Machine centered for noria louisville 07Presentation Transcript
Six Steps to aHealthy Machine Jim Taylorjim.email@example.com 765-366-4285 www.machineryhealthcare.com
BackgroundTechnology Centered: Machine centered: Optimizes individual Optimizes machine technology program health spreads cost over as Provide all needed many pieces of information to assess equipment as possible machines health Minimizes cost per Decide what PMs actually measurement improve or maintain machines health Provides full workload Family physician Keeps instruments in model use
Technology CenteredSpreads cost over as manymachines as possible Minimizes cost per data point Maximizes utilization of test equipment Provides evidence of full work load to supervision Each Technology Is Optimized but Machine healthcare is sub-optimized
Is This the Best Way?Would you be happy with your doctorif on your annual physical he onlytested your pulse rate? And then sent you out to contract your own blood work and interpret the results? Then based on that limited information, he makes the decision to do surgery. A pump overhaul is surgery!
Failure after breaking system boundry 2000 1800 1600 1400 1200Failures 1000 800 600 400 200 0 < 1 wk 1 – 2 wk 2 – 3 wk 3- 4 wk 1 – 2 mo 2 – 3 mo >3 mo Time after ov erhaul Study by Corio & Costantini
Application to Machinery Healthcare Don’t hurt me!!!To get a complete picture of machinehealth, you need to run a number oftests. You’re more likely to catch something early. And when that PM for overhaul (surgery) comes up, you can make an informed decision on whether to perform or defer it.
Advantages of a Machine Centered ApproachCollecting complete data on each trip to the machine • Less machines per day • More valuable information Lets you do 2 things: • Manage failure • Defer routine overhauls Optimize Machines Healthcare
Machine Centered ProcessIt’s nothing new Reliability Centered Maintenance formalizes itBut the fact is not everyone can do RCM • You can’t afford it • You don’t have the manpower • You can’t get approvalBut you still have to maintain the machine
Machine Centered Thought Process Which of How can What are the these we avoid possible failures are these failures? significant? failures? When we cant Collect allavoid failure, how Tailor a suite of tests to get information at one can we get an decision point. early warning? early warnings.
First ask: What are the possible failuresThink about the function of the machine.How can it fail to meet that function?
System BoundariesPick yourboundaries soyou have amanageableproblem
Motor-Drive System Functions Function Downstream (Load side) Start motorFunctions Stop motorof a Motor Deliver specified torque atDrive specified RPMSystem Specified speed ramp rate up Specified speed ramp rate down accelerate load from stop to operating speed
Function Functional Failure Mode FailureFunctional Start motor Motor will not turn winding failure (stator)Failure of a Insulation Failure (stator)Motor Drive Rotor failureSystem Bearing Seized Contactor Failed Loss of Power VFD Malfunction (Start) Stop Motor will motor not stop
Next ask:Which of these failures are significant?How often it happens - frequencyWhat’s the impact when it does - consequenceRisk = frequency x consequence
Criticality SurveyScore Frequency Effect 1 1/10 yrs None 2 1/ yr A little 3 1/ month Some 4 1/ week A lot 5 1/ day Complete Safety goes to the top
Then ask:How can we avoid these failures? Adjust, lubricate, … Preventive replacement Design changes
When we cant avoid failure, ask: How can we get an early warning? Process parameters Inspections Technology
Then:Tailor a suite of tests to get early warnings? • Only do the tests needed • Don’t test just because you can Appendix A to the paper has a partial list of tests & technologies
Motor Failure Failure Failure Symptoms Measurement Mode Causeswinding Conductor vibration > ips vibration failure failure monitoring (stator) Various MCSA Various MCE excessive vibration > ips vibration vibration monitoringInsulation Breakdown Polarization index Failure (Stator) R to gnd < ohms Megger excessive temperature > °F thermometer current amperes > A ammeter voltage spike power quality monitor excessive Motor temperature > thermometer temperatu °F re Ambient temperature > thermometer °F
Finally:Collect all information at one decision point. Most important step!
Machine Centered Thought Process Which of How can What are the these we avoid possible failures are these failures? significant? failures? When we cant Collect allavoid failure, how Tailor a suite of tests to get information at one can we get an decision point. early warning? early warnings?