PreDiCon

PreDiCon

SUPPLYING AFDABLE COMPLETE SOLUTIONS

Wilmar House, 23-25 Windermere Road,
Blackpool FY4 2BX
Tel (01253) 400541 Fax: (01253) 400552
Email: engineering@predicon.net

SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

AWARD WINNING
SYSTEMS

TRAINING

SYSTEM
SETUP

SYSTEM
AUDITS

ON LINE &
OFF-LINE
MONITORING

REMOTE
ANALYSIS
VIA
MODEM

TRIBOLOGY

TRAINING IN
VIBRATION ANALYSIS,
THERMOGRAPHY
& OTHER TECHNIQUES

CONSULTANCY
& TROUBLE
SHOOTING

CONTRACT
MEASUREMENT,
ANALYSIS
&
REPORTING

NEEDS
ANALYSIS

PreDiCon

SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

PreDiCon.

Company Profile

PreDiCon is the Predictive Maintenance (PdM) engineering company

specialising in the practical application of predictive maintenance
technologies. PreDiCon is fully independent and has no formal links with any
of the off-line PdM hardware manufacturers or PdM software houses; this has
been a conscious decision on behalf of the management at PreDiCon to
ensure that our customers realize that we have no axe to grind when making
equipment recommendations. If PreDiCon makes a recommendation for
monitoring equipment then that recommendation is made solely with the
customers interest at heart and with no regard for any commission from
subsequent sales. PreDiCon installs systems from all of the leading PdM
manufacturers including On-Line monitoring, Entek/IRD, CSI, SKF, DLI etc.
but is totally independent from all of them.

The Company

re
i

DC
on

Company Relationships

PreDiCon was incorporated in the USA in 1989 and in

England in 1999. PreDiCon has built an enviable
reputation for service and quality solutions supplied to
North American and European manufacturers. The
range of activities is extensive, but PreDiCon remains
totally committed and focused on providing the customer
with systematic solutions for maximizing equipment uptime and quality, while reducing the cost of maintenance
and non-production inventories.

Vibration Standards

PreDiCon can provide you with a complete service to ensure

that you achieve your internal objectives with minimal
disruption in the process. PreDiCon has successfully
installed PdM systems in many facilities in North America
and Mexico and the on-board engineers have installed
numerous systems world-wide. PreDiCon installed systems
have won several prizes for Excellence at the National (US)
PdM System of the Year Awards. These great honours are
not bestowed lightly and we at PreDiCon feel justly proud
of our achievements.

Potential Failure Analysis

PreDiCon has developed comprehensive standards of

vibration practice and acceptable levels for new and
rebuilt equipment. A copy of the standards is available
if required.

Work Procedures
PreDiCon has developed work procedures for all aspects
of work in the condition monitoring and predictive
maintenance technologies. All procedures are available
for inspection by our business partners.

Reporting
All analysis results and recommendations for PreDiCon
work are recorded in an Access database. Reports and work
requests are user definable and may be issued on paper or
electronically according to the customers requirements.
Special reports according to the customers requirements may
be defined so as to be automatically generated at given
periods.

The most challenging aspect of running and operating a

predictive maintenance system (bar none) is the initial
system set up. This is the stage at which the most
experience and operating knowledge of predictive
maintenance is required yet the set up is almost always
carried out by people who are new to the field. The
appropriate structure of the individual machine set up in
the database is crucial to successful implementation and
operation of the predictive maintenance system. The
Potential Failure Analysis is a method of formalizing the
set up and allows audit tracking and integration with
ISO 9000 Quality Assurance systems.
PreDiCon
developed the PFA structure and uses it at all levels of
operation.

Technical Authoring
PreDiCon engineers have been contracted to develop
many predictive maintenance technical papers and
procedures. The latest addition to our technical library
is the Press Monitoring Handbook which was written to
help PdM engineers understand the sometimes complex
failure mechanisms in large slow speed stamping
presses for the automotive industry.

Phone: (01253) 400554 Fax (01253) 400553 UK

(517) 764-6800 (phone) 6869 (fax) USA
E-Mail: engineering@predicon.net

PreDiCon

SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

PreDiCon.

