Preventive & Predictive Maintenance 005.ppt

PREVENTIVE & PREDICTIVE
MAINTENANCE

 Concepts and Maintenance Strategies
Preventive & Predictive Maintenance Understanding
 Preventive Maintenance:
o What is PM? tasks, values and activities
o Why using PM with PdM? When does PM make sense?
o What can a CMMS do for You?
o Permit To Work
o How can we measure the Preventive Maintenanc
Effectiveness?
 Predictive Maintenance:
o What is the PdM? Cost, primary uses and required elements
o Why we still have failures?
o Predictive maintenance techniques and applications
o Designing predictive maintenance program
o Basic steps & setting up PdM program
o Advanced CBM features in a CMMS
Course Contents:
Chapter 1
Chapter 2
Chapter 3
Hassan Hassan

 Reliability Centered Maintenance (RCM)
 Case Studies
 Risk Based Maintenance (RBM)
 Equipment Alignment
o What is shaft alignment
o Reversal Alignment
o Vertical misalignment
o Horizontal Misalignment
Chapter 4
Chapter 5
Chapter 6
Chapter 7
Hassan Hassan

Hassan Hassan
Proactive
MAINTENANCE DIFINITIONS
PLANNED UNPLANNED
Predictive
Preventive
CMMS OVERHAUL
MAINTENANCE
B- Turnaround
A- Routine C- Conditional
Monitoring
FOR CRITICAL
EQUIPMENT

Chapter 1
Preventive & Predictive
Maintenance Understanding
Concepts and Maintenance
Strategies
Hassan Hassan

Hassan Hassan
Maintenance Strategies
• Ultimately to reduce the current expenses
• To keep the plant equipment running on the optimum conditions
• To keep the plant operating with a high safety level
• Improve the equipment performance against the existing
conditions through the corrective maintenance
• To build up a clear and precise data for the vendors qualification,
through the maintenance historical data
and equipment failure analysis.
• This information will be an important guide for any
future project to accept or refuse vendors quotation.

• Extend machine life
• Increase productivity
• Lower daily operating costs
• Improve system reliability
• Decrease number of maintenance operations, causing a
reduction of human errors
• Better operations lead to lower production cost and lower use
of resources.
• As systems become more costly, and instrumentation and
information systems tend to become cheaper and more reliable
Maintenance strategy aims to:
Hassan Hassan

• Adjustments
• Cleaning
• Lubrication
• Repairs
• Replacements
• Revamping
This maintenance includes but is not limited to:
Hassan Hassan

Hassan Hassan
Before executing any maintenance program,
it is essential to answer the following questions:
a-What is to be maintained?
b-Why to do maintenance?
c-Who will execute maintenance?
d-Where to do maintenance?
e-When maintenance to be executed?
f- How to do maintenance?
Maintenance Philosophy

Hassan Hassan
In our case the maintenance will be for oil industry
equipment which mainly classified to:
a- What is to be maintained?
1-Mechanical equipment
3-Instrumentation
Heaters (vertical, horizontal)
Vessels (strippers,, knockout drums, etc--
Columns (Towers)
Pipe lines and fittings
Heat exchangers
Air coolers
Valves
Storage tanks
Ejectors
Hoisting devices
2-Electrical equipment
4- Civil
I-Stationary equipment

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II-Rotating equipment
Pumps (centrifugal, positive displacement)
Compressors (centrifugal, axial and reciprocating)
Expanders
Turbines (steam, gas turbines)
Air cooler fans
Mixers
Engines (gas, petrol and diesel)
Blowers
Electrical motors
Electrical generators

Hassan Hassan
b-Why to do maintenance?
• Ultimately to reduce the current expenses
• To keep the plant equipment running on the optimum
conditions
• To keep the plant operating with a high safety level
• Improve the equipment performance against the
existing conditions through the corrective maintenance
• To build up a clear and precise data for the vendors
qualification, through the maintenance historical data
and equipment failure analysis.
• This information will be an important guide for any
future project to accept or refuse vendors quotation.

Hassan Hassan
C- Who will execute maintenance?
1- In-house maintenance (Company manpower)
II- Outdoor maintenance (contractor manpower)
III- Manpower Supply (Daily rate Bases)

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1- In-house maintenance (Company manpower)
This way of maintenance based on a company maintenance team,
which are Managing staffs, Engineering, Forman, Technicians
Advantages
* Building up a well trained maintenance team knows how
to do perfect maintenance applying the safety regulation.
* Low spare parts expenses due to low spares consumption
from warehouse
* Maintenance team quick respond to execute the maintenance
work request due to team acquaintance to the plant equipment.

Hassan Hassan
Disadvantages
• Difficulty of replacement the weak or little experience persons
of the company maintenance team.
• High maintenance manpower expenses (Salaries, transportation,
accommodation, medical care and retirement budget)

Hassan Hassan
This choice of maintenance based on contractor maintenance team.
The contractor will supply all the necessary maintenance team and
execute the routine maintenance for the company equipment
according to a previous agreed program under his responsibility.
II- Outdoor maintenance (Contractor manpower)
• Easy to replace any weak or low experience persons in
maintenance team with higher experience ones.
• Low maintenance contract budget compared to in-house
maintenance expenses.
Merit

Hassan Hassan
III- Manpower supply (Daily rate bases)
The daily rate bases maintenance will be executed by
contractor manpower under the supervision and
responsibility of the company maintenance department
* High spare parts expenses due to high spare consumption
* Great time loss due to periodical replacement of some of
maintenance
team, the new maintenance crew is not familiar with the equipment
* Maintenance team need time & effort to be aware of safety
regulation
Demerit

Hassan Hassan
d-Where to do maintenance
1- Centralized Maintenance
The advantage of centralized maintenance is The flexibility.
The workforce is distributed throughout the plant but reports to
the maintenance manager.
This flexibility permits the most productive use of resources.
Maintenance manpower can be controlled to provide
the maintenance staff for plant maintenance.
The disadvantage of centralized maintenance is the separation
of maintenance and process staff creates an opponent relationship.
The maintenance organization does no have the sense of ownership
for the production systems.
Also, the process personnel do not feel that they have control of the
availability and reliability of their systems.

Hassan Hassan
2- Decentralized maintenance (Assigned Maintenance)
All maintenance personnel are assigned to process department full time.
They are distributed in many locations in the company production plants.
It creates a sense of teamwork between maintenance personnel.
As a result, the total manpower required for Decentralized maintenance
is 15 % higher than that required for centralized maintenance.
It lacks the flexibility required to achieve optimum labour utilization.
It needs excess manpower because of the following reasons:

Hassan Hassan
e- When maintenance to be executed
I- Planned maintenance
A- Routine maintenance: CMMS
B- Overhaul shutdown:
II- Unplanned maintenance
1-Interval bases
2-Running Hours bases

Chapter 2
Preventive Maintenance
Hassan Hassan

A- Routine CMMS
C- Conditional Monitoring CRITICAL EQUIPMENT
Preventive Maintenance:
B- Turnaround OVERHAUL MAINTENANCE
Hassan Hassan

Hassan Hassan
This type is executed According to Computerized Maintenance
Management System for the different equipment categories,
According to interval bases.
DAILY,
WEAKLY,
MONTHLY,
3MONTHS,
6 MONTHS
ANNUALLY
2YEARS
3 YEARS
The work orders will be delivered on weekly bases
Or according to hours bases such as on engines and gas turbines
A- Routine maintenance: CMMS

Computer Maintenance Management
( CMM )
A CMMS software package maintains a computer
database of information about an organization’s
maintenance operations, i.e. CMMIS –
computerized maintenance management
information system.
This information is intended to help maintenance
workers do their jobs more effectively
Hassan Hassan

Examples of CMM Information Help
Determining which machines require maintenance
and which storerooms contain the spare parts they
need)
Help management make informed decisions (for
example, calculating the cost of machine breakdown
repair versus preventive maintenance for each
machine,
Possibly leading to better allocation of resources).
CMMS data may also be used to verify regulatory
compliance
Hassan Hassan

