Future-Proofing Asset Monitoring at Port…

The infrastructure-heavy operation at seaport, marine and inter-modal terminals, face increasing demand for efficient and cost-effective operation. Advanced equipment and technology underpins port performance, and productivity hinges upon robust asset management.

The majority of port infrastructure (including Container Cranes, Straddle Carriers, Shiploaders and Hoppers) have a useful economic life of up to 50 years, however an increasing portfolio of ageing and expensive assets over time leads to an increase in exposure to business risk. Research suggests that issues resulting from the application of inadequate or incorrect maintenance procedures cause roughly 25% of the total cost of equipment damage and that satisfying short-term operational needs can lead to major asset downtime due to unplanned maintenance and catastrophic failure. 

Increasing global trade is increasing the demand for more infrastructure to combat port congestion problems. Subsequently there has been an increasing industry focus on equipment lifecycle management, and real-time condition monitoring and maintenance strategies as part of a wider approach to the managing of an entire portfolio of assets. 

Oil condition monitoring plays a fundamental role in total asset management. Accurate, high quality oil condition analysis provides a deep insight into the health and status of port equipment. Contamination can quickly lead to oil losing its lubrication properties and equipment damage. Small unseen issues, which if left to develop will cause a major breakdown, are reflected in changes in oil condition, and as oil condition degrades with use, you can pin-point the exact time for maintenance, extending intervals without risk.

Tan Delta sensors were fitted to the primary hydraulic systems of Container Cranes in a busy South African port. An operator panel was installed in each, providing a simple traffic light condition status, whilst live data was streamed back to the maintenance centre. The data enabled the port to extend the intervals between servicing thus reducing direct operating costs, also providing reassurance that in the event of an unexpected issue, an alert would be provided, and action taken in a planned and controlled manner before any equipment damage had occurred. 

“Since the installation we have seen a significant reduction of 32% in our oil consumption. We were replacing our oil prematurely and have since been able to streamline our maintenance across the whole port. With a total project payback of 6 months this technology forms a crucial part of our asset management strategy, and has helped provide complete visibility, tracking and actionable predictive insights across the port”. – Port Operations Manager, South Africa.

Would you like to see how we can save you money?

Contact, Lourens Janse Van Rensburg on +27 (0) 79 512 8027 or alternatively,

lourens-cisindustrial@outlook.com

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability!

Interrupted production can be costly!

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The IIot Motor Diagnostic System – Cracked Rotor Bar Defect

Interrupted production can be costly. Loss of production hours, output as well as the cost to repair mechanical faults or major machine breakdowns can severely impact production and maintenance budgets.

The IIot Motor Diagnostic System allows plant owners to prevent unplanned mechanical breakdowns through fault detection alerts enabling maintenance teams to act proactively.

The IIot Motor Diagnostic System installed at an international rubber and tyre manufacturer on a rubber-mixing mill saved the company many hours of unscheduled downtime and hundreds of thousands in production revenue.

The Roll Milling Machine applies a mechanical process to blend the ingredients into a homogeneous substance. Internal mixers fitted with two counter-rotating rotors in a large housing shear the rubber charge along with the additives.

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The IIot Motor Diagnostic System identified an existing Coupling/Bearing problem in the Roll Milling Machine. The system also flagged an immediate alert related to the Rotor Bar parameter.

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The trend visibly reflects how the Rotor Bar error advanced. Vibration measurements verified the presence of broken rotor bars, already identified by The IIot Motor Diagnostic System.

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The IIot Motor Diagnostic System in this instance demonstrated its ability to detect developing Rotor Bar faults, alerting the maintenance team. The necessary predictive and preventative maintenance actions were taken, resulting in no production loss recorded.

Can you imagine the impact on the production and maintenance budget if this fault were not detected?

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability!

Unscheduled downtime affects your production​!

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The IIot Motor Diagnostic System – Unbalance and Misalignment

Faults going undetected in an industrial plant can have serious negative implications on production and often safety. It is of the utmost importance for the Maintenance Department to always be alert and aware of any technical issues no matter how big or small, that can result in unplanned downtime.

The IIot Motor Diagnostic System installed at a major international manufacturer in the automotive industry did just this. The IIot Motor Diagnostic System unit first gave a warning of a problem on 16 October 2015 and diagnosed a looseness problem. Due to pressure to meet production targets a decision was made by the maintenance team to wait for further indications.

On 19 November 2015, a new alert reflected, which initiated an inspection, resulting in the discovery of a loose attachment bolt on a Cooling Tower Fan, responsible for cooling the water circulated in the tower.

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Next follows the sequence of alerts by the IIot Motor Diagnostic System unit at the time, as an example of the operation of the unit.

