Introduction to Condition-Based Maintenance Best Practices

Introduction to Condition-Based Maintenance Best Practices

Maintenance Strategy Breakdown Maintenance Preventive Maintenance (Time Base) Predictive Maintenance Proactive Maintenance

Rationalizing Spending Time and Money on Machine that are not broken

Modern Maintenance Technologies CONDITION-BASED MAINTENANCE Proactive Maintenance Root Causes Contaminant Monitoring Balancing and alignment tools Viscosity and AN Monitoring Fault-Free Machine Life Extension Predictive Maintenance Failure Symptoms and Faults Wear debris analysis, Vibration Analysis, Thermography, Motor Current Analysis Early detection of faults and failure

Benefits of Precision Maintenance

Reliability Circle Lifetime Reliability

Are you pulling your weeds out by the root?

Condition Monitoring Domains in Start Failure the PF interval curve Structure Borne Ultrasound Vibration Oil analysis Infrared Audible noise P P1 P2 P3 P4 Contact heat P5 Proactive Domain Predictive Domain Fault Domain P6 F

CBM Technology for Mechanical Equipment Ultrasound Vibration Infrared Thermography Oil Analysis

Condition Monitoring- Airborne Ultrasound Technology

Which type of ultrasound? PULSE ECHO Medical applications Thickness gauge Flaw detection in solids ULTRASOUND DIVISIONS POWER Cleaning Welding and cutting AIRBORNE AIR & STRUCTURE BORNE STRUCTURE BORNE

Why Ultrasound? Sound definition: Vibrations transmitted through an elastic solid, a liquid or gas, with frequencies in the approximate range of 20 to 20,000 hertz, able to be perceived by humans Sound (Audio Sound) is not directional and penetrates solid materials, making it difficult to locate. Ultrasound is defined from 20kHz to 100kHz Advantages are: Very directional Reflects on solid materials and does not penetrate Reduces in strength, making source locating easy We can use the information for condition evaluation Two ways to detect Ultrasound with our instruments: Airborne medium Structure borne medium

Typical application areas Leak detection Pressure or vacuum, any type of gas Heat exchangers Tanks and boilers Window seal inspections Valve inspection Valve leak detection Steam trap inspection Mechanical inspection Condition monitoring of bearings Condition based lubrication Pumps for cavitations Conveyor belt systems Electrical inspection Discharge testing on: Switchgears Power lines & isolators Transformers Circuit breakers (Tracking, Arcing, Corona & mechanical looseness) Specialty solutions for: Automotive WNWL Aircraft inspections Marine hatch testing

Electrical Inspection There are situations IR is difficult to use for getting a visual line For Ultrasound all we need is an open air connection Example enclosed transformer: Early stages of tracking, evolving into arcing.into catastrophic failure!

Economics: leaks cost money March 2012 Air Leaks Repaired Argon Leaks Repaired Helium Leaks Repaired Hydrogen Leaks Repaired Other Leaks Repaired Cost Avoidance CFM Cost CFM Cost CFM Cost CFM Cost CFM Cost Identified Repaired % Complete 0.0 $0.00 0.0 $0.00 0.0 $0.00 0.0 $0.00 0.0 $0.00 $12,781.00 $0.00 0% Record Number Group Name Location Name Type of Gas Pressure at Leak db Reading Problem Description Repaired (Y/N) Work Order Schedule # Identified Leaks Cost Avoidance Size of Leak (CFM) 1 fm5 Air 100 72 air leak N $1,159.23 5.6 9660 2 fm5 Air 100 69 air leak N $1,092.16 5.3 9101 3 fm5 Air 100 80 air leak N $1,343.53 6.5 11196 4 fm5 Air 100 72 air leak N $1,159.23 5.6 9660 5 fm5 Air 100 79 air leak N $1,320.07 6.4 11001 6 fm5 Air 100 82 air leak N $1,390.80 6.7 11590 7 fm5 Air 100 85 air leak N $1,462.58 7.0 12188 8 fm5 Air 100 94 airleak N $1,683.95 8.1 14033 9 fm5 Air 100 76 air leak N $1,250.41 6.0 10420 10 fm5 Air 100 61 air keak N $919.04 4.4 7659 Energy Avoidance (kwh)

Condition Monitoring Vibration Analysis

What does it mean.? How do you know when to take action? Standards are available. SPECTRA PRO removes the guesswork.

Vibration analysis on AHU Fan Bearing: Detect Early Bearing Fault Measuring date BC Alarm status Remarks 1 Tuesday, December 14, 2004 11:28 AM 3.66 Ok Bearing Fault Detect 2 Wednesday, January 19, 2005 10:00 AM 4.60 Warning Bearing Change Recommended 3 Thursday, February 17, 2005 01:42 PM 0.39 Ok Bearing Replaced SPECTRA REPORT 1 HV Air Handling Units\63001\Motor \DE Measuring date :Thursday, February 17, 2005 13:42 Total value = 15.19 mm/s RMS BC = 0.39 Shaft Speed=24.73 Hz

Condition Monitoring Thermographic Analysis

PUMPS ELECTRIC MOTORS CONDENSERS DIESEL GENERATORS Heavy EQUIPMENT/CRAN E CIRCUIT BREAKERS VALVES HEAT EXCHANGERS ELECTRICAL SYSTEM TRANSFORMER TANKS,PIPINGS Techniques and Applications TECHNOLOGIES APPLICATIONS VIBRATION MONITORING ANALYSIS X X X X LUBRICANT, FUEL ANALYSIS X X X X X BEARING TEMPERATURE ANALYSIS X X X X WEAR PARTICLE ANALYSIS X X X X PERFORMANCE MONITORING X X X X X X ULTRA SONIC NOISE DETECTION X X X X X X X X ULTRASONIC FLOW X X X X INFRARED THERMOGRAPHY X X X X X X X X X X X NON DESTRUCTIVE TESTING(THICKNESS) X X X VISUAL INSPECTION X X X X X X X X X X X INSULATION RESISTANCE X X X X X MOTOR CURRENT SIGNATURE ANALYSIS X MOTOR CIRCUIT ANALYSIS X X X

Reliability Circle Lifetime Reliability