SmartCBM Condition Monitoring

How do you ensure your assets are functioning well for maximum productivity? With smart condition-based maintenance from Allied Reliability, you get full visibility.

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SmartCBM Condition Monitoring

With IIoT capabilities, SmartCBM delivers manufacturing productivity gains while making condition monitoring dramatically more cost-effective. SmartCBM is Allied’s condition-based maintenance solution for early detection of component defects that cause failures. It prevents unplanned downtime while lowering maintenance costs, increasing equipment uptime, and improving reliability. End result? Higher productivity.

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Early Detection

SmartCBM is Allied Reliability's condition-based maintenance solution for early detection of component defects that cause failures.
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Less Downtime

SmartCBM prevents unplanned downtime while lowering maintenance costs and improving reliability.
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More Data

Always-on-intelligent monitoring systems for your most critical assets.
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Wireless Sensors

Sensors for next tier equipment with predictable operating states that may not be easily accessible.
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Flexible Deployment Options

Flexible deployment options that include route-based data collection for lower tier equipment.
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Fully Customizable

The ability to mix all condition monitoring platforms for an easily scalable, fully-customized solution.

SMARTCBM DEPLOYMENT METHODS

Our versatility offers you flexibility when choosing the delivery model that’s the right fit for your plant based on labor cost, personnel and equipment needs, timeline for implementation, and other relevant factors.
  • Directed
  • With SmartCBM Directed, Allied supplies the appropriate mix of analysts, technicians, and specialists to provide all related services. Data collection for the SmartCBM Directed deployment method is primarily route-based, though wireless and intelligent online equipment condition monitoring options can be integrated into the program as well.

    Route-based inspections are appropriate when:
    • Equipment is easy to access
    • Equipment operates in a single operating state
    • Multiple technology inspections may be appropriate for the asset

    With the SmartCBM Directed method, the full capabilities of Allied can be deployed quickly, enabling condition monitoring program results to be fully realized in a shorter time frame.

  • Remote
  • SmartCBM Remote integrates your existing site maintenance personnel and condition monitoring assets for technology-specific data collection and Allied’s resources for data analysis and troubleshooting into one seamless system.

    SmartCBM Remote is beneficial when:
    • You have available resources and a desire to integrate your maintenance staff into the condition monitoring effort, but level of effort or labor rules prevent outside data collection
    • It is cost prohibitive to have an analyst on site due to plant size or location
    • You want to reduce the cost of a current condition monitoring program
    • You need to quickly implement a condition monitoring program and do not have the time to train an analyst

    The SmartCBM Remote method reduces time and travel requirements for contracted services, enabling a lower cost solution. This shared application also utilizes the unique expertise of all participants, allowing for a quick implementation with highly skilled resources, generating virtually immediate results.

  • Connected
  • SmartCBM Connected delivers always-on intelligent monitoring systems for your most critical assets. Sensors provide daily (wireless) or continuous (inline) equipment condition monitoring, with no limit to the number of sensors that can be installed. SmartCBM Connected is valuable as a unique service or in addition to a balance of plant condition monitoring program, especially for:

    • Bad Actor equipment
    • Highly critical equipment
    • Equipment that is difficult or unsafe to access
    • Equipment with changing operating conditions or states

    SmartCBM Connected allows you to reduce the effort to collect inspection data and integrate all of your inspection technology data into a common open and analyzable format. This allows you to improve the competitiveness of production facilities, raise the quality of products, increase uptime and production capacity, and drive towards lower costs.

  • Enhanced
  • SmartCBM Enhanced is an integrated solution that gives you the flexibility to combine all inspection technologies into data collection systems spanning route based, inline, and wireless sensor topologies while integrating the data from control systems, CMMS or ERP systems, plant historians, and condition monitoring analytics. For customers seeking a digital transformation within their production facilities, SmartCBM Enhanced yields a fast return on investment with:

    • Always-on intelligent monitoring systems for the most critical assets
    • Wireless sensors for next tier equipment with predictable operating states that may not be easily accessible
    • Flexible deployment options that include route-based data collection for lower tier equipment
    • Functional failure monitoring utilizing plant historian control and process data
    • The ability to mix all condition monitoring platforms for an easily scalable, fully-customized solution

    Prevent Unplanned Downtime With Condition Monitoring

    Prevent full failures and the consequences that can result with condition monitoring from Allied Reliability. Using PdM technology and SmartCBM deployment, we monitor your high-value equipment to detect changes that could indicate a developing failure. Our experts select the correct combination of technologies, sensors and software so you can schedule maintenance, identify component defects and take proactive measures to prevent unplanned downtime.

    PdM Technologies

    Our predictive maintenance technologies help determine the condition of your high-value assets, alerting you to the presence of a machinery defect.

    Oil Analysis

    Often referred to as the lifeblood of equipment, oil can provide a great deal of information on the health of equipment, as well as indicate what might happen if action is not taken. Is there contamination? Has the chemistry of the oil been compromised? Is wear debris present?

    Oil analysis is one of the most commonly used condition monitoring technologies. It was originally used in the manufacturing world to detect water and the depletion rate of additive packages in the lubricant. Its use has since been expanded to include the detection of wear particles in the lubricant, as well as the presence of outside contaminants.

    Oil analysis detects:
    • Abrasive wear
    • Component fatigue
    • External contamination
    • Inadequate contamination control measures
    • Incorrect lubricant use/selection
    • Over extended oil drains
    • Poor handling/sampling practices
    • Sliding wear
    Vibration Analysis

    This technology identifies unhealthy vibration patterns in equipment before damage occurs resulting in expensive repairs. Vibration analysis is the most frequently deployed asset condition technology on the market today and can be an invaluable tool to improve maintenance and reliability.

