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Outer race
Case study from the Cement industry - Finish Mill Separator Machine: Finishing mill in a cement plant Problem description Bearing outer race fatigue Higher than normal vibration Spectrum indicating fault Test point:  Inboard West Motor Radial Analysis name:   Spectrum 60,000cpm or 1000hz Comment:   Note harmonics of outer race Spectrum indicating fault Test point:  Inboard West Motor Radial Analysis name:   Spectrum...
Gearbox
Problem description  24' Raymond was showing impacts in the time waveform consistent to a tooth problem Also, in velocity spectrum many sidebands of ring gear speed around gear mesh indicating problems with this ring gear This separator has had gearing problems 3 times in the last 2 years Analysis Time waveform indicating fault Single impacting at once per revolution and then...
Monitoring system
When push comes to shove, trust the system Modern, online diagnostic and monitoring systems are great things to have for safe and reliable machinery operation. Condition based maintenance, increase of uptime, efficient repairs and short MTTR with maximum MTBM – all these concepts and goals can be realized with state-of-the-art technologies and services.  But what if operators are reluctant to...
Summary In the process industry, it is still common that users strictly separate machine protection equipment from condition monitoring. Machine operators frequently face a time-consuming troubleshooting based on minimum diagnostic data e.g. from the DCS system. For many years, flight data recorders have been a common standard in the aviation industry to perform post-incident analyses of aircraft accidents. Such transient...
Reciprocating compressors
Monitoring and diagnostics for reciprocating compressors A guide to the purpose and terminology of monitoring systems that ensure effective operation of reciprocating compressors The only way to ensure safe, reliable, efficient and economical operation of reciprocating compressors is to monitor them continuously and to take appropriate action based on the information the monitoring systems provide. That simple objective, however, is difficult...
Broken piston rod
In December 2007, the online monitoring system avoided a major and cost-intensive damage at one compressor. The permanent piston rod position monitoring detected a cracked respectively a virtually broken piston rod at the 1st stage. Prior to a complete rod failure, the machine had been automatically stopped and costly consequential damages have been avoided. The urea plant operates, besides others,...
Avoiding ‘crater maintenance’ and the ‘doom loop’ Reciprocating compressors have a reputation as bad actors among the rotating equipment fleet, showing the highest number of damages while being process critical at the same time. Although this is a crucial combination, insufficient protection and condition monitoring systems can still be found on reciprocating machinery. PROGNOST asked a potential customer’s reliability engineer whether he...
Plunger pump
Integrating a new reciprocating pump into an existing system PROGNOST®-NT system used to troubleshoot installation of water-wash pump at refinery In past few years, the rising demand to increase efficiency of production plants has initiated many extension and de-bottlenecking projects in the oil and gas industry. Many of these extension projects require the installation of new machinery into existing plants. Interferences between...
When PROGNOST Systems project managers finalize the installation of your new system, it does not mean you are on your own. Our Customer Support team stands by in the critical moments, e.g. during initial system and machinery start-up and during the entire lifecycle of the installation.