Markus Brotsack BRCE2016

Bearing Reliabilty Conference & Expo
22. 23. March 2016

Markus Brotsack
PRUFTECHNIK Condition Monitoring
Markus Brotsack
Page 1
Facts and Figures
Made in Germany
1972
600
Founded by
Dieter Busch
Employees
Worldwide
18
Sales & Service

Subsidiaries
Belgium/Netherlands, Brazil, Canada,

China, France, India, Indonesia, Italy,
Japan, Middle East, Poland, Russia,
Singapore, Spain, Thailand, Turkey, UK,
USA
Markus Brotsack
Distributors in
70
Countries
Page 2
Facts and Figures (2)
300
20%
150
82
Patents
Worldwide
Trademarks
Worldwide
Sales
2014
R&D
Revenue in M
100
80
60
40
20
0
2009
2010
2011
2012
Markus Brotsack
2013
2014
Page 3
Company Activities
We make complex tasks easy to

achieve for our customers.
Our Mission
Our Core Activities
To be a leading single source

provider of premier measurement
and monitoring solutions for plant
maintenance and quality assurance.
Alignment Systems
Markus Brotsack
Condition Monitoring
Nondestructive Testing
Page 4
Laser Alignment Systems
Systems and services for laser

alignment of rotating machinery.
50% failures in rotating machinery are due to misalignment
Why alignment?
Our solutions
Misalignment increases
temperature, vibration and loads
Shaft alignment
Longer service life
Measurement of machine geometry
Increased MTBF and uptime
Misalignment increases wear of

bearings, couplings, seals and
shafts
Bore alignment
Lower power consumption
Monitoring positional changes
Downtime, production losses and

mechanical repairs generate high
operating and maintenance costs
Roll alignment with PARALIGN
Reduced temperature, vibration and

mechanical repairs
Benefits of alignment
Lower operating costs

Higher product quality
Markus Brotsack
Page 5
Condition Monitoring
Systems and services for vibration

analysis and monitoring of
machine condition.
Condition Monitoring can reduce operation and maintenance costs by up to 50%
Benefits of Condition
Monitoring
Why Condition
Monitoring?
Our solutions
Reduced machine lifetime due to

excess vibration and loads
Portable data collectors and

analyzers
Reduced machine availability due

to unplanned shutdowns
Online Condition Monitoring
Elimination of root cause before

failure occurs
Continuous wear monitoring
Reduced vibration and wear
Increased operating costs
Machine protection
Increased machine availability
Unavailability of machine health

data for CbM or asset reliability
Monitoring Services
Reduced operating costs
Certified Monitoring Center
CM feeds CbM and asset reliability

programs
Markus Brotsack
Early detection of machine problems
Page 6
Nondestructive Testing
Systems and services for

quality assurance and process
control in production of semifinished metal products.
Benefits of NDT
Why NDT?
Our solutions
Faults in products lower quality

and productivity
Eddy current testing equipment
Improved product quality
Flux leakage testing equipment
Optimized production processes
Impacts on competitiveness and

performance
Sensors and accessories
Reduced scrap
Turnkey systems from design

to commissioning
Improved productivity and

performance
Compliance to quality
standards is getting tighter
Markus Brotsack
Page 7
Worldwide Machinery Services
Laser Shaft Alignment
Turbine Alignment
Machine Condition Monitoring
Roll Alignment
Mobile Measurement
Geometric Alignment
Markus Brotsack
Page 8
Customer Support
Worldwide After-Sales Services
Calibration and Repair
Certified Monitoring Center
Telediagnosis
Remote Mentoring
Worldwide Training
CAT I-IV vibration training
Alignment training
Product training
Onsite training
Markus Brotsack
Page 9
Solutions for Manufacturing
We serve maintenance
professionals in any
industry where
rotating equipment is
in operation.
Markus Brotsack
Page 10
Poised for the Future
2015:
Merge of Alignment Systems and
Condition Monitoring business units
Optimize process efficiency and

customer orientation
Tight integration of Alignment
Systems and Condition
Monitoring
Markus Brotsack
Page 13
Equipment Alignment for Prolonged Life
Citation:
Industry worldwide is losing billions

of dollars a year due to misalignment
of machinery
Source:
John Piotrowski: Shaft Alignment Handbook,
CRC Press 20073rd
Markus Brotsack
2
Page 14
Agenda:
Short introduction to LCC
Costs over lifetime of a pump
Alignment of a motor pump systems
Relationship between alignment and costs of operation for a pump
Effects of misalignment
Possible savings a few examples
Summary
Examples of alignment in chemical industry
Contact data
Literature
Markus Brotsack
3
Page 15
LCC Life Cycle Costs