CMMS
Many CMMS packages can be either web-based,
meaning they are hosted by the company selling the
product on an outside server,
Scheduling jobs, assigning personnel, reserving
materials, recording costs, and tracking relevant
information such as the cause of the problem (if any),
downtime involved (if any), and recommendations for
future action.
Typically, the CMMS schedules preventive maintenance
automatically based on maintenance plans and/or meter
readings.
Different software packages use different techniques for
reporting when a job should be performed
Hassan Hassan

What can a CMMS do for You?
• Improve Planning and Decision Making
• Maintenance Management Software allows
you to schedule maintenance activities so you
can be proactive instead of reactive
• Store maintenance information with your
software. Retrieve information regardless of
personnel changes in your organization
• Make informed decisions about repair and
replacement
Hassan Hassan

• Improve Efficiency
• Minimize equipment downtime
• Improve scheduling of maintenance staff
• Manage routine maintenance tasks more
efficiently
• Save Money
• Prevent expensive repairs and expensive
equipment downtime
• Track parts costs and needs and make better
supplying decisions
Hassan Hassan

Scheduling Tasks
• As a team starts to schedule preventive
maintenance in advance, they need a reliable
work calendar.
• CMMS systems are especially good at
scheduling recurring work and sending
reminders to the right people.
• Organized scheduling helps even out the
workload for a maintenance team, and makes
sure that tasks don't get forgotten.
Hassan Hassan

Recording Asset History
• Many maintenance teams have to care for
assets that are 10, 20, even 30 years old.
These machines have a long history of repairs.
• When a problem comes up, it is always useful
to see how this problem was solved last time.
• In CMMS systems, when repairs are done,
they are recorded in the machine's history log
and can be viewed again by workers. This
saves a lot of time - technicians can rely on
past experience to solve problems
Hassan Hassan

Managing Inventory
• You might not think about it at first, but maintenance
people have to store and manage a lot of inventory:
spare parts for machines, and supplies like oil and
grease.
• CMMS systems let the team see how many items are
in storage, how many were used in repairs and when
new ones need to be ordered.
• This inventory management ability saves the
organization a lot of money, because purchases can
be pre-planned (shopping around for savings) instead
of done last-minute (paying any price just to have the
component now).
Hassan Hassan

• When you implement a Computerized Maintenance
Management System, you can expect these real-world
benefits:
• Less work outages: because it is easy to do preventive
maintenance, there are less surprise breakdowns.
• Better accountability: you can see if a technician did their
work on time, and get alerted when a task is complete.
• Less overtime: better scheduling of work means that your
team isn't sitting idle or working overtime, work can be
distributed evenly.
• Information capture: technicians can record problems and
solutions, so this information is in writing - not just in their
head.
Benefits of a CMMS system
Hassan Hassan

• Better accountability: you can see if a
technician did their work on time, and get
alerted when a task is complete.
• Less overtime: better scheduling of work
means that your team isn't sitting idle or
working overtime, work can be distributed
evenly.
• Information capture: technicians can record
problems and solutions, so this information is
in writing - not just in their head.
Hassan Hassan

Hassan Hassan
RECIPROCATING AIR COMPRESSORS
W
D M 6M Y 2Y
OPEN CONDENSATE WATER DRAIN BY BASS 1st & 2nd STAGES
CHECK 1st & 2nd STAGES AIR TEMPERATURE OUTLET
CHECK CRANK CASE OIL LEVEL
CHECK PISTON ROD PACKING
CHECK PISTON ROD GLAND STUDS TIGHTING
CHECK AND CLEAN WATER JACKET
CHANGE OIL FILTER CARTRIDGE
CHECK COMPRESSOR VALVES (REPLACE SEAT GASKETS)
CHECK AND CLEAN UNLOADERS)
CHANGE CRANK CASE OIL
CHECK CRANK & CONNECTING RODS CLEARANCE
CHECK RIDER RINGS/CYLINDER CLEARANCES
REPLACE VALVES PLATES AND SPRINGS
CHANGE MOTOR BEARINGS GREASE
CHECK COUPLINGS
OPEN & CLEAN OILCOOLERS
CHECK & INSPECT SAFETY VALVES
EXAMPLE 1

Hassan Hassan
W
D M 6M Y 2Y
CHECK THRUST BEARING VIBRATION LEVEL
CENTRIFUGAL GAS COMPRESSORS
CHECK JOURNAL BEARINGS VIBRATION LEVEL
CHECK BUFFER GAS CONSUMPTION
CHECK PRIMERY VENT GAS CONSUMPTION
CHECK OIL TEMPERATURE (OUT OF WATER COOLER )
CHECK BUFFER GAS PRESSURE
ANALYZE SAMPLE OF MAIN OILTANK
CHECK OIL LEVEL IN MAIN OIL TANK
CHECK OIL TEMPERATURE IN MAIN OIL TANK
CHECK GAP VOLTAGE OF THRUST BEARING
CHECK GAP VOLTAGE OF JOURNAL BEARINGS
CHECK AND CLEAN GEAR BOX
CHECK AND CLEAN COUPLINGS
CHECK AND CLEAN OIL COOLER BUNDLES
CHECK ALIGNMENT REAINGS
CHECK OIL TEMPERATURE OUT OF MOTOR BEARINGS
EXAMPLE 2

• (PM) is a planned maintenance activity
designed to improve equipment maintenance
includes:
• Inspection
• Detection
• Correction
• Prevention of incipient failures
What does Preventive Maintenance (PM) mean?
Hassan Hassan

• This Type of maintnance is carried out according to
predetermined intervals or prescribed criteria aimed at reducing
the failure risk or perforance degradation of equipment
• The maintenance cycles are planned according to the need to
take the device out of service. The incidence of operating faults is
reduced.
• Components are essentially inspected for corrosion and other
damage at planned intervals, in order to identify corrective
action before failures actually occur.
• Preventive maintenance performed at regular intervals usually
results in reduced failure rates.
• Preventive maintenance performed also on hours bases such as
on engines and gas turbines
Hassan Hassan

• Due to the varying needs of different plants, the type and
amount of preventive maintenance required varies greatly
from plant to plant.
• Due to this, it is extremely difficult to establish a successful
preventive maintenance program without proper guidelines
and instructions.
• The ANSI standards for preventive maintenance help to
determine the type and frequency of inspections and
maintenance procedures.
Hassan Hassan

Preventive Maintenace must be done according to the
following conditions
• Certified personnel in the factory
• Replacement of worn or faulty components with
original spare parts
• Use of “Upgrade Kits” to update the product with
state of the art technology
• Guarantee that high levels of product reliability in
compliance with maintenance plans are maintained
over time
• Integration of the latest technologies to increase
safety, performance and functionality
• Upgrade solutions to bring equipment in line with
current standards Hassan Hassan

1- The cost of breakdown maintenance is usually much greater
than preventive maintenance.
2-Preventive maintenance Keeps equipment in good condition
to prevent large problems
3- Extends the useful life of equipment
4- Finds small problems before they become big ones
5- Is an excellent training tool for technicians
6- Helps eliminate rework/scrap and reduces process variability
7-Keeps human, equipment and environment maximum safety
8- Parts stocking levels can be optimized
9- Greatly reduces unplanned downtime
Objectives of Preventive Maintenance
Hassan Hassan

Hassan Hassan
Planned Downtime = Hours used for all planned jobs (TPM)
Breakdown Time = Hours used for all unplanned jobs (TBD)
Standby Time = Hours used for standby time (TSB)
How can we measure the Preventive Maintenance Efficiency?
Availability Reliability Utilization
Total Period Hours = (TX)

Hassan Hassan
Reliability =
TX – ( TPM + TBD )
TX
(Re)
Utilization =
TX – ( TPM + TBD + TSB )
TX
(U t)
Av -
TBD
TX
TX
TX –TPM
-
TBD
TX
= =
1 -
TPM
TX
Availability =
TX – TPM
TX
(Av)
=
Re -
TSB
TX
= TX – ( TPM + TBD)
TX
TSB
TX
- =

