Energy from Waste
Enhanced predictive maintenance and planning capabilities.
Vibration Assessment and Management System (VAMS)
Implementation of REV’s Vibration Assessment and Management System.
Vibration condition monitoring and data management in a modern waste recovery park conjures up images of pages and pages of datasheets, with hundreds of measurement locations and millions of data points.
This project aims to prove that the whole process can be simplified and operated as a practical, cost effective solution without overcomplicating or overprotecting machinery, whilst ensuring the plant is maintained in an effective manner. Moreover, using the strategies and methodologies adopted; including targeted vibration monitoring, high resolution data analysis and concise data management techniques ensures lengthy and expensive breakdowns are minimised.
We have developed a standalone Vibration Assessment and Management System (VAMS) which can be utilised by our clientsto assist site operation and maintenance teams with advanced techniques of plant failure methodologies. One of our clients requested the implementation of the VAMS system across their Energy from Waste site, including Advanced Thermal Treatment, Anaerobic Digestor and Material Handling plants. The system had to be implemented and used by site operations and maintenance teams, to enhance maintenance capabilities, fault investigation and reduced downtime.
We performed an extensive baseline survey, gathering data and information on all rotating plant across the site, including each items control philosophy, normal operation conditions and whether the asset utilised a variable speed drive.
Once the information had been collated, we populated the site database, identifying the specific locations for measurement on each asset and designating an area route for the operator to follow therefore simplifying the measurement process.
Using the newly created database our engineers conducted tri-axial measurements and created base readings for each of the assets on several different occasions, identifying any areas for concern and highlighting these to our client. The baseline data capture allows for comparison of future recorded data, enabling the operator to identify any irregularities in the readings.
All measurements are recorded within our customized database and verified in accordance with ISO 10816-3. The initial baseline measurements incorporated a significant amount of data, which had up to thirteen graphs per measurement location, including ISO spectra, g-spectra, separate spectra for displacement, unbalance, misalignment and looseness, time waveform, trend line for ISO, Bearing Damage Units (BDU) and g.
As measurements are required to be taken on a live site, we had to investigate each asset relative to barriers and safety requirements. In situations where conveyors were present we designed the system to reduce human interaction with the asset, preventing unnecessary safety risks.
Training was provided for all operations and maintenance staff, consisting of both classroom and on-site modules. This training ensured that our client’s personnel were competent to use the system and understand what the measurements meant.
Within two weeks of utilising the VAMS, our client identified an unusual bearing reading on a critical asset.
Upon further investigation we confirmed that the unit was experiencing higher levels of vibration than previously found. From the measurements taken we identified the likely cause of the increase in vibration was a crack occurring on the inner race of the Drive End Bearing. We sourced a new bearing for the unit and had it available for repair later that day.
Once stripped down, it was confirmed that that the Drive End Bearing had indeed developed a small crack as suggested. We replaced the bearing and had the unit back in operation the same day.
Utilisation of the VAMS allowed for a potential failure to be identified before the situation became critical. It allowed for effective maintenance planning, with the correct parts being available when required and ensured that maintenance activities could be conducted at a point that would not be detrimental to the safe operation of the plant, as well as ensuring minimal commercial impact.