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CONDITION BASED MONITORING PRESENTATION

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CONDITION BASED MONITORING PRESENTATION

  1. 1. CONDITION BASED MONITORING A PROJECT ABOUT PLANT PREVENTIVE MAINTENANCE IMPLEMENTED AT BARNES REINFORCING INDUSTRIES (PTY) LTD
  2. 2. 1.WHAT IS CONDITION BASED MONITORING(CBM)? •DEFINITION : Condition-based monitoring (CBM) is maintenance that is regularly performed on a machine to lessen the likelihood of the machine to breakdown.
  3. 3. BACKGROUND/HISTORY :
  4. 4. 2.WHY IMPLEMENT CBM at BRI? • ADVANTAGES : REDUCES MAINTENANCE LABOR COSTS. MINIMIZE THE COST OF SPARE PARTS. ELIMINATES MANUFACTURING INTERRUPTIONS. PRODUCES MAXIMUM QUALITY OF PRODUCTS. INCREASES MACHINE LIFE SPAN.
  5. 5. 2.WHY NOT IMPLEMENT CBM AT BRI? • DISADVANTAGES : CONSUMES TOO MANY RESOURCES. MAINTENANCE DEPARTMENT MAY FIND IT DIFFICULT TO MANAGE CBM AND BREAKDOWNS AT SAME TIME. THERE IS NOT ENOUGH TIME AND MANPOWER TO MANAGE CBM AND OTHER IMPORTANT DAILY MAINTENANCE TASKS. IT TAKES LONG TO SEE THE RESULTS.
  6. 6. • Project aim: To monitor the condition of rotating and heating equipment in machines by means of condition-based monitoring and preventive maintenance.  To identify equipment failure which causes the machines to experience frequent breakdowns. 3.METHODOLOGY AND OBJECTIVE FOLLOWED :
  7. 7. • SPECIFIC TOOLS USED: TOPTRONIC T306 INFRARED THERMOMETER. 3.METHODOLOGY AND OBJECTIVE FOLLOWED :
  8. 8. •SPECIFIC TOOLS USED: Brit IR THERMOGRAPHIC CAMERA. 3.METHODOLOGY AND OBJECTIVE FOLLOWED :
  9. 9. • SPECIFIC TOOLS USED: SKF MACHINE CONDITION ADVISOR. 3.METHODOLOGY AND OBJECTIVE FOLLOWED :
  10. 10. • Project Objective: 1. Engineering trainees will determine the components to be monitored. 2. The project manager together with engineering trainees will determine the monitoring schedules for the equipment to be monitored. 3.METHODOLOGY AND OBJECTIVE FOLLOWED :
  11. 11. • Project Objective: 3. A monitoring procedure will be determined, which will demonstrate the methodology of conducting the project. 4. Tools for monitoring such as infrared thermometer, thermography camera, vibration analyser and other technologies will be determined and used by engineering trainees for monitoring equipment. 3.METHODOLOGY AND OBJECTIVE FOLLOWED :
  12. 12. 4.LIMITATIONS OF PROJECT: CBM took much time and sometimes produced little results. an urgency of continuation of production by management, whilst machines were scheduled for maintenance. routine tasks were done too often than required.
  13. 13. 5.BUDGET FORECAST: ACTIVITY COST REGISTRATION FOR P2 EXPERIENTIAL LEARNING R 1 750 STUDENT STIPENDS * X 12 MONTHS R 67 956 PROPOSAL PREPARATION AND SUBMISSION PRINTING COSTS R 200 LITERATURE STUDY AND INTERNET PROVISION R 1 000 OFFICE EQUIPMENT R 10 000 INSTRUMENTS/TOOLS FOR TESTING PURPOSES R 20 000 ELECTRONIC/MECHANICAL COMPONENTS NEEDED R 10 000 MACHINE INSTALLATION AND COMMISSION R 57 000 LANGUAGE EDITING, ADVISE AND BINDING R 0 OTHER R 10 000 TOTAL ± R169 656
  14. 14. 6.PROPOSED TIMETABLE: TO DO LIST…. PROPOSED CONDITION MONITORING REQUIREMENTS SHOULD BE COMMENCED BY BEGINNING OF SEPTEMBER 2016 COMPONENTS TO BE MONITORED MUST BE DETERMINED BY THE END OF SEPTEMBER 2016 THE REPORT SHOULD BE SENT IN FOR LANGUAGE EDITING AROUND THE ENDING OF NOVEMBER MONITORING SCHEDULES AND PROCEDURES SHOULD BE COMPILED AND APPROVED IN MID OCTOBER 2016 IDENTIFIED COMPONENTS SHOULD BE TESTED USING SPECIALIZED TOOLS BY END OF OCTOBER 2016
  15. 15. PRIORITY MACHINES MONITORED 1) EURA 16 2) EVG (LML) 3) HEAVY MESH LINE(HML) 4) STRAIGHT AND CUT MACHINES 5) WIREDRAW
  16. 16. Procedure: Monitoring an electric motor for temperature and vibration analysis Bearing temperature (fan side) Coil temperature Bearing temperature (drive side)Gearbox (overall vibration)
  17. 17. Procedure: Monitoring an electric motor for temperature and vibration analysis • Step 1: Mark the points of monitoring as shown in picture above • Step 2: Using a condition advisor tool place the tool on the green mark-ups to take reading of velocity(mm/s) • Step 3: Using an infrared thermometer aim the red light from the tool to the orange mark-up for readings of temperature in degrees (ºc)
  18. 18. Procedure: Monitoring an electric motor for temperature and vibration analysis • Step 4: Capture the readings in table form in accordance to the colour sequence • Step5 : Repeat step 1 to 5 until you have 3 tables for each machine monitoring. • Step 6:Draw a temperature VS velocity graph to analyse the results.
  19. 19. 7.PROJECT OUTCOME: VIBRATION ANALYSIS OF RESULTS As the results were analysed this was the outcome: Envelope acceleration classification 1= bearing bore diameter of 200mm-500mm = Shaft speed of 500 RPM = ALERT Envelope acceleration classification 2= bearing bore diameter of 300mm-400mm = Shaft speed of 1800 RMP = DANGER
  20. 20. 7.PROJECT OUTCOME: VIBRATION ANALYSIS OF RESULTS As the results were analysed this was the outcome: ALERT MEANS : 1) IT ‘S A WARNING THAT MONITORED COMPONENT NEEDS TO BE CHECK IMMEDIATELY FOR FAULTS 2) WARNS THAT IT MIGHT CAUSE BREAKDOWN LATER IF NOT ATTENDED SOONER
  21. 21. 7.PROJECT OUTCOME: VIBRATION ANALYSIS OF RESULTS As the results were analysed this was the outcome: DANGER MEANS : 1) THE COMPONENT MONITORED IS BEYOND REPAIR AND NEEDS TO BE REPLACED 2) IT IS A DANGER TO THE MACHINE , BREAKDOWN IS ABOUT TO OCCUR
  22. 22. 7.PROJECT OUTCOME: THE GRAPH OF ELECTRIC MOTOR PERFORMANCE
  23. 23. 7.PROJECT OUTCOME: EVG(LML) THE GRAPH OF ELECTRIC MOTOR PERFORMANCE
  24. 24. 7.PROJECT OUTCOME: WIRE DRAW LINE THE GRAPH OF ELECTRIC CONTACTOR PERFORMANCE
  25. 25. 8.SUMMARY OF OUTCOME As a result of completing the CBM procedure we found that most neglected mechanical faults were the main causes of major breakdowns compared to electrical faults. Bearings of motor posed as fault to the overall of machine due to overheating, fatigue failure, lubricant failure, misalignment and corrosion.
  26. 26. 8.SUMMARY (Let’s Recap!) BRI, a manufacturing organization is faced with the problem of experiencing maximized breakdowns. These breakdowns are caused by lack of proper maintenance and mechanical faults causing major breakdowns compared to electrical faults.  The aim was to monitor the condition of the identified heating and rotating equipment using condition-based monitoring. The practice of CBM is necessary to achieve reducing spare parts cost, maintenance labour costs, maximum machine life span, etc.
  27. 27. 8.SUMMARY (Let’s Recap!) Specialised tools such as infrared thermometer, thermography camera and vibration analyser were used to test for temperature and vibration. Condition-based monitoring is focused on correction of failure modes found in equipment of machines. It preserves, protects and extends the life of machine equipment. Condition-based monitoring reduces overall maintenance cost.
  28. 28. REFERENCE 1) Andrew K.S. Jardine , Daming Lin, Dragan Banjevic, “A review on machinery diagnostics and prognostics implementing condition-based maintenance” Mechanical Systems and Signal Processing 20 (2006) 1483–1510. 2)Y. Han and Y. H. Song, “Condition Monitoring Techniques for Electrical Equipment—A Literature Survey”, IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 18, NO. 1, JAN 2003
  29. 29. 10. ANY QUESTIONS ? ? ?

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