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An Introduction to Condition Based Maintenance (CBM)


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An approach to CBM Application and Management

An Introduction to Condition Based Maintenance (CBM)

  1. 1. An Introduction to Condition Based Maintenance (CBM)An approach to CBM Application and Management by: GAA Optima 4 July 2012 1
  2. 2. The CBM PhilosophyIt is about utilising the Condition Monitoring technologies topredict the failure pattern(s) of an asset.This will allow maintenance to be scheduled based onequipment condition and not time. 4 July 2012 4 July 2012 2
  3. 3. The Vision is to attain:Meaningful set of maintenance schedules (TechnicalBasis of Maintenance - TBoM)Improved operating performanceEnsure safety & environmental protectionReduced maintenance costsComprehensive maintenance database (Centralised)Clearer view of resource requirementsCBM attains lasting benefits & can be applied across all orjust selected equipment 4 July 2012 4 July 2012 3
  4. 4. The MethodologyThe strategy uses a two level approach by overlaying Techniques &technologies on monitored componentsLevel one (Short term): Identify and reduce equipment failures across site  Use technologies to troubleshoot and examine poor performing assets  Energy usage examinationsLevel Two (Medium to long term): reduce maintenance exam tasks, extendmaintenance exam and Overhaul periodicities (TBoM integration)  Use technologies to reduce maintenance costs  Effective utilisation of work force  Increased knowledge of asset performance and condition  Feedback into TBoM 4 July 2012 4 July 2012 4
  5. 5. CBM Financial Impact Easy to Labour Low on services measure Overheads profit Reliability Safety Legislation Design Scrap out Availability Catastrophic Poor failures maintenance Breakdowns & Repairs Use of skills Warranty Low Flexibility Hard to High on measure profit
  6. 6. Some of the CBM Technologies employed 4 July 2012 4 July 2012 6
  7. 7. Oil and Grease AnalysisThree dimensions: Wear  Ferrous  Nonferrous Contamination  Dust  Water  Fuel Chemistry  Oil  Additive 4 July 2012 4 July 2012 7
  8. 8. Portable Vibration AnalysisWhat does it monitor?Imbalance ProblemsMis-alignment ProblemsBearing ProblemsElectrical DefectsWhere?CranesAir Compressor motorsBrake resistor / Traction cooling fansHVAC equipmentAlternatorsTurbo chargerGearboxes (wheel lathe)Electrical motorsCooling system pumpsLubrication oil system pumpsFuel PumpsDiesel EngineAxle boxes 4 July 2012 4 July 2012 8
  9. 9. Portable Ultrasonic AnalysisWhat does it monitor?Air Leak ProblemsElectrical ProblemsMechanical ProblemsLocation?Leak DetectionValvesAir supply linesFlexible hosesPneumatic systemsPressurised systems ElectricalVacuum system problems  Arcing DetectionCompressor MechanicalSteam Traps  Bearing defects  Lack of Lubrication  Over Lubrication 4 July 2012 4 July 2012 9
  10. 10. Portable Thermography AnalysisWhat does it monitor?Electrical ProblemsMechanical ProblemsPipework ProblemsProblems detected?Electrical ProblemsHigh resistance connectionCorroded / hot connectionsEarth returns – Higher loadingRelay problemsInternal fuse damageInternal circuit breaker faultCracking insulationOverload or unbalanced loadBusbar faultsCouplingsCooling jackets 4 July 2012 4 July 2012 10
  11. 11. Questionsabas@gaaoptima.comWill be happy to answer 4 July 2012 11