TRAINING PROGRAM ON TRAINING PROGRAM ON PREDICTIVE MAINTENANCE PREDICTIVE MAINTENANCE (CONDITION B (CONDITION B ASED MAINTENANCE) ASED MAINTENANCE)
Maintenance strategy & cbm basic introduction
Jan 20, 2015
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TRAINING PROGRAM ON TRAINING PROGRAM ON PREDICTIVE MAINTENANCE PREDICTIVE MAINTENANCE
(CONDITION B(CONDITION BASED MAINTENANCE)ASED MAINTENANCE)
MAINTENANCE STRATEGIES
FOUR MAINTENANCE STRATEGIES
On-Failure (B/D)Fix it when it fails
Fixed TimeMaintain based Upon calendaror running time
Condition BasedMaintain based uponknown condition
Design OutDesign out cause offailure
Maintenance Plan
• Applicable to plant that exhibits wear out - but must be used in conjunction with other strategies
• Only effective if correctly implemented
CONDITION BASED MAINTENANCE (CBM)
• Advantages
Allows shutdown before severedamage occurs
Allows run to failure
Production can be modified toextend unit life
Cause of failure can be analysed
• Advantages
Permits maintenance to be planned
Labour to be organised
Spares to be assembled
Modifications can be planned
CONDITION BASED MAINTENANCE (CBM)
What is Condition Monitoring?
CM depends on the trending of parameters which are indicators of the condition of key equipment failure modes
0
10
20
30
40
50
60
Life Units
0
10
20
30
40
50
60
Life Units
Failure Characteristic
B < 1
Wear out Random dominated
Early life
Failure Probability graphB > 3
Difficult Expensive
Easy Cheap Difficult Expensive
Easy Cheap
High Low High Low High Low
Condition Monitoring
Mean time between failure
Strategy in order of preference
Fixed – time Operate-to- failureCondition based Design out
Condition- based Fixed-time Operate- to-failure Design- out
Condition based Operate- to failure
Design- out Condition -based Operate- to failure
Design- out Operate- to failure Condition based
Design-out Condition- based Operate-to failure
Analysis of Maintenance records permits an effective strategy to be chosen
1 < B < 3
HUMAN VS MACHINE
NDT/CBMHUMAN VS MACHINE
SYSTEM
/MONITORING
HUMAN MACHINE / PROCESS
TEMPERATURE FEVER / OTHER HOT SPOT
MECHANICAL ELECTRICAL PROCESS SYSTEM
INTERNAL TESTS PATHOLOGICAL TESTS X- RAYS CT SCAN, MRE ULTRASOUND ANGIOGRAPHY
DEBRIS ANALYSIS OIL QUALITY NDT FLAWS RADIOGRAPHS
EXTERNAL TESTS BLOOD PRESSURE ECG
OVERALL VIBRATION VIBRATION SIGNATURES
NDT/CBMHUMAN VS MACHINE
TYPE OF MAINTENANCE
HUMAN MACHINE / PROCESS
CONDITION BASED MAINTENANCE
MONITORING OF BLOOD PRESSURE CHLOROSTROL LEVEL SUGAR FEVER CANCER CELLS PATHOLOGICAL TESTS ULTRASOUND ANGIOGRAPHY X- RAYS CT SCAN, MRE
VIBRATION MONITORING THERMOGRAPHY QUALITY / DEBRIS
PARTICLES TRENDS THICKNESS / CRACK
MEASUREMENT PERFORMANCE / VISUAL
MONITORING OTHER CBM TECHNIQUES
(CORROSION, AEM ETC)
NDT/CBMHUMAN VS MACHINE
TYPE OF MAINTENANCE
HUMAN MACHINE / PROCESS
PREVENTIVE MAINTENANCE
PREVENTIVE REMEDIAL MEASURES / CARE AS PER CBM MONITORING DIET CONTROL WEIGHT MONITORING MEDICINE MEASURES CHECKS AT REGULAR
INTERVAL ADVANCED TESTS –
ECG / SCANS
CHECKS / MEASURES
AGAINST DETERIORATION PREPARATION OF S/D AS
PER MONITORING CONTROL ON DEBRIS BY
FILTRATION VIBRATION CONTROL BY
ALIGNMENT, BALANCE PM /PI SCHEDULE AS PER
EQUIPMENT COMPONENT
LIFE / DETERIORATION
TRENDS
NDT/CBMHUMAN VS MACHINE
TYPE OF MAINTENANCE
HUMAN MACHINE / PROCESS
BREAKDOWN MAINTENANCE
(WITH OUT ANY CARE)
HEART ATTACK /
BY - PASS SURGERY INSULINE DROPS –
UNCONSCIOUS KIDNEY PROBLEM CRONIC TYPHOID TUMOUR / ULCER
BEARING SEIZED SYSTEM BREAKDOWN
DUE TO PROCESS/
MECHANICAL /
ELECTRICAL FAILURES PANEL BURNOUT
CONDITION BASED CONDITION BASED MAINTENANCE MAINTENANCE
TECHNIQUESTECHNIQUES
Human SensesVISUAL MONITORING
Touch Sight Smell Hearing
The simplest techniques are often the best - but to be effective any evaluation must be quantifiable
Thermal Techniques
Contact Sensors
(Cheap but have limitations) PaintsThermocouplesLiquid expansion
Infra-red Cameras & Videos
(Expensive but very powerful)
Thermal Techniques
Applications : Pipe work
Insulation breakdownleaks
Electrical High resistance jointsOverheating componentsHot motors /Blocked cooling filters
MechanicalBearingsCoolant Gear Box etc.
Vibration MonitoringVersatile tool for condition monitoring of
rotating & reciprocating plant
Wide range of techniques and instrumentations
Careful selection and application of technique is essential for success
Vibration Monitoring: Techniques
Overall Acceleration, Velocity & Displacement
Vibration Spectral Monitoring
Run-up/down tests
Phase plots
Time Signature Analysis
Vibration Monitoring:Rolling Element Bearing MonitoringRolling Element Bearing Monitoring
Spike Energy/HFD High Frequency Velocity Overall Acceleration Shock Pulse
Performance MonitoringInvolves the use of existing data,
Current Temp Pressure Flow rate
Performance MonitoringAny variable which is indicative of a failure mode
Thermal efficiencyWear rateCompressor loading / unloading timeProduct Accuracy
Wear Debris Monitoring Techniques
Spectrographic Oil Analysis (SOA)
Ferrography (direct & analytical)
Particle QuantifierMicroscopic optical assessment
Choice of technique is critical to success
Non Destructive Testing Ultrasonic Methods Radiography Dye Penetrant Magnetic Particle
Corrosion Monitoring Visual Inspection Ultrasonic Leak Detection Coupons Electrical Resistance Probe
CRITERIA FOR SELECTION OF CBM TECHNIQUE
CBM TECHNIQUE TYPE OF EQUIPMENTVIBRATION ANALYSIS All Rotating Equipment - Fans, SPM Compressors, Pumps, high LASER ALIGNMENT speed Gear boxes, Motors etc.
THERMOGRAPHY & All Electrical PCC, MCC, THERMAL IMAGING High Tension Switch yards Motors, Mech. Drives etc. NDT THICKNESS/ FLAW All type of Tubes, Pipes & DETECTION Vessels, Plates, Shaft etc.LUBRICANT & WEAR All Type of Lubricating &
DEBRIS MONITORING Hydraulic OilsDISSOLVED GAS All Transformer OilsANALYSIS
EQUIPMENT CAUSES OF FAILURE
TECHNIQUES COMMENTS
Fan Out of balance Misalignment Bearing
damage Aerodynamic
forces Belt problems
Overall acceleration Spike energy
measurement Overall vibration Vibration analysis Flow measurement Motor current
measurement
Simple application using windowed spectra to trend deterioration in specific faults.
Equipment performance is monitored by measuring process parameters
SAMPLE APPLICATION OF MONITORING TECHNIQUES
EQUIPMENT CAUSES OF FAILURE
TECHNIQUES COMMENTS
Pumps Misalignment Bearing
damage Cavitation Impeller
damage Hydraulic
forces
Overall vibration Vibration analysis Overall acceleration Spike energy
measurement Flow measurement Motor current
measurement
Windowed spectra to trend deterioration in specific failure modes. Cavitation can be detected using frequency analysis. Often blade pass frequency indicates hydraulic problems
SAMPLE APPLICATION OF MONITORING TECHNIQUES
Identify Equipment & CBM Technique
Schedule & Planning Measurement
Unscheduled JobsScheduled 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
FUNCTION AND FLOW OF CBM SYSTEM
VIBRATION INSTRUMENTS
IRD Model - 306 M
Model PL-31 ANALYZER SPM A 30
INFRARED THERMOMETERSCONTACT THERMOMETERS
THERMAL IMAGER Model IRISYS
THERMOGRAPHY INSTRUMENTS
LUBRICANT OIL TESTING
WEAR DEBRIS /PARTICLE ANALYSIS - SEPARATE INFRASTRUCTRUE /LAB
ULTRASONIC THICKNESS GAUGE make - MODSONIC
ULTRASONIC FLAW DETECTECTORS
ULTRASONIC FLAW DETECTOR MODEL GAILLILO-100
Condition Based MaintenancePump Vibration Measurement Non contact temperature Measurement
Thermography of switch Yard Wear debris analysis ( External)
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