOn Of EqUIpMEnt Just because an asset is part of the process creating the aggressive environment, does not mean it physically needs to be there. There are few applications in which you cannot create enough distance between a motor and a gearbox, for example. In fact, driveshafts of up to 10m in length are entirely possible if engineered- in at the design stage.


4. chEcK yOUR aSSEtS havE thE RIght Ip RatIng Even the cleanest production lines spread contaminants, which ultimately leads to the expansion of the aggressive environment. Make sure, therefore, that any component working as par t of the process has the correct IP rating, whether it is based directly within the aggressive environment, or not. If it only has a standard IP rating, it will not be long before its performance and reliability are affected.


5. DEfEnD yOUR aSSEtS A good defence should be the final step before implementing condition monitoring. Consider moulded-oil bearings and super seals to increase protection against contaminant ingress. Automatic lubricators are also effective, because they place positive pressure on the lubricant within the bearing.


ERIKS UK & Ireland www.eriks.co.uk


12


October 2018 Instrumentation Monthly


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