LCC includes following details:
LCC = Cic + Cin + Ce + Co + Cm + Cs + Cenv + Ccip + Cqu + Cd

Whereas
Cic
Cin
Ce
Co
Cm
Cs
Cenv
Ccip
Cqu
Cd
Original asset costs

Costs for installation
Costs for energy consumption
Costs for operation
Costs for mainteance
Costs for production downtime
Costs for environmental protection
Cleaning costs
Costs for quality improvments
End of life costs
Quelle: dena
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Page 16
25% other costs for

operation
23% original asset costs
LCC of a large water pump
32% cost for energy consumption
Maintenance cost
8%
20% costs for maintenance
Purchase cost
5%
Power consumed
87%
At least 1/3, even up to 4/5, of the LCC are used up for

energy, depending on type of pump and application
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Page 17
Shafts are aligned, if the two shafts

are in line during operation conditions.
Markus Brotsack
Page 18
vertical angle
vertical offset
horizontal angle
horizontal offset
Markus Brotsack
Page 19

Intelligent condition based maintenance on rotating equipment is part of maintenance
strategies. This also includes precise alignment of shafts.
Analyzing the root causes of break down at rotating machinery it is found that over 50%
are due to misalignment.
Markus Brotsack
Page 20
Results of misalignment
Increased abrasive wear of following parts:

Bearings
Seals
Couplings
Shafts
Reduction of MTBF Mean Time Between Failure

Extreme: Noise due to increased vibrations
Increased power consumption
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Page 21
Signs for a misaligned shaft system:
Strong radial and axial vibrations

Strong abrasion at bearings, sealings, couplings and broken shafts
(extreme)
Oil leakage at the bearings
High temperature at bearings and couplings
Loosing of bolting
Increasing energy consumption
And others more
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Page 22
Example: Increase temperature at coupling and

Bearing of a motor pump systems (infrared image)
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Page 23
The reality concering alignment in industry:

Example of a chemical company, England
160 randomly chosen machines

3.000 rotations per minute
Machines have been aligned with conventional 11%
method (dial gauge / straight edge)
7%
10%
18%
Offset (mm)
Measured machines
0,00 0,05
0,06 0,10
0,11 0,20
0,21 0,50
0,51 1,00
> 1,00
7% acceptable alignment
10% out of tolerance
23%
31%
Source: large chemical company in England
Only 7% of measured machines were aligned within tolerance
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Page 24
Lifetime of bearing
The smaller the offset of the two shafts at the coupling, the longer the
expected lifetime of the bearings.
Courtesy of The University of Tennessee
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11
Page 25
Lifetime of bearings
Maximal percentage of the expected lifetime of a bearing at the example
of a gearbox bearing, relative to a perfect aligned system.
90%
Max. Offset
0,13 mm
80%
Max. Offset
0,25 mm
50%
Max. Offset
0,89 mm
Courtesy of The University of Tennessee
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Page 26
Repair of mechanical seals

The number of the repair of seals is reduced by 65% after consequent
and regular laser optical alignment has been introduced.
Courtesy of Hoechst AG Gendorf/Germany
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Page 28
Repair of mechanical seals

The lifetime of seals increases significantly with the precise alignment of
shafts.
80
Max. Offset
0,05 mm
3,5
Max. Offset
0,65 mm
1,5
(month)
Max. Offset
1,2 mm
Courtesy from Durametallic plus AES Seals
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15
Page 29
Repair of pumps
The number of pump repairs is droping 30% after the consequent and
regular introduction of laser optical alignment.
Courtesy of Hoechst AG Gendorf/Germany
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Page 31
Changes in terms of energy consumption

Significant savings concering the energy consumption can be achieved
due to precise shaft alignment
Perfect alignment reduces restoring forces and reduces the energy
consumption up to 10%
Source: UK pump association
Courtesy of an UK major chemical plant
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Page 33
Advantages of precis shaft alignment:
Optimizing the lifetime of assets

Cost reduction due to increased lifetime of wear parts (bearings, seals)
Reduction of longterm maintenance costs
Optimising reliability of the production process
Increase the availability of assest
Reduce the energy costs
Improve the safety in total
Contribution to a cleaner environment
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Page 36
Shaft alignment systems

