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Francis ConceminoAssociate Engineer (Reliability and Maintenance)Inland Empire Utilities Agency
What is Maintenance?
The performance of the task(s) necessary to preserve the function of an asset in its current environment.the function of an asset in its current environment.
Maintenance Progressiong
2000•Condition monitoring
2000
1990
•Design for reliability and maintainability•Hazard studies•Small, fast computers
il d ff l i1980
1970
•Failure modes effects analysis•Expert systemsYear
1970
1960•Schedule overhauls•Systems for planning and controlling work•Big slow computers
3
19501940 •Fix it when it broke
Asset Condition Monitoring
The utilization of information obtained by methodically collecting and analyzing vital data to determine the health, performance, and maintenance requirements for an asset This strategy reduces downtime and mitigatesan asset. This strategy reduces downtime and mitigates the consequences of failure.
Machine Life Cycle‐ Bath Tub Curvera
teFa
ilure
r
Early life Useful life Wear out
F
Time in service
P‐F Curve*
*Courtesy of Vesta
Medical Analogy
7Source:
Condition Monitoring Techniques
Oil Analysis
Vibration Analysis
Motor Circuit Analysis
Thermography
Ultrasonic Monitoring
Performance Monitoring
Oil AnalysisOil AnalysisOil AnalysisOil Analysis
Function of Lubricants
Reduces wear by reducing friction between moving parts.
Cooling to reduce temperature
Power Transmission
Inhibits Corrosion
Total Lubrication Management Standards, Consolidation and Procurement
Lubricant Storage and Handling
Oil Sampling Techniques and Procedures
Contamination Control
Training, Skill Standards and Qualifications
Lubricant Analysis
Continuous Improvements
T t l L b i ti M tTotal Lubrication ManagementUndesirable Lube Oil Storage Condition Optimum Desired Stateg p
Oil Analysis
The process of collecting and testing new oil or used oilThe process of collecting and testing new oil or used oil samples, to determine the condition of the oil and the health of machines.
Oil Analysis Wear products andOil Analysis‐Wear products and Contaminants Analysis
Oil Analysis
Lubricant Machine Lubricant Condition
Machine Condition
Is oil up to spec? Is the oil contaminated?
Wear particles present?
Does the particles signifies type of metals and wear
patterns?
Oil A l i T tOil Analysis Tests Viscosity
Water Contamination
Neutralization Numbers
hSpectrography
Particle Counting and Analysis (Ferrography)
Lube Oil Analysis: Sample Report
Particle Count
i i d l f lCase in point: Secondary Clarifier Drive FailureLube Oil Particle Analysis Report
High concentration of Iron indicates wear
Case in point: Secondary Clarifier Drive Failure
Consequences of Failure:• Equipment downtime
• Loss of Production
• Overtime labor hoursOvertime labor hours
• Drive Unit Replacement
R l t L d ti• Replacement Lead time
Vib ti A l iVib ti A l iVibration AnalysisVibration Analysis
Vibration Analysis Vibration Causes andVibration Analysis‐Vibration Causes and TransmissionMachines and components vibrate in response to one or more pulsating forces, called excitation.
l b lExample: mass unbalance.
The magnitude of vibration is dependent not only on th f b t l ti f th t b ththe force but also properties of the system, both may depend on speed.
Vibration can be used to identify defects that arise Vibration can be used to identify defects that arise from defective design, misalignments, and unbalance.
Vibration Analyzer
Vibration Analyzer Accelerometers
Vibration Analysis
How Bad?
Wh t C t?What Component?
26 - Aux. WasteHeat Loop Pump #326 Aux. WasteHeat Loop Pump #326J-140 -P1H Pump Inboard Horizontal
Trend Display Overall Value
0.20.30.40.5
K In
/Sec
ALERT FAULT
R t S t0.05
0 300 600 900 1200 1500
0 0.1
Days: Nov-18-01 To Oct-11-05
P
WARNING
Route Spectrum Dec-05-01 18:55:48 OVERALL= .0611 V-DG PK = .0609 LOAD = 100.0 RPM = 1800. (30.00 Hz)
00.010.020.030.040.05
PK In
/Sec
Route Waveform Dec-05-01 18:55:48 0.4
0.8
-s ALERT FAULT
0 10 20 30 40 50 60 70 80 90
0
Frequency in Orders
RMS = .1056 PK(+/-) = .2971/.3198 CRESTF= 3.03
0 40 80 120 160
-0.8
-0.4
0
Acc
in G
- ALERT
ALERT FAULT
Date: Dec-05-010 40 80 120 160Time in mSecs
Time: Ampl:
18:55:47 .06113
22 P2 SECONDARY TREATMENTPOINT: G6H - MORE THAN ONE EQUIPMENT
0.6
0.8
1.0Max Amp .91
Sec
0
0.2
0.4
0.6
K V
eloc
ity in
In/S 0
02-Oct-02G3 -G6H
12-Sep-02H3 -G6H
PK
09-Jul-02F3 -G6H
0 10 20 30 40 50 60 70 80 9009-Jul-02E3 -G6H
RPM= 55.43 11:36:28 02-Oct-02 Point= G6H G3
Ordr: Freq:
64.193557 8
Frequency in OrdersFreq: Sp 3:
3557.8 .701
Motor Circuit Motor Circuit AnalysisAnalysisAnalysisAnalysis
Motor Circuit Analysis
Motor Circuit Analysis
A computerized evaluation that combines several tests to determine the overall condition of an Electric Motor.