Hassan Hassan
1 -
TPM
TX
Availability =
(Av)
Av -
TBD
TX
Reliability =
(Re)
Utilization =
(U t)
Re -
TSB
TX

Hassan Hassan
EXAMPLE
MAINTENANCE STOPS FOR A COMPRESSOR WAS AS FOLLOWS:
TOTAL PERIOD OF 3 MONTHES
PM = 216 HRS
BD = 216 HRS
SB = 532 HRS CALCULATE AV , Re , Ut
= 0.8
Reliability =
216
2160
(Re)
= 80
0
0
0.9 -
Utilization =
(U t)
0.8 -
532
2160
= 0.6 = 60
0
0
= 0.9
Availability =
216
2160
(Av)
= 90
0
0
1 -
Solution

B- Turnaround OVERHAUL MAINTENANCE
The period of shutdown preparation lasts about two years.
Overhaul shutdown duration and periodical time between two
shutdowns will be decided according to Company strategy.
And product stock quantity.
This type is executed According to the decision of maintenance
department and company managerial level . The hole
production in the field will stop until accomplishment of all
maintenance activities
Hassan Hassan

Hassan Hassan
I - PRE-SHUTDOWN INFORMATIONS
1- MASTER EQUIPMENT FILE
a- How many of each group of equipment complete with data sheet, tag no.
b- Location of each equip. distributed as areas 1,2,3,...
c- Job to be done (instrument, electric, insulation, scaffolding, mechanical)
d- Safety precautions ( gas excavation, gas test, radiation check --------)
e- Mobilization i.e. ( cranes, fork lift, hoisting, trucks,... ..)
This well be decided by the company board
2- SHUTDOWN PERIOD
3- CLASSIFICATION OF EQUIPMENT.
Mechanical Job. Electrical Job.
Instrumentation Job. Civil Job.

Hassan Hassan
4- SCOPE OF WORK
A- Process department will provide the schedule of units shutdown
dates and time complete with handing over permits and precaution.
(Hazop study)
C- Sequence of equipment and units return to Process dpt. from
maintenance dpt. according to its starting up priority.
B- Also Process .dpt. gives the necessary recommendation to change
replace or revamp any equipment internal deteriorated components.
based on inspection dpt. Reports.

Hassan Hassan
5- TASK SHEET FOR EACH EQUIPMENT
6- INHOUSE OR OUT DOOR MAINTENANCE.
It will be decided by management board according to merits and
demerits of each method.
7-METHOD OF S.D.. APPLICATIONl2*8 OR! * l20R2* 12)
Many parameters are controlling this item.
8-IN-HOUSE S.D. SUPERVISION TEAM
This organization chart will help the contractor working team to now
the level of in-house responsible engineers during the SD. period.

Hassan Hassan
This organization chart will help in-house working team to
know the level of contractor rep. during the S.D. period.
9-CONTRACTOR ORGANIZAT1ON CHART
A clear information of warehouse spare parts availability,
and arrival schedule of the ordered ones, complete with confirmed
shipping status must be in hands of SD. committee.
The SD. coordinators should follow up.
10- WAREHOUSE SPARES AVAILABILITY
The S.D. coordinators should follow up the special tools availability
in warehouse and report to the S.D. committee.
The S.D. coordinators should go through the vendors special tools
list of all major equipment.
11- SPECIAL TOOLS AVABILIIY

Hassan Hassan
Manpower has to be interviewed before starting any job.
The contractors and in-house maintenance responsible engineers
have to submit a complete knowledge about manpower before
starting the shutdown to be accepted by the shutdown manager.
These information will be delivered to the computer system to
accomplish the S.D. global task sheet.
12-MAN POWER CLASSIFICATION FOR EACH JOB
I3-COST LIST OF MANPOWER SUPPLY
This will be a base of extra manpower supply cost.

Hassan Hassan
II- PRE-SHUTDOWN PREPARATION
1- W .0. & Entry and boxing UP permits.
According to task / equipment list, a paper works to be prepared
complete with safety precautions and demands such as:
These permits will be handed over to the contractor representative
consequently according to work progress.
* Work orders
•Work permits, complete with manpower, duration, gaskets,
hoisting and scope of work.
* Entry permits

Hassan Hassan
Scaffolding will be prepared before shutdown for the non-accessible
altitudes, Such as:
* Storage tanks for repair and painting,
* Overhead piping,
* Vertical columns
* High altitude works for maintenance, inspection or revamping.
2- Scaffolding.
To be marked and punched in the insulation aluminium covers
ready to be used by the inspectors during the shutdown.
3- Inspection holes.

Hassan Hassan
These will be prepared in the workshop according to operation
department list through a work requisition.
Spades will be inserted into its position and pulled out by production
manpower and under their responsibility.
4- Spades with colour tags.
Carbon steel spades with collared tags for all flanges sizes starting
from 1/2 inches up to the maximum size used in the plant.
According to equipment history, inspection and modification
committee recommendation spares will be delivered to site, Such as:
* Heat Exchangers bundles ,
* Piping, fittings and studs.
* Pumps,
* Valves or any other spares to be on site near to the defected
complete part.
5-Spares delivery to site

Hassan Hassan
Maintenance department will deliver to site the major equipment
special tools such as:
Testing rings for heat exchangers
Special tools for centrifugal and axial compressors
Hydraulic hoisting cranes, etc
6-Special tools delivery to site.
Modifications committee and inspection recommendation will be
pre-fabricated in workshop and shifted to site complete with fittings
and instrumentation devices if any.
If any electric modifications, cables to laid down, switches and any
electric works to be prepared.
7-pre-fabrications of modifications& new connections

Hassan Hassan
DAYS
PERCENT
OF WORK
PROGRESS
100 %
“ S “ CURVE
ACTUAL
ESTIMATED
8- ESIMATE “ S” CURVE

Hassan Hassan
A complete study for mobilization to be ready before
S.D. starting 1- How many cranes needed
2- Capacity of each
3- Timing, duration
4- Cranes types.
This study will be also for Trucks, Fork Lifts and Hoisting tools.
Instrumentation department will prepare for Safety
Valves Testing Benches to be ready for testing all plant
sizes. In both cases In-house or out-door maintenance
during S.D. period.
9-Safety Valves Testing Benches
10-Mobilization (Cranes, Trucks Fork Lifts Hoisting,..)

Hassan Hassan
Electrical department will maintain and repair any defect in U.P.S.
before S.D. commencing; this will be followed by a U .P .S .
maintenance completion report submitted to the managerial level.
Instrumentation department will manage to maintain and calibrate
All monitoring and controlling devices before S.D. commencing.
Such as :
* Gages calibration ( P.I , P. T , T .I , T .A.H , T .S , L.C , L.A , etc.
* Safety Relief valves sitting
* Control valves
*Measuring devices using simulation signals
11- Monitoring Devices Calibration
12-U.P.S. in a perfect condition

Hassan Hassan
It is very essential to check that all maintenance
activities could be executed without any obstacles.
Water, Steam, Fire water pumps, soda ash or pure water,
testing pumps, h.ex. tube plugs , tube bundle, pulling devices
and H.ex testing rings.
13- Availability of maintenance and testing facilities
14- Maintenance facilities checking

Hassan Hassan
C- Conditional Monitoring
This type of maintenance is monitoring, reporting
and instant repair for non spare or critical equipment.
For example; Centrifugal compressors, gas turbines,
large size pumps, steam turbines and high voltage
electric motors.