Contract services for Predictive Maintenance

PreDiCon has implemented PdM solutions for many industries encompassing many PdM vendor solutions. We have
installed and operated systems of all sizes with PreDiCon installed systems winning joint first and first runner up in
the last independent PdM awards. All PdM services are performed by engineers with experience in implementing
multiple vendor and technology solutions. PreDiCon is not tied to any particular vendor and can give completely
independent advice.
Outside of the vendors themselves we have setup more off-line vibration, on-line vibration and thermographic systems
from many different vendors in a variety of applications than anyone we know. This has provided us with a sound
grasp of what makes PdM work in industry

PdM feasibility studies

On-Line Remote Vibration Analysis

Our engineers have the expertise to identify whether PdM will

work effectively for your plant, focused on your particular
equipment and program goals. We will recommend the best fit
solution for your needs and help you and train you in how to
best implement it.

If your capital expenditure will not allow you to purchase an online monitoring system, let us install a system and we will
interrogate the system remotely on a daily basis. All data is
transferred via internet and we report back to you immediately
we find an exception condition. We also provide a full report
every month giving you an overview of all monitored
equipment.

Existing system audits

Thermographic Surveys

If you are an existing system user and are not achieving the
goals intended there may be a reason. We have the experience
to find the causes and get you back on track.

Our qualified technicians and engineers can carry out a

thermographic survey of your plant. The survey is carried out
on equipment that you nominate and we will tell you the
condition as determined by the infra-red signature.

On Site Vibration Analysis Surveys

Training

If you are an existing PdM user but lack the experience for
detailed data analysis, let us do it for you. Either you collect
the data and modem it to PreDiCon for analysis or we will send
in one of our engineers to take the readings for you. We do the
analysis and send you results.

PreDiCon offers focused on-site and off-site training programs

aimed at equipping your people with the knowledge they need
to be successful with applying PdM. techniques. We focus on
programmatic implementation as well as data analysis and offer
tailored programs to fit your needs.

Phone: (01253) 400554 Fax (01253) 400553 UK

(517) 764-6800 (phone) 6869 (fax) USA
E-Mail: engineering@predicon.net

PreDiCon

SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

PreDiCon.

On Line Continuous Vibration Monitoring Carried Out

Remotely by our Engineering Staff

Effective, continuous condition monitoring for less than the cost of a data collector system!
Vibration analysis provides an indication of the health of a machine and is non-intrusive.
When we know the condition of the machine, we can decide to carry out maintenance or
repair work only when needed, avoiding production losses through machine failure as well
as avoiding excessive machine outages because of unnecessary maintenance. Often we
would like to monitor the vibration of a machine but we feel we cannot due to any of a
number of reasons such as cost, safety or extreme machine operating conditions. For the
first time it is now possible to install an on-line, full capability, spectral vibration analysis
system, which is extremely easy to use, for less than the price of a data collector and
software.

Quick & Effective Vibration Analysis

For the first time, a system is available which can provide
inexpensive and effective vibration analysis - the On-Line
monitoring on-line monitoring system. The new On-Line
monitoring system has the following advantages:
Improved Safety
No manpower requirement
Excellent reliability
Data collection interval improved from once per

month to less than 30 seconds

Quick failure mechanisms can be trended &
predicted
Excellent data consistency

All this for less than the price of a data collector and
software!

The software
PreDiCons On-Line monitoring system is based on the industry
standard Windows NT operating system. Navigation through
the software is carried out via the intuitive photo/graphical
interface. Once all connections are made and PreDiCon has
carried out the necessary configuration, the user monitors all
attached machines through the straightforward on-line screen.
Once the on-line screen displays an alarm (yellow or red
depending on severity), it is a simple matter to click on the
analyze button and the software will then tell the operator the
cause of the problem and the recommended course of action.
This system is very easy to use, belying the hidden complexity
which drives the expert system.
Below are three analysis results from the same point taken at
different times and indicating the differing levels of machine
degradation.
Level 1 Green The vibration is normal and does not indicate a
defect.
Level 2 Yellow Gives early warning of a developing problem.
Level 3 Red

