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Maintenance strategy & cbm basic introduction
Condition-based maintenance (CBM) involves monitoring key parameters that can indicate equipment failure. CBM allows maintenance to be planned before severe damage occurs. The document discusses CBM techniques like vibration analysis, thermography, performance monitoring, lubricant analysis, and non-destructive testing. It provides examples of applying techniques like vibration, temperature, and flow measurements to monitor fans, pumps and detect issues like imbalance, bearing damage, cavitation. A successful CBM program incorporates monitoring, data analysis, reporting, and corrective actions.
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Maintenance strategy & cbm basic introduction
- 1. TRAINING PROGRAM ONTRAININGPROGRAM ON PREDICTIVE MAINTENANCEPREDICTIVE MAINTENANCE (CONDITION B(CONDITION BASED MAINTENANCE)ASED MAINTENANCE)
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- 3. FOUR MAINTENANCE STRATEGIES On-Failure(B/D) Fix it when it fails Fixed Time Maintain based Upon calendar or running time Condition Based Maintain based upon known condition Design Out Design out cause of failure Maintenance Plan • Applicable to plant that exhibits wear out - but must be used in conjunction with other strategies • Only effective if correctly implemented
- 4. CONDITION BASED MAINTENANCE (CBM) •Advantages Allows shutdown before severe damage occurs Allows run to failure Production can be modified to extend unit life Cause of failure can be analysed
- 5. • Advantages Permits maintenanceto be planned Labour to be organised Spares to be assembled Modifications can be planned CONDITION BASED MAINTENANCE (CBM)
- 6. What is ConditionMonitoring? 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
- 7. Failure Characteristic B <1 Wear out Random dominated Early life Failure Probability graph B > 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- failure Condition 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
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- 9. NDT/CBM HUMAN VS MACHINE SYSTEM /MONITORING HUMANMACHINE / 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
- 10. NDT/CBM HUMAN VS MACHINE TYPEOF 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)
- 11. NDT/CBM HUMAN VS MACHINE TYPEOF 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
- 12. NDT/CBM HUMAN VS MACHINE TYPEOF 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
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- 14. Human Senses VISUAL MONITORING Touch Sight Smell Hearing The simplest techniques are often the best - but to be effective any evaluation must be quantifiable
- 15. Thermal Techniques Contact Sensors (Cheapbut have limitations) Paints Thermocouples Liquid expansion Infra-red Cameras & Videos (Expensive but very powerful)
- 16. Thermal Techniques Applications : Pipework Insulation breakdown leaks Electrical High resistance joints Overheating components Hot motors /Blocked cooling filters Mechanical Bearings Coolant Gear Box etc.
- 17. Vibration Monitoring Versatile toolfor condition monitoring of rotating & reciprocating plant Wide range of techniques and instrumentations Careful selection and application of technique is essential for success
- 18. Vibration Monitoring: Techniques Overall Acceleration,Velocity & Displacement Vibration Spectral Monitoring Run-up/down tests Phase plots Time Signature Analysis
- 19. Vibration Monitoring: Rolling ElementBearing MonitoringRolling Element Bearing Monitoring Spike Energy/HFD High Frequency Velocity Overall Acceleration Shock Pulse
- 20. Performance Monitoring Involves theuse of existing data, Current Temp Pressure Flow rate
- 21. Performance Monitoring Any variablewhich is indicative of a failure mode Thermal efficiency Wear rate Compressor loading / unloading time Product Accuracy
- 22. Wear Debris Monitoring Techniques SpectrographicOil Analysis (SOA) Ferrography (direct & analytical) Particle Quantifier Microscopic optical assessment Choice of technique is critical to success
- 23. Non Destructive Testing Ultrasonic Methods Radiography Dye Penetrant Magnetic Particle
- 24. Corrosion Monitoring VisualInspection Ultrasonic Leak Detection Coupons Electrical Resistance Probe
- 25. CRITERIA FOR SELECTIONOF CBM TECHNIQUE CBM TECHNIQUE TYPE OF EQUIPMENT VIBRATION 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 Oils DISSOLVED GAS All Transformer Oils ANALYSIS
- 26. EQUIPMENT CAUSES OF FAILURE TECHNIQUESCOMMENTS 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
- 27. EQUIPMENT CAUSES OF FAILURE TECHNIQUESCOMMENTS 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
- 28. 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
- 29. VIBRATION INSTRUMENTS IRD Model- 306 M Model PL-31 ANALYZER SPM A 30
- 30. INFRARED THERMOMETERSCONTACT THERMOMETERS THERMALIMAGER Model IRISYS THERMOGRAPHY INSTRUMENTS
- 31. LUBRICANT OIL TESTING WEARDEBRIS /PARTICLE ANALYSIS - SEPARATE INFRASTRUCTRUE /LAB
- 32. ULTRASONIC THICKNESS GAUGE make- MODSONIC ULTRASONIC FLAW DETECTECTORS ULTRASONIC FLAW DETECTOR MODEL GAILLILO-100
- 33. Condition Based Maintenance PumpVibration Measurement Non contact temperature Measurement Thermography of switch Yard Wear debris analysis ( External)
Editor's Notes
- #4 Key Points An effective Maintenance Plan depends on the targeted use of the appropriate strategy for each significant failure mode. Notes
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- #16 Notes
- #17 Notes
- #18 Notes
- #20 Key Points Spike Energy/HFD : The bearing damage signal is measured in units of acceleration and band pass filtered between 5-20KHz. The output gives a number indicative of bearing condition. High Frequency Velocity : higher frequency peaks typically between 2-5KHz arising from the bearing damage signal exciting the resonance of the transducer. Overall Acceleration : Similar to High Frequency Velocity but can confuse with gear noise or cavitation Envelope Analysis : The complex signal from a bearing is conditioned and then enveloped to filter out unwanted vibration data. The resultant spectrum gives a clear indication of bearing repetition frequencies and problems Shock Pulse : The impacts caused by bearing damage produce shock pulses. These pulses are detected using a transducer which is tuned to resonate at 32 KHz. Analysis of Peak and ‘Carpet’ levels gives good indication of bearing condition and lubrication state. Kurtosis : This is a statistical method based on comparison of the fourth power of the vibration signal averaged and the square of the signal averaged. Not in widespread use.
- #21 Notes
- #22 Notes
- #23 Key Points Effects of Particle Size : As wear progresses, the average particle size tends also to increase, from less than 10 microns to over 1000 microns. This means that techniques such as SOA are good at detecting early wear, but can give deceptive results as the wear progresses, and the average particle size becomes too large to be detected by this technique. This is where simple techniques such as basic wear debris measurement can be very effective. Notes