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Table of Contents Introduction................….........................................….................................... 1 CMS Document Fields ………………………………….……………….…. 2 How to Use This Book …………………………………...……………….… 4 Condition Monitoring Standards…..…………..……….……….………… 9 206 Belt, Magnet 207 Belt, Scale 208 Cleaner, Through Flow 209 Conveyor, Screw, Enclosed 210 Coupling, Chain 211 Coupling, Locking 212 Coupling, Rigid 213 E-Stop, Push Button 214 Filter, In-Line 215 Filter, Vacuum, Belt 216 Filter, Vacuum, Rotary, Drum 217 Generator, Diesel 218 Mill, Ball 219 Mill, Impact 220 Mobile, Forklift 221 Pump, Lobe 222 Pump, Pitot Tube 223 Reducer, Cycloidal 224 Ring, Slewing 226 Rolls, General 227 Seal, Mechanical, Double 228 Valve, Hydraulic 229 Valve, Knife Gate 230 Valve, Pressure Relief, Spring Loaded 231 Valve, Rupture Disc
Vol. 5 Introduction © IDCON, INC. 2001 - 2023 0 Index of Other Condition Monitoring Standard Volumes CMS# Volume 1 CMS# Volume 2 CMS # Volume 3 100 Motor, AC 125 Motion Detector, Magnetic 150 Universal Joint 101 Coupling, Tire 126 Backstop, Sprang Clutch 151 Rope Sheaves 102 Coupling, Sure Flex 127 Pump, Centrifugal 152 Regulator, Air 103 Coupling, Grid 128 Heat Exchanger 153 Pump, Progressive Cavity 104 Coupling, Thomas 129 Bearing, Pillow, Flange 154 Blower, Rotary Lobe 105 Coupling Wrap/Atra Flex 130 Drive, Chain 155 Belt, Cog 106 Coupling, Gear 131 Hydraulic Unit 156 Doctor Blade 107 Coupling, Jaw 132 Feeder 157 Brake, Disc 108 Coupling, Magnetic 133 Seal, Mechanical, Single 158 Bolts and Nuts 109 Coupling, Torus 134 Packing 159 Cylinder, Pneumatic 110 Pump, Vacuum Nash 135 Valve, Check 160 Pump, Diaphragm 111 Pump-Vertical, Multistage 136 Screen, Reciprocating 161 Motor, DC 112 Tank, Non-Pressurized, Insulated 137 Drive, V-Belt 162 Valve, Air Actuator 113 Conveyor, Screw, Open Top 138 Screen, Vibrating 163 Clutch, Centrifugal 114 Valve, Solenoid 139 Screen, Disc 164 Expansion Joint 115 Air Breather, Desiccant 140 Screen, Bird 165 Coupling, Fluid 116 Flinger 141 Lube Oil System 166 Hydraulic Cylinder 117 Reducer, Gear 142 Fan, Radial 167 Bearing, Sleeve, Water Cooled 118 Conveyor, Belt 143 Pump, Sliding Vane 168 Motor, Hydraulic 119 Conveyor, Drag 144 Pump, Gear 169 Pump, Multistage 120 Fan, Axial 145 Pump, Axial Piston 170 Governor 121 Agitator Mixer 146 Steam Trap, Mechanical 171 Pneumatic, Filter, Oil Mist 122 Compressor, Rotary Screw, Quincy 147 Steam Trap, Thermostatic 172 Piping & Hangers 123 Dryer System, Air Desiccant 148 Steam Trap, Thermodynamic 173 Steam Turbine, Small 124 Steam Joint, Valmet 149 Actuator, Valve 174 Caterpillar D11 Tractor CMS# Volume 4 CMS# Volume 4 175 Pump, Centrifugal, Double Suction 192 Motor Starter, Magnetic 176 Refiner, Pulp, Beloit Double Disc 193 Accumulator, Compressed Air 177 Refiner, Pulp, Classic Conical 194 Conveyor, Belt, Small Production 178 Refiner, Pulp, Conical Disc 195 Switch, Limit, Linear 179 Refiner, Pulp, Single Disc 196 Switch, Limit, Rotary 180 Debarker, Drum 197 Strander, Carmanah Disc, Operational 181 Switch, Proximity, Capacitive 198 Strander, Carmanah Disc, Stopped 182 Switch, Proximity, Inductive 199 Lubrication, Single Point Unit 183 Switch, Proximity, Acoustic 184 Coupling, Safeset 185 Coupling, Flexible Compression Sleeve 186 Pump, Peristaltic 187 Meter Flow Magnetic 188 Pump, Diaphragm Metering 189 Pump, Vertical, Pedestal Sump 190 Drives, Index, Rotary 191 Accumulator, Hydraulic Bladder
www.idcon.com ©2023 IDCON, INC. CMS 209 Page 1 of 4 919-847-8764 Do Not Copy Conveyor, Screw, Closed CMS209 Condition Monitoring Standards Basic Principle A closed screw conveyor uses a motor to rotate a shaft with a screw, pushing material as the screw rotates. Screw conveyors can operate horizontally, vertically, or at an angle.