Motor Circuit AnalysisFault Zones
Power QualityQ y
Insulation
Power Circuit
Stator
Rotor
Air Gap
Motor Circuit AnalysisS f El t i M t F il
Bearing, 41%
Summary of Electric Motor Failures
Stator, 37% 41%
Rotor 10%
Other, 12%
Rotor, 10%Source: Combined EPRI and GE Study
Infrared Infrared ThermographyThermographyThermographyThermography
Infrared Thermography Based on the principle that all objects above absolute
zero (‐273 o C) emit infrared radiationzero (‐273 C) emit infrared radiation
Images are captured on electronic cameras that make the
radiation optically visible in an image of different colors
Can see temperature differences as small as 0 1 oF or lessCan see temperature differences as small as 0.1 F or less
Source- RCM II by John Moubray
RVFD#3 SLATER PS E90105 Spot 2
168.4*>233.7°F
R
199.1200.0
100.0
*<27.9°F
Infrared Thermography ElectricalInfrared Thermography‐ Electrical Applications
Relays and circuit breaker
B d f tiBus and fuse connections
Disconnects
Thermal overloads
Generator and motor windings
Motor control centers
Infrared Thermography MechanicalInfrared Thermography‐Mechanical Applications
Boilers and refractories
H t E hHeat Exchangers
Bearings
Couplings
Steam traps
Wall and roof insulation
l ll lUltrasonic AnalysisUltrasonic Analysis
Ult i O tiUltrasonic‐Operation Ultrasound technology is concerned with high Ultrasound technology is concerned with high
frequency sound waves above human perception (20 Hz to 20kHz) ranging between 20kHz to 100kHz.
High frequency sound waves are extremely short and tend to be fairly directional.
Ultrasound equipment filters out surrounding noise and other unwanted frequencies.
Readings displayed visually or as an audible signal on headphones.
Source- RCM II by John Moubray
Ultrasonics Instruments Modulate ultrasonic frequencies to the range of human hearing.
Output of the device is provided by earphones small speaker Output of the device is provided by earphones, small speaker or a screen.
Ultrasonic Applications Leak detections
Valve seat integrity Valve seat integrity
Pump Cavitation
Steam Traps Blow‐by Steam Traps Blow‐by
Detecting High Frequency Defects
Performance Performance AnalysisAnalysisAnalysisAnalysis
Performance Analysis
The analysis of a machine to determine its performance by using pressure, temperature, flow or other readily
available process parameter(s).
Performance Analysis The tools needed are in most cases already available, hence capital cost is low.
Repeatability of measurement is essential rather than absolute accuracyabsolute accuracy
It may be possible to find one parameter that indicates the overall condition of the machine or a distinct part ofthe overall condition of the machine or a distinct part of it.
Performance Analysis
Pumps
Heat exchangers
Steam Turbines
AnalyzersAnalyzers
Compressors
C i P i T i Fil T bidi A l ICase in Point: Tertiary Filter Turbidity Analyzer Issue
Implementation CostImplementation CostTechnique Hardware Software Training/
Certification
Vibration $15,0000‐
$20,000
$2,000‐
$20,000
$10,000
Infrared $10,000‐
$50,000
$5,000‐
$10,000
$6,000
Oil Analysis $10,000‐
$80,000
$5,000‐
$10,000
$10,000
Ultrasonics $3,000‐
$8,000
$2,000‐
$5,000
$2,000
MCA $4 000 $5 000 $8 000MCA $4,000‐
$70,000
$5,000‐
$10,000
$8,000
f f dBenefits of Asset Condition Monitoring
Warning of most problems in time to minimize unexpected failures.
Increase awareness of equipment condition.
Allows for the safe elimination of a significant amount of o s o t e sa e e at o o a s g ca t a ou t opreventive maintenance.
Reduces requirements for spare parts.q p p
How to start a Condition MonitoringHow to start a Condition Monitoring ProgramDon’t apply technology to all assets.
Be selective! Attack the critical assets first.
Carefully select suitable technology and monitoring frequency for each asset.
Budget appropriately for program and include ongoing software, hardware, and training cost.g
How to start a Condition MonitoringHow to start a Condition Monitoring ProgramGet the necessary training – when in doubt seek advice from expertsexperts.
Document successes and failures (i.e. KPI’s).
Provide management with frequent updates.
Train others when confidence level increase.
How to start a Condition MonitoringHow to start a Condition Monitoring Program
Keep the program transparent‐ share analysis results with all stakeholders.
Be open‐minded and listen to your customers.
Pride and arrogance will kill the program.
Questions?Q