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Industrial Machine Vibration Analysis and Condition Monitoring

Posted by Hydraulic Filtration Team on 31 Jul 2019

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Industrial Vibration Analysis and Condition Monitoring - industrial pumps and motors Parker Kittiwake A condition monitoring system is concerned with the early detection of failure. Vibration monitoring systems, whether they use traditional techniques based on displacement or acoustic emission sensor techniques, form part of your condition monitoring (CM) tool chest. 

Machinery vibration analysis equipment is part of a machine monitoring system that aims to provide months of warning of developing issues before they become bigger problems. This can save your company from serious disruption by avoiding unnecessary downtime and delays. There is also the potential for both on and offline implementation of these systems, subject to capability and level of available technology for the techniques, which makes them perfect for the food and beverage, power generation, marine and offshore industries. 

If you are interested in learning about our vibration analysis or monitoring systems and equipment, please contact us today to speak to one of our engineers.


Vibration monitoring techniques

Vibration monitoring equipment uses techniques based on the use of accelerometers, which are well known in the field of CM, and can be classified into three main categories:

VM Vibration Monitoring (ISO 10816): Perfect for maintenance engineers, vibration monitoring ISO 10816 offers an instinctive understanding that a machine is vibrating unusually from the non-rotating parts. Great for small machines, electric motors and pumps and production motors.

VA Vibration Analysis (ISO 13373): A mainstream CM option and essential addition to any other technique used, vibration analysis offers a more sophisticated improvement in signal to noise ratio for repetitive defect signals. This highlights what is internally causing the vibration.

AE Acoustic Emissions (ISO 22096): This technique looks for high-frequency signals from cracks or impact rather than a repetitive movement from vibration. As a passive technique, acoustic emissions can diagnose incipient machinery prior to undertaking a lengthy diagnosis. Highly effective in detecting the very early onset of machinery fault conditions where needed most.
 

Acoustic emission machinery

There are many approaches which fall under the umbrella term condition monitoring, each with its own features and areas of excellence. These include machinery vibration monitoring and analysis, and also acoustic emission analysis systems. 
 

Industrial Machine Vibration Analysis and Condition Monitoring - Relative Inputs into CM Assessment

Techniques in BLUE = Technologies available from Parker Kittiwake


Parker Kittiwake focuses on techniques such as an acoustic emission system that provides for the greatest protection or longest period of warning for potential damage and eventual failure. While machine vibration monitoring systems can help prevent the worst cases of damage. 

The use of two (or more) appropriate technologies can provide a more complete picture of the likely failure mechanism, thus offering you reduced machinery downtime and more efficient recovery. The table below identifies the variations of expertise that different condition monitoring options cover.
 

Industrial Machine Vibration Analysis - comparison of the main machinery CM techniques - Parker Kittiwake

 

CM machinery techniques that are available from Parker Kittiwake:

Industrial Machine Vibration Analysis - Condition Monitoring machinery techniques - Parker Kittiwake


Industrial Vibration Analysis and Condition Monitoring - Contact Us - Parker Kittiwake If you are interested in any of the above vibration analysis products and services, or you would like to speak to an engineer about which vibration monitoring option would best suit your needs, please contact us today.

 

Article contributed by the Hydraulic Filtration Team, Parker Kittiwake, part of Parker's Hydraulic and Industrial Process Filtration Division.

 

Additional resources

Bunker Quality: Why Changes to ISO 8217 Increase the Need for Condition Monitoring

What You Need to Know About Testing Your Hydraulic System for Particle Contamination

Reduce Failure of Hydraulic Systems with Preventive Maintenance

Reliability Centered Maintenance Reduces Costly Downtime in Oil & Gas Applications

 

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  • Listening, Learning and Applying Knowledge in Product Development_Filter and Dispense System Scanner_Parker Bioscience FiltrationAlthough bulk filtration of a product prior to shipping was one of the first bioprocessing steps to benefit from single-use technology, it has been one of the last to benefit from single-use automation.

    Indeed, for many biopharmaceutical manufacturers, the process has changed very little from the days before single-use technology was adopted: the main differences have been the replacement of the stainless steel tank with a bag and the steam cross with aseptic connectors. 

    Parker Bioscience Filtration was approached by a customer to develop a solution that would address concerns around the bulk filtration unit operation. 

     

    Listening, Learning and Applying Knowledge in Product Development_Implementation of Single-Use in Drug Substance Filling Before Transportation White Paper_Parker Bioscience Filtration

     

     

     

    To learn more, download the full white paper: Implementation of Single-Use in Drug Substance Filling Before Transportation

     

     
            What were the customer's concerns?
    • Protection - As the customer was filling high potency active pharmaceutical ingredients (HPAPIs), it needed to eliminate open processing to protect the operator and the product. 