The hardware
The system hardware consists of a server PC and several data
collection nodes. Each node has sixteen channel inputs which
may be configured as a dynamic vibration input or as a simple
voltage input. Each channel may be configured with up to 4
different types of readings. Nodes can be ordered in ARCNet or
Ethernet configuration.
Many machines may be connected and monitored
simultaneously. The node is very easy to configure and install.
All data collection configuration is done through the software.
This system is very sophisticated but with an easy to use,
intuitive interface. Advances in micro-electronics allow us to
offer this system for sale at a hitherto unheard of low price
making our On-Line monitoring the most effective and costeffective machine monitoring system in the world. We can
provide the system on a direct sale basis or on an ongoing
contract basis where we install the system and carry out routine
vibration analysis from our office on a daily basis. All data is
transferred by internet connection. We assess the data every day
and report back to you immediately we find a problem. We also
provide a full report every month giving you an overview of the
condition of all monitored equipment.

The most serious warning level. At this stage the

machine is suffering (or is very close to) actual
damage.

Phone: (01253) 400554 Fax (01253) 400553 UK

(517) 764-6800 (phone) 6869 (fax) USA
E-Mail: engineering@predicon.net

PreDiCon

SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

PreDiCon.

Data Collection & Reporting

Vibration analysis can be very difficult to analyze. Why not get the experts to carry out all
of the work for you and present you with a simple set of results and recommendations
after every visit? Our engineers are the best in the business and we will ensure that the
reports give you good, practical advice.
After each visit for off-line or every day for on-line remote, you will receive a verbal report
immediately if anything is dangerously close to failure. For off line systems you will then
get a fax or e-mail report within 2 working days and a complete written report mailed to
you within one week. On-line remote monitoring systems will provide a same day verbal
and e-mail report and a full condition analysis every month.
Vibration Analysis

Thermography

The written reports for vibration analysis include not only a copy
of the plot but also, more importantly, recommendations for
repair. Reports are stored in a database for easy data retrieval
and custom report generation. A cost analysis module is
available if required.

The thermographic reports include the thermal image as well as

a digitally stored visual image.
A further report may be
generated if required after the repair work is carried out.
Reports may be custom designed at no extra charge.

Typical Vibration Analysis Report

Typical Thermographic Report

Phone: (01253) 400554 Fax (01253) 400553 UK

(517) 764-6800 (phone) 6869 (fax) USA
E-Mail: engineering@predicon.net

PreDiCon

SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

PreDiCon.

Infra Red Thermography

As an object gets hotter, it emits more radiation in the infrared part of the
electromagnetic spectrum. With a device that could measure infrared radiation you
could indirectly measure the temperature of an object. We call this device an infrared
camera and we call the science of its use Infrared Thermography. PreDiCon has the
best cameras available with a reporting system second to none. Thermographic
techniques can be used to detect a host of different problems. Our engineers are all
qualified in the use of thermographic cameras and have extensive experience in the
various applications.

*>60.5C

Electrical Defects

60.0

Switch room and bus surveys are quick and extremely effective. One section of blown bus
can put your factory out of operation for a full day. Compare that cost to a single day for one
of our engineers with an infra red camera at a cost of 300 (or 55 p.h. for smaller jobs)
including a comprehensive written report.

55.0
50.0
45.0
40.0
35.0
30.0
25.0
20.0

Area4
Min Mean Max
31.0 51.2 73.7

15.0
10.0
5.0

*>49.7C

Mechanical Defects

Spot 1
45.2
Area1
Min Mean Max
24.8 39.7 49.3

45.0
40.0

Bearings with lubrication problems, dry push rods or screws, slipping belts, bad compressor
valves, insulation defects, bad steam traps - the list goes on and on. If the defect causes a
temperature change, we can see it and tell you about it.

35.0
30.0
25.0
20.0
15.0

Spot 2
45.4

Spot 3
45.6

Spot Welding Problems

We have a wealth of experience in detecting problems in secondary weld cables,
transformers, and weld guns. This image shows a weld tip with a cooling water connection
that is too short causing overheating of the weld tip - resulting in bad welds.