Condition Based Maintenance
Hassan Hassan

• Condition-based maintenance (CBM) is a maintenance
technique that involves monitoring machine condition and
predicting machine failure.
• Many CBM systems are controlled by computers. CBM
systems can be used in aircraft as well as other high-tech
industries for corrosion detection.
• Condition monitoring is the process of monitoring a
parameter of condition in machinery (vibration, temperature
etc.), in order to identify a significant change which is
indicative of a developing fault.
What does Condition-Based Maintenance (CBM) mean?
Hassan Hassan

• It is a major component of predictive maintenance.
• The use of conditional monitoring allows maintenance to be
scheduled, or other actions to be taken to prevent failure and
avoid its consequences
• Condition monitoring has a unique benefit in that conditions
that would shorten normal lifespan can be addressed before
they develop into a major failure. Condition monitoring
techniques are normally used on rotating equipment and
other machinery (pumps, electric motors, internal combustion
engines, presses), While periodic inspection using non-
destructive testing techniques and fit for service (FFS)
evaluation are used for stationary plant equipment such
as steam boilers, piping and heat exchangers.
Hassan Hassan

• The following list includes the main condition
monitoring techniques applied in the industrial and
transportation sectors:
• Vibration condition monitoring and diagnostics
• Lubricant analysis
• Acoustic emission
• Infrared thermography
• Ultrasound emission
• Motor Condition Monitoring and Motor current
signature analysis (MCSA)
Hassan Hassan

Condition Monitoring
Condition Based Maintenance (CBM)
• Visual inspection is the most cost-effective and widely used type
of condition monitoring.
• This type of monitoring is often performed by the equipment
operators themselves, who are typically the most familiar with
these machines.
• During a visual inspection, operators look for signs of a potential
problem, including things like leaks, cracks, rust, or corrosion.
• The inspector may also check for loose bolts or bearings, as well as
misalignment or other issues that could lead to equipment failure.
• Visual condition monitoring may also include checking filters or
simply inspecting the machine for debris that could clog the inner
mechanisms.
Hassan Hassan

• In addition to visual inspections, companies can also benefit from
more advanced forms of condition monitoring.
• One example is the Thermography, in which inspectors use special
infrared scanners to spot internal problems within a piece of
equipment.
• This type of monitoring may also involve things like oil analysis,
which can alert operators to issues like wear or contamination.
• The most advanced systems rely on special sensors to provide
constant feedback about the equipment.
• These sensors send information to a computer, where maintenance
personnel can analyze current conditions and keep an eye out for
anomalies or failures.
Hassan Hassan

• Condition monitoring is the ongoing observation and inspection
of equipment and machinery.
• This process is a part of preventative or predictive maintenance,
• This is used to identify problems with a machine before it can
break down.
• While condition monitoring in itself does not involve actual
repairs, it does help to alert firms of the need to schedule repairs
or maintenance work.
• This process can be applied to virtually any type of equipment,
from boilers and heat exchangers to rotating equipment and
other machinery found in an industrial setting.
Hassan Hassan

• The condition monitoring process offers numerous benefits to
companies.
• Regular monitoring and predictive maintenance can reduce the
risk of machine failure, which helps to minimize downtime and cut
repair costs over time.
• Equipment that is under observation and properly maintained is
also less likely to contribute to accidents, which not only helps to
keep insurance costs low, but also protects workers from injury.
• This process often helps businesses create more accurate budgets
by providing accurate information about the current condition of
major equipment and machinery
Hassan Hassan

Hassan Hassan
Isolation Standards
What types of process isolation do we have?
Single Block
Double Block and Bleed
Rated Spade or Spectacle Blind
Disconnection or Line Removal
Positive
Isolations

Hassan Hassan
Which Isolation do we need?
Depends on:
Pressure Rating of system
Type of work to be done
System Description Type of work Minimum Isolation requirement
ANSI Class 900 and above
H2S at more than 500ppm
ANSI Class 900 and above
H2S at more than 500ppm
ANSI Class 600 and below Major work
Single leak-tight valve to
enable a positive isolation to
be installed.
ANSI Class 600 and below Minor work Single leak tight valve
Minor work
Major work
Double block and bleed to
enable positive isolation to be
installed.
Double block and bleed.

Hassan Hassan
Which valves can be used?
Not all valves can be used for isolations.
Butterfly valves, Check valves and Control Valves
cannot be considered to be part of an isolation.

Hassan Hassan
Single Valve Isolations
For Minor Work on ANSI 600 and below
Note: ANSI 600 has a Maximum Working
Pressure of 99.3 Bar

Hassan Hassan
Double Block and Bleed Isolations
For Minor Work on ANSI 900 and above
Note: ANSI 900 has a Maximum Working
Pressure of 149 Bar

Hassan Hassan
Rated Spade or Spectacle Blind
Suitable for all isolations
Usually needs valve isolation first to allow
spade or spec blind isolation

Hassan Hassan
Suitable for all isolations
Physical Disconnection (Line Removal)

Hassan Hassan
150#
1 Bar
600#
80 Bar
1 Bar
Pump Isolations
Suction may be different pressure rating than discharge
Possibility to over-pressurise suction
Sequence of isolation very important
The Correct Way Normal
Condition,
Pump Shut
Down and
Electrically
Isolated
1) Close the
Discharge Valve
2) Open the pump
vent or drain.
3) Listen for signs
of passing valves.
1.Close Discharge
Valve.
2. Close Suction
valve making sure
that Pump pressure
does not rise.
3. Slowly open
drain valve and
observe pump
pressure fall to
zero.
0 Bar

Hassan Hassan
Pump Isolations - What can happen
Suction can be pressurised from discharge
Suction line can be damaged and personnel
can be injured
150#
1 Bar
600#
80 Bar
1 Bar
The Wrong Way
If the suction valve
is closed first, look
what happens:
1) NRVs usually
pass.
2) The Pressure
Builds up at the
pump suction.
10 Bar
20 Bar
30 Bar

Hassan Hassan
Example: Shipping Booster
What type of
isolation is
required?
Why?
How would
you do it?

Hassan Hassan
Example: LP Water Pump
What type of
isolation is
possible?
Is it good
enough?
How would
you do it?
NRV
NRV
BUTTERFLY
CONTROL
VALVE
BUTTERFLY

Hassan Hassan
Introduction
PURPOSE
OBJECIVES
PTW.
1-PROTECT PERSON
2-PROTECT EQUIPMENT
3-PROTECT OTHERS
4-PROTECT ENVIRONOMENT
1-CONTROL THE JOB
2-DETERMINE ATHORIZATION
3-NOT TO DUPLICATE THE WORK
4-TO MAKE RECORDS

•Understand hot work & area classifications
and level of authority
• Identify the type of work and permit required
• Identify Hazards and controls
• Apply Proper Isolation techniques
• Monitor safe confined space/vessel entry
• Ensure only “competent” staff are issuing and using
PTWs.
Key objectives

Hassan Hassan
• Hot work
• Cold work
• Confined space entry
• Well services
• Each of these categories has its own check sheet
• Check sheets must be attached to the PTW
The 4 PTW types
What is Hot work ?
Any work that provides a positive or potential source
of ignition

Hassan Hassan
• Naked flames
• Electric welding
• Heating and stress relieving (above 200 Deg C)
• Portable grinders
• Electrical drills and heat shrink blowers
Positive sources:
Potential sources:
• Grit and shot blasting
• Needle guns, wire power brushes and
• Battery operated cameras
• Spark ignition engines, Diesel engines
• Pagers and portable phones
• Use of sparking tools

Hassan Hassan
• Hazardous zone 0:
• An area in which a flammable atmosphere is continuously present or
is present for long periods
• An area in which a flammable atmosphere is
likely to occur under normal operating conditions
What are Hazardous zones?
An area in which a flammable atmosphere is not likely to occur
under normal operating condition
• Non Hazardous zone:
Any area not classified as either hydrocarbon or H2S zones 0 & 1 or
2

Hassan Hassan
• Golden Rule on hot work in hazardous areas is DO
NOT DO IT unless it is essential and there is no
alternative.
When do we do Hot work
• It is not allowed to do hot work in haz. zones 0 or 1.
• Dispensations to carry out hot work in haz. zone 2 areas
required from the FM.
• Hot work in hazardous areas covered in the HOT WORK
MATRIX.

