Automated machine monitoring for reliable rotation
As a chemical company, safety is of the highest importance for BASF, as their production processes must comply with safety regulations including having online condition monitoring systems on all critical applications as standard.
BASF had been looking at condition monitoring systems with wireless sensors for critical and semi-critical applications for a long time due to their practicality in both cost and ease of installation.
After testing systems from various brands, BASF were interested in the IMx-1 and its possibilities. As soon as they had the opportunity, a number of IMx-1 systems were delivered to the Caprolactam production location. Initial results gave such a positive impression that the test range was immediately expanded to a total of 70, installed at key measurement locations.
Good cooperation
"18 months ago, SKF introduced us to their new generation of sensors and we were immediately interested", says Raf van Gastel, Central Maintenance Reliability Expertise at BASF. "Now we are conducting the tests, SKF are a very flexible organization and that is partly why the system is quickly configured and operational. Moreover, the wireless IMx-1 system also appears to work well over longer distances".
Various pumps that are used for the test are next to ATEX motors and although the IMx-1 sensors are not yet ATEX approved, sometimes they have to bridge 40 meters. This is possible because the sensors also communicate with each other and act as routers.
Prevent premature outages
"Immediately after installation, the SKF IMx-1 system highlighted a defect at a bearing location that could have caused an early failure," says Sabine Spapen, Business Manager Condition Monitoring Solutions at SKF. "Optical inspection did not show any significant damage, but further microscopic examination revealed fatigue symptoms on the outer ring".
Widely applicable
For BASF, working via the cloud is a big advantage. Raf van Gastel: "It took a while for our IT department to be convinced that everything is done in a secure way, but the SKF IMx-1 system offers so much added value for our operators. The extensive and wireless measurements provide us with enormous insight which can optimize our processes. We have always taken offline measurements, but now that everything can be done wirelessly, our people can focus more on analyzing instead of collecting data in the field. It offers us a platform that we can use to expand into in the future".
Rotating Equipment Performance
The IMx-1 will be launched worldwide in 2020 and the practical tests at BASF show how effective the system can be in the field.
Sabine Spapen: "We discuss their needs with customers and then offer the most relevant system and service options available so we can take care of the entire process from installation to remote monitoring. This is the basis of our Rotating Equipment Performance approach that guarantees machine performance!”
Who is BASF?
BASF Antwerp is the largest integrated chemical production center in Belgium and the second most important production site of the BASF group worldwide with fifty production facilities on site. The BASF Antwerp product range includes basic chemistry and specialized chemicals, plastics and precursors, breeding products and inorganics.
BASF Antwerp's products are used in almost all processing sectors, including automotive and construction sectors, in the production of paper, leather goods and sporting goods, as well as textile, food and pharmaceutical sectors.
At the BASF Antwerp production site, safety is a top priority. Employees, partners, contractors, visitors ... BASF involves everyone in its safety policy.
The SKF test setup at BASF
The SKF Enlight Collect IMx-1 system is installed on seven standard centrifugal pumps, which are directly connected to an electric motor. The pumps operate at varying speeds from 1000 to 3000 rpm. The available motor, pump and rolling bearings all vary in configurations.
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