Conception RELIABILITY TECHNOLOGIES. Portable devices for thermography, vibration analysis, oil analysis, dynamic balancing, shaft alignment and induction heater for mounting rolling bearings. - презентация

1 2017 Strategic conception RELIABILITY TECHNOLOGIES

2 BALTECH DEPARTMENT of marketing and sales Department of marketing and regional sales Department of technical services Training center Supply Department of procurement and logistics Department of production and development of new technologies Department of engineers, electronics computer programmers BALTECH organization

3 Our strategy is developed based on the statistics

4 BALTECHs activities: Dynamic equipment (pumps, fans, compressors, gearboxes, motors, turbines and bearings) Production and delivery devices Training center (training for technical specialists) Technical service for industrial enterprises Repairing devices

5 Our new concept: Reliability technologies Our old concept: Reliable equipment:2010

6 QUALITY RELIABILITY VS

7 Terms relating to quality: quality degree to which a set of inherent characteristics fulfils requirements Requirements: needs or expectations that may be stated, generally implied or obligatory Reliability a collective term used to describe the availability performance and its influencing factors: reliability performance, maintainability performance and MRO (Maintenance, Repair & Overhaul) performance Quality management systems Fundamentals and vocabulary NOTE Reliability is used only for general description in non-quantitative terms. [IEC :1990]

8 Requirements to product suppliers Supply with training materials and regulations Personnel Training and Certification Technical Service Center Management and supply of Technical Diagnostics Audit of reliability control system Technical Audit of maintenance and repair system

9 Three key ideas, defining success of an enterprise: General idea about need of transformation (task description and selection of a solution). Aiming for introduction of new progressive technologies and state- of-the art equipment. Desire to support processes for introduction of new technologies and a qualitatively new culture of maintenance and a new work culture Understanding of need of transformation Introduction of new and progressive technologies Perfection of culture of work

10 Maintenance typesCharacteristics Reactive (reacting) maintenance (expenses $25 on 1kW per year) High probability of unplanned stops of the equipment and unexpected outages Scheduled-preventive maintenance (expenses $18 on 1kW per year) Planned and periodic carrying out of scheduled maintenance, drawing up and keeping of the graphic schedule Maintenance on actual technical condition (expenses $12 on 1kW per year) Maintenance of only defective equipment in combination with prevention of unplanned outages Pro-active maintenance (expenses $8 on 1kW per year) Prolongation of repair and check intervals Concept «Reliability technologies» A comprehensive and universal approach by equipment type

11 Maintenance tasks

12 Consept «Reliability Technologies» MAIN REASONS FOR EQUIPMENT BREAKDOWS Purchase of defective goods 30-50% - Equipment, bearings, tools, lubricant, ets Breaking of recommendations and norms for product transportation and storage 15-25% - Violation of requirements for storage facilities - Reconservation of stored production Operation by violation of technical specifications 5-70% - Vibration - Temperature - Lubricant parameters - Other parameters Low-quality maintenance 10-50% - There is no description of reliability tasks - Misaligning or residual imbalance - Repair without pullers or heaters Defects during assembling and dismounting 15-45% - Bearing misalignment - Improper bearing assembly and coupling mounting - Bearing overheating or overload - Fitting and foundation fitting

13 Consept «Reliability Technologies» MAIN REASONS FOR EQUIPMENT BREAKDOWS Natural wear 5-25% - Lubricant and oil degradation Defects of own production of spare parts 2-10% - Incoming and outgoing inspection Low personnel qualification 30-40% - Shortage of specialists Low production standards 70-90% - The social and production factors Reliability triad isn't applied 80-90% - Reliability level measurement, - Deep analysis of outage reasons, - Actions for reliability improvement

14 Technical diagnostics - detection and studying of equipment defect symptoms for the prediction of possible deviations in their operation modes

15 Effect from technical diagnostics Quality products Enterprise productivity The structure of the financial cost of the plant (department) What equipment is used Types of maintenance

16 MethodEquipment Vibration diagnostics and vibration monitoring Electromechanical equipment with moving parts Acoustic emission diagnosticsPressure vessels, tanks, pipelines, supports Quality analysis of lubricants and oils and detection of wear particles Rubbing elements (bearings, critical power mechanical equipment) Thermal imaging and termographyElectrical equipment, heat-exchange equipment, thermal insulation, furnaces etc. Analysis of currents and electrical pulse check Conductive part and equipment isolation Aero-ultrasonic leakage check (vacuum leakage) Compression equipment Ultrasonic defectoscopyWall condition and thickness of pipelines, vessels and tanks Parametric diagnostics of technological process Technological or mechanical degradation, corrosion, etc.

