The document discusses ways that test tools can improve safety when working around rotating machinery. It recommends (1) being careful of moving parts, (2) working from a distance using wireless tools like vibration meters and infrared cameras, and (3) quickly identifying faults on machines before catastrophic failure using vibration analysis to reduce time spent near machinery. The tools can help technicians work more safely by monitoring machines remotely, reducing entry/exit times near moving parts, and taking faulty machines offline before hazardous conditions occur.

1. Ways test tools can improve safety
around rotating machinery
Presented by John Bernet
Fluke Corporation
Hosted by:
Transcat, Inc.
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1. Be very careful of moving shafts and other components
2. Work from a distance, further away from potential danger
3. Use wireless tools and sensors whenever possible
4. Use a vibration meter to quickly screen for faults spending less time near rotating machinery
5. Quickly evaluate the risk associated with machine faults and secure machine before catastrophic failure
Ways test tools can improve safety
around rotating machinery
The electrical hazards associated with electromechanical equipment are severe and the electrical
safety PPE requirements are extensive.
But what about safety concerns from the mechanical side of rotating machinery?
The three main objectives of mechanical safety are:
1. Perform work from a safer distance from rotating parts and reduce number of entries/exits
2. Take faulty machinery offline BEFORE a hazardous condition occurs
3. Increase the safety of maintenance tasks and prove compliance by using the correct tools
How to work more safely on moving parts
When the situation calls for working near operational machines with moving parts, take
every opportunity to be as safe as possible.

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1. Be very careful of moving shafts and other
components
Wear safety glasses and other PPE. Never wear dangling lanyards or
necklaces. Make sure that cables are equipped with the proper
breakaways in case a cable is dropped into a moving shaft.

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2. Work from a distance, further away from
potential danger
Common mechanical applications:
 Identify rotational speed of moving components
 Visually inspect fast moving parts without system shutdown
 Find belt slippage by comparing pulley speeds
 Identify part numbers, nameplates or other markings on rotating machinery
without shutdown
 Inspect leading edge damage and material buildup on fan blades
 Investigate and observe repetitive moving processes for flaws, timing
problems, or misfires
 At max flash rate, Stroboscope doubles as a bright work light
a. Stroboscope
Touching the moving shaft with a contact tachometer may be risky. Use an LED stroboscope,
instead. The LED stroboscope “freezes” motion to measure speed, read information from moving
parts, or identify potential problems without stopping the machinery or endangering personnel.

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2. Work from a distance, further away from potential danger
b. IR camera
Applications:
Electrical systems Mechanical Process
• (3 phase) Power
distribution
• Fuse boxes
• Cables & connections
• Relays/Switches
• Insulators
• Capacitors
• Substations
• Circuit breakers
• Controllers
• Transformers
• Motors
• Battery banks
• (Motors
• Pumps
• Heat exchangers
• Bearings
• Gearboxes
• Drive belts
• Refractory insulation
• Tanks and vessels
• Steam systems/traps
• Pipes and valves
• Heaters/Furnaces
• Manufacturing equipment
• Plastics Industry (Molding)
• Pulp & Paper (Rollers,
handling equipment, etc)
• Metal Foundry
• Boilers and Reactors
• Research & Development
Thermography is non-contact and applies to most all types of equipment and conditions. It is obtained without
disturbing production, quickly identifies detects problems before failure and large areas can be scanned quickly.

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3. Use wireless tools and sensors whenever possible
a. Wireless tools:
Cables from tool to the sensor often gets in the way during test measurements. And, the longer the
job takes, the more time accidents have to happen. A wireless tool doesn’t have cables and can stay
away from the immediate work area. Smart tools are designed for maximum efficiency. They walk
the user through the task quickly and easily, reducing the time in the danger zone.
When performing corrective actions on machines, like laser
shaft alignment, ensure that the machine is secured and tagged
out.

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3. Use wireless tools and sensors whenever possible
b. Wireless sensor:
Remote screening /alarming of machine health without putting operators / technicians in harms way.
Real-time measurements with no labor or route-based collection needed.