    Vibration analysis is, by far, the most powerful condition monitoring technology for rotating equipment. While there are some problems with rotating equipment that vibration analysis cannot detect, it stands alone as the most comprehensive method for defect detection in rotating equipment. All rotating equipment vibrates to some degree, but as parts reach the end of their product life or begin to fail due to non-age-related causes, they begin to vibrate more dramatically and in distinct ways. Ongoing monitoring of equipment allows these signs to be identified well before the damage becomes an expensive problem. 

    Vibration analysis detects:
    • Gear wear
    • Cavitation
    • Imbalance
    • Misalignment
    • Cracked or broken gear teeth
    • Chain looseness
    • Rolling element bearing defects
    • Resonance
    • Bent shaft
    • Bearing issues
    • Structural looseness
    • Sheave run-out
    • Many electrical problems
    • Fluid and airflow problems
    Infrared Thermography

    Commonly used for both mechanical and electrical applications, infrared thermography is one of the most diverse and widely accepted condition monitoring technologies on the market today. Thermography also plays an integral role in evaluating and identifying energy-efficient opportunities to save you money. 

    When using thermography on mechanical systems, an effective approach is to focus on elements of the systems such as seals, lubrication points, cooling circuits, and powertrains. In electrical systems, there are several causes of thermal anomalies, such as hot spots in loose mechanical connections, overloaded phases, and corroded conductor terminations. Electrical resistance converts electrical energy to thermal energy, which can lead to higher temperatures and wasted electrical power. Integrating thermography into routine energy audits such as heat loss surveys, piping insulation surveys, building envelope, and steam system analysis will enable your energy management team to identify defects that cause increased energy consumption. 

    Infrared analysis detects:
    • Bearing and couplings defects
    • Seals issues
    • Barrier system failures
    • Alignment issues
    • Heat dissipation
    • Lubrication issues
    • High resistance connections
    • Faulty fuse clips
    • Loose connections
    • Faulty transformer bushings
    • Heat exchanger Issues
    • Boiler inefficiencies
    • Steam trap failures
    • Refractory degradation
    • Insulation failures
    • Building envelope defects
    Ultrasound Analysis

    Ultrasound is high frequency sound waves above 20 kilohertz (kHz) up to 300 kHz. As a comparison, the average human’s hearing perception falls around 16 kHz. Commonly used for leak detection, mechanical, and electrical inspections, ultrasound is one of the more flexible condition monitoring technologies on the market.

    Ultrasound technology is a selective method that highlights mechanical defects at the earliest stages with great effectiveness in both high- and low-speed equipment. One of the most common applications for airborne ultrasound is compressed gas leak detection. Ultrasonic inspections of an entire steam system will reveal system leaks, blockages, stuck valves, and failed traps. For electrical applications, safety is always a concern. Ultrasound can be used as a safety precaution for identifying failure modes such as arcing, tracking, and corona, thus helping to prevent arc-flash incidents.

    Ultrasound analysis detects:
    • Compressed gas leaks
    • Arcing
    • Tracking
    • Corona
    • Bearing faults
    • Gear problems
    • Coupling defects
    Motor Circuit Analysis

    Motor Circuit Analysis (MCA) is the most powerful condition monitoring technology for evaluating the health of your electrical motor circuit, from the load side of the motor starter all the way through the motor windings.  In the hands of a capable analyst, MCA effectively identifies defects causing motor failures as well as energy inefficiencies within the motor windings. MCA can deliver desired returns on energy savings, equipment reliability improvements, and increased production capacity.

    Offline testing is commonly used as a Quality Assurance (QA) tool for acceptance testing of new or reconditioned motors prior to them being stored or put into service. Offline testing is also commonly used as a troubleshooting tool to test the integrity of an installed motor’s insulation system. Online testing is performed while the motor is operating within its normal environment and operating conditions and provides insight regarding power quality and conditions such as voltage levels, unbalances, and distortion, as well as any defect in the mechanical drivetrain causing torsional loads back onto the motor such as misalignment, coupling problems, and certain bearing defects.

    MCA detects:
    • Current imbalance and loading issues
    • Power quality disturbances (harmonics, voltage imbalance, power factor anomalies)
    • Circuitry and motor insulation breakdown/degradation
    • Rotor damage (loss of torque, loss of HP)
    • Loose motor foundation (soft foot, sprung foot)
    • Eccentricity in rotors (motor, sheaves, fans)
    • Belt defects
    • Vane/blade pass
    • Gearing defect (broken tooth, backlash, looseness)
    • Bearing defects

    Our Results

    %
    Reduction in Annual
    Maintenance Spend
    %
    Increase in
    OEE in 3 Years
    %
    Increase in Production
    Over 3 Years

    CASE STUDIES

    See how Allied Reliability’s solutions have had an impact on business operations for companies in a variety of industries.

    Power
    of MCA

    The motor at a coal-fired steam plant was experiencing increased vibration levels. We used motor circuit analysis to find the cause.
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    Grinding Mill Vibration Analysis

    After repeated failures of the rotor bearings in a grinding mill, we utilized condition monitoring and reliability engineering to find a resolution.

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    Vib-IR
     

    A health treatment facility noticed an elevated temperature with a fan assembly breaker. We used multiple technologies to find more faults with increased certainty.
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    Advanced Vibration Analysis

    Advanced vibration analysis was performed on the blower and supporting base structure to determine the root cause of the elevated vibration levels that were affecting this equipment.
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