The first Kiln monitoring system that Yellotec installed is still in operation since 2013 which makes it a very reliable solution. The system detected faults and prevented catastrophic failures and saving our customers millions of Rands since the installation. The Kiln Monitoring system is inexpensive compared to possible failures and is very low in maintenance cost. The team at Yellotec are very proud to build and supply the complete solution for continuous kiln shell monitoring.
A recap of our previous article:
In the previous article that was written in 2014, we looked deeper into the world’s first Kiln Shell Monitoring System based on Microbolometer Infrared Camera Technology.
IRT KilnMonitor® is a full-featured computer system that allows you to monitor, process and trace data from rotary cement kilns. Unlike existing solutions, it is based on standard microbolometer radiometric infrared cameras, as used in a variety of different applications.
The system has major advantages over other methods. Including, reduced maintenance costs, high-resolution thermal profiles, and internal refractory profiling via 3D modelling, significantly reduced capital costs, and maximised up times – the revolution has finally started.
Key features of the Virtual 3D Kiln Display:
Kiln “pipe” with infrared image on the surface.
The kiln is rotating at a real speed.
Rings and other shadow zones.
Position of the top-kiln.
Real coordinates ruler with the kiln refractory and shadow zone’s structure.
And many more!
Staying up to date with Kiln Monitoring:
Kiln monitoring is important, and you must monitor the degradation of the material and detect damaged or fallen bricks. The easiest way to do this is to monitor the temperature of the kiln shell. Infrared technology has been favoured in the past to perform this task. Sophisticated user interfaces have been designed to make the data easier to analyse and understand. Recently, high demands have led to the development of more complex products that do a lot more than just measure temperature.
The Thermal Imaging Cameras of the Kiln monitoring system provide accurate temperature measurements in a visual format, with high detector resolution. This enables the user to extend equipment life and allow money-saving on maintenance programs. This infrared technology contributes to improving production in quality and quantity while reducing downtime and energy consumption.
Benefits of Kiln Monitoring:
Higher field of view for new larger kilns (up to 4 thermal cameras with 110º view angle)
Higher resolution (up to 3.200 measuring points per line) for refractory detail
High sensitivity to identify even the smaller temperature changes and hot spots.
Easy integration and communication of all data to Plant Control System.
Pre-wired and pre-tested for an easy installation.
Calibration checks are not required.
Fibre optic communication
Training and commissioning support by a highly qualified and experienced team.
What Yellotec offers in terms of Kiln Monitoring Technology:
Yellotec partnered with Grayess, who is an Infrared Thermography Software Developing Specialist with software that is:
easy to use,
highly sophisticated,
high compatibility,
ease of data exchange and
has more than 3000 installations worldwide!
Today, it is impossible to imagine the building industry without cement. Cement is one of the most valuable and useful products in the world. It is an important part of mortar, concrete, manufacturing and more. Cement production is a complex process, in which one of the steps consists of blending limestone with other components in big rotary furnaces. These furnaces or kilns are a critical asset of a cement production plant, heating their contents to temperatures up to 1,500 °C. There is a risk of overheating, which can cause serious damage to the kiln shell. It is important to monitor this delicate heating process and prevent possible damage to the kiln. Thermal imaging cameras are great to use in this situation as they are used to measure temperatures on a 24/7 basis.
The IRT KilnMonitor® system is an advanced computer system that allows cement production operators to monitor, process and trace data from several kilns at once. IRT KilnMonitor® systems protect your plant and machinery constantly. Yellotec is proud to be able to provide this dependable turnkey solution. We have trust in the brands that we represent and the solutions we can create with our partners. If you would are interested in Kiln Monitoring equipment. Please feel free to contact us by visiting, calling, emailing or filling in the contact form and one of our experienced team will get back to you with everything you need.
Understanding Motion Amplification and why it is the perfect tool for vibration monitoring
In this article, we will be looking at what is motion amplification and how it works. Yellotec offers a variety of instruments to perform motion amplification and this article will provide more information for each product.
What is motion amplification?
With motion amplification, vibration problems are made visual. This technology implements a video-processing method that detects very small movement and amplifies it. Motion amplification is used to help you visualize vibration issues that may not be visible to the naked eye. This tool can save time and costs in vibration analysis, routine condition monitoring programs, troubleshooting and root cause analysis.
As industrial equipment, machinery, and other components operate, they produce very small vibrations and movements. These vibrations are at times extremely small that they can often go undetected and can be destructive to your machinery and equipment. As pieces of machinery vibrate, components can become misaligned, imbalanced, loose, cracked, or worse. These unnoticed movements and vibrations can significantly reduce the efficiency of the machine and can often lead to catastrophic failures.
By using motion amplification technology, it is possible to detect these subtle movements. It provides a better understanding of the existing defects and the increased failure risk on the equipment. Motion amplification will enable you to visually see what the immediate impact on your machinery is.
Reliable machine monitoring systems?
Motion amplification technology can help in many industries as it enables people to visualize machinery and structural movements, accurately measure displacement data that is generated by millions of camera pixels and solve underlying problems.
With motion amplification, you can easily visualize and quantify data. It also enables you to receive data on machinery detection and early prevention of structural inefficiencies, imbalances, wear, and other faults that affect operational safety, efficiency, and output.