www.idcon.com ©2023 IDCON, INC. CMS 209 Page 2 of 4 919-847-8764 Do Not Copy OPERATIONAL KEY WHAT WHY Frame Inspect the frame, base and foundation for damage and excessive corrosion. • In concrete foundations, inspect for cracks, erosion, and unevenness. • On a steel base, inspect for corrosions and cracks. Corrosion does not necessarily appear as rust. Properly drain process fluids, slurry, water, or seal water away from the foundation and base. Foundation and base should be clean and dry. A damaged base and/or foundation will cause misalignment and vibration. Bolts & Fasteners Check that all mounting bolts and anchor bolts are tight and free from corrosion. A corroded bolt is a loose bolt, or it will become loose soon. Make sure washers and bolts are made of the same material or combinations of material. If a loose mounting bolt is found, make a note, tighten at next downtime opportunity, and then recheck alignment. Loose mounting bolts will gradually cause misalignment. Two dissimilar metals will corrode when put together. Tightening a bolt may pull equipment out of alignment. Trough Inspect trough of conveyor for corrosion. Inspect outer shell for any damage or leaks. Check the mating surfaces, making sure no product is leaking from the gasket surfaces and that there are no holes in the outer shell. Reference CMS 133 or 134 for information on seals or packing. Excessive corrosion and leaks can cause a sudden failure of structural components.
www.idcon.com ©2023 IDCON, INC. CMS 209 Page 3 of 4 919-847-8764 Do Not Copy KEY WHAT WHY Noise Check for any unusual noise from the screw conveyor. Listen for scraping or clicking. Unusual noise or vibration can be an indication that there is misalignment or broken parts in the screw conveyor or that the bearings do not have enough lubricant. Scraping sounds may indicate that the screw is contacting the housing. Clicking sounds may be an indication of loose fasteners or misalignment. Detailed Cleaning Inspect cleanliness of screw conveyor exterior, inlet, and outlet to allow maintenance checks to be done accurately. Picture courtesy: powderbulksolids.com Keeping the screw conveyor exterior clean will allow maintenance checks to be done faster and more effectively. Vibration Measure vibration of bearing housings with vibration pen. Increased levels of vibration can indicate bearing failure or other problems. Temperature Measure temperature of bearing housings with IR temperature gun. Increased temperature can indicate impending bearing failure or misalignment.
www.idcon.com ©2023 IDCON, INC. CMS 209 Page 4 of 4 919-847-8764 Do Not Copy STOPPED KEY WHAT WHY Internal Components Inspect screw conveyor internals looking for any damage to the screw or bearings. Inspect trough liner for any damage to the liner. Damage to the internals of the screw conveyor can lead to further damage or loss of function. Detecting damage early can help avoid unnecessary downtime. LUBRICATION KEY WHAT WHY Bearing Lubrication Lubricate bearings according to manufacturer’s recommendations or use an ultrasonic probe to hear when the grease reaches the bearing. Follow the ultrasonic instrument manufacturer’s recommended grease procedure. Improper lubrication can result in premature bearing life. Including damaged seals, higher temperatures, and damage to bearing race and/or rolling elements. The principal of ultrasonic greasing is that when the grease enters the bearing, friction will decrease and lower the ultrasonic signal. Pumping too much grease will increase friction and the ultrasonic signal will increase.
