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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

IRIS M: ‘Motion Studio’ Update

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Brand New Software Features for IRIS M, Motion Amplification Software.

GVS Reliability Products and Optical Motion Technologies have some great news regarding advances in the IRIS M, Motion Amplification system! To learn more, see below for the entire press release from RDI founder and CEO, Jeff Hay.

IRIS M: ‘Motion Studio’ Update

RDI Technologies is excited to announce a new update for the Iris M, Motion Studio. This software update brings new video editing capabilities to the Iris M. Create videos that are more powerful than ever with the Iris M in this new application.

Click on the following  video link to learn more.

Some notable features include:

  • Motion Studio – Motion Studio brings video editing capability into the RDI software suite. Movie projects can be created using previously created MP4 videos, photos, images, and text slides. All content can be annotated during the creation of the movie project. Effects such as fade-in and fade-out are also supported.
  • Composite Content – Motion Studio supports Composite Items in its movie projects. These composite items allow up to four different videos or images to be displayed at once. This may be used to display different views of an asset at the same time. It can also be used to show before and after videos simultaneously.
  • Enhanced Annotations – The annotation capabilities of Motion Amplification have been significantly enhanced for Version 2.3. Image annotations are supported and these annotations allow the display of images in the main workspace. Plot annotations are also supported, and these annotations allow plots associated with defined ROIs to be displayed in the workspace.
  • Enhanced MP4 Export – The export capabilities of Motion Amplification in Version 2.3 include the ability to add plots to the exported video. A preview of the video to be exported is also supported. The ability to control the layout of the export content is also included.

 

 

Regards,

Jeff Hay, Ph.D.

Founder & CEO

RDI Technologies Inc.

www.rditechnologies.com

RDI’s Motion Amplification

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RDI’s Motion AmplificationTM, finding a better way to detect premature failures!

RESULTS

  • Captured Motion AmplificationTM (MA) videos and diagnosed the fault in the field within 1 hour
  • Visualisation of the root cause (coupling wear, loose hold down bolts and failed welds) of the high axial vibration that had been difficult to identify with traditional vibration analysis techniques
  • Remediation work during a low load period reduced the high axial vibration at the fan drive end bearing by more than 70%
  • Solution implemented at a time when substantial

“Motion Amplification technology allowed us to identify movement in the bearing pedestal…With this knowledge and by calculating the predicted failure date the fan was proactively removed from service to repair during low load periods.”

Maintenance Engineering Lead

COMPANY

Power Generator

LOCATION

Australia

PROBLEM

There are two Induced Draft (ID) Fans critical to the operation of each 700+ megawatt turbo generator at this Power Station. Staff had been monitoring a steady increase in axial vibration at the Fan Drive End Bearing of one of the two ID Fans for Unit 3 turbo generator. The axial vibration amplitude had increased from 1.75 mm/sec RMS to 8.5 mm/sec RMS over a 2-month period. The vibration analysts were finding it difficult to identify the root cause of the increasing trend and noise coming from the coupling through traditional vibration analysis techniques. Historically this type of fault would have been left to run to failure resulting in a $70k/hour loss of generating revenue for the business.

SOLUTION

In alliance with the generator’s engineering team a leading global consulting company, ALS Industrial, applied RDI’s Motion AmplificationTM (MA) technology to help solve the emerging ID Fan problem. From arriving at the location of the ID Fan in the power station, setting up the video camera and acquiring several MA videos it took less than one hour. This hour included the time to analyse the results all of which was done in the field. The MA videos helped identify several problems including: coupling wear and movement on the shaft, bearing housing hold down bolt looseness, frame pedestal bolt looseness and cracked welds between the bearing housing spacer block and fan drive bearing pedestal. During a low load period and a 300MW restriction the coupling, bearing housing and bearing pedestal issues identified were rectified. When the fan was returned to service the high axial motion and vibration had been reduced by more than 70% and was now 0.6 mm/sec RMS. The solution to this problem was expedited and better understood through the application of RDI’s Motion AmplificationTM technology.
View the before and after video at this link along with a full range of case studies at this link.

Another update for IRIS M Motion Amplification

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Dear IRIS M Motion Amplification user,

All IRIS M MA users are receiving this update notification.  During the installation process of the new update the license management application will check the status of your license to ensure that you are entitled to the new update.  Entitlement is guaranteed within the initial 12 month period following your IRIS M MA system purchase or with a current RDI Technologies Maintenance Agreement.