Motion amplification in the Aerospace and defence industry:
By visualizing and measuring movements happening at microscopic levels, motion enhancement technology ensures that the latest aerospace and defence technology performs at higher levels. The aerospace and defence industries demand rigorous testing and development standards. Having the right tools to evaluate equipment and technology is critical and understanding their applications or potential.
Motion amplification in the Automotive industry:
The automotive industry is always at work on new designs, components, technologies, and processes that make automobiles safer, faster, and more efficient. The automotive industry requires a lot of testing and evaluation as they incorporate many components such as auto bodies, engines, myriad parts and all the pieces in between.
Motion amplification technology can play a critical part as you can detect vibrations throughout an automobile’s body, or within a specific component, or even a specific portion of a vehicle. This can offer insight into the automobile’s performance, health, and comfort in terms of the driver.
Motion Amplification in the Manufacturing industry:
Motion amplification cameras can help keep an eye on the machinery and components that are needed for any manufacturing site. The motion amplification, Iris M, takes millions of measurements in a fraction of a second, making it a one-of-a-kind system for equipment monitoring or root cause analysis.
Manufacturing relies solely on productivity for its success. Therefore, it is important to minimize equipment downtime and costly repairs. To do this, it is essential to make predictive maintenance your top priority. All those pieces and components are often subjected to common issues and failures. Such as looseness, misalignment and imbalanced machinery. Time will pass, and equipment will age, but maintaining machinery is the only way to keep small problems from becoming catastrophic failures.
Keep your manufacturing site running efficiently and smoothly by letting motion amplification technology see the problems before you do.
Motion Amplification in the Oil and Gas industry:
The power generation industry involves many types of industries, commodities, and resources. There are traditional fossil fuels, nuclear power, wind energy, hydropower, and other sources of energy to power our world. Almost all of these resources involve large machinery that contains pumps, turbines, and other rotating components that are subject to frequent vibrations.
It is essential to track and monitor vibrations in the power and generation industry, as any power plant needs to be reliable and capable of continuous operation. Downtime can have huge effects on downstream consumers, which includes essentially all other industries, and anyone connected to the power grid. Downtime at a power station often results in increased load shedding.
The motion amplification, Iris M, the camera has been deployed to several power plants to help route out the underlying causes of vibrational problems. Looking at various types of power plants and the extent of their issues involving vibrational forces solidifies the importance of motion amplification vibration analysis and monitoring for this critical industry.
Motion Amplification in the Oil and Gas industry:
At Yellotec we sell a variety of RDI motion amplification products. Our vibration analysis and monitoring equipment now also include:
The IRIS M platform monitors critical manufacturing machinery, operations, process lines, structural components, quality control, and other factors that affect plant reliability and productivity.
RDI’s patented technology measures deflection, displacement, movement, and vibration not visible to the human eye. It utilizes video camera technology in conjunction with software and processing algorithms to extract meaningful data.
By turning every pixel in the camera into a sensor, Iris M takes millions of measurements in a fraction of a second. This is done with no physical connection or disruption to your operations, machinery, or plant assets.
The results lend themselves to a visualization of the motion. You can measure and quantify any structural assets that the camera can see. Motion amplification is an exclusive video processing algorithm that detects subtle motion then amplifies that motion until it is visible to the naked eye and enhances the understanding of the components and the cause of the motion or vibration.
What differentiates Iris M from traditional tools is that it simultaneously monitors all points of your process and machinery, and it does this with no impact on your flow of business. Iris M is completely non-contact and provides a comprehensive analysis while the machinery is operating. With Iris M, you move well beyond data collection to problem-solving.
IRIS MX
The IRIS MX from RDI Technologies expands upon its revolutionary Iris M product to open the world of motion amplification to high-speed applications. Like the Iris M, the Iris MX utilizes millions of pixels to measure deflection, displacement, movement, and vibration normally not visible. The Iris M can detect a wide range of possible defects in machine condition monitoring. With the Iris MX, we have you covered no matter what the speed of your machine.
The software module allows you to draw regions of interest and return a time waveform and spectrum in both the horizontal and vertical directions from those locations. Also included are new features in the acquisition software that assist in making measurements of displacement.
This allows you to manage all your motion amplification data from one place. You will now be able to preview your recordings, organize your data in a hierarchical structure, and associate files such as PDFs and MP4s with your recordings.
IRIS CM
The IRIS CM is the power of motion amplification with the benefits of continuous monitoring. Iris CM is a continuous monitoring system that records millions of measurements with no physical connection to your machinery or equipment. With Iris CM, you are now able to see what is happening to your machines 24/7. Even when you are away.
Once configured, Iris CM can continuously monitor your asset with live motion amplification, trigger, and store recordings, and provide all the data analysis using motion amplification software. Best of all, once you solve the problem with your asset, just move the system to the next asset and start all over. Solve your toughest problems. Solve your intermittent problems. Solve it with Iris CM.
Final Thoughts:
Yellotec believes that it is vital to use predictive maintenance on your machinery, equipment, and assets. Motion amplification can save time and costs in vibration analysis, routine condition monitoring programs, troubleshooting and root cause analysis. Motion amplification has a wide array of uses, including vibration analysis and predictive maintenance.