Hassan Hassan
• Dispensation from FM for Zone 2 and positive source
of ignition
• Only one hot work at a time in any one area
• Continuous gas monitoring is mandatory
• Diesel engines must be rated for Zone 2 area
• If not rated for Zone 2 areas, must be kept a
minimum of 5 meters away from any potential leak
source
Hot work in Hazardous Zones

Hassan Hassan
• Any enclosed or partially enclosed space where
getting in and out is difficult.
What is confined space ?
• Examples of confined spaces are tanks, vessels, well cellars,
drains, pits, ducts, trenches and hoppers
Gas test requirements for confined space entry
• Oxygen: > 19% and < 22% by volume
• Flammable Gases: not exceeding 2% LEL
• Hydrogen Sulfide: (H2S) less than 5 p.p.m
• If these levels are achieved then it is CONFORMING

Hassan Hassan
Process isolation
• Authorized Person will initiate a process isolation certificate.
• A valve/spade list and marked up P+ID showing the isolation
points.
• Isolation points will be identified with tags.
GREEN TAG - VALVE OPEN.
YELLOW - SPADED/BLINDED
RED TAG - VALVE CLOSED.
• The tags are of 2 parts. One fixed on the equipment and the
other attached with Isolation certificate.
• Red plastic chains and tie wraps to be applied on boundary
isolation valves.

Hassan Hassan
Electrical Isolation certificate
• Raised by the Authorized person.
• It is an Electrical Safety Document.
• Two or more PTWs shall not share the same Electrical
Isolation.
Tool Box talk
• Given by the Permit Holder at work site before start to
work
• Covers the work plan
• Explains the hazards
• Explain about Emergency Response
• Signed and attached to the PTW

Hassan Hassan
PTW Procedure - Holder
• Confirms work description is correct
• Confirms that all hazards are identified
• Checks he has all the certificates
• Signs the PTW
• Conduct Tool Box Talk at work site
• Ensures all documentation available on site
• Be on site at all times
• Responsible for Safety at work
• Be aware of any change to work scope and conditions at
the work site
• Return the permit to the Responsible Supervisor at the end
of the day

Hassan Hassan
PTW - permit validity and renewal
• PTW is only valid when signed by all parties
• only valid for one day
• can be revalidated by the Responsible Supervisor for
max seven days
• ONLY revalidate if job, permit holder and conditions
are not changed
• revalidation must be applied for when returning PTW
at close of work

PTW FLOW CHART
RESPONSIBLE
SUPERVISOR
OPERATIONS
SECTION HEAD
SUPERINTENDENT AREA
OPERATOR
PTW
CO-ORDINATOR
RESPONSIBLE
SUPERVISOR
Serving all sections
PERMIT HOLDER
HIGH RISK
GAS TEST
ELEC. ISOLATION
PROCESS ISOLATION
APPLICANT
Hassan Hassan

Chapter 3
Predictive Maintenance
Hassan Hassan

• The main promise of Predicted Maintenance is to allow convenient
scheduling of corrective maintenance, and to prevent unexpected
equipment failures.
• The key is "the right information in the right time". By knowing
which equipment needs maintenance,
• Maintenance work can be better planned (spare parts, people, etc.)
• What would have been "unplanned stops" are transformed to
shorter and fewer "planned stops", thus increasing plant availability.
• Other potential advantages include increased equipment lifetime,
increased plant safety, fewer accidents with negative impact on
environment, and optimized spare parts handling.
What is the PdM? Cost, primary uses and
required elements
Hassan Hassan

Hassan Hassan
Learnings
Predictive
 Technical Integrity
 Operating Procedure
Changes
FCP (Failure cause prevention)
 Equipment Design
 Materials Selection
These
activities
prevent
periodical
failures
Preventive
This event is
not the best
type of
maintenance
Why we still have failures? test your program

Hassan Hassan
Proactive Maintenance
Define the problem
Measure the parameters,
Analyze results,
Improve the operating conditions
Control the failure causes

Designing predictive maintenance program
• PdM to evaluate the condition of equipment by performing
periodic or continuous (online) equipment condition
monitoring. The ultimate goal of PdM is to perform
maintenance at a scheduled point in time when the
maintenance activity is most cost-effective and before the
equipment loses performance within a threshold.
• This is in contrast to time- and/or operation count-based
maintenance, where a piece of equipment gets maintained
whether it needs it or not.
• Time-based maintenance is labor intensive, ineffective in
identifying problems that develop between scheduled
inspections, and is not cost-effective
• Vibration analysis is most productive on high-speed
rotating equipment and can be the most expensive
component of a PdM program to get up and running.
Vibration analysis, when properly done, allows the user to
evaluate the condition of equipment and avoid failures.
Hassan Hassan

• The latest generation of vibration analyzers comprises more
capabilities and automated functions than its predecessors.
• Many units display the full vibration spectrum of three
axes simultaneously, providing a snapshot of what is going
on with a particular machine.
• But despite such capabilities, not even the most
sophisticated equipment successfully predicts developing
problems unless the operator understands and applies the
basics of vibration analysis.
• Most PdM inspections are performed while equipment is in
service, thereby minimizing disruption of normal system
operations. Adoption of PdM can result in substantial cost
savings and higher system reliability.
Hassan Hassan

Predictive Maintenance
• The "predictive" component of predictive maintenance stems
from the goal of predicting the future trend of the
equipment's condition.
• This approach uses principles of statistical process control to
determine at what point in the future maintenance activities
will be appropriate.
• Sonic monitoring equipment is less expensive, but it also has
fewer uses than ultrasonic technologies.
• Sonic technology is useful only on mechanical equipment,
while ultrasonic equipment can detect electrical problems and
is more flexible and reliable in detecting mechanical
problems.
Hassan Hassan

Predictive maintenance techniques and applications
• Infrared monitoring and analysis has the widest range
of application (from high- to low-speed equipment),
and it can be effective for spotting both mechanical
and electrical failures;
• Some consider it to currently be the most cost-
effective technology.
• Oil analysis is a long-term program that, where
relevant, can eventually be more predictive than any of
the other technologies.
• It can take years for a plant's oil program to reach this
level of sophistication and effectiveness.
Hassan Hassan

• Predictive maintenance tends to include direct
measurement of the Equipment.
• Example, an infrared picture of a circuit board
to determine hot spots.
• While Preventive Maintenance includes the
evaluation of particles in suspension in a
lubricant, sound and vibration analysis of a
machine
Hassan Hassan

Oil Analysis
• Analytical techniques performed on oil samples can be
classified in two categories:
• Used oil analysis and wear particle analysis.
• Used oil analysis determines the condition of the
lubricant itself, determines the quality of the lubricant,
and checks its suitability for continued use.
• Wear particle analysis determines the mechanical
condition of machine .
• You can identify the composition of the solid material
present and evaluate particle type, size, concentration,
distribution.
Hassan Hassan

Corrective maintenance is a maintenance task
performed to identify, isolate, and rectify a fault
so that the failed equipment, machine, or system
can be restored to an operational condition within
the tolerances or limits established for in-service
operations
corrective maintenance“ can be defined as:
Maintenance which is carried out after failure
detection and is aimed at restoring an asset to a
condition in which it can perform its intended
function
Corrective Maintenance
Hassan Hassan

Corrective Maintenance
What does Corrective Maintenance mean?
• Corrective maintenance is a maintenance task or
operation done in order to identify, isolate or separate and
rectify a particular fault.
• This is performed in order to restore the failed machine,
equipment or system to an operational condition.
• Corrective maintenance can be subdivided into:
Immediate corrective maintenance - in which work
starts immediately after a failure
Deferred corrective maintenance - in which work is
delayed in conformance to a given set of maintenance
turnaround.
Hassan Hassan

Reliability Centered Maintenance (RCM)
Chapter 4
Hassan Hassan

Reliability Centered Maintenance (RCM)
• Reliability-centered maintenance, or RCM,
emphasizes the use of predictive maintenance
(PdM) techniques in addition to traditional
preventive measures.
• When properly implemented, RCM provides
companies with a tool for achieving lowest
asset Net Present Costs (NPC) for a given level
of performance and risk.
Hassan Hassan

Hassan Hassan

RCM
It is generally used to achieve improvements
in fields such as the establishment of safe
minimum levels of maintenance, changes to
operating procedures and strategies and the
establishment of capital maintenance
regimes and plans.
Successful implementation of RCM will lead
to increase in cost effectiveness, machine
uptime, and a greater understanding of the
level of risk that the organization is managing
Hassan Hassan

7 Questions to be answered by RCM
1.What is the item supposed to do and its associated
performance standards?
2.In what ways can it fail to provide the required functions?
3.What are the events that cause each failure?
4.What happens when each failure occurs?
5.In what way does each failure matter?
6.What systematic task can be performed proactively to
prevent, or to diminish to a satisfactory degree, the
consequences of the failure?
7.What must be done if a suitable preventive task cannot be
found?
Hassan Hassan

RCM
The important functions (of a piece of equipment) to preserve with
routine maintenance are identified, their dominant failure modes and
causes determined and the consequences of failure ascertained.
Levels of criticality are assigned to the consequences of failure.
Some functions are not critical and are left to "run to failure" while
other functions must be preserved at all cost.
Maintenance tasks are selected that address the dominant failure
causes. This process directly addresses maintenance preventable
failures. Failures caused by unlikely events, non-predictable acts of
nature, etc. will usually receive no action provided their risk
(combination of severity and frequency) is trivial (or at least tolerable).
When the risk of such failures is very high, RCM encourages (and
sometimes mandates) the user to consider changing something which
will reduce the risk to a tolerable level
Hassan Hassan

Case Studies
Chapter 5
Hassan Hassan

Corrective or Proactive maintenance applications
1 - Cold liquid pumps mechanical seal
failed in a short period.(6 months to 1year)
2 – Multi stage pump discharge side
mechanical seal failed in a short period.
3 – Fire water pump failed to start due to
over-load current, After 8 years operation.
4 – Turnaround maintenance budget was
very high, significant reduction is required
The following case studies had been studied
and optimum remedy had been applied.
5– Gas reciprocating compressor maintenance expensive is very high
Hassan Hassan

Hassan Hassan
1 - Cold liquid pumps mechanical seal
failed in a short period.(6 months to 1year)
A team had been assigned
to do an enhanced study. RCFA
Ask Why, Why, Why…..
Use Data, Not Opinion
Seek All Clues
Involve Others…People Close to the
Problem
Ask Who, What, When, Why Where,
How????

VENDOR MTBF. = 3 YEARS
LIQUID PUMPED. MANUALS = AS PER
VIBRATION. = WITHIN LIMIT
ALINGMENT. = WITHIN LIMIT
M/S”S COMPONENT MATERIAL = AS PER VENDOR STD”S
OPERATING CONDITIONS. = AS MANUAL
INSTRUCTION
TEAM SURVEY
TYPE OF FAILURE = CARBON RING WEAR
STATIONARY RING MATERIAL = SILICON RESISTANT C.S.
Hassan Hassan

Hassan Hassan
ASSIGNED TEAM RECOMMENDATIONS
UPGRADING THE STATIONARY RING,
FROM SILICON RESISTANT C.S.
TO SILICON CARBIDE
OR TUNGSTEN CARBIDE
EXTRA EXPENSES WILLBE
RECOVERED WITHIN 6 MONTHS

2 – Multi stage pump discharge side
mechanical seal failed in a short period.
LIQUID PUMPED. = AS PER MAMUAL
M/S”S COMPONENT MATERIAL = AS PER VENDOR STD”S
OPERATING CONDITIONS. = AS MANUAL INSTRUCTION
TEAM SURVEY
ALINGMENT. = WITHIN LIMIT
TYPE OF FAILURE = CARBON RING WEAR
STATIONARY RING MATERIAL = SILICON CARBIDE
DISCHERGE STUFFING BOX PRESSURE IS HIGHER
THAN SUCTION STF/BOX PRESSURE BY 20 BARS
Hassan Hassan

Hassan Hassan
RCFA RESULTS
PLUGGING OF BALANCED LINE WAS THE
CAUSE OF DISCHARGE M/S FAILURE.
CLEAN BALANCED LINE TO COMPENSATE
AND EQUALIZE THE DISCHARGE AND
SUCTION STUFFING BOX PRESSURE.

Pd
Pd
BALANCED
ZONE
Pd
BALANCED
ZONE
Pd
UNBALANCED
ZONE
Pd Pd
UNBALANCED
ZONE
PUMP ROTOR
AXIAL THRUST
PS
PS
Hassan Hassan

Pd
PS
PS
BALANCED
ZONE
BALANCED
ZONE
Pd
Pd
Pd
Pd
Pd
Pd
UNBALANCED
ZONE
UNBALANCED
ZONE
Hassan Hassan

P4 – P0
P4 – P0
BALANCING DRUM
P4
P0
P1 P2 P3
P0
P4
P0
P4
P1 – P0 P2 – P1
+
P3 – P2
+
P4 – P3
+ P4 – P0
BALANCING LINE
Balancing Drum
Balancing Room
P1
+
–P0 –P1 +
P2
+
–P2
P3 –P3
P4
Hassan Hassan

40
40
BALANCING DRUM
42
2
12 22 32
2
42
2
42
12– 2 22– 12
+
32– 22
+
42– 32
+ 42 – 2
BALANCING LINE
Balancing Drum
Balancing Room
12 +
–2 –12 +
22 +
–22
32 –32
42
Hassan Hassan

P4
P4
P
P
Ps
Ps
Mechanical seal and bearings arrangement
Balancing
Pressure
Room
Hassan Hassan

Hassan Hassan
P4
P4
Ps
Ps
Ps
Ps
Balancing
Pressure
Room

Hassan Hassan
3 – Fire water pump failed to start due to
over-load current, After 8 years operation.
LIQUID PUMPED. = WATER
OPERATING CONDITIONS. = AS MANUAL INSTRUCTION
TEAM SURVEY
TYPE OF FAILURE = PUMP FAIL TO START
IMPELLER MATERIAL = CAST IRON
ROTOR FREE ROTATION = NORMAL
CURRENT AMPS. SITTING = NO CHANGE

Hassan Hassan
SETTING AMPS A Set = 200 amps
NORMAL OPERATING AOP = 160 amps
IMPELLER DIAMETER D1 = 10 ”
FLOW RATE Q 1 = 200 m3 / hr
DIFFERENTIAL PRESSURE P1 = 15 bars
MOTOR HORSE POWER HP1 = 150

Hassan Hassan
RCFA RESULTS
CROSS AREA A = D * B
D
B
B
Q = CROSS AREA * VELOCITY
B
H
P
H
P I * V
Q (D * B ) * VELOCITY
Q B
Q * P
H
P
I
H
P B
AMPS

Hassan Hassan
1- REPLACE THE IMPELLER BY NEW ONE
2 - IF NEW IMPELLER IS NOT AVAILABLE
REDUCE IMPELLER DIAMETER TO BE 9” INSTEAD OF 10”
D2
D1
= 0.9
9
10
=

Hassan Hassan
APPLYING AFINITY LAWS
P2
P1
= 0.9
D2
D1
=
2 2
= 0.81 P2 = 15 * 0.81 = 12.2 bars
HP2
= 0.9
D2
=
3 3
=0.73
HP1 D1
HP2 = 150 * 0.73 = 120 hp
I 2
=
I1
HP2
HP1
= 0.9
3
= 0.73 I2 = 200 * 0.73 = 146 amps
Q2
Q1
= 0.9
D2
D1
= Q2 = 200 *0.9 = 180 m3/hr

Hassan Hassan
4 – Turnaround maintenance budget in a refinery
was very high, significant reduction is required
TOTAL COST OF = 2,642,500 $
MECHNICAL MAINTENANCE
STATIONARY EQUIPMENT = 1,531,000 $
ROTARY EQUIPMENT = 1,110,500 $
TEAM SURVEY
MAINTENANCE TYPE OUT DOOR MAINTENANCE
CONTRACTING ISSUES FOR BOTH
( STATIONARY & ROTARY EQUIPMENT)

