PCMS Engineering Prediction. Prevention. Profit. www.pcmseng.co.uk
Services Overview Whatever the scale of project, we can provide a solution and work with your organisation to integrate tools, techniques and technologies to increase business productivity and efficiency. Take the first step to making PCMS Engineering your chosen reliability partner by contacting us on +44(0)1709 876712 or email us at info@pcmseng.co.uk Part of the PCMS Eng Group About us Maximising machine productivity, reducing unscheduled downtime and preventing equipment failures are critical in every industry. Unreliable equipment can lead to lost production time, expensive repair costs and compromise safety. We understand that every business is different. That s why our condition based maintenance programmes are tailored to your exact requirements and aim to deliver a maximum return on your investment whatever your budget. What sets us apart from the competition is our commitment to delivering exceptional results. Our expertise, track record and heritage ensures that we deliver a first-class service to our clients by having a clear understanding of their requirements. At PCMS Engineering, our unique portfolio of services, products and training are designed to save you money and confront even the toughest maintenance challenges, keeping your critical assets operating efficiently, effectively and safely. From condition monitoring technologies designed to keep key equipment operating, to training packages aimed at improving the skills of your workforce, we can deliver a complete portfolio of intelligent maintenance solutions all in one place. Since 2003, we have implemented cost-effective maintenance strategies for organisations of all sizes across every major industry sector. Many of our customers have become long-term partners and trust us to deliver the best possible solution. CORPORATE MEMBER 2 Your Challenges. Our Solutions. Extraordinary Results. Services Training We offer a range of services, advanced maintenance technologies and asset management solutions specific to your requirements. We are an approved training organisation (ATO) for the British Institute of Non-Destructive Testing (BINDT) and provide courses and training in a range of subjects. These technologies include vibration analysis, oil analysis, laser alignment, thermography, remote data analysis, ultrasonic inspections, energy surveys and factory exit approvals. These subjects include condition monitoring, vibration analysis (BINDT Accredited), thermography, lubrication management, laser alignment, dynamic balancing, enveloping and stress wave. Products Consultancy We supply, commission and repair a range of condition monitoring products to help organisations work more effectively and efficiently. We use recognised industry best practice standards to assess, design and implement continuous improvement strategies to achieve maximum equipment reliability. We are an official distributor for leading condition monitoring manufacturers such as Emerson, Gill Sensors & Controls, Ronds, IFM, Fluke, Hammer Laser, Hansford Sensors and SDT Ultrasound. Our consultancy services include integrated work management, asset management, condition based maintenance, equipment reliability services, criticality assessments and maintenance optimisation. www.pcmseng.co.uk/services 3
Condition Based Maintenance (CBM) At PCMS Engineering, we have the expertise and resources required to implement cost-effective CBM programmes that help organisations of all sizes move from reactive maintenance to predictive maintenance by using a combination of tools, products and technologies. What is CBM? Condition based maintenance (CBM) is a maintenance strategy which, simply put, measures operational parameters in assets to determine a change in their condition, performing maintenance only when the need arises. By using instrumentation to monitor equipment performance in real time, maintenance personnel can identify an adverse change in one or more operational parameters and trigger corrective action to ensure ongoing performance preventing in-service failure. Similar to an overall health check at the doctors to detect any underlying issues that might arise with age, or regularly maintaining your car to keep it running, CBM uses various process parameters (e.g. pressure, temperature, vibration, flow, noise, visual, thickness etc.) and material samples (e.g. oil, air etc.) to monitor conditions in machines. Engineers can then measure equipment health, performance, reliability and integrity to understand how machines perform, as well as predicting and preventing failures before they happen. How CBM Works The techniques used to monitor the performance of machinery or a component whilst in operation is known as condition monitoring. Condition monitoring techniques such as vibration analysis, ultrasonics, thermography and oil analysis can be used solely or in combination and are vital in making sure maintenance is only performed when absolutely necessary. Generally, condition monitoring techniques are used on a variety of assets such as pumps, electric motors, internal combustion engines, gearboxes, fans, electrical control panels, compressed air and hydraulic systems etc. The Value of CBM The main benefits of applying an effective CBM programme are that maintenance and repairs can be scheduled during non-peak times and machine productivity and service life are enhanced. Repair costs due to a loss of production time and secondary damage from failure are eliminated. Identifying Critical Assets The key