At Yellotec we take pride in the products that we sell and want our customers to get the very best! If you would like to know more about Motion Amplification and about the products we offer that are perfect for motion amplification. Contact us today
For more information about any of the products that we have spoken about, other Yellotec products that we offer or just want to know more about Yellotec, you can contact us either by visiting us, emailing us, calling us. Or filling out the form and someone from our technical sales team will give you a call to see how we can best assist you.
In this article, we will be looking at why the team at Yellotec love the Pruftechnik brand when it comes to Laser Shaft Alignment.
Pruftechnik’s laser shaft alignment tools are the most efficient way to align machine shafts. These tools are great as they save you time, money, increases machine availability, prolongs service life and maintenance intervals, as well as lowers your power consumption. If this doesn’t convince you to use an adaptive alignment system instead of conventional tools, then we don’t know what will. Alignment tools from Pruftechnik can adapt to virtually any asset, situation, or user skill level, making these tools perfect for anyone. There are four different types of laser shaft alignment tools that you can choose from, all with unique features and benefits, that will be an incredible fit for your needs and wants. The four different types of tools are:
ROTALIGN Touch
OPTALIGN Touch
SHAFTALIGN Touch
ROTALIGN Touch EX
The ROTALIGN Touch
The ROTALIGN Touch was designed by some of the world’s leading alignment experts to solve problems in the easiest way possible. This Pruftechnik tool is known to be the most adaptable laser shaft alignment tool. The ROTALIGN Touch combines high precision on-site measuring tasks and cloud connectivity for worldwide data access and transfer. With the sensALIGN® 7, the ROTALIGN Touch uses laser and sensor heads that offer a full range of everyday alignment routines, up to expert degree alignment jobs, such as Cardan shaft alignment or aligning up to six sequential couplings in a row.
Achieve unrivalled precision, even in harshest conditions and on highly demanding jobs with the use of the ROTALIGN single-laser technology. This tool is great for beginners and experts as it has an intuitively guided user interface that can be operated by almost anyone. Users will need to follow the three steps of shaft alignment: dimension, measure, and result.
There are also many benefits when using Pruftechnik’s ROTALIGN Touch tool. With its advanced features, this laser shaft alignment tool can help solve virtually any alignment challenge. If you need a tool that can handle alignment issues on standard machines such as motor pump assets up to large steam turbines, and everything in between, then this is the perfect tool for you! Save your time and effort with the guided user interface. The ROTALIGN Touch interface fully adapts to all your needs by displaying coloured real 3D machine models with tablet-like navigation for full control of your measurements. Not only does the ROTALIGN Touch enhance your communication options, but it also increases your visibility. This laser shaft alignment tool has an integrated RFID tag reader which will help users to identify the asset needing inspection and remediation. You can also find convenience in the Pruftechnik ARC 4.0 cloud transfer where your machines data notifications can be pushed to computers worldwide.
The ROTALIGN Touch tool is ready to tackle alignment challenges in any industry and can withstand any industrial environment, no matter what and where. This premium laser shaft alignment system can be used independently throughout all your branches, industries, and assets. Yellotec is proud to sell this amazing laser shaft alignment tool and if you would like to see how the ROTALIGN Touch tool can adapt to your assets, contact us and we will get back to you promptly to offer our expertise.
The OPTALIGN Touch
The OPTALIGN Touch is the everyday tool that no workshop should be without. This tool is perfect for everyday alignment and measurement tasks in the industry. This tool is known for setting the benchmark for solving common alignment problems. The OPTALIGN Touch also features the unique sensALIGN® 5 laser and sensor heads. This enables powerful, fast, and efficient alignment on rotatable shafts and machines.
Thanks to its Adaptive Alignment features such as single-laser technology and Active Situational Intelligence, the OPTALIGN Touch tool can easily adapt to the situation, asset, and technician experience level. The Pruftechnik OPTALIGN Touch tool combines hardware, software, and WiFi connectivity to deliver precise alignment data via the cloud, making it a dream for anyone that needs to share machine data. With the intuitively guided user interface, the OPTALIGN Toch can be operated by almost anyone. This laser shaft alignment tool is any technicians dream as it is waterproof and dustproof, oil-proof and waterproof (IP65), dirt-resistant, scratch-resistant, and impact-resistant.
Users can also upgrade their OPTALIGN Touch tool by simply adding sensALIGN® 7 laser and sensor heads to receive the unlimited power of Pruftechnik’s adaptive alignment world.
There are so many reasons and benefits to using the OPTALIGN Touch tool. This tool ensures that you work faster without having to sacrifice accuracy. This is an easy-to-use handheld device that enables complex alignment jobs to be done quickly with no loss in accuracy with its intuitive setup and data acquisition. The OPTALIGN Touch tool allows you to leverage advanced laser shaft alignment capabilities. With amazing and powerful hardware and software features, the OPTALIGN Touch simplifies the way you perform mounting, measuring, and shimming. With mistake-correcting capabilities, this tool adapts to both the alignment challenge and experience level of the user. Easily transfer your data to and from the cloud. You can send and receive alignment data from and to the ARC 4.0 PC software via an integrated WiFi connection which enables you to easily monitor and trend your data for analysis and action.