www.idcon.com © IDCON, INC. 2023 CMS 210 Page 1 of 4 919-847-8764 Do Not Copy Coupling, Chain CMS 210 Condition Monitoring Standards Basic Principle A chain coupling is classified as a rigid coupling that allows for some relative movement between two shafts. The chain coupling attaches two shafts using gears on both hubs and a chain laying over the teeth of both gears. Maximum misalignment is limited to 1 degree angular and 2% of chain pitch for parallel misalignment. Picture courtesy: Arrow Engineering Components
www.idcon.com © IDCON, INC. 2006-2023 CMS 210 Page 2 of 4 919-847-8764 Do Not Copy OPERATIONAL KEY WHAT WHY Guard Check that the guard does not have any damage, is secured properly, and allows for on-the-run inspections. Coupling Guards suit electric motor/gearmotor connections Picture courtesy: thomasnet.com Proper guarding allows for safe inspection. A loose or missing guard is a safety hazard and should be repaired/replaced as soon as possible. Noise Listen for any abnormal noise coming from the coupling, such as clunking or clinking of the chain. Unusual noise can indicate a damaged, loose, or misaligned chain/gears. Leaking Grease Inspect coupling and guard for signs of leaking grease. Leaking grease leads to premature coupling failure.
www.idcon.com © IDCON, INC. 2006-2023 CMS 210 Page 3 of 4 919-847-8764 Do Not Copy KEY WHAT WHY Visual Inspect chain coupling using a stroboscope. Check for excessive misalignment, leaking lubricant, damage to the chain itself, or loose sprockets. Different chains allow for different degrees of misalignment. Follow the owner’s manual recommendation to ensure that the chain coupling is within the degree of misalignment allowed. Some chain couplings do not require lubrication, but the use of a guard and lubricant will extend the life. Comintec GC Chain Couplings Picture courtesy: marshward.com Misalignment is one of the most common causes of a broken chain coupling. Pressure caused by misalignment acts on the chain until it breaks. Loose sprockets can cause the chain to become misaligned and lead to further damage. A damaged chain can lead to further damage or a break. Lubricant provides protection to the chain from frictional damage. If there is leaking lubricant, there could be a break in the guard. Keyway Inspect key and keyway of both coupling halves. Worn or damaged keys and keyways will lead to loss of coupling function and possible secondary damage. Temperature Measure temperature across coupling with IR temperature gun. Increased temperature can indicate misalignment, lack of proper lubrication, or other problems.
www.idcon.com © IDCON, INC. 2006-2023 CMS 210 Page 4 of 4 919-847-8764 Do Not Copy STOPPED KEY WHAT WHY Internal Inspection Disassemble coupling and inspect chain for damage and excessive wear. Inspect sprockets for damage or wear to the gear teeth. Ensure that set screws are secure. Dodge 100496 $503.45 12020 CHAIN COUPLING CHAIN ASSY, Bore dia, Bore Length Picture courtesy: Zoro.com TSUBAKI Power Transmission Products Roller chain coupling Picture courtesy: tsubakimoto.co.jp A damaged chain decreases efficiency and can lead to further damage in the chain and sprockets. Damaged gear teeth can lead to misalignment and further damage. Loose set screws can lead to misalignment and further damage. Guard If the guard is not designed for on-the-run inspection, perform relevant inspection tasks while stopped. Update inspection route and check sheets accordingly. If on-the-run inspections are desired, schedule the guard to be modified. When modifying guard, refer to OSHA standard 1910.212 (for USA). The size of the wire mesh depends on the distance from the coupling to the mesh. For example, a 1-inch (25.4 mm) wire mesh must be at least 1.5 inches (38.1 mm) away from the coupling. If your plant applies higher standards than OSHA, make a wire mesh according to OSHA standards, then apply a hinged lid over the wire mesh. Without the ability to check the coupling on the run, health must be checked while stopped. Guard modification such as inspection ports with wire mesh or inspection lids with hinge are a prerequisite for performing safe and effective condition monitoring on-the-run. LUBRICATION KEY WHAT WHY Grease Change Ensure that the chain is properly lubricated according to the owner’s manual by using a grease gun or checking oil level. Ensure that oil reaches all parts of the chain that need lubrication. Not all chain couplings use lubrication, but lubrication can drastically extend the life of a chain coupling. Lubrication allows the chain to run smoother and causes less friction and wear over time.
