CBM PPT

1. Presented by:
RAJKUMAR S WAGMARE
1MS15MSE03
1st sem M.Tech MSE
M.S.RAMAIAH INSTITUTE OF TECHNOLOGY
BANGALORE
(AUTONOMOUS INSTITUTE,AFFILIATED TO VTU)

2. CONDITION BASED
MAINTENANCE

3. CONTENTS
⚫Introduction to Condition Based Maintenance (CBM)
⚫Benefits of CBM
⚫Principle of CBM
⚫Methods of CBM
⚫Advantages and Disadvantages of CBM
⚫Applications of CBM

4.  Condition Based Maintenance (CBM) or predictive
maintenance is a technology thatstrives to identify incipient
faults before they become critical which enables more
accurate planning.
CBM is a set of maintenance actions based on real-time or
near-real time assessment of equipment condition which is
obtained from embedded sensors
 Itallows maintenance to be scheduled, orotheractions to be
taken toavoid theconsequences of failure.
 CBM is the meansof improving,
1. Productivity
2. Product Quality
3. Overall effectiveness of manufacturing
4. Availabilityof process machinery
.
INTRODUCTION

5. INTRODUCTION
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CBM Optimizetotal plantoperation
It isa comprehensive predictive maintenance management
Reduce greatlycost of maintenance
Lower maintenance cost
Fewer repairs down time
Reduced small parts inventory
Longer machine life
Increased production
Improved operatorsafety
Overall profitability

6. INTRODUCTION
⚫Condition monitoring is the process of monitoring a parameter
of condition in machinery, such that a significant change is
indicative of a developing failure.
 Condition monitoring includes:
 Vibration measurement and analysis
 Infrared Thermography
 Oil analysis and Tribology
 Ultrasonics
 Motor current analysis
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7. o Conditional Monitoring includes 3 Steps:
• Detection (when) of thedeveloping fault atan early stage.
• Diagnosis (what) of itsorigin so thatspare partscan be ordered.
• Prognosis (forecast) subsequent measurementwhich will thenestablish
the trend and enable the repairscheduled to be planned.
Detection(when) Diagnosis(what) Prognosis(forecast)

9. Principle of CBM
Two main methods used forcondition monitoring
 Trend monitoring
Condition checking
Trend monitoring
This is thecontinuousorregular measurementand interpretationof data,
collected during machine operation, to indicate safe and economical
operation.
The principle involved is as illustrated

10. This follows the normal Life Curve Condition (Bath Tub Curve).
o Rapidly decreasing failure rate in earlyfailure by lasts several weeks to few
months
o Failure rate levels off long period is called stable failure period and last begins
to increase material wear out and degradation failure occurs at an ever
increasing rate
o Thedecay in early life and the increase in final life can beconsidered to be
Exponential
V= E exp (-t/e) + M + F ((t/T)/f)
E & e control thevariousdecay in early life
M isvibration in mid life
F & f aregrowth in vibration during final life leading up to machine failure
near time T

11. PERFORMANCE AND BEHAVIOR MONITORING
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⚫ It involveschecking the performanceof a machineorcomponent tosee
whether it is behaving correctly. This may, for example, involve
monitoring the performanceof a bearing by measuring its temperature
to see whether it is carrying out its function of transmitting load
between moving surfaceswith the minimumof friction.
 Condition Checking
In which particular or instant condition while machine is running
readingscan be taken
This is where a check measurement is taken with the machine
running, using some suitable indicator and then this is used as a
measure tocheck machinecondition.

12. METHODS OF CONDITION MONITORING
⚫Visual monitoring
⚫Vibration monitoring
⚫Temperature monitoring
⚫Lubricant monitoring
⚫Leak detection
⚫Noise monitoring
⚫Corrosion monitoring

13.  It involves inspectionand recording of surfaceappearance.
This may involve the useof Boroscopes tosee inaccessible places,
 the useof photographyorsurface imprinting forrecord purposes
1. Visual Monitoring

14. ⚫It involves theattachmentof a transducer (velocity probe,
accelerometerorproximity probe) toa machine to record
its vibration level. Special equipment is also available for
using theoutput from the sensorto indicate the natureof
thevibration problemand even its precisecause.
2.Vibration Monitoring

15. 3. Temperature Monitoring
The Temperature Monitoring sensitiveaspects of a unitcan
be readily monitored.
These include contact Thermometers, Thermocouple,
Thermistor, Temperature chalksand paints and infrared
detectors.

16. 4.Lubricant Monitoring
The use of magnetic drain plugs in unit lubrication
sumps is well known. The existence of magnetic debris
gives information on the surface condition of load
bearing parts

17. 5. Leak Detection
⚫A number of leak detecting techniques are
available, including soap and water methods . the
use of proprietary preparation can make this
method moreeffective. Ultrasonic detection is one
of the powerful techniques

18. ⚫It is usually applied to fixed plant containing aggressive
materials is intended to monitor the rates of internal
corrosion of the walls of the plant. This may be done by
drilling sentinel holes partway through the wall, which can
be plugged when they leak or by inserting readily
removable coupons of material of which the corrosion rate
is assumed to relate to that of the plant
6. Corrosion Monitoring

19. 7. Wear Debris Monitoring
⚫Itworkson the principle that theworking surfacesof a
machine are washed by their lubricating oil, and any
damage to them should be detectable from particlesof
weardebris in theoil. If thedebrisconsistsof relatively
large ferrous lumps such as those generated by the
fatigue of rolling element bearings and gears or the
pitting of cams and tappets, these can be picked up by
removable magnetic plugs inserted in the oil return
lines. For smaller debris particles, spectrographic
analysis or microscopicexamination oil samplesafter
magneticseparation arecommonlyused techniques.
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20. Advantages
Studies haveestimated thata properly functioning of CBM orpredictive
maintenance program can provide a savings of 8% to 12% over
preventive
maintenance program alone.
Independentsurveys indicate the following industrial average savings :
• Reduction in maintenancecosts: 25% to 30%
• Eliminationof breakdowns: 70% to 75%
• Reduction in equipmentorprocess downtime: 35% to 45%
• Increase in production: 20% to 25%.
• Increased componentoperational life/availability.
• Allows forpreemptivecorrectiveactions.
• Decrease in costs forparts and labor.
• Betterproductquality.
• Improved workerand environmental safety.

21. Application of Condition Based Maintenance
 Used in detecting the malfunctioning
 Detectionof component failure
 Used in assessing the formalized techniques
 The CBM processcan beapplied to maintain activities in all industries, including:
 DoD weapons systems
 Jetengines
 Wind turbinegenerators
 Marinediesel engines
 Natural gascompression
 Circuit card manufacturing

22. Disadvantages of CBM
⚫Diagnosticequipment being costly has increased the
investment
⚫Staff training increased the investment
⚫Managementcannotsee readily potential savings

23. Now floor is open for…
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