If you need a highly intelligent and versatile tool for your plant floor. Look no further, at Yellotec we will be happy to assist you in your purchase and point you to the products that will suit your needs the best.
The SHAFTALIGN Touch
The new ShaftAlign Touch laser alignment system provides digital, cloud, and other advancements over the widely used dial indicator and feeler gauge of past decades. This tool masters virtually any alignment task on standard machines driven by rotating shafts. This laser shaft alignment tool has laser precision results, improving on those of conventional measurement equipment.
The SHAFTALIGN Touch tool also offers simple and quick setup, intuitive handling through a computer-based and guided user interface, and an insightful visualization of results on the bright coloured 3D rugged tablet-like display. This new laser alignment system can handle almost any standard machine alignment challenge due to its 3D rugged sensALIGN® 3 sensor and reflector. This tool has incredible problem-solving Adaptive Alignment features. This amazing tool offers an unbeatable price-performance ratio.
The SHAFTALIGN Touch has a user-friendly system that combines single-laser technology with Active Situational Intelligence to empower teams of varying experience levels to align any asset with new levels of precision and speed.
The benefits of using the SHAFTALIGN Touch are unmatched. This laser shaft alignment tool ensures that you achieve high performance and precise results. This is accomplished as the SHAFTALIGN Touch leverages single-laser technology to provide high-precision, high-performance alignment measurements. The SHAFTALIGN Touch also allows for quick setup with its intuitive user interface. This makes the SHAFTALIGN Touch tool more user-friendly than any of the conventional measurement methods. Data can be shared via the cloud. This means that you can use its integrated WiFi cloud solution to easily transfer measurement data from the SHAFTALIGN Touch handheld device to the ARC 4.0 software.
The SHAFTALIGN Touch tool features an integrated Thermal Growth Calculator. Industrial materials such as steel and alloy typically expand when heated up. Only a few degrees are enough to impact the machine’s behaviour when running compared to the usual cold condition when alignment measurements are taken. The Thermal Growth Calculator automatically factors the expected deviation into the measurement result.
The SHAFTALIGN Touch tool is user-friendly and easy to transport. If this sounds like the device you need, speak to one of our Yellotec sales consultants and they will be more than happy to provide you with some more information.
The ROTALIGN Touch EX
Last but not least, the ROTALIGN Touch EX tool is the only adaptive laser shaft alignment system for EX areas. The ROTALIGN Touch EX reaches machines and systems in potentially explosive areas that are not accessible with normal devices as it is ATEX /IECEx zone 1 certified.
Hazardous work areas, such as oil refineries, utility gas plants, plastic plants, and more, have their fair share of machinery alignment challenges. This is because these environments have a high potential for explosion due to flammable gases, ignitable fibres, or high-voltage electrical equipment, making these areas are highly regulated. The ROTALIGN Touch EX tool is an advanced, high-precision laser alignment system that is intrinsically safe. That means it is certified (by ATEX/IECEx Zone 1) for safe use in hazardous areas. It also can be used without obtaining a hot work permit.
This powerful laser shaft alignment tool adapts to the asset and alignment situation, even in extreme environments. It also adapts to the user’s experience and skill level. With its rugged exterior, the ROTALIGN Touch EX can withstand the harshest of conditions. This tool is waterproof and dustproof (IP68), oil-proof and waterproof (IP65), dirt-resistant, scratch-resistant, and impact-resistant. The touchscreen is also suitable for gloves, making it easy to use in hazardous work areas.
The key benefits of the ROTALIGN Touch Ex tool are that it is ATEX/IECEx Zone 1 certified. This means that it is safe to use in explosive atmospheres where there is a mixture of air or flammable substances, in the form of gas, vapours, and mists, which is likely to occur during normal operation. The ROTALIGN Touch EX tool saves you time and effort. This rugged tool has a guided user interface that fully adapts to your needs. It also has coloured displays with real 3D machine models. The tablet-like navigation allows you to have full control of your measurements. This tool also ensures measurement accuracy and repeatability. With single-laser technology and sensALIGN® 5 EX, the ROTALIGN Touch EX has high precision and can adjust to any situation or asset.
If you need a laser shaft alignment tool that is intrinsically safe and safe for hazardous work areas, the ROTALIGN Touch EX tool is the perfect fit for you. At Yellotec we will gladly assist you in your purchase if you are interested in the ROTALIGN Touch EX.
Final Thoughts:
Pruftechnik is a global company that offers innovative solutions to their customers in machine alignment, condition monitoring and non-destructive testing. We love Pruftechnik because they include intelligent and precise measurement and testing systems in all their laser shaft alignment tools. Their laser shaft alignment tools are also set to global standards for the maintenance of rotating equipment and quality assurance. With Pruftechnik’s goal being “to offer our customers the perfect solution, anywhere in the world.” You won’t be sorry for choosing a Pruftechnik laser shaft alignment tool, we, at Yellotec, trust Pruftechnik and their precision on measurements.
At Yellotec we take pride in the products that we sell and want our customers to get the very best! If you would like to know more about Pruftechnik’s laser shaft alignment tools, contact our team today and we will get back to you as soon as possible.
For more information about any of the products that we have spoken about, other Priftechnik products that we offer or just want to know more about Yellotec, you can contact us either by visiting us, emailing us, calling us. Or filling out the form and someone from our technical sales team will give you a call to see how we can best assist you.