Building Structural Surveys

Concrete structures are vulnerable to internal delamination and debonding of render coatings
or other surface finishes. This may be a result of corrosion of the internal reinforcing bars or
may have been a result of the original pour due to poor compaction. Thermography can
detect the areas of delamination or debonding by measuring the heat transfer.

Wall Insulation & Flat Roof Surveys

Use thermography to detect excessive heat loss or external draughts. Avoid the huge
expense of a complete roof repair by using thermography to pinpoint the areas where
repairs are necessary.

Underground Pipe Leak Detection

The traditional method for locating leaks is to isolate one section of the system at a time until
the general area of the leak is identified and then dig several trial holes on a hit and miss
basis. Using thermography, any leak or defective insulation will cause a slight increase in the
temperature of the ground above the leak enabling quick accurate location..

Phone: (01253) 400554 Fax (01253) 400553 UK

(517) 764-6800 (phone) 6869 (fax) USA
E-Mail: engineering@predicon.net

PreDiCon

SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

PreDiCon.

Predictive Maintenance Consultancy & Trouble- Shooting

In many cases it is difficult for the maintenance or production engineer to identify the cause
of a fault. Very often the cause can be traced back to a structural natural frequency
coinciding with a machine operating speed or other forcing function. Using advanced
techniques and equipment, our engineers have the knowledge and experience to help identify
the causes of such problems and recommend realistic solutions. We have identified several
case histories from our files and include these as examples.

Vibration Analysis
Vibration influence on a load cell
We were called in to investigate a
problem that a client of ours was
having with a load cell on a copper
smelter.
The problem was
variations in the poured weight of
the copper and the engineer in charge had a suspicion that
environmental vibration could be playing a role. There is a
load cell under each spoon, which accurately measures the
weight of the copper during the pour process so that the
finished product is at an exact weight. Variations in the weight
appeared to occur randomly so our engineer set out to
determine any causal link between vibration and load cell
output.
The time trace showed that vibration was measurable at the
load cell. The surprise was that this vibration was caused not
only by the pour process but also by exterior influences such as
the movement of the overhead cranes and fork-lift trucks. The
time trace below shows the filter-out vibration over one full
operating cycle.
The next stage was to
identify the vibration
source.
An FFT
spectrum of the floor
showed a dominant
frequency at about 7
Hz. This was shown to be the natural frequency of the floor
and was excited by all of the external forces named above.
The spectrum analyzer was then connected to the voltage
output of the load cell. Interestingly, the load cell output also
showed a frequency at about 7
Hz. It was now obvious that
the vibration in the floor was
directly affecting the load cell
output.
The intermittent
nature of the problem was due
to the random impacting from
external influences and the
fact that the controller samples
twice during each process
pour.
The answer was to first put a notch filter in the load cell output
to remove the problem frequency and secondly to install
vibration isolators under the load cell feet. The long term
solution is to grout under the floor to remove the vibration
completely.
Machine Operator Vibration Induced Sickness
One client called us in to identify the cause of excessive
vibration at the operator station. The vibration was causing the
operator to feel nauseous at particular machine speeds.

The subject machine was

an extruder used in the manufacture of insulation for electrical
cables. Noise and vibration frequency domain readings showed
that the main frequency of concern was at 300 Hz. The
amplitude at this frequency was extremely severe at specific
speeds of the extruder but became innocuous (although always
measurable) at other speeds.
Operating the machine over a wide speed range, our engineer
saw two main frequencies of vibration caused by the DC motor
electrical drive (constant at 300 Hz) and the frequency of the
main drive gears which changed with the speed. When the
speed was such that the gear meshing vibration coincided with
the DC drive vibration, amplitudes were measured in excess of
75 mm/s RMS.
The cause of the problem was two-fold. There was an SCR
fault on the motor drive and one gear wheel had been
incorrectly machined to give an inaccurate tooth profile. The
SCR was repaired and the gear wheel renewed. The machine
now operates satisfactorily and at low noise and vibration
levels.