    • Standardization and simplification - The customer needed to standardize the filling platform in order to create a standard operating procedure (SOP); this would simplify training and eliminate process variation.

    • Hygiene -The customer wanted to reduce the number of people involved directly in the filling. 

     

    How Parker helped

    Working closely with the customer, Parker Bioscience Filtration developed the Generation One SciLog® Filter and Dispense System. This enabled fully enclosed automated bulk filling of the HPAPI into bottles in preparation for transportation to a filling site. 

    Parker was able to identify several benefits of automated closed filling:

    • No more false positives - The elimination of false positives meant that the customer would not be exposed to the costs (and lost time) of the quarantine and investigation process related to a false positive. Nor would it be exposed to the risk of a batch being rejected. 

    • Saving time - Comparing manual filling and automated filling, data was generated on time savings based on two filling volumes and a set batch size. If these time savings were applied to a facility producing 35 batches per year, the cost reductions generation could run into €100,000s.

    • Reduction in clean room personnel required - As the process is fully enclosed and automated, the need for QC sampling and QA oversight was reduced - this meant fewer staff were required in the clean room. 

    • Standardization driving simplification - Training and SOP became simpler as a result of standardization. The risk of deviation and human error was also reduced, and the supply chain and handling process was simplified. 

     

    The development of the generation two system

    Although we had developed a solution for a fully enclosed and automated filling process, collaboration with the customer did not stop there. The safe arrival of the bottles at a filling site was the customer's priority - and taking into account their feedback, we developed the generation two SciLog® Filter and Dispense System.

     

    How did Parker do it? Increasing the filling accuracy

    The filling accuracy of the generation one system was +/- 10 percent - initially deemed acceptable.

    However, the filling accuracy was increased to a much higher level of +/- 100 mg following feedback from the customer's QA team and our knowledge of how many bottles they needed to fill, as well as product and consumable reconciliation. 

    With the generation one system, based on a 20 L and a 500 ml fill, anywhere between 36 and 44 bottles were required. With the generation two system, the maximum number of bottles required is 40 and the minimum is 39. 

    Improving the filling process

    As the generation two system allows a rapid fill to 90 percent of target volume, the process can be run at a slower rate to ensure accuracy. This balances the requirement for product quality and process efficiency.

    Parker also introduced a J-tube system which diverts the flow of liquid to the side of the bottle. This was developed to prevent the foaming that would occur if liquid was dropped into a bottle vertically. 

    Component selection driven by process facility knowledge

    It is essential to choose materials that can support the process - and this can only be done if the full extent of the storage conditions is known. A solution may be filled following cold storage at 4°C, for instance, but may then be stored in dry ice at -78.5°C. This will have a critical impact on the choice of materials. In addition, not all products will be compatible with all of the materials used in a single-use assembly. Again, knowledge is key.

    Validating the system

    While the system was validated to perform the fully automated and contained filtration and dispense of bulk APIs, this was not the end of the validation process. 

    Shipping of the product to the final destination was also part of the solution Parker needed to provide for the customer and, therefore, this also needed to be validated. To do this, Parker subjected the bottles to further testing to demonstrate their post-shipping integrity — a crucial final step in validating the entire process.

     

    Conclusion

    Our work in developing the generation two SciLog® Filter and Dispense System underlined the importance of truly understanding what matters to a customer — and in this case, that went beyond the system's functionality.

     

    Listening, Learning and Applying Knowledge in Product Development_Implementation of Single-Use in Drug Substance Filling Before Transportation White Paper_Parker Bioscience FiltrationTo learn more download the full white paper: Implementation of Single-Use in Drug Substance Filling Before Transportation

     

     

    Listening, Learning and Apply Knowledge in Product Development_Guy Matthews_Parker Bioscience Filtration

    This post was contributed by Guy Matthews, division marketing manager, Parker Bioscience Filtration, United Kingdom

    Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more.

     

     

    Related content

    Automation of Final Bulk Filtration and Container Fill Step in GMP Environment

    Automating and Enclosing Bulk Fill Operations - the Way Forward?

    Automated Single-Use Technology and Its Impact on Quality

    Four Sources of Process Variation in Biopharmaceutical Manufacturing

    Five Critical Challenges in Single-Use Bioprocessing

    How to Successfully Scale-Up Automated Single-Use Bioprocesses

     

     
    Bioprocess Pharmaceutical Filtration Team
    Bioprocess Pharmaceutical Filtration Team
    • 21 Nov 2019
    Listening, Learning and Applying Knowledge in Product Development
    Although bulk filtration of a product prior to shipping was one of the first bioprocessing steps to benefit from single...
  • Early Adoption Single-Use Technology Can Ensure Successful Process Scale-Up_Filter Trials with SciLog FilterTec System_Parker Bioscience FiltrationWhether you are running a process in a 30,000 L bioreactor in fed-batch mode, a 200 L continuous process, or have scaled-out (rather than up), you will start at small scale and look to increase the volume - scale-up - to some degree.