In this article, we will be comparing the difference between online and portable tools for vibration analysis.
Vibration analysis
Equipment vibration/motion reveal tell-tale indications of machine/equipment health. Vibration analysis is performed on the data which is captured from equipment through the conversion of this mechanical motion into digital signals that can be post-processed.
These signals are then evaluated against known failure metrics, which help predict potential failures and make it a useful tool for planned condition-based maintenance, increasing equipment safety, life cycle, reliability, increased productivity, improved return on investment and preventing unscheduled downtime.
Vibration analysis tools have grown from large bulky machines to lightweight handheld devices and cost-effective continuous monitoring instruments. Continuous monitoring instruments have even joined the Internet of Things (IoT) galaxy.
It’s not a secret that vibration analysis is essential and will reduce your company’s expenses regarding machine failure and unplanned stoppages and breakdowns. There are many devices to choose from, and this can be overwhelming at first, but we will be discussing the various vibration analysis instruments and what will be the best fit for your plant and budget.
Online vs Offline – Either or both?
It is rare that all machines on a site are suited only to online or offline monitoring, usually a combination of both disciplines provides the optimal solution. In most FMEA analyses or similar processes there are five important factors to consider when determining which method and system are better suited for your business:
Safety
Production Loss
Capital Costs
Spares availability / Lead time to repair
Redundancy
Online
Handheld
Safety
✓✓
✓
Production Loss
✓✓
✓
Capital Cost
✓✓
✓✓
Spares availability
✓✓
✓✓
Redundancy
✓
✓✓
These are very broad guidelines and will vary from plant to plant, and machine to machine. The best practice before deciding is to have the site Reliability/Risk Engineers evaluate Possible Maximum Loss for each machine (using unplanned failure and planned shutdowns after fault detection models), usually referred to as an FMEA Analysis. This exercise will also offer a great benefit after the systems have been implemented, as the cost analysis for prevented failures will be available for ongoing evaluation for the return on investment (ROI) of the condition monitoring project.
Portable Vibration Analysis Instruments
Portable vibration analysis instruments as the name implies are mobile digital signal analysers that can collect vibratory motion from a transducer that is connected to the machine either permanently (according to safety or environmental considerations) or temporary via studs, quick connects or magnet mounts. These devices enable users to collect data by measuring many points on one machine with one sensor. Portable devices are a lower-cost solution that has the added benefit of a technician making visual observations of an asset’s condition during collection. Portable devices are handheld and ensure that technicians can walk around and assess their machinery as and when needed.
They are generally used for less critical or semi-critical assets where periodic scanning is effective to detect changes in the machine condition, and interventions with the machine can be planned/executed to improve conditions detected. Yellotec has clients where overall plant uptime/reliability of machines on this system was permanently increased from 85% to 99.5% within the first 12 months after implementation.
What Portable Vibration Analysis Instruments does Yellotec offer?
At Yellotec we supply a variety of portable instruments with various functions and benefits that will be accommodating to either the expert or to the beginner. We supply the VibScanner II and the VibXpert series from Prüftechnik. Combined with the Omnitrend Analysis Software for analysis of online and offline data.
VibScanner II
The VibScanner II is a portable offline data collection system, having comprehensive measuring functions from either single-axis or triaxial transducers. This handheld all-rounder is the ideal partner for your daily measurement and inspection rounds, if the triaxial option is used it also speeds up data collection by reducing the time spent at the machine by capturing data in three directions of freedom simultaneously.
The VibScanner II is protected by a rugged, waterproof, and dustproof case. You are also able to order the Zone 2 version of this instrument.
If the VibScanner II doesn’t sound like a portable instrument for you, it’s time to look at the VibXpert instrument series.
VibXpert II
The VibXpert II is a high-performance vibration data collector and signal analyser. It is known for its sophisticated and refined technology. The VibXpert II combines the proven features of its predecessor with the advantages of rapid processors and a brilliant energy-efficient colour display. This portable instrument demonstrates that the use of powerful components does not rule out low power consumption.
The VibXpert II allows easy condition monitoring of equipment found in many industries such as power generation, petrochemical, pulp and paper. The VibXpert II collects field data including the ability to perform extensive analysis functions. Facilitating data analysis and condition diagnostics at the machine. For in-depth analysis, archiving and documentation VibXpert II passes the collected information to the Omnitrend maintenance software.
These portable instruments are great if you need a device that is easy to use, for daily vibration analysis and for machinery that does not need to be monitored 24/7.
The instrument is available in single or dual-channel configuration, as a Data collector or Data Analyser with the added option of including a balancing program
Yellotec also sells Ex versions of these instruments. These specific instruments are intrinsically safe and allow for easy condition monitoring and troubleshooting of rotating equipment in explosive environments such as petrochemical plants, refineries, offshore oil rigs, etc.
Online Vibration Analysis Instruments
Online vibration analysis utilizes a system of permanently mounted sensors to enable the recording of vibration measurements without human intervention. Online monitoring could consist of more than just vibration sensors, especially because there are many different failure modes, and it is best to utilize a variety of sensor types to monitor the necessary variables to ensure that early signs of wear and tear or failure are noted.