17 Basic principles of TECHNICAL DIAGNOSTICS Technical diagnostics are about estimation and forecast of technical condition of a diagnostic object according to the results of direct or indirect measurements of condition or diagnostic parameters. To estimate a technical condition of object it is necessary to know not only actual values of the parameters, but also reference values corresponding to them. The difference between actual θact and reference θref values is called as a diagnostic symptom. = θ act - θ ref = θ act - θ ref

18 Shaft Alignment systems BALTECH SA series BALTECH SA-4000 BALTECH SA-4100 BALTECH SA-4200 BALTECH SA-4300 BALTECH SA-Pro BALTECH FG

19 Calibrated shims for shaft alignment series BALTECH-23458N

20 BALTECH DM - self-adjusting chocking elements for the vertical machine movement

21 a universal leveling laser transmitter a laser transmitter a 2-axis receiver a receiver with a laser 80 mm Laser geometry measurement system BALTECH LL («LaserLevel» series)

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23 Use for: Leveling Flatness Straightness Squareness Parallelism Alignment Reporting Objects Foundations Bearing rollers, shafts Frames, guides Cranes, tables Processing equipment Pipes, bearings Shaft lines Flanges / Machine beds Rails / Telphers Laser geometry measurement system BALTECH LL-9100 («LaserLevel» series)

24 BALTECH VP-3405 (-2)BALTECH VP-3410 BALTECH VP-3450 BALTECH VP-3470 BALTECH MCB-6150 BALTECH Balance Systems for vibration check, vibration diagnostics and balancing in own bearings («VibroPoint» series) BALTECH VP-3460

25 Balancing machines BALTECH HBM Horizontal Balancing Machines series The BALTECH company is an exclusive representative of an international producer of balancing machines Balancing machines BALTECH allow to perform balancing of rotors weighting from 0,1kg up to 95000kg

26 IR - control (Infrared termography) Advantages of termography: Noncontact method Clear and visual method It isn't necessary to put the equipment out of operation Detection of defects early on their appearance Personnel safety Practical implementation of the program of scheduled preventive maintenance, maintenance on actual technical condition, proactive maintenance Prevention of production accidents EXAMPLE No. 2: Strong local heating of bearings close to the first gear and minimized heating close to the third gear. EXAMPLE No. 1: Pulp and paper mill vacuum compressor. The thermal fields meet temperature tolerances.

27 Examples of thermal imaging method: E Heating of journal bearings of shaft drives in an oil-filled housing Heating of an outer wall of the oil-filled journal bearing of the lifting electric motor

28 Electric: electric power lines, transformers, switching equipment of electric chains, switches, safety catches, automatics, etc. Mechanical: bearings, gear drives, shafts, couplings, belts and pulleys, compressors, turbines, etc. Defects of a fire-resistant lining: heating, drying furnaces and burners, chimneys, boilers, etc. Inspection of buildings and constructions for reduction of energy losses Heating of screw connection for grounding because of loose bolts Heating of the journal bearing on the electric drive of the conveyer belt of a rotor excavator

29 BALTECH TR thermal imagers allow detecting overheated mechanical and electric components without contact with object. Thermal control. BALTECH TR thermal imagers (infrared thermography of the «ThermaRed» series)

30 Thermal imaging cameras BALTECH TR Zorro

31 Advantages: 1. wide temperature range -50°C °C, 2. low cost of devices and their service (depends on FOV), 3. cheaper pyrometric inspection, 4. simple devices for training, 5. fast and effective implementation of works with the Methods of pyrometric inspection". BALTECH TL-0208C, C, C (Infrared thermometers «ThermaLine» series)

32 Oil analysis Oils and lubricants are designed for reduction of friction between moving parts of devices and machines, and as a rule it will show up under unfavorable conditions in the form of increased temperatures, high pressure and in the content of corrosion and active metals. In addition to properties of general purpose and oxidation stability the key operational parameters of oils and lubricants are the foaminess, evaporation losses, deemulsification and other properties having direct impact on lubricant abilities.