to having a cost-effective and balanced CBM programme is to assess which machines have the most impact on operational/production if they fail. This is done by performing an asset criticality audit which addresses the safety, operational and environmental impact of temporary or permanent loss that a key asset would have on your business. The characteristics that make an asset valuable aren t always obvious, which is why it s important to rank assets based on the significance a failed asset has on your business. For example, a small motor gearbox with a replacement cost of a few hundred pounds, which can be sourced quickly, is not critical equipment that needs constant monitoring. In contrast, a motor gearbox that powers a major conveyor belt with a replacement cost of thousands of pounds, which could take weeks to source and halts your production line until it s repaired or replaced, is a critical piece of equipment that needs to be monitored around the clock. Implementing CBM The first phase in implementing a CBM programme is to identify your critical assets by conducting a CBM survey. Our reliability experts will discuss your maintenance requirements, identify critical assets and pinpoint maintenance resources to where they are needed most. If you are looking to increase productivity, lowers costs and improve the bottom line throughout your entire organisation, then contact us to discuss how we can implement an efficient and effective CBM strategy. Condition Monitoring Tools and Techniques Outsourced, hybrid and in-house condition based maintenance services. The following techniques can be used solely or in combination as part of a condition based maintenance (CBM) strategy to monitor the performance of machinery or a component whilst in operation. Vibration Analysis Oil Analysis Laser Alignment Vibration Analysis detects early problems in rotating machinery such as gearboxes, motors and diesel engines. We can perform one-off troubleshooting vibration analysis reports. Oil analysis is a proven technique for predicting a machine s condition by periodically gathering and analysing oil samples. Reduce maintenance costs and keep on top of your machine s condition by periodically gathering and analysing samples. Ultrasonic Detection Thermal Imaging Remote Analysis Leaking air lines, couplings, air tools hoses and other defective compressed air components can be major sources of energy loss. We identify and quantify costly leaks on compressed air and gas systems. We process over 50,000 oil samples each year in our in-house oil lab. Temperature is one of the most fundamental indictors to possible faults, defects or ineffiencies in a component or machine. Our visual, fact-based reports are written in plain English. We ensure asset longevity and reliability is achieved with high accuracy. Get the benefits of condition based maintenance directly to your facility/fleet regardless of size or location. Get full access to our expertise, diagnostic tools and services. 4 Preserving Your Investment. www.pcmseng.co.uk/services/condition-monitoring 5
Fast, Reliable Oil Analysis Service Oil Analysis is a proven technique for accurately predicting component wear and lubrication life in your machinery to determine its exact condition. It works by periodically gathering samples of lubricant oil and analysing the samples for characteristics such as contamination, chemical content and viscosity. Whatever your industry, regular oil analysis helps eliminate costly repairs by increasing the reliability and availability of your critical equipment. How it works 1 Oil samples are collected by our engineers or your maintenance staff and sent to our lab using our free postage service. 2 Our experienced lab technicians analyse your samples and perform requested oil analysis tests. 3 A lab analyst reviews your sampling data and details your oil samples cleanliness and provides recommendations. 4 Your oil sampling results, along with our recommendations, are uploaded to our online reporting platform. 5 An email notification is sent to notify you that your oil analysis results have been uploaded. 6 Any serious defect conditions discovered during analysis will be immediately notified to you by telephone. Our in-house oil laboratory is based in Rotherham, South Yorkshire. Trusted and Reliable Service 1-3 Working Days Turnaround Time Full Range of Test Types and Suites Free Web-Based Reporting Platform Over 50,000 oil samples analysed each year. Fast and accurate oil analysis service. Flexible test methods where required. 24/7 access to your oil sampling data. Our oil analysis laboratory complies with ISO 9001:2008 standards, meaning you are guaranteed a quality, consistent and certified service that is always striving for perfection. We aim to provide fast results in order for you to make time-critical decisions. From the minute your samples arrive at our laboratory, we make it our goal to process them within 1-3 working days. We understand that sometimes you require more than ASTM standard testing. That s why our testing types can be customised to better suit specific requirements. Our free online reporting platform is revolutionising the way oil analysis data is managed and evaluated, providing secure access to your data from anywhere at any time. 6 Fast. Efficient. Reliable. www.pcmseng.co.uk/services/oil-analysis 7
