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Commissioning equipment with IRIS M Motion Amplification™

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Notes from the Field – Commissioning New Equipment with IRIS M™ Motion Amplification

Commissioning a new piece of equipment is a stressful and exciting time for all parties involved. You have spent a lot of time on this process. You have worked hard on planning, money and time have been spent on construction, and of course the hard work and effort to put in the new equipment. The goal is to get the piece of equipment into production as quickly as possible. The challenge in commissioning is having the confidence that the new and unfamiliar piece of equipment is operating the way it’s designed.

When commissioning new equipment, there are a couple of items you want to determine. The first is what the new piece of equipment should be doing, building a baseline for future reference. The other is looking for defects or deficiencies that are the result of the manufacturing, engineering, or installation process of the equipment itself. These defects, deficiencies, installation, or design issues often result in excessive vibration that is most often detectable using Displacement or Velocity. Motion Amplification™ is the ideal technology for this because Motion Amplification™ is a displacement-based measurement and shows the movement in the above-mentioned defects very well. It shows ALL the movement, piping, wiring, base, grout, concrete, etc. For example, when commissioning a pump and motor we would typically take 10 vibration measurements on the bearing housings (4 horizontal, 4 vertical and 2 axial). It is possible for the discharge piping on an overhung pump to be resonant, but the pump NDE bearing vibration to be within spec. This resonant pipe could shorten bearing life, crack pipe supports, and cause much larger issues long after the equipment is commissioned. Issues like these are design or installation problems and should be handled by the installing contractor, or plant personnel before the equipment is put into service.

Motion Amplification™ is a great tool when commissioning a new piece of equipment. The videos show how the equipment is moving. This insight helps all parties communicate effectively through the commissioning and establishes a baseline of operation before the equipment is put into production.

 

Commissioning Case Example

A large multinational mining company purchased the IRIS M™ for the purpose of commissioning a new facility in Mexico. They were on a tight schedule to bring the new equipment online. Acceptance testing of all new assets included an assessment using IRIS M™ before site acceptance testing (SAT) sign off with the original equipment manufacturer (OEM).

Before and After Video description: This was a tank that they caught vibrating with the IRIS M. They notified the original equipment manufacturer (OEM) of the issue and the OEM stated there was no problem with the tank. Upon seeing the tank in the MA video, the OEM immediately acknowledged the problem and redesigned the tank.

To learn more about how IRIS M™ can assist commissioning machines at your plant please contact GVS Reliability Products Pty Ltdsales@gvsensors.com.au

V2.5 Software Release from RDI Technologies

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Announcing the 2.5 Software Update

GVS Reliability Products and Optical Motion Technologies is pleased to announce the newest update to the award-winning software for the Iris M™ and Iris MX™ systems from RDI Technologies.  This new update will be available for all eligible customers.  It will expand the use of Motion Amplification™ software to new applications and make it easier and more robust to use.

Key Features in the 2.5 Software Release 

  • Analysis of Rotating Shafts: Several features related to the analysis of rotating shafts have been added including shaft inspection recordings, high-density recordings, shaft turning speed detection, shaft displacement measurements.
  • Enhanced MP4 Export: MP4 export now lets you specify the resolution format and quality of the video that is produced. Users will be able to select Full HD, HD, and SD formats enabling them to control the size and quality of the files.
  • Trim Recordings: Motion Amplification™ now supports the ability to trim unwanted content from existing recordings.
  • Relative Phase Calculations: Motion Amplification™ now supports relative phase calculations. Specify a phase reference and frequency of interest and relative phase values will be calculated for all of the displayed waveforms. This will allow the user to not only be able to see that an asset is out of phase but also calculate an exact number to pinpoint relative motion within the context of an image and more effectively find the fault.
  • Filtering: More efficient filtering options allow users to filter based on amplitude thresholds and isolation of peaks using a graphical interface.
  • Batch Amplification: Users will also be able to apply Motion Amplification™ to entire batches of data, preventing the user from having to wait on the amplification of individual recordings.

Download the Acquisition Software Download the Analysis Software

 

Free 1-Hour Short-Course on the New 2.5 Features for Customers

We are offering a live free one-hour short-course for our customers on all the new updates in version 2.5 of the software.  Our expert will take you through each of the features and give you advice on how to use them in the field.  The live sessions will be held on the following dates and times:

August 8, 2019, at 3 PM EDT
August 13, 2019, at 10 AM EDT
August 13, 2019 at 7 PM EDT
August 15, 2019, at 3:30 PM EDT

*Space is limited so reserve your spot today – Click below to register

Register for the 1-Hour Short-Course on the New Features

Contact sales@gvsensors.com.au if you need any further information on the 2.5V software update

Why RDI’s IRIS M™ Motion Amplification™ is ESSENTIAL technology

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RDI’s IRIS M™ Motion Amplification™ takes Asset Management and Reliability to another level

Problem

The industrial landscape in Australasia is ultra-competitive with companies always looking for technologies that will propel them to best in class for their industry.