    However, we are recognizing that some biotech companies aren't adopting single-use automated technology until the process reaches pilot scale. This can reduce the likelihood of a successful outcome or the speed of the development process, as process rework may need to be managed further along the manufacturing development process. In some cases, changes to inefficient processes may be more difficult to implement, especially if they have already been approved.

    The adage "start with the end in mind" has never been more relevant. For scale-up to be successful, we recommend using the same automated single-use equipment, strategies and materials from the R&D stage through to manufacturing scale. That way, speed to market can be optimized through simplified technology transfer of optimal process. You will also avoid unexpected rework that may come about due to material compatibility or availability issues.

    Start as you mean to go on

    Speed to market is of critical importance, both from a return on investment point of view, but also with the benefits to patients in mind.

    Having single-use automated technology in place at the R&D stage can make the move into the manufacturing stage more efficient.

    The benefits include:

    • Materials are pre-qualified at the R&D stage and approved for use in the application.
    • Vendors are pre-qualified, audited and already in the supply chain.
    • Operator training time is reduced.
    • User confidence with the technology is increased.
    • Using scalable automation solution and single-use components increases the likelihood that control parameters developed on a smaller scale system are available on a larger system.

    And, if you use single-use technology during R&D you can also benefit from:

    • Decreased turnaround times - as components don't require cleaning or regeneration.
    • More consistent results - from using pre-made disposable manifolds, rather than building a flow path for each different processing run.

    However, there are a few common pitfalls to avoid, which include making incorrect assumptions regarding how processes will behave at larger scale.

    Ensuring successful scale-up in single-use bioprocessing webinar

    Parker Bioscience Filtration is delivering a webinar on November 12th, 2019 which will help biopharmaceutical manufacturers build a strategy for effective scale-up of filtration and single-use processes that will facilitate technology transfer, in order to avoid delays in commercialization caused by inconsistent scale-up of a single-use process between R&D and manufacturing.

    It will explain how to conduct a small-scale filtration trial using an automated single-use system at laboratory scale and examine the advantages this provides.

    The webinar will also further explore the benefits of single-use technology in both R&D and manufacturing, and consider how to ensure successful implementation of single-use automation from laboratory scale through to large-scale production.

     

    Register now for our webinar: Ensuring Successful Scale-Up in BioprocessingEarly Adoption Single-Use Technology to Ensure Successful Scale-Up_Webinar sign up now icon_Parker Bioscience Filtration

     

     

     

     

    Early Adoption Single-Use Technology to Ensure Successful Scale-Up_David Heaney_Parker Bioscience FiltrationThis post was contributed by David Heaney, market development manager (life sciences), Parker Bioscience Filtration, United Kingdom.

    Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more.

     

     

     

    Related content

    Overcoming Barriers to Single-Use Implementation

    Protecting Your Bioprocess From the Risk of Human Error

    How to Successfully Scale-Up Automated Single-Use Bioprocesses

    Automating and Enclosing Bulk Fill Operations - the Way Forward?

     

    Bioprocess Pharmaceutical Filtration Team
    Bioprocess Pharmaceutical Filtration Team
    • 30 Oct 2019
    Early Adoption Single-Use Technology Can Ensure Successful Process Scale-Up
    Whether you are running a process in a 30,000 L bioreactor in fed-batch mode, a 200 L continuous process, or have scaled...
  • Making Connections? Make the Right Choice for Your Single-Use Process_CPC Connector_Parker Bioscience FiltrationSingle-use solutions have been widely adopted on a global scale within the biopharmaceutical industry due to the many advantages and process improvements they offer.

    Key applications for single-use assemblies include the creation of process fluid flow paths, buffer/product storage solutions and sampling systems on varying scales. 

    Most of these systems will start with either a bioprocess container or a tubing option and require the ability to connect to further pieces of equipment or additional single-use systems/manifolds.

    In order to achieve this connectability, some form of connection needs to be selected — but with so many different connection types available, where should biopharmaceutical manufacturers start?

    There are many different options available when embarking on the selection process. Consideration must be given to whether the connection type needs to be aseptic to provide quick and easy sterile connections, (even in non-sterile environments) or non-aseptic (to provide quick and easy non-sterile connections).

     

    How do you choose the correct option?