OCTOBER 2015

The system indicates looseness, and then the problem disappeared. Numerous alarms flagged in the software that related to foundation issues, including unbalance as well as misalignment alerts.

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NOVEMBER 2015

Continuous monitoring of foundation problem followed.

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DECEMBER 2015

The IIot Motor Diagnostic unit continuously reported a unbalance, and misalignment problem.

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DECEMBER 2015

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FEBRUARY 2016

Scheduled maintenance took place in February 2016, where the foundation problem was corrected.

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RESULT: The IIot Motor Diagnostic System unit detected an Unbalance and Misalignment concern well in advance. Due to the early warnings provided by the IIot Motor Diagnostic unit an informed decision was made by the maintenance team to run and monitor the fans for any drastic changes that could affect production until the problem could be resolved during scheduled downtime.

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Making the correct maintenance decisions can be an easy task if you have access to accurate information to base your decision making on.

Can you afford unscheduled downtime?

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability!

 

Asset Management and Energy Efficiency Toolkit

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Asset Management Toolkit (AMT), is an Asset Management and Energy Efficiency Toolkit, which use three-phase voltage and current signals to diagnose existing electrical and mechanical problems.

Check-Up for Motor Driven Equipment – routine check-up and early diagnosis of equipment prevents catastrophic damages and helps to reduce energy consumption and operating costs.

HOW IT WORKS

Asset Management Toolkit (AMT) is equipped with a computer, which is optional as the client can also supply their own PC, meeting the required specifications if preferred, fully functional AES software for AMT Toolkit hardware, current transformers, and cables.
Asset Management Toolkit (AMT) is connected to motor cables using clamp-on current sensors and voltage cables. It collects data from motor driven systems and also has the ability to measure equipment driven by the motor, for example, a gearbox, and saves it to an SQL database. At the end of the testing period, the toolkit generates a condition assessment report, which indicates existing faults of the system, time to failure information, recommended corrective actions, and effects of these faults on energy efficiency.

Fault Coverage

  • Loose foundation/components
  • Unbalance/misalignment/coupling
  • Transmission faults
  • Driven equipment faults
  • Bearing faults
  • Rotor faults
  • Stator/insulation faults
  • Voltage unbalance
  • Current unbalance
  • Internal and external electrical faults

Process Faults

  • High energy consumption
  • Low efficiency
  • Cavitation in pumps
  • Flow turbulence in fans, blowers
  • Filter and heat exchanger fouling
  • Lubrication
  • Oversize/undersize motors

Parameters

  • RMS values of three phase voltages and currents
  • Frequency
  • Power factor
  • Active power
  • Reactive power
  • Total Harmonic Distortion
  • Harmonics up to 13th
  • Voltage and current balances

WHAT ARE THE KEY BENEFITS OF THE ASSET MANAGEMENT AND ENERGY EFFICIENCY TOOLKIT?

  • Immediate payback by corrective action
  • Instant condition assessment report
  • Advanced analysis and reporting
  • No sensors on motor or equipment
  • Improved efficiency and reliability of plant and processes
  • Increased machine availability

Software Features

  • Classification of data into companies and motors
  • Instant Condition Assessment Report
  • Instant PSD download for frequency spectrum analyses
  • Instant voltage-current waveform download

Current Transformers included in the Asset Management Toolkit (AMT)

  • 4 sets split-core current transformers
  • 400/5A, 300/5A, 200/5A, and 100/5A, Class 1
  • Frequency range 50/60 Hz
  • System rated voltage 0.72/3kV
  • Isolation voltage 3kV (1 minute)
  • Continuous current 1.2xrated current

Immediate Payback

Taking corrective action for existing equipment faults will eliminate unplanned downtime, improve energy efficiency, reduce maintenance cost and extend equipment lifetime.

Energy Consumption

Motor-driven systems consume 66% of the electrical energy in an industrial plant. Any improvement can yield a considerable amount of energy saving.

Operations and Maintenance

It has been estimated that Operations and Maintenance programs targeting energy efficiency can save up to 20% on energy bills without a significant capital investment. From small to large sites, these savings can represent thousands to hundreds-of-thousands of Rand each year, and many can be achieved with minimal cash outlays.

SECTORS

Asset Management Toolkit (AMT), can be used in all industrial sectors ranging from; Oil & Gas, Energy, Cement, Metal, Pharmaceutical, Automotive, Water, Transportation, Food & Beverages, Building and more.

APPLICATIONS

Applications typically range from; compressors, fans, pumps, conveyors, generators to motor driven equipment.

DIMENSIONS

The Asset Management Toolkit (AMT) is compact in size, 550x310x190mm, and the unit comes in a handy protective dust and waterproof case.

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability!