Ultrasonics equipment reduces machine downtime

An economic predictive maintenance system, using ultrasonic sound detection equipment, has reduced downtime and enhance the performance and safety of equipment at a printing works.

Technology developed by Monition, the UK's leading independent monitoring and maintenance company, has allowed News International to install an economic predictive maintenance system to reduce downtime and enhance the performance and safety of equipment at Wapping UK.

Nottinghamshire-based Monition, who provide reliability focused maintenance solutions for industry, transportation and buildings, used the latest in ultrasonic sound detection equipment to identify potentially dangerous air leaks in pneumatic systems at Europe's largest newspaper printing works.

Wapping UK senior engineer John Rafferty said: "Weeping valves were causing the inconsistent speed of operation of equipment and our engineers had to react immediately to ensure it did not develop into a health and safety issue.

Thankfully, Monition brought in their ultrasonic equipment that was capable of identifying minor air leaks before they affected the operation of the equipment.

This solved the problem and we now use ultrasonic detectors to test for air leaks every three months.

Ultrasonic detecting is often the only method used to check pneumatic systems.

It has eliminated the previous step-by-step replacement of valves, which took as long as 4 to 8 hours per faulty system.

The ultrasonic test now requires 15 to 20 minutes.

It translates inaudible, ultrasonic frequencies, into a variety of recognisable sounds and meter readings and is capable of locating liquid and gas leaks as well as diagnosing a number of maintenance problems.

The benefits are considerable and include reducing costly unplanned downtime by detecting such mechanical problems as bearing deterioration, hydraulic failure, gear breakdown, lubrication failure and deteriorating valve seats which caused the air leaks at Wapping UK.

News International are also using Monition's state-of-the-art Novameter vibration monitoring systems to help detect problems such as unbalanced operation, misalignment, loose parts and worn components, which all factor in to poor equipment performance and eventual failure.

"We've been using the Monition Novameter for approximately one month and it has already identified several potentially serious problems including wrongly fitted fans and worn bearings.

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