www.idcon.com ©2023 IDCON, INC. CMS 218 Page 1 of 4 919-847-8764 Do Not Copy Mill, Ball CMS218 Condition Monitoring Standards Basic Principle A ball mill is used to reduce the size of solid substances to a designated size by using a cylinder rotating typically around 30-40 RPM filled with balls (sometimes water depending on the ball mill) to grind the solid into an acceptable size. A motor spins a large cylinder filled with balls that are typically 2-4 inches in diameter. Solid material is fed into the machine and ground by balls that bounce and spin around in the cylinder. At the end or bottom of the cylinder, there is a grate that allows solid material of a certain size (sometimes water depending on the ball mill) to pass through the grate. Some ball mills may also be a dust collection at the top of the cylinder. Ball Mill Picture courtesy: researchgate.net
www.idcon.com ©2023 IDCON, INC. CMS 218 Page 2 of 4 919-847-8764 Do Not Copy KEY WHAT WHY OPERATIONAL Frame Inspect the frame of the ball mill. Look for signs on leaks or cracks and inspect for corrosion. Reference CMS 129 for information related to bearings. A corroded or damaged frame can indicate structural problems and can cause catastrophic failure. Base & Foundation Inspect the base and foundation for damage and excessive corrosion. • In concrete foundations, inspect for cracks, erosion, and unevenness. • On a steel base, inspect for corrosions and cracks. Corrosion does not necessarily appear as rust. Properly drain process fluids, slurry, water, or seal water away from the foundation and base. The foundation and base should be clean and dry. Inspect mounting bolts and shims for tightness and corrosion. Metal bases, shims, and locking bolts should all be of same or similar metals. A damaged base and/or foundation will cause misalignment and vibration. Two dissimilar metals will corrode when put together. Bolts & Fasteners Check that all mounting bolts and anchor bolts are tight and free from corrosion. A corroded bolt is a loose bolt, or it will become loose soon. Replace corroded bolts. Make sure washers and bolts are made of the same material or combination of materials. If a loose mounting bolt is found, make a note, tighten at next downtime opportunity, and then recheck alignment. Loose mounting bolts will gradually cause misalignment. Two dissimilar metals will corrode when put together. Tightening a bolt may pull equipment out of alignment. Detailed Cleaning Thoroughly clean ball mill frame and exterior. Remove product buildup from pillow block bearings, rollers, and frame so that deficiencies can be accurately identified. Excess dirt and debris can hide signs of failure.
www.idcon.com ©2023 IDCON, INC. CMS 218 Page 3 of 4 919-847-8764 Do Not Copy KEY WHAT WHY STOPPED Liners Inspect the liners inside the ball mill. Look for any loose or missing pieces including grouting between the ceramic liner. Protective liners/armor should be checked for excessive wear based on the owner’s manual. Grinding balls should also be replaced based on the owner’s manual’s suggestions. Internal view of a two-chamber ball mill Picture courtesy: researchgate.net The balls and solids inside the ball mill will wear away the liner, and over time they will have to be replaced. If they are not replaced, there is nothing to protect the cylinder from damage, and the efficiency of the ball mill will decrease. Feed Chute Inspect the feed chute of the ball mill. Look for any loose or missing pieces or holes in the chute. The feed chute should be inspected for any damage or cracks that could lead to or cause the feed chute leaking material. If the discharge chute body is damaged, there could be a leak of material outside the machine. Discharge Chute Inspect the discharge chute of the ball mill. Look for any loose or missing pieces or any holes in the chute. The discharge chute and grate should be inspected for any damage, breaks, or cracks. If the discharge chute body is damaged, there could be a leak of material outside the mill. If the grate is damaged, the solids of a larger size than the designated size can pass through the chute.
www.idcon.com ©2023 IDCON, INC. CMS 218 Page 4 of 4 919-847-8764 Do Not Copy LUBRICATION KEY WHAT WHY Bearing Lubrication Lubricate pinion and trunnion bearings according to manufacturer recommendations or use an ultrasonic probe to hear when the grease reaches the bearing. Follow the ultrasonic instrument manufacturer’s recommended grease procedure. Improper lubrication can result in premature bearing life, including damaged seals, higher temps, and damage to bearing race and/or rolling elements. The principal of ultrasonic greasing is when the grease enters the bearing, friction will decrease and lower the ultrasonic signal. Pumping too much grease will increase friction and the ultrasonic signal will increase.
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