Solution

RDI’s IRIS M™ Motion Amplification™ is one of those ESSENTIAL technologies that will take your Asset Management and Reliability to another level.

  • IRIS M™ enables Proactive (Precision) Maintenance Reliability activities such as precision commissioning, precision installation and DEFECT ELIMINATION
  • Visualisation of the root cause of unacceptable vibration detected via routine and online PdM programs
  • Through visualisation, transition to root cause problem solving
  • IRIS M™ is the perfect tool for screening assets, fault finding, commissioning new assets, and pre/post repairs or retrofits
  • Communication tool between technical and non-technical personnel, enhancing the decision-making process

Contact sales@gvsensors.com.au to learn more about IRIS M™ Motion Amplification™

Click to play MP4

Iris MX™ from RDI Technologies Wins Reliability Web’s Solution Award!

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Dr. Jeff Hay, CEO of RDI Technologies, accepts the Solution Award for Asset Condition Monitoring at the Reliability Conference in Seattle, WA for the Iris MX. #MotionAmplification.

RDI Technologies received the award for Asset Condition Management from Reliabilityweb.com, for the Iris MX. Since 2015, RDI Technologies has specialized in using machine vision technology to revolutionize the industrial sector. RDI Technologies developed and patented a technology platform called motion amplification that is capable of measuring vibration or displacement not visible to the human eye and then visualizing that motion to help customers solve the root cause of their problems. The award was accepted by Dr. Jeff Hay, CEO, Bob Wilson, President, and Jenna Johns, COO of RDI Technologies.Click here for the full press release from Reliabilityweb.com.

Cost Analysis of Utilising Motion Amplification Technology

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Evap Pumps — Motion Amplification Case Study — Cost Justification

At a continuous production plant a new installation of critical Motors and Pumps was signed off from the Projects Team to Operating Team as complete and in good order, ready to use in the process. However, bearing and coupling failures were occurring within 6 weeks of installation and continued for 12 months of operation resulting in 6 failures and 1 incident of reduced plant throughput.

Cause No. of Fails Costs Costs
Pump Seal Failure 2 £4800 seal & Labour x 2 £9600
Bearing Failures 4 £6825 (30% of ERV) x 4 £27,300
Plant on Half Rates 1 8Hrs x £5000 cost to biz £40,000
Total Cost to Business £76,900

Motion Amplification was deployed to review the machines and found the root cause of the issue within 15 minutes. The bases were poorly installed and of insufficient design quality. All 3 motors and pumps needed to come offline, be removed and have the bases remanufactured to ensure lower vibration levels and reliable continued operation. The visual side of the videos was key in proving the bases were poor.

Had Motion Amplification technology been utilised at the commissioning stage the poor installation of the pumps would not have been signed off for use on plant and the base improvement works would have been completed before completing commissioning and handing over to Operating Team.

Cost of Iris M Deployment at site – £27,475

Cost of Iris M Deployment at site £27,475
Cost of failures to business £76,900
Total Potential Cost Avoidance £49,425

The site has upwards of 800 machines with nearly 400 critical machines to which the plant will either reduce to half rates or complete stop if failure conditions arise unexpectedly. While CM is used to avoid rapidly arising issues, MA is now used to ensure a minimum of human error during the commissioning phase, integrity during normal conditions and root cause analysis when repeat problems arise.

MX new high speed camera

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RDI Technologies adds high-speed camera solution to its revolutionary
Iris M product line

 

New Iris MX camera allows acquisition at a higher frame rate with a full field of view in HD

The new Iris MX expands on the revolutionary Iris M product capabilities to open the world of Motion Amplification to high-speed applications. Like the Iris M, the Iris MX utilizes the millions of pixels in today’s modern cameras to measure deflection, displacement, movement, and vibration not visible to the human eye. The Iris M software converts those millions of pixels into individual data points, measuring extremely small vibrations or motions with a high degree of accuracy. It then displays the results in an amplified video that brings the problems to live in a visual form, seeing truly is believing. The Iris M covers a large percentage of faults at a plant, but now with the Iris MX, we can visualize a broader range of fault types.

The Iris MX utilizes the same software as the Iris M and is plug and play with current user’s software. RDI Technologies has combined the ability to reach 1,400 frames per second in HD resolution with their seamless user intuitive software opening possibilities in the industrial market beyond current technologies.

“As the user base of the Iris M has grown, so has the use cases,” said Jeff Hay, CEO of RDI Technologies. The Iris MX is the result of that. The Iris MX can see frequencies much higher than the Iris M and capable of imaging machinery in a large field of view at those higher frequencies. Faults typical in turbomachinery, blade pass frequencies and higher orders of synchronous machinery can all be imaged at a larger frame size. If you need higher speed, we have you covered.

You can view more about this product on our Iris MX Spec Sheet