33 Oil and lubricant analysis Why is the analysis of oils and lubricants necessary? 1. Detection of oil contamination (water, dirt, penetration of processed materials, etc.) 2. Detection of temporal changes of lubricant properties (oil degradation) 3. Control of condition of the greased equipment (wear of greased surfaces)

34 Mounting kit BALTECH Tools Improper bearing installation leads to 12% of premature failure of bearings and, as a result, of the whole bearing unit. For reliable, exact and fast installation of seals, sleeves, guides of bearing roller and sheaves on a shaft BALTECH recommends to use a special tool kit BALTECH TOOLS. The kit consists of shockproof polymeric rings that prevent contact of metal surfaces and thus avoid possible defects of shaft surface.

35 1. Correct mounting of a bearing prolongs its lifetime 2. Opportunity for independent setting and control of temperature and heating time 3. Induction heating saves time and energy as bearing preheating becomes unnecessary 4. A bearing heats up quickly, uniformly on a mounting surface and without damages 5. Heating process is safe: the heater and the yoke remain cold, only mounting surfaces heat up 6. Environmentally harmless process: without smoke and smells 7. There is no need to use massive oil baths with technical oils Advantages of Induction Heaters BALTECH HI-1610, -12, -30, -33, -50, -60, -70, -90

36 Unique induction heaters with several inductors BALTECH HI-1612,-1633 New series Heater Induction

37 TypeBALTECH HI-1610BALTECH HI-1630BALTECH HI-1650BALTECH HI-1670 Electrics Nominal power 2,5 kVA3,6 kVA10 kVA12 kVA Voltage/current 220 V/10 А220 V/16 А380 V/25 А380 V/32 А Frequency 50 Hz Rotatable yoke no yes Heated part Maximum bearing weight, kg 12 kg55 kg210 kg560 kg Minimum inner diameter d, mm 10 mm20 mm45 mm60 mm Maximum outer diameter D, mm 210 mm480 mm720 mm1020 mm Yoke dimensions Yoke width, mm 10;14;20;30;40 mm14;30;45 mm30;40;50;65 mm40;60;85 mm Yoke length, mm 150 mm250 mm370 mm600 mm Control panel Temperature setting, °С Maximum temperature, °С 240ºС Automatic power reduction yes Dimensions Dimensions, mm 240х200х230 mm470х210х260 mm470х440х330 mm1390х600х1080 mm Heater weight (without yoke), kg 8 kg25 kg51 kg200 kg Demagnetization yes

38 Seminars and training courses 1. Training courses for specialists on topics: TOP Professional course for shaft alignment and geometry measurement TOP Dynamic balancing in own bearings and on machines TOP-103 – Fundamentals for vibration diagnostics TOP-104 – Thermal imaging method of non-destructive control TOP Tribodiagnostics. Oil and lubricant analysis BA Reliability of bearing units RT Concept "Reliability technologies" 2. On-site technical seminars at industrial enterprises 3. Technical audit of industrial enterprises 4. Providing training and reference materials, state standards and technical specifications

39 Equipment maintenance by specialists of the BALTECH company Equipment maintenance can be conducted with different periodicity: - One time (scoping of works for the current maintenance and scheduled preventive maintenance); - Periodic (once a month, a quarter, etc.); - Constant (management of database for equipment in operation. Maintenance is performed for the following directions: 1.Vibration diagnostics 2.Bearing vibration diagnostics of bearings with a shock impulse method 3.Balancing (up to 3 planes, up to 16 planes) 4.Laser shaft alignment (horizontal on couplings, vertical on flanges) 5.Laser alignment of pulleys and belt drives (belts, chains, tapes) 6.High-precision laser geometry measurement of the equipment 7.Thermal imaging inspection of the equipment and protective structures 8.Quality check of rolling element bearings at stands

40 Repair and metrology (device calibration, check and diagnostics) BALTECH performs diagnostics, calibration and verification of portable devices and systems.

41 BALTECH Russia St. Petersburg, , Chugunnaya, 40 Tel/fax: +7 (812) , Internet: Kazakhstan Astana city, Pobeda Avenue (Avenue Jenis) 79B, office number 408 Tel/fax: +7 (7172) , , , Internet: Germany Kronsforder Allee 45, 23560, Lübeck Tel: +49 (0) , Fax: +49 (0) , Internet: