4.5 g Maintenance Strategy by Deepak Sahoo

DN : BAL/DS/CBM/A1004 BAL - Internal Use Only. CBM – Part - I 4.5 Generation

Maintenance Strategy Doc. No : BAL/DS/CBM/A1004 CBM – Part - I

An Introduction To Condition Based Maintenance (CBM)

Prepared By : DEEPAK SAHOO

Internal Use only. For Balasore Alloys Limited, Balasore.

DN : BAL/DS/CBM/A1004 BAL - Internal Use Only. CBM – Part - I

Agenda

Introduction

Maintenance Strategy

Types of Maintenance

More about CBM / CM

CBM/CM Tools

- i - INDEX Prepared By : DEEPAK SAHOO, Manager - TPM


Introduction

Accident Rate in Aviation industry.

- 01 - INDEX Prepared By : DEEPAK SAHOO, Manager - TPM

The 2011 global accident rate (measured in hull losses per million flights) was 0.37, the equivalent of one accident every 2.7 million flights.

0.1 0.45 0.34 0.8 0.72

1.87

7.41

0

1

2

3

4

5

6

7

8

N O R T H A M E R I C A

E U R O P E N O R T H A S I A

A S I A -P A C I F I C

M I D D L E E A S T A N D

N O R T H A F R I C A

L A T I N A M E R I C A

A F R I C A

ACCIDENT RATE IN AVIATION INDUSTRY

Data collected from IATA. http://www.iata.org/pressroom/pr/pages/2011-02-23-01.aspx


Introduction

Maintenance Strategy in Aviation industry.


CBM++ RCM



Reactive

Preventive

Predictive

Proactive.

RCM – Reliability Centered Maintenance » Aviation Industry.

» Spacecraft Industry.

» Nuclear Industry.

» Petrochemicals.

» Oil & Gas




What is Maintenance and Its Objective ?


Maintenance is a set of organised activities that are

carried out in order to keep an item in its best

operational condition with minimum cost acquired.

PLANT

M

A

I

N

T

E

N

A

N

C

E

Reduce Breakdowns

Reduce Downtime

Improving Equipment

Efficiency

Improving Inventory

Control

Implementing Cost

Reduction

Maximising Production

Optimising Resources

Utilisation

Optimising Useful Life

of Equipment

Minimising Energy

Usage

Providing Budgetary

Control


Type of Maintenance

Run to Failure Maintenance (RTF)

Preventive Maintenance (PM)

Corrective Maintenance (CM)

Predictive Maintenance (PDM)

Improvement Maintenance (IM)



Type of Maintenance


MAINTENANCE

UNPLANNED MAINTENANCE (REACTIVE)

BREAKDOWN

EMERGENCY

PLANNED MAINTENANCE

(PROACTIVE)

CORRECTIVE MAINTENANCE

REMEDIAL DEFERRED

PREDECTIVE MAINTENANC

E

CONDITION - BASED

STATISTICAL - BASED

PREVENTIVE MAINTENANC

E

ROUTINE RUNNING

DESIGN - OUT ENGINEERING SERVICES

WINDOW

IMPROVEMENT MAINTENANCE

SHUTDOWN CORRECTIVE

SHUTDOWN PREVENTIVE

SHUTDOWN IMPROVEMEN

T

OPPORTU-NITY


Type of Maintenance

Run to Failure Maintenance (RTF)

– Emergency maintenance: It is carried out as fast as

possible in order to bring a failed machine or facility to a safe

and operationally efficient condition.

– Breakdown maintenance: It is performed after

the occurrence of an advanced considered failure for which

advanced provision has been made in the form of repair

method, spares, materials, labour and equipment.



Type of Maintenance

Preventive Maintenance (PM)


• Routine maintenance which includes those maintenance activities that are repetitive and periodic in nature such as lubrication, cleaning, and small adjustment.

• Running maintenance which includes those maintenance activities that are carried out while the machine or equipment is running and they represent those activities that are performed before the actual preventive maintenance activities take place.

• Opportunity maintenance which is a set of maintenance activities that are performed on a machine or a facility when an unplanned opportunity exists during the period of performing planned maintenance activities to other machines or facilities.

• Window maintenance which is a set of activities that are carried out when a machine or equipment is not required for a definite period of time.

• Shutdown preventive maintenance, which is a set of preventive maintenance activities that are carried out when the production line is in total stoppage situation.


Type of Maintenance

Corrective Maintenance (CM)


• Remedial maintenance, which is a set of activities that are performed to eliminate the source of failure without interrupting the continuity of the production process.

• Deferred maintenance, which is a set of corrective maintenance activities that are not immediately initiated after the occurrence of a failure but are delayed in such a way that will not affect the production process.

• Shutdown corrective maintenance, which is a set of corrective maintenance activities that are performed when the production line is in total stoppage situation.