Please refer to the “IRIS M new release history” attached for a summary of all the updates over the past 18 months.

RDI Technologies is excited to announce a new update for the Iris M.  This software update brings an exciting set of new features to the product.  These features are the most requested by our users.

Some notable features include:

  • Calculate Spectrum from Portion of Waveform – Calculate spectral data from a specific part of the available waveform.  This is accomplished graphically from the waveform plot, and calculated spectra are updated dynamically as the region over which they are calculated is modified.
  • Bulk Filtering – Using Motion Explorer, copy the filters from one recording and apply them to one or more recordings.  This means that you only have to set up the filters once if applying the same filters to multiple recordings on the same asset.
  • Spectrum Harmonic Cursor – Harmonic cursors are now supported in spectrum plots.  This allows harmonic frequency content to be more quickly recognized.
  • Autoscale Across Plots – Autoscaling the amplitude axis across plots of the same type (e.g. spectrum or waveform plots) allows quick recognition of relative amplitude values.

There are 2 software configurations.

Acquisition System (RDI Acquisition and Motion Amplification) – includes both Acquisition and Motion Amplification software.  This will need to be installed on the dedicated tablet/laptop for field use with the Iris M system

Stand Alone – This is the Motion Amplification analysis software only.  This is a single license and can be installed on another computer (laptop or desktop) for office analysis of the captured data.

To install,

  1. Download the zipped files at below links to the dedicated tablet/laptop acquisition computer
  2. The default license verification process requires an internet connection so please make sure your computer is connected to the internet prior to running ‘setup’
  3. Double click on the ‘setup.exe’ file
  4. Follow the prompts.

Please note:

  • Following the above steps will install directly over your previous installation.
  • There is no need for users to delete any files.
  • The computer will auto restart so please close/save any other work before undertaking the install.

If you do not have direct access to the above links via the dedicated Iris M tablet/laptop, please follow these steps

  1. Download the software to a computer with internet access.
  2. Copy the downloaded files to a USB drive.
  3. Transfer the copied files to the dedicated Iris M tablet/laptop.
  4. Once copied to your Iris M tablet/laptop, double click “setup.exe” file
  5. Follow the prompts.

For further details on the installation process, if required, please reference the Motion Amplification User’s Manual.

You can download the latest software here:

A 1hr webinar covering the New Update and notable features will be run next Wed 30 May 2018 commencing at 14:00hrs AEST.  You will receive a separate webinar invitation. Please contact sales@gvsensors.com.au to book into the Webinar.

IRIS M Update; Introducing ‘Motion Explorer’

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GVS Reliability Products and Option Motion Technologies are excited to announce RDI Technologies latest update to the powerful IRIS M product; Motion Explorer.

Motion Explorer is a brand-new App for the IRIS M platform. The inclusion of this app to the IRIS M products, creates higher visibility and functionality by giving clear and concise access to previously captured and amplified footage. With Motion Explorer, users will now be able to preview recordings, organize data in a hierarchical structure and add/include associated files such as PDFs and MP4s in the same tree structure.

Basically, the app allows users to store all Motion Amplification data in one place for easy and fluid access.

For a simple explanation of the new app and features, click here for the showcase video.

Along with Motion Explorer, users will also receive an exciting set of new features for the Iris M.

Region Based Amplification – Users can overlay shapes to define what regions are amplified and an unlimited number of regions can be applied
Image Thresholds – Users can choose what portion of the camera’s available dynamic range is displayed on the screen and exported into the MP4
Rotate Image – Users can rotate the collected recordings by 90°, 180°, and 270° and the acquisition software shows a live preview of the rotated view
Multiple Distance Measurements – Users can drop pins on multiple locations and enter associated distances to be retrieved in Motion Amplification for analysis of multiple locations

If you are a IRIS M user you can download the latest software here:

Acquisition System Install 
Analysis Only Install

Make sure you keep up to date with all of the great video examples on YouTube, channel links are listed below.
RDI Technologies Channel
Option Motion Technologies Channel
Motion Amplification UK Channel

If you would like to learn more about the technology and real success stories, call GVS Reliability Products today