Standard and mobile shaft alignment products
OPTALIGN smart RS5
ROTALIGN Ultra iS
ROTALIGN touch
The power of precision shaft

alignment
The intelligent alignment platform
Cloud-enabled laser shaft alignment

system
SHAFTALIGN OS3
tab@lign
The efficiency of laser shaft

alignment
Laser shaft alignment on tablets

ans smartphones
Markus Brotsack
Page 37
Geometrical measurement systems

Geometrical laser alignment products
LEVALIGN expert
LEVALIGN Ultra iS
PENTALIGN
Flatness and level with a spin
Flatness, perpendicularity, level,

easily done!
Perpendicularity and parallelism

of axes and planes
PARALIGN
CENTRALIGN Ultra expert
OPTALIGN smart RS5

Straightness
The revolutionary method for roll

alignment
Turbine alignment with high accuracy

in less time
Straightness measurement in two

dimensions
Markus Brotsack
Page 38
Portable Systems
for machine condition monitoring
Data collectors, vibration analyzers and balancers
VIBXPERT II
VIBXPERT II Balancer
VIBSCANNER
The Expert in data collection,

vibration analysis and field
balancing
On-the-spot field balancing - simple,

fast and accurate!
The clever data collector &

vibration analyzer
VIBROTIP
The 5-in-1 data collector for
machine condition monitoring
Markus Brotsack
Page 39
Online Condition Monitoring Systems
VIBGUARD
VIBNODE
VIBRONET Signalmaster
Advanced Online Condition

Monitoring
Standard Online system for

individual aggregates
Proven Online Monitoring for

industrial plants
VIBROWEB XP
VIBGUARD portable
VIBCONNECT RF
Compact Online Diagnostic

Monitoring
Advanced Condition Monitoring

on the move
Wireless Online Monitoring
Markus Brotsack
Page 40
Contact data:
Markus Brotsack
Tel.:
+49 89 99 616 144
Mobil: +49 160 906 906 51
E-Mail: markus.brotsack@pruftechnik.com
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Page 41
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Page 42
Literature:
Dena: System Effizienz Pumpen; http://www.industrieenergieeffizienz.de/fileadmin/InitiativeEnergieEffizienz/referenzprojekte/images/Pu

mpensysteme_alleFactsheets.pdf
Herborner Pumpentechnik:Lebenszykluskosten Erluterungen und

Berechnung; http://www.herborner-pumpen.de
Investigations at University Tennesee
UK pump association
Investigations at Hoechst/Gendorf in cooperation with PRFTECHNIK
Investigations at ICI (Imperial Chemical Industries) in Great Britain in
cooperation with PRFTECHNIK
John Piotrowski: Shaft Alignment Handbook; CRC Press; 20073
PRFTECHNIK Alignment Systems Machinery Service Team
ALIGNMENT newsletter Ausgaben 1/2006 und 3/2009
Research in Wikipedia
Markus Brotsack
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Page 43
Thank you
QUALITY MEANS TO US:
TO MAKE A DIFFERENCE EVERY DAY.
www.pruftechnik.com
Markus Brotsack
Page 44

Markus Brotsack BRCE2016

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Bearing Reliabilty Conference & Expo

22. 23. March 2016

PRUFTECHNIK Condition Monitoring

Facts and Figures

PRUFTECHNIK Condition Monitoring

Sales & Service

Belgium/Netherlands, Brazil, Canada,

Facts and Figures (2)

PRUFTECHNIK Condition Monitoring

We make complex tasks easy to

Our Core Activities

To be a leading single source

PRUFTECHNIK Condition Monitoring

Laser Alignment Systems

Systems and services for laser

50% failures in rotating machinery are due to misalignment

Longer service life

Measurement of machine geometry

Increased MTBF and uptime

Misalignment increases wear of

Lower power consumption

Monitoring positional changes

Downtime, production losses and

Roll alignment with PARALIGN

Reduced temperature, vibration and

PRUFTECHNIK Condition Monitoring

Lower operating costs

Systems and services for vibration

Condition Monitoring can reduce operation and maintenance costs by up to 50%

Reduced machine lifetime due to

Portable data collectors and

Reduced machine availability due

Online Condition Monitoring

Elimination of root cause before

Continuous wear monitoring

Reduced vibration and wear

Increased operating costs

Increased machine availability

Unavailability of machine health

Reduced operating costs

Certified Monitoring Center

CM feeds CbM and asset reliability

PRUFTECHNIK Condition Monitoring

Early detection of machine problems

Systems and services for

Faults in products lower quality

Eddy current testing equipment

Improved product quality

Flux leakage testing equipment

Optimized production processes

Impacts on competitiveness and

Sensors and accessories

Turnkey systems from design

Improved productivity and

PRUFTECHNIK Condition Monitoring

Worldwide Machinery Services

Laser Shaft Alignment

Machine Condition Monitoring

PRUFTECHNIK Condition Monitoring

PRUFTECHNIK Condition Monitoring

Solutions for Manufacturing

PRUFTECHNIK Condition Monitoring

Poised for the Future

Optimize process efficiency and