Type of Maintenance

Improvement Maintenance (IM)


Design-out maintenance which is a set of activities that are used to

eliminate the cause of maintenance, simplify maintenance tasks, or raise

machine performance from the maintenance point of view by redesigning

those machines and facilities which are vulnerable to frequent occurrence

of failure and their long term repair or replacement cost is very

expensive.

Engineering services which includes construction and construction

modification, removal and installation, and rearrangement of

facilities.

Shutdown improvement maintenance, which is a set of improvement

maintenance activities that are performed while the production line is in a

complete stoppage situation.


Type of Maintenance

Predictive Maintenance (PDM)

Condition-based predictive maintenance depends on

continuous or periodic condition monitoring equipment

to detect the signs of failure.

Statistical-based predictive maintenance depends on

statistical data from the meticulous recording of the

stoppages of the in-plant items and components in

order to develop models for predicting failures.



CBM

What is CBM ?

Definition – CBM is a set of maintenance actions based on real-time

or near-real time assessment of equipment condition which is obtained from embedded sensors and/or external tests & measurements taken by portable equipment.

Purpose – The purpose of CBM strategy is to perform maintenance

only when there is objective evidence of need, while ensuring safety, equipment reliability and reduction of total ownership cost.



CBM

3 Levels of CBM?

Human Senses. – See, hear, Touch, Smell etc.

Asset Performance Indicator. – BMS, DCS incorporating statistics.

Applied Technologies. – Vibration Analysis, IR Thermography, MCSA, WDA, NDT

etc.



CBM – How it Works.

- 14 - INDEX Prepared By : DEEPAK SAHOO, Manager - TPM E

ther

net

Data-base

Network Data Server

LAN

Trend Data

Workstation

LAN-connected

Maintenance Workstation

Junction Box

Temperature

Pressure

RPM

CFP

A

V

Vibration

Vibration Junction Box

Voltage

Current

Embedded Sensors

Data Bus

Computer

Low Speed DAQ

High Speed DAQ

(At System) (Off System)

Portable Maint Aid

Workstation

Workstation

Workstation

(On System)

Computerized Maintenance

Management System


CBM – How it Works.

Identify Equipment & CBM Technique

Schedule & Planning Measurement

Unscheduled Jobs Scheduled Jobs

Data Entry

Analysis Abnormal Reading Normal Reading

Exception Report for Corrective Action Report Generation

Corrective Action by DEPT. Abnormal Reading

Feedback from DEPT.

Re Measurement Normal Reading

Trend for History

and Analysis

Re circulation of Report



CBM



CBM

Formulate CBM Strategy


PLAN

Management formulate CBM strategy and provides

the vision and mission.

SHARE

Share with employees in

Engg. Functions.

UNDERSTAND

Employees understand the vision of Management and benefits of CBM Activities.

Process

of CBM Activities

start


CBM - Applied Technologies Tools

Vibration Analysis

IR – Thermography

WDA – Wear Debris Analysis

Motor Current Signature Analysis

Rotor balancing

NDT

Radiography (RT)

Magnetic Particle Testing (MT)

Ultrasonic Testing (UT)

Penetrant Testing (PT)

Acoustic Emission Testing (AE)





Condition based management

Visual Inspection

Vibration analysis

Ultrasonic

Pressure analysis

Temperature analysis

Oil analysis

Efficiency analysis

Wear analysis



Thermal Techniques

Contact Sensors, Paints, Thermocouples, Liquid expansion

Infra-red Cameras

Application Pipe work

Insulation breakdown

leaks

Electrical

High resistance joints


Overheating components Hot motors /Blocked cooling filters Mechanical Bearings Coolant Gear Box etc.






Vibration Analysis

Vibration Analyser

Vibration Meter / Tester

Probe

Application

All Rotating Equipment - Fans, Compressors, Pumps, high speed Gear boxes, Motors etc



CBM – Vibration Analysis

What is vibration?

Oscillatory / repetitive motion of a body about its equilibrium is called vibration.

Simple Harmonic Motion




Vibration Monitoring Devices

Online Vibration Monitoring

E.g.: CSI Online monitoring system, Bentley Nevada, Shinkawa etc.

Offline / Portable Vibration Monitoring

Handheld Vibration Meter.

Handheld Vibration Analyzer ( A single channel / dual channel analyzer)




Vibration Monitoring Sensor

Proxy Probes ( measures only Displacement)

Velocity Pick Up (measures Displacement & Velocity)

Accelerometer ( measures Displacement / Velocity / Acceleration.




Methods of Communication from Sensor to Device

Traditional : Wired System

The Future : Wireless System


CSI 9420 Vibration Transmitter.


Thank you.

END INDEX Prepared By : DEEPAK SAHOO, Manager - TPM

4.5 g Maintenance Strategy by Deepak Sahoo

Business

opportunity maintenance

set of maintenance activities

maintenance cbmprepared

deferred maintenance

breakdown maintenance

window maintenance

maintenance strategywhat

planned maintenance