WHEN Tui Industries CEO Jason Sulzberger decided he wanted to improve the way vibration monitoring of machinery was done, he knew where to start.

With 60pc of time taken up in collecting data, and a lack of consistency in the data even before it could be analysed and diagnosed, he set his team to the task of eliminating the need for manual field monitors.

The result is the development of a sensor system that is continually on-line, allowing the time previously used in data collection to be applied to analysis and monitoring of the condition of machinery in a plant.

The Tui system allows the vibration monitoring to be completely controlled by external experts, who can focus solely on the function of the individual machines without the distraction of the plant operations.

The worldwide vibration monitoring service, based in Queensland, now services a range of major clients including servicing BOC Gases Australia in eight different countries.

The low-cost system has many superior features in comparison to both manual collection and other sensor systems.

Low capital expenditure

Tui’s business model allows companies to gain approval for the project more easily than the traditional model and proceed with online conditioning monitoring without delays.

All hardware except the cabling is included in the monthly service fee and is installed and monitored by Tui at no extra expense.

This lowers the cost of the system by tens of thousands of dollars.

“We can offer a vibration monitoring system that is more effective and reliable at a lower cost,” Mr Sulzberger said.

Smooth installation

Tui spent time during the design period ensuring that initial installation was seamless and simple.

“As the system was developed from scratch, we spent time optimizing the installation process and constructing components to enable us to have quick and easy placement,” Mr Sulzbeger said.

Thanks to this initial attention, Tui can place sensors quickly with minimal interruption to the operations.

For a client who orders 180 sensors, at six per machine, the sensors can be installed within five days, in most cases while the machines are operating.

Alternatively, on-site personnel can be trained to install any additional sensors the customer wishes to order at a later date.

Optimal placement

Tui has calculated the optimal number of sensors required that will both provide accurate data and avoid unnecessary expense.

It aims to apply one sensor per radial bearing and one per axial shaft, resulting in, for example, three sensors for an electric motor.

The Tui sensors need only be placed strategically on the weakest axial bearing which helps the clients save money.

“Normally motors will not have much in the way of axial vibration, however, the axial sensor will pick up a range of faults that arise such as coupling issues alignment, bearing preload, unbalance and poor installation practices,” Mr Sulzberger said.

Experts on the job

Staff retention and expertise has always been an issue in the vibration monitoring industry, as often the job is given to entry level staff who then move on quickly.

Staff with the knowledge and competence required to properly collect and analyse data are continually lost, which greatly affects the quality of the data.

Condition monitoring relies on consistency as well as regular and tight intervals at the point of collection.

A manual monitoring system uses at least 60pc of the time to simply collect the data, a process which requires running a hand-held sensor over a selected location on each machine individually, and then returning after an interval to repeat the process exactly.

According to Mr Sulzberger, the accuracy of this system is usually around 40-60pc, a figure that is heavily dependent on the quality of the data collection, as opposed to a 98+0pc accuracy rate with Tui’s online system.

Various literature states 40pc of bearing faults are random, but this has proven not to be true.

Usually, the main problem is the collection interval is not set correctly to capture the failure mode.

The interval of the manual monitoring data collection can vary from two weeks to once a year, making analysis difficult.

The Tui system overcomes this by replacing manual monitoring staff with a sensor that streams data to qualified engineers who assess the information that comes in continually as online data.

The analysis can be done by Tui, the clients condition monitoring team, or jointly.

This internal photo of a compressor shows where faults were detected by Tui on the first and second stage bearings.

Pin-pointing the faults

Vibration monitoring is essentially looking for change, often subtle

If the vibration signature starts to change then that is an overt sign of malfunction within its workings.

With online sensors placed at the bearings, the signs of malfunction can be picked up long before the vibrations themselves are noticeable.

The constant stream of data allows incremental changes to be picked up by Tui analysts in real time and the amount of data allows Tui to provide accurate information about what the fault actually is.

It can then notify the client and help it assess and decide on how to proceed regarding maintenance.

Using the information

Tui monitors not just the information provided by the sensors but the sensors themselves, with a monthly audit.

If the sensors are not sending data, then either they are not working, or the machine is turned off.

This can be cross checked with the other sensors in the machine – if all three are not reporting data then the machine is off, otherwise the issue is with the sensor itself.

Identifying machines that are offline for some time can also help the client to ensure that its protocols are being adhered to.

The data can identify machines that have not been turned on for several months.

Many issues arise if a machine is left idle.

Valves can cease to function or in the case of pumps, calcium build-ups can block the volutes – issues which may only be noticed when the machine is required and doesn’t function.

Tui can identify the level of criticality of a fault that arises by the sensor output – if faults arise at more than one sensor then the level is raised higher.

“The smallest of machinery can take out an entire operating process, hence the system was designed to cover a wide range of equipment, not just the high capital machines” Mr. Sulzberger said

Case study

Tui was monitoring a motor which failed very quickly, a condition which it alerted the client to as soon as it was detected, prior to the failure.

The client proceeded to conduct repairs based on its own diagnosis which unfortunately resulted in inaccurate machine repairs.

After the second fail, Tui repeated its diagnosis based on its streamed data and convinced the client to send the parts back to OEM for professional repairs.

Its diagnosis proved correct and the motor was repaired correctly, allowing the machine to provide many more years of service.

Without Tui’s accurate diagnosis based on consistently provided data, the collapsed internal cage of the motor would have created structural damage to the machine and it would have needed to be replaced.

On a $100,000 machine, faults can have disastrous consequences but with the accurate pin-pointing available from Tui’s online sensor analysis, these ramifications can be avoided.

The installation of Tui’s vibration monitoring sensor system is a positive investment, allowing machines to be assessed for faults before they happen.

Tui’s diagnosis and evaluation process will allow repairs to be made in a timely manner, ensuring ongoing operations and massive cost savings.

More information:

Phone: 07 37157800
Email: [email protected]

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