The Walling Company of Iowa

Predictive Maintenance

The Walling Company’s Predictive Maintenance (PdM) solution offers effective strategies that allows for a systematic method of monitoring and trending equipment solutions.  This in turn allows for scheduling of maintenance (have the least effect on scheduled activities), minimizing unexpected equipment failures and ultimately promotes reduced maintenance costs.

All machines vibrate. The amount of vibration and the rate at which it occurs determines how long a machine can tolerate this vibration before a failure occurs. Vibration Analysis is compared to a “doctor” listening to your heart. The vibration we listen to is the heartbeat of the machine. The vibrations given off by the machine tells us if the machine has a cold, a temperature, the sniffles, or a low blood count. The health of the machine is trended over time or just a one time spot check can tell you when repairs should be made. Not a catastrophic failure at midnight!

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Infrared thermography is an exciting technology with diverse applications used in numerous industries. Thousands of utilities worldwide have used infrared thermography to avoid costly failures, improve service reliability, and prevent electrical fires. Infrared identifies problems, prevents unscheduled downtime, identifies corrective action and improves plant safety, saving time and money in a wide range of commercial and industrial facilities. Infrared Applications include: Asphalt, Automation and OEM Applications, Building Diagnostics, Food Industry, Law Enforcement, Manufacturing, Predictive Maintenance, Pulp and Paper, R&D/Testing, Roofing, Steel, Utility Market, and Veterinarian. 

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Some of the most common plant applications are: leak detection in pressure and vacuum systems (i.e., boilers, heat exchangers, condensers, chillers, distillation columns, vacuum furnaces, specialty gas systems), bearing inspection, steam trap inspection, valve blow-by, pump cavitation, detection of corona in switch gear, compressor valve analysis, integrity of seals and gaskets in tanks, pipe systems and large walk-in boxes. All operating equipment and most leakage problems produce a broad range of sound. The high-frequency ultrasonic components of these sounds are isolated from background noises to detect their exact location.

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Oil

Regular inspection of lubrication level, color and viscosity are all part of Oil Analysis. The results of these tests yield information that can save maintenance dollars, avoid unnecessary repairs, and help lower repair costs. Particles, moisture, soot, heat, air, glycol, fuel, detergents, and process fluids are all contaminants commonly found in industrial lubricants and hydraulic fluids. However, it’s particle contamination that is widely recognized as the most destructive to the oil and machine. This explains why the particle counter is the most widely used instrument in oil analysis today.

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By reducing the amount of imbalance in a piece of equipment you reduce the load on the support bearings. 
When imbalance is reduced electrical energy usage, heat in the bearings and belt slippage all are reduced.
Most fans gain 5+ rpm (V belt applications) after balancing.

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Services

  • Portable Dynamic Balancing
  • Vibration Data Collection and Analysis
  • Infrared Data Collection and Analysis
  • Airborne Ultrasonic Data Collection and Analysis
  • Oil Sampling and Analysis

Consulting Services:

  • Customer Assistance in Data Analysis and Collection for Infrared, Vibration, Airborne Ultrasound, Oil Analysis, Motor Current Analysis
  • Electric Motors Failures
  • Root Cause Failure Analysis
  • Remote Sensor Installation and Testing
  • Visual Inspections

Onsite Customer Training:

  • Infrared
  • Vibration Analysis
  • Airborne Ultrasonic Leak Detection

 

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