Hassan Hassan
CONVERT METHOD OF MAINTENANCE
FOR ROTARY EQUIPMENT
INHOUSE
MAINTENANCE
TO
OUT DOOR
CONTRACTING
FROM

4 Stages Reciprocating Air comp has
outlet pressure P4 = 80 brag
what are the intermediate pressures
P1
2nd
stage
P3
P4
80 brag
4th
stage
P0
0 brag
1st
stage
P2
3rd
stage
Hassan Hassan
5– Gas reciprocating compressor maintenance S/D is
very long and liquidated damage is very high

P0
0 brag
P1 P2 P3 P4
80
brag
1st
stage
2nd
stage
3rd
stage
4th
stage
r =
P1
P0
P4
P3
=
P3
P2
=
P2
P1
=
Assume
r is The equal Pressure Ratio between stages.
r =
4 P4
P0
R
r =
4
r = R
4
Generally
r = R
N
R =
P4
P0
AND
r =
P1
P0
P4
P3
*
P3
P2
*
P2
P1
*
4
Hassan Hassan

P4 = r * P3 = 3 * 27 = 81 Bara = 80 brag
P0
0 brag
P1 P2 P3
P4
80 brag
1st
stage
2nd
stage
3rd
stage
4th
stage
N 4
r = R = 81 = 3
P1 = r * P0 = 3 * 1 = 3 Bara = 2 brag
P2 = r * P1 = 3 * 3 = 9 Bara = 8 brag
P3 = r * P2 = 3 * 9 = 27 Bara = 26 brag
(80 +1)
R =
P4
P0
= (0 +1)
81
= 1 = 81
Hassan Hassan

Example 2
3 Stages Reciprocating Gas compressor has
Outlet pressure P3 = 127 brag
Inlet pressure P0 = 1 brag
what are the intermediate pressures
P0
1 brag
1st
stage
P2
3rd
stage
P3
127 brag
P1
2nd
stage
Hassan Hassan

P0
1 brag
1st
stage
P1
2nd
stage
P2
3rd
stage
P3
127 brag
Assume
P3
P2
*
P1
P2
*
r
P1
P0
=
R
P3
P0
=
3
r
P3
P0
=
BUT
3
r
P3
P0
=
r = R
3 3
r = R
3
Hassan Hassan

P3 = r * P2 = 4 * 32 = 128 Bara = 127 bar g
3
r = R = 64 = 4
=
(127 +1)
(1+1)
=
128
2 = 64
P1 = r * P0 = 4 * 2 = 8 Bara = 7 bar g
P2 = r * P1 = 4 * 8 = 32 Bara = 31 bar g
P3
P0
3
r
=
R =
Hassan Hassan

P1 3 Barg
P0 0 Barg
PT 255 Barg P2 15 Barg
N 4 stages No
P3 63 Barg
P4 255 Barg
R T 256
1/N 0.25
r 4
P0
1st
stage
P1
2nd
stage
P
2
3rd
stage
P3 P4
4th
stage
Hassan Hassan

Risk Based Maintenance
(RBM)
Chapter 6
Hassan Hassan

Risk Based Maintenance
• Maintenance carried out by integrating analysis, measurement
and periodic test s activities to standard preventive
maintenance.
• The gathered information is viewed in the context of the
environmental, operation and process condition of the
equipment in the system. The aim is to perform the asset
condition and risk assessment and define the appropriate
maintenance program.
• Critical machinery - Machines that are vital to the plant or
process and without which the plant or process cannot function.
Machines in this category include the steam or gas turbines in a
power plant, crude oil export pumps on an oil rig or the cracker
in an oil refinery.
Hassan Hassan

With critical machinery being at the heart of the process it
is seen to require full on-line condition monitoring to
continually record as much data from the machine as
possible regardless of cost and is often specified by the
plant insurance.
Measurements such as loads, pressures, temperatures,
casing vibration and displacement, shaft axial and radial
displacement, speed and differential expansion are taken
where possible.
These values are often fed back into a machinery
management software package which is capable of
trending the historical data and providing the operators with
information such as performance data and even predict
faults and provide diagnosis of failures before they happen.
Hassan Hassan

General purpose or balance of plant machines - These are
the machines that make up the remainder of the plant and
normally monitored using a handheld data collector as
mentioned previously to periodically create a picture of the
health of the machine
A risk based maintenance strategy prioritizes maintenance
resources toward assets that carry the most risk if they
were to fail.
It is a methodology for determining the most economical
use of maintenance resources
This is done so that the maintenance effort across a facility
is optimized to minimize the total risk of failure
Hassan Hassan

• Risk-based maintenance is a suitable strategy for all
maintenance plants.
• As a methodology, it provides a systematic approach to
determine the most appropriate asset maintenance plans.
• Upon implementation of these maintenance plans, the risk of
asset failure will be acceptably low.
• The risk-based maintenance framework is applied to each
system in a facility.
• A system, for example, may be a high-pressure vessel. That
system will have neighboring systems that pass fluid to and
from the vessel.
• The likely failure modes of the system are first determined.
Then, for the typical risk-based maintenance framework is
applied to each risk. The framework is shown in the diagram.
Suitable Applications for Risk Based Maintenance
Hassan Hassan

3 May 2006
ENG / HASSAN A.MONEM
Hassan Hassan
Equipment Alignment
Chapter 7

ALIGNMENT
It is collinear of two center lines
TYPES OF COUPLINGS
1 -Rigid Couplings : It is a metal to metal contact (%100 collinear)
2 -Flexible Couplings
* Spacer with shims
* Gear
* Grid
* Rubber
* Others
* Torque converter
Hassan Hassan

Motor
Coupling
Equipment
Hassan Hassan

Pump Grouting
Special grouting concrete
Hassan Hassan

What is shaft alignment
Shaft alignment is the proper positioning of the shaft
centerlines of the driver and driven components
(i.e., pumps, gearboxes, etc.) that make up the
machine drive train.
Alignment is accomplished either through shimming
and/or moving a machine component.
Its objective is to obtain a common axis of rotation at
operating equilibrium for two coupled shafts or a train
of coupled shafts.
Hassan Hassan

Shafts must be aligned as perfectly as possible to maximize
equipment reliability and life, particularly for high-speed
equipment.
Alignment is important for directly coupled shafts, as well
as coupled shafts of machines that are separated by distance
spool (those using flexible couplings).
It is important because misalignment can introduce a high
level of vibration, cause bearings to run hot, and result in the
need for frequent repairs.
Proper alignment reduces power consumption and noise
level, and helps to achieve the design life of bearings, seals,
and couplings.
Why it is important to make shaft alignment?
Hassan Hassan

It is important because misalignment can introduce a high
level of vibration, cause bearings to run hot, and result in
frequent repairs of bearings, seals, and couplings.
Proper alignment reduces power consumption and
noise level, and helps to achieve the design life of bearings,
seals, and couplings.
Driver
Equipment
Alignment
Hassan Hassan

Driver
Equipment
Hassan Hassan

1 -Rigid Couplings
Driver
Equipment
2 –Flexible Couplings
Driver
*Spacer with shims
Equipment
Hassan Hassan

*Spacer with shims
Hassan Hassan

*Spacer with shims
Equipment Driver
Spacer is not connected directly to both hubs,
but through the shims
Hassan Hassan

*Gear
Equipment Driver
Hassan Hassan

Equipment
*Grid
Driver
Hassan Hassan

Turbine
Stationary
Guide wheel
Primary
Shaft
Secondary
Shaft
Packing
Torque
converter
Liquid
Pump
Impeller
Cooling water
Hassan Hassan

Pumps Turbine
MOTION
HYDRAULIC
ENERGY
HYDRAULIC
ENERGY
MOTION
Hassan Hassan

Normal speed
Normal
Guide Blades
Higher speed Lower speed
Diversion
Guide Blades
Conversion
Guide Blades
Hassan Hassan

Parallel misalignment
Equipment
Vertical
OR
Horizontal
Driver
Hassan Hassan

A- Parallel Misalignment in Vertical Plane
Equipment
Shims
Correcting of Misalignment
Hassan Hassan

Angular Misalignment
Equipment
Vertical
OR
Horizontal
Hassan Hassan

Angular Misalignment in
Vertical Plane
Equipment
Shims
Hassan Hassan

169
HORIZONTAL PLANE
Hassan Hassan

170
PARALLEL HORIZONTAL
3
1
2 4
Hassan Hassan

171
ANGULAR HORIZONTAL
3
1
2 4
Hassan Hassan

Dial indicators
Types and Functions.
Hassan Hassan

• 1- Balanced-Type
10
-10
-20
30
40
-50
20
-30
40
50
Negative direction
Stem moves out
positive direction
Stem moves in
Dial indicators Types and Functions
Hassan Hassan

• 2 - Continuous Type
10
30
20
40
50
Small needle
60
70
80
90
100
110
120
130
140
150
160
170
180
190
Hassan Hassan

Preparation and
Orientation on
Alignment
Hassan Hassan

• Measure and correct
* Magnetic centre
*Mechanical centre
* Thermal growth
* Run out
* Soft foot
* Pipe strain
Hassan Hassan

EQUIPMENT
PLANT LINE
• * Pipe strain
X
PLANT LINE
Maximum 0.002 “
Hassan Hassan

• * Soft foot One driver leg is not
settled on the base
Maximum 0.002 “
Hassan Hassan

• * Run out
Maximum 0.002 “
Hassan Hassan

Driver
* Thermal growth for hot liquid pumps
X = Shaft Thermal growth
Equipment
1- Apply the alignment procedure for the pump at ambient Temp.
2- Heat up the pump by opening the start up bypass for ½ hrs.
3- Put the dial indicator on the coupling rim and adjust to zero reading
4- close the bypass
5- Take the dial indicator reading after 24 hrs.
6- This reading is the thermal growth
7- Add the centre line thermal growth reading as a shims under the driver legs
Hassan Hassan

Equipment
1- Apply the alignment for the compressor at ambient Temp.
2- Go to manufacturer catalogue and read the thermal growth amount.
3- Add the centre line thermal growth reading as a shims under the driver legs
4- If the prime mover is generating heat (its centre line thermal growth to be
taken into consideration )
* Thermal growth for Compressors
X = centre line Thermal growth
Driver
After minutes of
Starting
Hassan Hassan

182
Equipment
This design is to avoid
any thermal growth
As thermal expansion
will be in all directions
Cooling
water
Hassan Hassan

Driver
183
• *Magnetic centre.
Magnet
Magnetic centre
Run the motor
Electrical motors have no thrust bearings
as they have instead a magnetic center
Hassan Hassan

Measurement of
bar sag.
Hassan Hassan

SAG
The attachment that will be used
Bar Sag on 12 O'clock Position
Measurement of bar sag.
Piece of Pipe
Steel block
Hassan Hassan

SAG
SAG
Piece of Pipe
Hassan Hassan

HOW TO DO
ALINGMENT
Hassan Hassan

Equipment
188
Driver
Gauge Pointer
does not move around the rim
Motor and Equipment shaft
Rotate in the same time
Hassan Hassan

Equipment
Driver
Equipment
Driver
PARALELL READINGS
Hassan Hassan

VERTICAL READINGS
Parallel actual
misalignment
Parallel reading 2x
Dial indicator
x
Hassan Hassan

Parallel actual
misalignment
HORIZONTAL READINGS
2x
x
If both shafts rotate
or one shaft rotates,
the dial indicator
reading is the same,
and is equal to double
value of the actual
Misalignment amount
Hassan Hassan

D2
D3
D1
Reversal Alignment
F
M
Inboard Out board
Driver
Equipment
Hassan Hassan

PARALELL READINGS
194
12 Ock
6 Ock
Fixed Movable
0
0
36 0
0
64
12 Ock
6 Ock
Hassan Hassan

PARALELL READINGS
195
12 Ock
6 Ock
Fixed Movable
0
0
20
0
0 40
12 Ock
6 Ock
Hassan Hassan

1-Reversal
Alignment
Calculation
Method
CHAPTER 4
Hassan Hassan

HORIZONTALLY
D 1
INBOARD +
FH
{
= MH - FH } D 2
D 1 =
D 2 =
D 3 =
Sag = ( 0 )
OUTBOARD +
FV
{
= MV - FV } D 3
D 1
OUTBOARD +
FH
{
= MH - FH } D 3
D 1 Mils
VERTICALLY
INBOARD +
FV
{
= MV - FV } D 2
D 1
MV +32
/ 2
/ 2
18
FV
MH
/ 2
+20
/ 2
FH
10
F M
0
0
36
20
0
0 40
64
Hassan Hassan

Inboard
D1
D2
F
FV
198
VERTICALLY
INBOARD + FV
{
= MV - FV } D 2
D 1
M
MV
INBOARD = X + FV
FV
MV- FV
X
D2
D1
MV- FV
X = }
}
X
=
D2
D1
MV- FV
Hassan Hassan

Out board
D1
F
FV
199
VERTICALLY
M
MV FV
MV- FV
Y
D3
OUTBOARD + FV
{
= MV - FV } D 3
D 1
OUTBOARD = Y + FV
D3
D1
MV- FV
Y = }
}
Y
=
D3
D1
MV- FV
Hassan Hassan

D1 = 4 in
D2 = 8 in
D3 = 16 in
Sag = ( 0 )
HORIZONTALLY
4
INBOARD + 10 = + 30
{
= 20 -10 } 8
OUTBOARD + 18 = + 74
{
= 32 - 18 } 16
4
VERTICALLY
INBOARD + 18 = + 46
{
= 32 -18 } 8
4
OUTBOARD {
= 20 - 10 }16
4 Mils
+ 10 = + 50
MV +32
/ 2
/ 2
18
FV
MH
/ 2
+20
/ 2
FH
10
F M
0
0
36
20
0
0 40
64
Hassan Hassan

D1 D 2 D 3
4 8 16
0 64
ADD shims
20 0 0 40 REMOVE shims
Move towards 9
Move towards 3
36 0
18 -1 32 1
18 32
10 18 20 32
Inboard (vertical)
Outboard (vertical)
Inboard (Horiz.)
Outboard (Horiz)
0
0
0 REMOVE shims
0 REMOVE shims
Move towards 9
Move towards 9
Bar
Sag(F)
Bar
Sag(M)
0 0
46
74
30
50
M
F
Hassan Hassan

Hassan Hassan
Reflector
Inboard Out board
Driver
M
Equipment
F
Optical Alignment
Transducer

Hassan Hassan
Reflector
Shaft
Bracket
Bracket
Chain
SIDE VIEW
Transducer

Hassan Hassan
Chain
VERTICAL
POSITION
ADJUSTTMENT
Bracket
90 PRISM
0
HRIZONTAL
ANGLE
ADJUSTTMENT
Shaft

Hassan Hassan
SCRATCH-RESISTANCE
LENS
POEWR
DATA CABLE
GREEN LED:
INDICATES BEAM
ADJUSTEMENT
RED LED:
LASER ON
WARNING
LOCKING
KNOB
HOUSING MARK
= CENTER OF
BRACKET POSTS
Transducer

Hassan Hassan
REFLECTOR
Rotate the side thumb
Wheel to raise or lower
the reflector
This lever to lock
The reflector position
1- PRESS and remove transducer cap.
-The laser beam now is on.
-Leave the reflector cap on for now.
-Beam strikes the cap, it should be visible.
- Hold a sheet of paper to locate the beam
M

Hassan Hassan
HORIZONTAL
ADJUSTMENT
VERTICAL
ADJUSTMENT
REFLECTOR

Preventive & Predictive Maintenance 005.ppt

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