FEATURE DATA COLLECTION MANAGEMENT
Digital data collection: The benefits for CM practices Digital condition monitoring technology has
revolutionised the way data is collected from critical assets. However, its real value lies in how that data can be accessed, analysed and responded to in real time, as Oliver Pogmore of AVT Reliability explains
I
n terms of workforce welfare, the value of a cloud-based CM (condition monitoring) system
is self-evident. As data can be collected from up to 50m away using a standard Android tablet or smartphone, operatives avoid proximity to large or moving assets and do not have to negotiate hard-to-reach collection points carrying a traditional wired accelerometer. In fact remote access is even more crucial today, with social distancing measures. The most advanced systems offer long range
Bluetooth routers which can connect up to 100 vibration sensors to the internet via ethernet, Wi-Fi or 3G/4G cellular network, removing the need for manual data collection and freeing up operatives for more productive tasks. However, data is of little value unless it is
properly analysed and used to inform a proactive maintenance plan. An Automated Diagnostic Assistant (ADA) is a central element of a cloud based CM system. Algorithms informed by years of vibration data and in-the-field experience are able to identify a wide range of bearing issues and other common fault conditions. Every piece of information collected can
be used intelligently to identify ‘bad actors’ and propose an action plan to prevent an impending issue from developing into costly equipment failure and unscheduled downtime. Repairs can therefore be factored into planned routine maintenance activity. These advantages alone present a powerful
incentive to make the shift from traditional pencil and clipboard to wireless technology and sensors. However, there are other significant benefits to be gained from the digital management of assets.
REMOTE ACCESS TO DATA Data collected digitally is stored securely in the cloud where it can be accessed by any authorised user, from anywhere in the world, via a standard web browser – the value of which was brought home to many companies during the recent lockdown. From their laptop or smartphone, key members can access a vast amount of information and measurements such as vibration, thermal imaging, oil analysis, or simply pictures from visual inspection, all collated on one single interface. Initial fault diagnostic findings from the Automated Diagnostic Assistant (ADA) will also be immediately available.
32 AUTUMN 2020 | ENERGY MANAGEMENT Key data is automatically presented
as an asset status summary on an easy to read dashboard. Information encompassing anything from the latest monitoring readings to maintenance activity and operative comments is available within minutes of it being completed. And it is possible to drill down to view the data on any individual asset. The upfront costs of installing digital CM are
low. Web based software means installation and setup does not demand any complex or costly IT input and a condition maintenance plan can be implemented to the highest standards without the need for highly skilled operatives. The likelihood of a swift return on investment is high and improved asset reliability and long term financial savings a certainty. When the far-reaching benefits of a digital CM
approach are considered, for companies wishing to weather the challenging months ahead the concept of allowing critical assets to ‘run to failure’ has surely run its course.
HIGHLAND SPRING So let’s take a look at Highland Spring Group, the largest producer of naturally sourced bottled water in the UK. The company operates with highly critical assets throughout its manufacturing plants – including blow moulders, rinsers, fillers and labellers. If one of these assets goes down, production comes to a halt, so it is key that the health and condition of these assets is continuously monitored and maintained. Highland Spring Group selected AVT Reliability
to assist with their condition monitoring (CM) journey, with the goal of increasing plant reliability and protecting these critical assets. The project aims were to: increase productivity; extend machinery lifespan; optimise the periodic maintenance programme; and reduce machinery maintenance expenditures. AVT Reliability has
products and services to suit different scenarios and following a site survey our engineers advised
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that the best suited CM technique to increase plant reliability was vibration analysis using Machine Sentry Online. MOS-1 is ideal for vibration monitoring on continuously running, highly critical assets. The data being recorded is trended in real time, which allows remedial works to be carried out during a planned outage. Readings are automatically uploaded to the cloud-based platform, Machine Sentry, and secured to ISO27001, one of the most widely recognised international standards for industrial supply chain security. As the platform is cloud based, engineers are able to analyse and report on data within minutes, wherever they are in the world. All asset health and analytics are completed in the system, meaning all data remains in one location. In January this year, the MSO-1 system at
Highland Springs Group generated an email alert which identified increasing vibration
levels on the outfeed start wheelbearing. This allowed engineers to take action as soon as possible. Following analysis from expert engineers at AVT Reliability and discussion with the client, the conclusion was reached that the vibration increase was due to a possible bearing issue. As the fault was found early, further damage to the asset was prevented. Undetected, there could have been catastrophic damage. MSO-1 allowed engineers to analyse the data
collected and predict when a failure was going to happen. The engineers at Highland Spring Group were then able to plan scheduled downtime and complete the planned work scope within three days, saving 48 hours of repair time, amounting to a total of £16,800. When the cost of the Machine Sentry system is removed, the actual saving is £10,300 after this one incident alone. The table below shows the cost of maintenance
for both the planned and unplanned scenarios for Highland Spring Group, for the bearing failure which was detected using Machine Sentry. Following the work completed by AVT
Reliability, David Simpson, site engineering manager at Highland Spring Group said: “The benefits are huge, with the early warning reports identifying potential issues and reporting recommended actions, which we add to our weekly maintenance plan and rectify. Machine Sentry Online will be my option as we roll this excellent analysis tool out to other production lines.”
AVT Reliability
www.machinesentry.com
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