Ultrasound Condition Based Monitoring Case Study
Reducing operations costs also means reducing wasted energy consumption. Organizations are challenged to dedicate themselves to energy-saving opportunities while maintaining steady production.
A Corporate Program for Corrugated Plants
CTRL helped one of the largest manufacturers of corrugate integrate ultrasound CBM for critical asset management because vibration analysis was not an option for the small maintenance staffs at the plant.
As a result of training and consultation, CTRL worked with the client to modify standard operating procedures and communications of reporting to management for informed decisions on asset purchases and reduce overall operating costs.
- ROI in first use – discovered bad bearing on major gearbox with a 22 month rebuild or replacement estimate
- Improved asset life 100% – 1 ½ years to 3 years – $150k savings per asset
- Reduced critical asset catastrophic failure – just 1 bearing failure in first 7 years of program
What is Acoustic Ultrasound Condition Based Monitoring?
CTRL’s definition of Condition Based Monitoring (CBM) is the process of knowing current operational conditions of various key components of your equipment and indicating when the slightest changes first present themselves to allow time to plan and take corrective action.
In this economy, we are challenged to do more with less. More production, less maintenance; more programs, less manpower.
Now you can diagnose machine condition or unexpected problems while in full operation with non-destructive testing (NDT) before catastrophic failure. This timely information will minimize and even eliminate production downtime by scheduling a call to action during a shutdown. Scheduling around production saves time and money and increases reliable productivity.
CTRL combines its quality ultrasonic products (the earliest technology which can detect change) and cloud-based software analysis into programs designed specifically for your organization’s needs. Our turnkey approach helps integrate this new technology for a quicker return on investment while sustaining measurable success (equipment reliability). This allows for better corporate communication of results and benefits, all the while enhancing the capabilities of your experienced workforce.