Our latest innovation in
reliable rotation
As the Industrial Internet of Things continues to grow, plants can take advantage of a range of exciting new technologies that can not only improve performance and reliability, but also free up skilled workers to focus on important tasks. One such example is the scalable SKF Enlight Collect IMx-1 that creates an easy to set-up mesh sensor network to collect data on rotating components. We sat down with Chris James, Product Line Manager at SKF Group to learn how and why the IMx-1 was created and find out what future developments SKF have planned.
What were your main strategic drivers for developing the IMx-1?
Our strategy doesn’t start with our bearings; it starts with our customers. They tell us they want to keep their rotating equipment running reliably, so we look at everything it takes to achieve that over the entire life cycle of their machines. The bigger picture includes bearings, seals and lubrication, of course, but it also includes gathering vibration and temperature data in condition monitoring programs; using that to feed SKF remote diagnostic centres using AI, machine learning and human experts to provide insights into machine health; and predicting failures far enough in advance that corrective action can be taken, to avoid unplanned downtime and collateral damage.
Today, much of that data is still collected manually in “walk-around” routes with portable measurement equipment, but an industry trend is to automate much of this task with easy-to-fit wireless sensor networks that can collect data more often and detect problems more quickly – hence the SKF Enlight Collect IMx-1.
There are many companies offering customers wireless vibration sensors these days, but for SKF the IMx-1 is a tool we use in delivering mechanical services for reliable rotation, rather than a technology product to sell.
In developing the IMx-1, what were your key considerations?
Actually, the first key consideration was whether to develop in the first place – the “make or buy” decision. When we looked around the industry, we saw many possible candidates for a “buy” – from organisations ranging from technology start-ups to large corporations. However, when we dug into technical details, although we found lots of wireless connectivity benefits, the vibration measurements they could achieve were confined to a velocity band defined by ISO 10816. This is fine for detecting common machine problems such as unbalance or looseness, but not so good for early detection of bearing damage – a detail which is, of course, something of importance to the world’s largest bearing company. So that meant a requirement to align to the quality of measurements that we have successfully used for decades in our other condition monitoring products and programmes and led us to the “make” decision.
Another key consideration was the environments in which SKF products work – there are many. However, the main industries that would need the IMx-1 would be heavy ones – steel, mining, pulp and paper. In these applications, the environment around the bearing – where the sensors would need to be located – is far from that of a nice clean and dry manufacturing plant. There are high temperatures, moisture, dust, debris, and lots of metal surroundings – a challenge for wireless transmissions. The pain points for a user of this technology are reliability, quality of measurements, and a cost that is economic enough to contemplate replacing manual measurements. So, matching those points to the environment was a significant challenge.
What sort of feedback have you seen from those already using this system?
With our wired online systems, we’ve been achieving great results for many years in the toughest of applications. This new wireless solution builds on this experience in a wider scope. We have only recently released the product and have had positive feedback from the customer sites that have used it so far. They’ve reported the product to be relatively quick and easy to install, which is an important factor when you think about the scalability to eventually replace walk-around monitoring.
We’ve also seen some “saves” from the system – insights into mechanical condition of machines that, if they had gone unnoticed, would have led to failures. That has confirmed that the quality of measurements is aligned with those we would have taken with our portable devices.
So overall the feedback so far is that it looks like we’re on track to release skilled manpower, which is currently tied up in data collection tasks, to higher value work.
Where do you see the future developments for the IMx-1 program maybe over the next year?
What we have developed already stands up very well, but we are constantly working to increase the value we can create for our customers. Over the next year or so we will be looking to expand the measurement capability of the IMx-1. Future-proofing has been achieved by making sure we can add features by “over the air” firmware updates to the same installed hardware – just like how apps in your pocket add new features without you needing to buy a new phone.
Automated machine monitoring for reliable rotation
As a chemical company, safety is of the highest importance for BASF, as their production processes must comply with safety regulations including having online condition monitoring systems on all critical applications as standard.
BASF had been looking at condition monitoring systems with wireless sensors for critical and semi-critical applications for a long time due to their practicality in both cost and ease of installation.
After testing systems from various brands, BASF were interested in the IMx-1 and its possibilities. As soon as they had the opportunity, a number of IMx-1 systems were delivered to the Caprolactam production location. Initial results gave such a positive impression that the test range was immediately expanded to a total of 70, installed at key measurement locations.
Good cooperation
"18 months ago, SKF introduced us to their new generation of sensors and we were immediately interested", says Raf van Gastel, Central Maintenance Reliability Expertise at BASF. "Now we are conducting the tests, SKF are a very flexible organization and that is partly why the system is quickly configured and operational. Moreover, the wireless IMx-1 system also appears to work well over longer distances".
Various pumps that are used for the test are next to ATEX motors and although the IMx-1 sensors are not yet ATEX approved, sometimes they have to bridge 40 meters. This is possible because the sensors also communicate with each other and act as routers.
Prevent premature outages
"Immediately after installation, the SKF IMx-1 system highlighted a defect at a bearing location that could have caused an early failure," says Sabine Spapen, Business Manager Condition Monitoring Solutions at SKF. "Optical inspection did not show any significant damage, but further microscopic examination revealed fatigue symptoms on the outer ring".
Widely applicable
For BASF, working via the cloud is a big advantage. Raf van Gastel: "It took a while for our IT department to be convinced that everything is done in a secure way, but the SKF IMx-1 system offers so much added value for our operators. The extensive and wireless measurements provide us with enormous insight which can optimize our processes. We have always taken offline measurements, but now that everything can be done wirelessly, our people can focus more on analyzing instead of collecting data in the field. It offers us a platform that we can use to expand into in the future".
Rotating Equipment Performance
The IMx-1 will be launched worldwide in 2020 and the practical tests at BASF show how effective the system can be in the field.
Sabine Spapen: "We discuss their needs with customers and then offer the most relevant system and service options available so we can take care of the entire process from installation to remote monitoring. This is the basis of our Rotating Equipment Performance approach that guarantees machine performance!”
Who is BASF?
BASF Antwerp is the largest integrated chemical production center in Belgium and the second most important production site of the BASF group worldwide with fifty production facilities on site. The BASF Antwerp product range includes basic chemistry and specialized chemicals, plastics and precursors, breeding products and inorganics.
BASF Antwerp's products are used in almost all processing sectors, including automotive and construction sectors, in the production of paper, leather goods and sporting goods, as well as textile, food and pharmaceutical sectors.
At the BASF Antwerp production site, safety is a top priority. Employees, partners, contractors, visitors ... BASF involves everyone in its safety policy.
The SKF test setup at BASF
The SKF Enlight Collect IMx-1 system is installed on seven standard centrifugal pumps, which are directly connected to an electric motor. The pumps operate at varying speeds from 1000 to 3000 rpm. The available motor, pump and rolling bearings all vary in configurations.