Why choose to work with PCMS Engineering? We have a proven success in working with organisations of all sizes to integrate tools, techniques and technologies to increase business productivity and efficiency. 1 2 3 4 5 6 Dedicated Oil Laboratory We analyse over 50,000 oil samples each year for a range of industrial clients and provide detailed reports via our unique web-based maintenance tool, OMEGA. 8 Trusted. Honest. Reliable. www.pcmseng.co.uk/about-us Complete Reliability Service We can support your organisation with everything from implementing condition based maintenance programmes to oneoff thermal imaging surveys. Expert knowledge Our reliability experts have over 30 years experience in developing strong maintenance strategies for organisations of all sizes across every major industry sector. Proven Success We have implemented successful condition based maintenance programmes for globally renowned companies such as TATA Steel, Sellafield Site Limited, London Midland and many more. Comprehensive Product Portfolio As an official distributor for leading condition monitoring manufacturers, we have access to the latest technologies and cutting-edge products. Long Term Customer Focus Our partnerships with our clients are built on trust, hard work and honesty. That s why our very first customer still uses our services today. Fast, Reliable Oil Analysis Service We analyse over 50,000 oil samples each year in our in-house oil laboratory and upload sample results to our free web-based reporting platform. 9
Achievements and Case Studies GulfMark GulfMark worked with PCMS Engineering to roll-out a condition based maintenance programme to ensure their maintenance strategy met their customers expectations. Condition Based Maintenance Programme Results in 295,000 Cost Avoidance GulfMark, a provider of marine transportation services, tasked PCMS Engineering with rolling out a condition based maintenance (CBM) programme throughout their fleet with the goal of improving their maintenance strategy and reducing maintenance costs. By implementing vibration and stresswave technologies, GulfMark staff were able to utilise the data, analysis and technical readings to make critical maintenance decisions on key assets to optimise maintenance actions, ensuring maximum asset availability. The Challenge Monitoring support bearings within tunnel thrusters is a complex task due to the difficult-to-access location of the thruster bearings. PCMS Engineers utilised multiple CBM technologies to determine the asset condition and remaining life-span, which is a key part of the PCMS service offering. The Solution By using vibration and stresswave technologies to determine transmitted vibration from the depths of the machine, PCMS Engineers were able to indicate activity relating to bearing deterioration. The ability to detect minute levels of vibration within a signature is due to the distance from the point of deterioration, which is a key benefit of stresswave technology. The correct application of technology enables Gulfmark to optimise its maintenance planning to avoid costly stoppages whilst offshore and means that the exact fault location can be pin-pointed, avoiding a complete dismantling and overhaul. The Results PCMS Engineers detected deterioration in the first support bearing on the input shaft to the thruster, which required consistent monitoring over a period of time to determine the rate of deterioration. The rate of change detected indicated that the bearing needed to be replaced. The bearing replacement and general inspection was completed during a port call with minimal interruption to the vessel s operations and, upon inspection, the poor condition of the input bearing was confirmed. PCMS Engineering provided a first-class service and implemented a successful condition based maintenance programme that saved us 295,000 in charter penalties. Jim Bradford, General Manager Operations Condition monitoring tools extends service life of train operator s fleet. Due to maintenance capacity and spares availability issues, a major train operator s vehicles were likely to be taken out of service due to a pending overhaul of axle bearings. In order to prevent this, PCMS Engineers were tasked with providing evidence that the vehicles were safe. By applying stresswave technology, PCMS detected a wealth of component data to predict when the axle bearings would fail. This resulted in the train operator extending the in-service life of their vehicles. Integrated work management underpins 15 million productivity improvements. Sellafield Ltd, a nuclear fuel reprocessing and nuclear decommissioning site in Cumbria, tasked PCMS to work alongside their central improvement teams to implement work management procedures to improve plant performance. PCMS implemented a consistent work management programme and developed a central coaching team, resulting in increased workforce utilisation, efficiency and productivity savings. Vibration analysis saves UK Coal 400,000 in lost production time. UK Coal Ltd was the largest coal mining business in the UK. PCMS carried out a vibration check on their shearing arm after noticing excessive noise and vibration emitting from the drive. PCMS provided analysis and guidance on the location of the fault, allowing engineers to carry out repairs. After collecting data using a CSI 2140, PCMS inspected components within the gearbox and detected light tooth surface damage in the gear wheels indicating the fault was likely to be a sub-surface defect. 10 Tested. Proven. Trusted. www.pcmseng.co.uk/case-studies 11
Get in Touch PCMS Engineering Unit 3a, Adwick Park, Manvers Rotherham South Yorkshire S63 5AB Phone +44(0)1709 876712 Email info@pcmseng.co.uk Web www.pcmseng.co.uk @PCMSeng PCMS Engineering /PCMSengineering