PROFITABLE CONDITION MONITORING

Transcription

1 PROFITABLE CONDITION MONITORING

2 Profitable Condition Monitorin g edited by B. K. N. RAO * SPRINGER SCIENCE+BUSINESS MEDIA, B.V.

3 ISBN DOI / ISBN (ebook) Front cover courtesy of K. F. Martin, University of Wales, UK. All Rights Reserved 1993 Springer Science+Business Media Dordrecht Originally published by Kluwer Academic Publishers in 1993 No part of the material protected by this copyright notice may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without written permission from the copyright owner. Produced by Technical Communications (Publishing) Ltd., Letch worth, England.

4 This volume consists of papers presented at the 4th International Conference on Profitable Condition Monitoring, 8-10 December 1992 in Stratford-upon Avon, UK, organised by BHR Group Ltd. Technical Advisory Committee Prof B K N Rao (Chairman) Mr J Hickman Mr I Hunt Mr M Jones Mr D Miller Dr R Milne Southampton Institute Bruel & Kjaer Fulmer Systems Research University College of Swansea BHR Group Ltd Intelligent Applications Ltd International Corresponding Members Prof Dr-Ing D Barschdorff Germany Mr J Fitch Mr B Kuhnell Mr 0 K Kwon Mr N Myshkin Russia Prof Dr-Ing habil A Sturm Mr T J Walter Un i versi tatgesamthochschulepaderbom, Diagnetics Inc, USA Monash University, Australia Korea Advanced Institute of Science and Technology, Korea Byelorrussian SSR Academy of Sciences, Technische Hochschule Zittau, Germany Shaker Research Division, USA Organised and sponsored by BHR Group Ltd Co-sponsored by: The Institution of Mechanical Engineers The Institution of Chemical Engineers The British Computer Society The Institute of Measurement and Control Comadem International Ltd

5 CONTENTS FOREWORD KEYNOTE ADDRESS The role of expert systems in condition monitoring R Milne, Intelligent Applicarions Ltd, UK PROFITABLE CONDITION MONITORING Implementing a cost effective machinery condition monitoring program P Shrieve, ATL Condition Monitoring Division, UK Interpreting contaminant analysis trends into a proactive and predictive maintenance strategy j C Fitch, H j Borden, DiaKnerics Inc, USA The effective integration of condition based maintenance into profit orientated business management S Trevenna, Vosper Thornycroft (UK) Lrd, UK Profitable condition monitoring and diagnostic engineering management B K N Roo, Comadem InterniJIional and Southampron Institute, UK CONDmON MONITORING THROUGH PERFORMANCE EVALUATION On-line diagnostic expert system for gas turbines R Milne, Intelligent Applications Lrd, UK Performance monitoring system for centrifugal compressors on Heimdal gas field o johansen, Elf Petroleum Norge AIS, Norway Energy saving in pumping in the UK water industry M A Yates, AEMS Ltd; A Willey, Yorkshire Water Services Ltd, UK Condition monitoring and fault diagnosis with applications to machine tool subsystems K F Martin, University of Wales, UK The deterministic chaos method application for a condition monitoring system M Pisljar, B Simk, Turboinsrirur Ljubljana, Slovenija

6 INDUSTRJAL CASE STUDIES ON CONDITION MONITORING The development of condition monitoring within the chemicals division of SmithKline Beecham G J Flavelle, SmithKline Beecham Pharmaceuticals, UK Efficient power generation through predictive maintenance R A Thomas, C Davies, Hyconrrol Technology LId, UK A new way of life J D Mil/ns, Scunthorpe Rod Mill, UK Application of knowledge-based machinery diagnostic system in an Indian cement industry A Mathur, Larsen & Toubro Ltd, India HUMAN FACTORS APPROACH TO CONDITION MONITORING Vibration based predictive maintenance. The training requirement S Courtney, IRD Mechanalysis (UK) LId, UK The human pilot and the automated aeroplane A H Roscoe, MD, UK An engineer's view of human error T A Klerz, Process Safety COn.lulranr, UK Advanced methods of capturing and using maintenance data in the field T Gray, Tangenr Technology Design Associares LId, UK CONDmON MONITORING USING NEURAL NETWORKS Neural networks - theory and practice C Sheppard, EDS-Scicon, UK Neural network solution to coolant system diagnostics K F Martin, M H Marzi, University of" Wales, UK

7 VIBRATION CONDITION MONITORING Bearings - condition monitoring, condition measurement and condition control G A W Se(ford, SPM Instrumenr UK Ltd, UK Alternative methods of diagnosing gear box faults M N M Radi, D J Dell, A Fellows, University of Her(fordshire, UK The development of a data collector for low-speed machinery T J Murphy, TEC Europe, UK Condition and trend monitoring of rotating machines V Kamala, Bharat Heavy Electricals Ltd, India CONDITION MONITORING OF FLUIDS IN MACHINERY Profitable condition monitoring: the role for contamination control M H Jones, A R Massoudi, University of Wales, UK The rise and fall, and rise again, of wear debris monitoring T M Hunt, Consulting Engineer, UK The measurement of wear debris quantity in mechanical machinery E A Gooding, A R Massoudi, M H Jones, B J Roylance, University of Wales, UK

8 FOREWORD To engineer and manufacture is human. Manufactured goods are subjected to severe international competitive forces. Consumers' perceptions towards total quality, reliable performance, health and safety, environmental issues, energy conservation and cost of ownership are changing day by day. Manufacturers have no alternative but to satisfy the consumer's increasing demands with maximum efficiency and profitability with minimum delay. Failure to meet such a challenge is clearly undesirable and will, no doubt, result in the closure of manufacturing activities, which is still regarded by many as the backbone of our national economy. Manufacturing for profitability should be the number one concern of all serious minded and responsible people. To help the industries to meet these challenges and to manage efficiently well into 1990s and beyond, the Technical Advisory Committee in their wisdom decided the appropriate theme, Profitable Condition Monitoring, for this year's International Conference, to coincide with the great European market to be opened in The benefits from condition monitoring are well documented. Condition monitoring is now an affordable technology which is waiting to be fully exploited by all sectors of industry, both big and small. Many companies have realised the following benefits from condition monitoring: optimisation of profits maximisation of production cost-effective maintenance minimisation of product liability maximisation of total quality. As the contents of this proceedings reveal, there have been a number of significant advances in condition monitoring of which companies ought to be taking full advantage. The scope of the Conference proceedings cover the latest in the field of condition monitoring technology including: profitable condition monitoring condition monitoring through performance evaluation condition monitoring of fluids in machinery industrial case studies on condition monitoring condition monitoring using neural networks vibration condition monitoring human factors approach to condition monitoring.

9 A broad geographical scope is also reflected by the authorship of excellent papers contained in this proceedings, who come from diverse regions of the world, but are united by a common interest in condition monitoring technology and a common desire to playa vital part in making our industry more efficient, profitable and our life worth living. On behalf of the Technical Advisory Committee, I would like to thank all the authors who were keen to share their experiences and expertise by providing their papers. The valuable assistance of the members of the Technical Advisory Committee, the International Corresponding Members, and the members of the panel of referees is gratefully acknowledged. Thanks are also due to Carl Welch and Tracey Peters of BHR Group for their invaluable co-operation throughout the event. Eur Ing Professor B K N Rao October 1992