Online monitoring systems can be wired, or wireless. With recent advances in battery and wireless transmission technology, wireless online monitoring of machine conditions has become easier, less costly, and technologically advanced as compared to traditional wired solutions.
There are two main types of online vibration monitoring: protection systems and continuous monitoring. Protection systems are typically wired solutions with permanently mounted sensors used to protect equipment. Protection systems adhere to the API (American Petroleum Institute) 670 industry standard.
Continuous monitoring vibration analysis systems are vibration surveillance systems that are gaining popularity as the cost of these technologies continues to decline. These systems have also traditionally been wired but with new advances in technology, they are quickly adopting a variety of wireless options. Continuous monitoring vibration systems are not API protection systems, they are, however, very well suited for most rotating mechanical equipment and enhance your ability to diagnose machine health and warn of changing conditions remotely 24/7.
What Online Vibration Analysis Instruments does Yelltoec offer?
At Yellotec, we sell various online instruments that will be well-suited to any type of customer. The VibGuard platform is an easily scalable solution for various applications.
The VibGuard is a condition monitoring system that not only monitors your machine’s health but also provides production security and improves the efficiency of your assets. The VibGuard allows critical machines with highly dynamic processes and complex monitoring tasks to be included in a reliability-oriented maintenance schedule.
There are many great features that this online vibration analysis instrument has, it is safe, modular, autonomous, and flexible. Omnitrend Centre is the perfect companion for the configuration of measurement channels, data analysis and reporting. A clear structure makes it very easy to use and provides a working environment where the user feels at home immediately. Advanced functions and the perfectly tailored user interface fulfil even the highest requirements.
VibGuard forms an integral part of the PRÜFTECHNIK condition monitoring concept which consists of handheld instruments and online monitoring systems. This allows the optimum monitoring solution that meets budgetary and technical requirements to be realized for each plant.
Choosing Online or Portable?
When it comes to choosing the correct instrument for you, there are many features that need to be considered. When choosing between portable and online, you really need to think of which instrument will be best for you and your situation. If you have a few machines that need to be constantly monitored, then online instruments will be the right fit for you.
When choosing between portable and online, you really need to think of which instrument will be best for you and your situation.
If you have one or two small machines that need to be monitored every few days, then a portable device will be great for you. Portable devices are perfect for daily use.
For more about Online & Portable Vibration Analysis Instruments
We know this process can be overwhelming but at Yellotec we strive to give our customers the best and our competent sales team will walk through this process with you and give their expert opinion and advice on which device will suit you and your needs.
If you are looking for any more information on any of our products, please don’t hesitate to contact us today.
In this article, we will be taking a deeper look at our three favourite products for August. The products that we will discuss are the FLIR A400/A700 Smart Sensor, the Midas Ferrous Quantifier and the Ultraprobe® 15,000 Touch.
FLIR A400/A700 Smart Sensor
Is your company looking for a head start with a camera that offers unmatched power and flexibility? Then here is your answer!
The ROTALIGN Touch was designed by some of the world’s leading alignment experts to solve problems in the easiest way possible. This Pruftechnik tool is known to be the most adaptable laser shaft alignment tool. The ROTALIGN Touch combines high precision on-site measuring tasks and cloud connectivity for worldwide data access and transfer. With the sensALIGN® 7, the ROTALIGN Touch uses laser and sensor heads that offer a full range of everyday alignment routines, up to expert degree alignment jobs, such as Cardan shaft alignment or aligning up to six sequential couplings in a row.
The FLIR A400/A700 Smart Sensor is a thermal camera that more than meets the eye, with the cutting-edge technology it allows for complex monitoring applications, including critical infrastructure, product quality, and early fire detection. This camera is a perfect fit for customers who prefer to have built-in analytic capabilities which allows them to transfer complete and actionable results to their very own systems.
Not only is the FLIR A400/A700 Smart Sensor easy to configure; it is easy to add and operate while enabling you to tailor the system to your company’s quality, productivity, maintenance, and safety needs.
This infrared thermography camera can be used in various environments and for various purposes. Types of monitoring include:
Used at checkpoints to screen for elevated skin temperatures.
Spotting temperature anomalies in production lines.
To watch for signs of failure in utility lines.
Sound an alarm when heat build-up could spark a fire.
Monitoring machinery over time for signs of wear.
If you need a camera that can help your company to protect its assets, improve safety, maximize uptime, and minimize maintenance costs, then the FLIR A400/A700 Smart Sensor is the advanced thermal camera you need!
We, at Yellotec, are passionate about our products and want to ensure that we supply the best brands with the best quality. The FLIR A400/A700 Smart Sensor is an innovative infrared thermography camera that is easy to configure and use, making it a dream for any customer.
Midas Ferrous Quantifier
The Midas Ferrous Quantifier is another great product that should not be overlooked. This lightweight, robust, and portable product is essential in many businesses and can be used in oil analysis labs, transportation, manufacturing, aerospace, oil refineries and many more.
What makes this oil analysis device unique is its outstanding sensitivity to detect ferrous debris in any oil sample, making it the perfect device to complement any on-side or oil analysis laboratory. As machine preventative measures go, this is one of the best devices to use. Frequent metal analysis of machine lubricants will provide you with early warning signs of impending faults and will provide insights to determine whether your equipment is operating normally or if additional analyses are required.