    The choice should be guided by the process itself — and the capability of the manufacturing plant should also be taken into account. 

    Key factors which will determine the correct choice of connection type include:

    • Whether the connection is to be made inside or outside of a laminar airflow hood.
    • Whether the connection needs to address any specific safety requirements.
    • Process conditions and compatibility.
    • Bioburden control.
    • Experience of operatives.
    • Suitability for purpose.

    Only when these factors have been addressed can the end-user begin to fully specify the connection type required. 

     

    Connection types The Luer connector

    The Luer connector is the simplest connector. It consists of both a male and female form, and the connection is made using a twist-lock action. These connections are suited to sample lines (with syringe connectivity) and low flow narrow-bore tubing applications and can be used within a laminar airflow hood to create aseptic connections.

    However, there is a downside: potential misconnections can occur when they are not mated correctly. 

    Quick connector

    Quick connectors such as the MPC, MPX or MPU from CPC (Colder Products Company) are similar to Luer connectors in that they can be used within a laminar airflow hood to create aseptic connections. They have the added security of a push-fit feature with a secure locking mechanism. 

    Triclamp

    Triclamp (sanitary style) fittings can be used as connectors. While these are effective and secure connections, care must be taken to position the required o-ring seal within the connection prior to fixing the connection using an external clamp. The sheer size of the external clamp may make this an unsuitable method for connecting narrow bore or thin-walled tubing due to the weights involved and the potential for kinking/doubling of the attached tubing. Triclamp connections can be used within a laminar airflow hood to create aseptic connections. 

     

    Connections outside of a laminar airflow hood

    Should aseptic connections be required to be made outside of a laminar airflow hood, two options are available, which both allow the connection of varying tube sizes:

    Gendered aseptic connector

    The first option for connecting aseptically in a non-aseptic environment would be to use a gendered aseptic connector, such as CPC AseptiQuik® gendered, which has both a male and female version. The benefit of using a gendered connection is that it can help by safeguarding which lines can be connected to certain points in the process; this helps to mitigate against human error and the accidental connection of the incorrect lines/equipment.

    When designing single-use assemblies using a gendered connector approach, care must be taken to ensure that the correct male / female side is designed into each part; this in itself can also create some areas for error to creep in. 

    Genderless aseptic connector

    Should the end-user not have any concerns over an accidental connection to the incorrect lines/equipment, or simply want to remove the error of male/female connector type which can creep in during design, there is the genderless aseptic connector, such as CPC AseptiQuik® genderless. These connectors take out the requirement for designing in the correct male/female orientation and can enable universal assemblies to be manufactured and connected with many other assembly/equipment types. 

    Both gendered aseptic connectors and genderless aseptic connectors operate via a mechanism that enables connection in non-sterile environments to be made possible. This is because of the use of proprietary seals which mate together before a protective seal is removed, thus keeping the process stream in its aseptic/sterile condition. 

     

    Connecting stainless steel and single-use

    Should sterile connections between traditional stainless steel biopharmaceutical processing equipment and single-use assemblies be required, there is another option:

    Steam-to connectors

    Steam to connectors, such as CPC Steam-Thru®, work by allowing steam to pass through the section connected to the stainless steel equipment. Once steamed and connected, a valve within the connector is manipulated, creating a sterile or aseptic flow path. 

     

    Conclusion

    It is apparent that there are many connections capable of creating or maintaining an aseptic/sterile environment, but without the correct process condition assessment, operator care or design considerations, biopharmaceutical manufacturers could be looking at a costly connection failure. 

     

    Making Connections? Make the Right Choice for Your Single-Use Process_Single-Use: The Next 5 Challenges to Conquer White Paper_Parker Bioscience Filtration

     

     

    Download our white paper to find solutions to more single-use challenges: Single-Use Technology: The Next 5 Challenges to Conquer

     

     

     

     

     

     

    Making Connections? Make the Right Choice for Your Single-Use Process - Graeme Proctor_Parker Bioscience Filtration

     

    This post was contributed by Graeme Proctor, product manager (single-use technologies), Parker Bioscience Filtration, United Kingdom.

    Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more. 

     

    Related content

    Eliminating Leaks and Faults: Single-Use vs Stainless Steel Systems

    Five Critical Challenges in Single-Use Bioprocessing

    5 Benefits of Single-Use Technology vs Stainless Steel

     

     

    Bioprocess Pharmaceutical Filtration Team
    Bioprocess Pharmaceutical Filtration Team
    • 15 Oct 2019
    Making Connections? Make the Right Choice for Your Single-Use Process
    Single-use solutions have been widely adopted on a global scale within the biopharmaceutical industry due to the many advantages...
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