Thermography
Induction heating of a weld robot wrist

This data was captured during a routine check of the secondary

circuit weld cables on a spot welding robot at an automotive
fabricating plant. High temperatures were noted at the robot
wrist at 28C (50F) above ambient. PreDiCon was asked to
find the cause of the over-heating. The initial avenue of
research was to look for a mechanical source of heat at the
wrist. The advanced analytical capabilities of the thermal
imaging software indicated that the source was internal rather
than external. The wrist bearings were ruled out as a source as
the bearings were not in the same place as the source. It was
then noticed that that the weld secondary circuit jumper cables
were unusually routed on either
side of the wrist. It became
apparent that the very high
currents (>15kA) in the secondary
circuit were developing high
magnetic fields resulting in
induction heating of the wrist.
The jumper cables were re-routed
and the problem disappeared.

Phone: (01253) 400554 Fax (01253) 400553 UK

(517) 764-6800 (phone) 6869 (fax) USA
E-Mail: engineering@predicon.net

PreDiCon

SUPPLYING AFFORDABLE COMPLETE SOLUTIONS

PreDiCon.

Predictive Maintenance Training for Industry

PreDiCon. has developed a modular approach to training PdM technology users, aimed at
developing an effective PdM program. We focus not only on the technology and how to
interpret data, but we also provide help in program set up and tracking your PdM goals.
Courses can be tailor made to suit your individual requirements and are held either at our
comprehensive training facility or at your plant.
Training courses start from as little as 140 per student.

Modules
I.

PdM Management
a.
b.
c.
d.
e.
f.

II.

III.

IV.

V.

VI.

VII.

2 day
XII.

a.
b.
c.
d.
e.
f.

1 day

2 days

1 day

1 day

Identifying potential failures

Determination of applicable technologies
Definition of suitable measurement parameters

Specialized training courses

IIX.

PdM on Rolling Element Bearings 1 day

a.
b.
c.
d.
e.
f.
g.

IX.

Bearing construction
Elastohydrodynamic lubrication
stages of bearing failure
Failure modes
Fault frequency generation
Vibration examples of common defects
Tribology

PdM on AC & DC Motor

a.
b.
c.

1 day

Theory of operation
Failure modes
Vibration examples of common defects
Performance analysis
Adjusting bedplate resonance

PdM on Large Stamping Presses 2 day

Ultra sound theory

Detecting leaks
Electrical applications
Mechanical applications
Integration into spectrum analyzers

Potential Failure Analysis

a.
b.
c.

a.
b.
c.
d.
e.

1 day

Centrifugal pumps - theory of operation

Centrifugal pump construction
Positive displacement pumps construction
Failure modes
Vibration examples of common defects
Performance analysis

PdM on Fans

Infra red theory

Qualitative thermography
Radiometric thermography
Fault analysis
PdM integration

Passive Ultra Sound in PdM

a.
b.
c.
d.
e.

XI.

File capture of vibration data

Variable speed machines
Triggering
Measurement parameters
Capture and display options
Two-channel functions
Impact testing

Industrial Thermography
a.
b.
c.
d.
e.

2 day

Vibration examples of common defects

Motor current analysis
DC motor construction
Failure modes
DC drives
Vibration examples of common defects
Thermography

PdM on Pumps
a.
b.
c.
d.
e.
f.

Resonance
Dynamic range
Frequency calculations
Effects of windowing
Amplitude demodulation
Phase
Fault analysis
Single plane balancing
ODS

Two Channel Analysis

a.
b.
c.
d.
e.
f.
g.

X.

Frequency -v- time domain

How the FFT works
Examples of basic defects
Transducers
Accelerometer mounting
Measurement parameters

Advanced Vibration Analysis

a.
b.
c.
d.
e.
f.
g.
h.
i.

1 day

Maintenance strategies
Project management
Choosing the right technologies
Integration into maintenance
Procedures
Reporting

Basic Vibration Analysis

a.
b.
c.
d.
e.
f.

d.
e.
f.
g.
h.
i.
j.

1 day

AC motor construction
Failure modes
Generation of electrical frequencies

Phone: (01253) 400554 Fax (01253) 400553 UK

(517) 764-6800 (phone) 6869 (fax) USA
E-Mail: engineering@predicon.net

Press construction
Failure modes
Specific monitoring problems
Sensors & installation
Defining vibration measurements
Using advanced vibration techniques