The Midas Ferrous Quantifier is well-known for its accuracy and easy-to-use solution for offline and at-line measurements of ferrous wear debris concentrations. What we love the most about this product is that it provides exceptional sensitivity to emerging problems and can often detect problems well in advance of vibration analysis, thermography, or other indirect monitoring methods.
Whether you are in mining, manufacturing, automation or plant maintenance, this product will not disappoint. At Yellotec we believe that being proactive is better than being reactive and with this device, you will prevent machine failure and reduce unexpected expenses. Oil analysis is a crucial component in machine health and is a key predictor of catastrophic failure. Read more about the Midas Ferrous Quantifier
Ultraprobe® 15,000 Touch
Last but not least, the Ultraprobe 15 000 Touch is an ultrasonic condition monitoring laboratory that fits in the palm of your hand! This advanced and futuristic device is a super detection system that combines state-of-the-art technology to meet every plant inspection requirement needed.
This condition monitoring device can be used to perform on-board spectral analysis, record the sounds of test equipment, measure, and record temperature, take photographs with flash as well as storing and managing data.
The Ultraprobe 15 000’s unique touch screen feature uses icons to easily control and manoeuvre around any of the Ultraprobe’s display screens. Touching the screen allows you to be able to view decibel level, temperature, control sensitivity, change frequency, view an FFT and record sounds and images.
With this device, you will be amazed at how quickly your inspection capabilities will improve. This ultrasonic condition monitoring laboratory will help to increase your asset availability throughout your plant while reducing energy waste. The reports that will be generated from the Ultraprobe 15 000 will also help management to understand the importance of improving your company’s profitability with your ultrasonic condition monitoring program.
We love this sophisticated device as it is the most efficient ultrasound data collection, inspection & analysis instrument available today. You can now test the way you want to test with all the features you need for accurate results. With the Ultraprobe 15 000, you can now truly read the future and report it.
Final Thoughts:
We hope you found this article helpful and informative. We, at Yellotec, are proud of our products and we are happy to have shared our three favourite products of August with you. You can trust Yellotec to supply you with the best products, whether it is automation, oil analysis, infrared thermography, ultrasound, or condition monitoring.
If you are interested in any of these products and want more information. You can visit us, call us, email us or let us contact you by sending us an enquiry.
When it comes to the purchasing of any product, we often tend to focus on three major aspects; quality, cost and usability.
However, when it comes to purchasing a thermal camera, there are a few more things we need to take into account before we make our decision.
Factors to consider when choosing your next thermal camera
To do this, we have put together a list of 6 factors to consider when purchasing your next thermal camera.
Factor 1: A thermal camera that fits your needs.
As the first factor, we thought we would start with the most important one. Purchasing one that fits your needs. Having a thermal camera is an important tool for a wide variety of tasks such as machine condition monitoring and plant safety and monitoring. This is why it is important to fully understand your needs for the thermal imaging camera.
Here are some questions to ask when picking your next thermal camera
1. What areas am I trying to monitor?
2. Does it need to be fixed or portable?
3. Do I need easy access to the images on hand?
Once the questions have been asked, it is easier to identify the thermal imaging camera that best suits your needs.
Factor 2: A Thermal Camera with Easy Access to Data
There is nothing worse than collecting data and not being able to access it easily and painlessly. That is why we recommend choosing a camera that not only allows you to access your images easily but also saves them easily as well.
We even suggest looking at one with Wifi capabilities with access to software that all images are directly uploaded to. Looking for more information. The Yellotec team would be more than happy to help answer your questions and give you the best advice.
Factor 3: The Battery Life & Type of Recharging
Once you have an understanding of your thermal image needs, it would give you an idea of the type of battery that you would need. This will determine the type of camera to look for.
When considering a camera based on battery type & life, these are some of the qualities to look at.
Time: How long does the battery last and how long does it take to charge?
How easy is it to charge? Is it a removable battery or a charging cable that goes straight into the camera? Which would be a good option when looking at a camera that will need to be fixed.
Is battery replacement easy? If needed. Could the battery be replaced easily and accessible or would it have to be taken to a specialist and have to be opened to replace the battery?
Does a battery icon show? There is nothing more frustrating than going to work and having to stop because the camera turned off due to a flat battery because there was no way to identify if the battery was fully charged.
Factor 4: The Specs of the Thermal Camera.
When deciding on a Thermal Imaging Camera, it is important to look at the capabilities of the camera. But sometimes this can be a bit overwhelming when we aren’t quite sure what to look for. This is why we have given a little breakdown of some of the capabilities that can be focused on when choosing your right camera.
Range: When selecting a camera, we suggest looking at one with a controllable temperature range, perhaps one that automatically selects the range based on your scene. Being able to control the temperature range is a great way to monitor when something is not quite right.
Resolution: Having a camera with the best detail and image quality that suits your needs is important. And having a camera with a strong resolution is beneficial to this. This Resolution is made of pixels which are little blocks that are used to make an image. The higher the pixels, the higher the quality of the image.
Focus: This is a specification that will vary on your needs. When looking at the focus, you have three options. Fixed: This means that we won’t have to make adjustments to obtain the focus. Manual: Where the user adjust the focus of the camera Auto-focus: Which focuses automatically based on what it can see for contrast on the scene.