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Example rotating machine applications
Hydraulic (Oil)
Pump
Blower - Fan typeFans Belt driven Gearbox & Rollers
Blower -
Centrifugal
Common problem:
Fans have access
problems, with
bearings under guards
or the whole fan is in a
room that you can’t
access in normal
operation without
shutting down the fan
Common verticals:
• Commercial and
Industrial buildings
Common problem:
Large motors and
gearboxes driving a
bunch of little machines.
The gearbox is commonly
in the middle of the
system and getting into it
would shut down the
whole system
Common verticals:
• Food and Beverage
• Distributor center
• Mining
Common problem:
There is a need to
put a lot of aeration
in big tanks.
Downtime would
lead to
environmental
concerns.
Common vertical:
• Water treatment
plants
Common
problems:
Blower mounted
up high where it is
a challenge to get
to. High temps at
blower make area
unsafe for techs.
Common vertical:
• Boilers and
steam plants
Common problems:
High temperature /
difficult to reach area
Pumping hydraulic for
critical machines
Common verticals:
• Machine tools
• Paper Plants
• Power

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Example rotating machine applications
Chiller Centrifugal Pump Single Stage Gearbox Axial Flow Fan
Common problem:
Compressors used for
chilling the air or
freezing product can
carry hazardous
materials in pipes.
Common verticals:
• Food and Beverage
• Medical Facility
• Data Centers
Common problem:
Small motors and
gearboxes that drive the
conveyors are all behind
panels with no access.
Common verticals:
• Distribution Centers
• Food an Beverage
Common problem:
Small fans in the duct work
in overhead areas that are
hard to reach.
In places like clean rooms,
when these small fans go
down they can cause health
and safety problems.
Common vertical:
• Medical/ Pharma
• Manufacturing
• Data Centers
Common problems:
Used in high temperature /
difficult to reach areas
Pumps can be pumping
hazardous materials
Common verticals:
• All Facilities

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Identify faulty machines before failure
There are many ways that machine failure can cause an accident or a health and environmental problem:
• Catastrophic failure of machine causes injury to nearby personnel by release of moving parts
• Simple failure of machine releases product to environment–very high temperature, caustic chemicals, bio
hazardous sewage or other, flammable material, etc.
• Secondary damage of machine leads to structural or foundation failure leading to injury
4. Use a vibration meter to quickly screen for faults
spending less time near rotating machinery
Spend seconds instead of 30 minutes of more measuring and
diagnosing every machine for faults. Screen out hundreds of healthy
machines looking for early warning signs of potential failure. Add the
vibration meter to operator inspection routes and take the 30 seconds
to verify machine conditions haven’t deteriorated.

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5. Quickly evaluate the risk associated with machine
faults and secure machine before catastrophic failure
Just like a doctor that diagnoses most problems
without the need to see a specialist—90 % of
machines are standard motors, pumps, fans,
compressors, blowers, gears, belts that have
very few variables.
If you do identify a change in severity of machine fault, you’ll need to quickly determine whether
the fault is moderate (you still have months to go) or extreme (it could go at any time). A bearing
that is ready to fail can lead to a catastrophic failure that destroys the entire shaft, the entire
machine, stops production, leaks caustic materials, or injures someone nearby. Facilities running
large mechanical equipment increasingly use vibration testers to diagnose the most common
mechanical faults. The tester assesses the fault level and provides a detailed report of the fault,
including the severity and the repair recommendation.

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820-2 LED
Stroboscope
810 Vibration Tester
3561 FC Wireless
Vibration Sensor
and Gateway
3561 FC Wireless
Vibration Sensor
and Gateway

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1. Be very careful of moving shafts and other components
2. Work from a distance, further away from potential danger
3. Use wireless tools and sensors whenever possible
4. Use a vibration meter to quickly screen for faults spending less time near rotating machinery
5. Quickly evaluate the risk associated with machine faults and secure machine before catastrophic failure
Summary / Questions?

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15. Questions or Comments?
Email Nicole VanWert-Quinzi
nicole.vanwert@Transcat.com
Transcat: 800-800-5001
www.Transcat.com
For related product information, go to:
www.Transcat.com/Fluke