Colour Palette: Having a Thermal Image Camera with multiple Palettes is highly beneficial for monitoring and finding obvious anomalies. This is why it should be easy to change the palettes either on the camera or on the software.
Field of View: Field of View determines the extent of a scene seen by the camera at any given moment. For work being done close-up, you need a lens with a wide-angle FOV (45° or higher). For long-distance work, you need a telephoto lens (12° or 6°). Some cameras may be available with multiple lenses for different applications.
Factor 5: Technical Support & Training
And lastly, when choosing a Thermal Imaging Camera, it is so important to purchase from a reputable manufacturer or supplier who has a post-sale customer support service as well as training for when those moments occur where you just cannot get it to monitor exactly how you want.
Or when a production error occurs, which does happen, and you can contact the manufacturer and the problem can be rectified.
Wrapping it up.
We hope that you found this article about what you need to consider when choosing a thermal imaging camera helpful and informative. If you need to know any more information about thermal cameras, or you are still unsure which one to choose from. Why not give the yellotec team a shout and we will assist you in any way we can.
Yellotec strives to offer the most effective and efficient technology in all machine health and reliability monitoring equipment. As well as providing services and training that help plant and equipment managers to predict all failures as well as prevent major failures in the future.
Ideal for Quickly Detecting Elevated Skin Temperature
The IR200 is ideal for quickly screening individuals for elevated skin temperature. This infrared thermometer has a non-contact design that eliminates the need for replacement probe covers and other supplies. The IR200 is accurate to 0.5°F (0.3°C) with 0.1°F/°C resolution when measuring skin temperatures between 89.6°F to 108.5°F (32.0°C to 42.5°C).
Features
Measures skin temperature from 89.6 to 108.5°F (32.0 to 42.5°C) without contact
Accurate to 0.5°F (0.3°C) with 0.1°F/°C resolution; fast response (0.5 seconds)
Optimum measurement distance of 1.9 to 5.9 in (5 to 15 cm)
Non-contact design eliminates need for replacement supplies
Adjustable alarm alerts user visually and audibly when temperature exceeds programmed limit
Memory stores up to 32 readings for easy recall
Large backlit LCD display
Complete with 2 AA batteries and pouch
Note: This thermometer is intended for screening individuals or monitoring an individual for potential elevated skin temperatures. It is not a substitute for a clinical thermometer. Always use a clinical thermometer when high accuracy body temperature measurements are required.https://youtu.be/dKMUHfLv84g
So far in the Oil Lab Series, we have covered the benefits of an on-site oil analysis laboratory, what your investment (and return thereof) could be, all the factors you need to keep in mind when building your lab, as well as Yellotec’s recommended 3 Phased Approach to set up your on-site lab.
In our last article of this series we will be looking at a case study of how an on-site laboratory and regular routine used oil analysis enabled a company to avoid a major costly failure.
During routine used oil analysis conducted at an on site laboratory situated on an opencast mine, the lab picked up an anomaly from a dump truck engine used on the mine. The lab observed an abnormal condition whereby the sodium increased and copper wear was observed within the oil samples over time.
If this anomaly was never detected, and the dump truck engine failed because of it, the cost to rebuild the whole engine would easily have been estimated to be R 5.4 million. Luckily, early detection of the fault condition, and subsequent intervention of the maintenance department, brought the actual cost to repair the failed cylinder liner down to R63 000.
Because of the company’s ability to take daily samples and perform immediate analysis in their on-site lab, they were able to observe the results of an oil change on the health of the machine, as well as effectively take remedial action when the liner was replaced. Clearly in this case, the on-site lab’s prompt response enabled this company to save millions.
Sample data:
Report examples showcasing progression and criticality of fault.
Thank you for following the Oil Lab Series. We hope it helped to provide you with a better understanding of the benefits and possibilities of setting up your on-site oil analysis laboratory.
Don’t hesitate to contact our Specialist Oil Lubrication team for more information.
Previously in the Oil Lab Series we looked at tips to design your lab, specifically looking at your physical space as well as safety concerns. In this article we are expanding on your testing needs.
The below diagram breaks down the most important instruments, as well as the test that they perform.
At Yellotec, we recommend using a 3 phased approach to build and grow your laboratory. These 3 phases will allow you to set up your onsite lab whilst maximising your available budgets, as well as allowing you to expand your test slate without needing to replace instruments to upgrade. Here are the 3 phases:
Phase 1
Oil Shaker
Blotterspot
Wear debris with Filtergram analysis
Crackle test
Ferrous Quantifier
This phase will enable you to do basic “Go Nogo” tests onsite to identify immediate problems that can be fixed before severe damage occurs to the lubricated machine.
Phase 2
Reporting Software
FTIR
Viscometer
After this phase you will be able to analyse your samples in more depth, such as measuring the viscosity and chemical compounds found in the oil. The LIMS software allows you to collect test data in a organised database from which reports can be generated.
Phase 3
Spectrometer
Karl Fischer
Refractrometer
PH meter
Flash Point Tester
Talk to our expert Oil Lubrication team at Yellotec if you need any guidance with your Oil Analysis testing needs, as well as how you can use the 3 Phased Approach to expand your laboratory capabilities.
