Post on 16-Jul-2018
TM
ADVANCED MAINTENANCETECHNOLOGIESTECHNOLOGIES
Condition Monitoring andTotal Reliability Management
© 1999-2013 IMPACT Engineering, Inc.
OverviewOverview
What is Predictive Maintenance?What is Predictive Maintenance?
What benefits can be achieved from a Predictive M i t ?Maintenance program?
What are the elements of an effective Predictive Maintenance program?
What is required to achieve Total ReliabilityWhat is required to achieve Total Reliability Management (TRM) ?
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Maintenance MethodsMaintenance MethodsTotal ReliabilityTotal Reliability
ManagementMaintenance Methods
Reactive(RM)
Preventive(PM)
Predictive(PDM)
Pro-Active(PAM)
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Reactive MaintenanceReactive MaintenanceRun machinery to failureyIf machinery is running, everything is fineMost common maintenance practice!p
Positive:– If it ain’t broke, don’t fix it– May be cost-effective for small components
Negative:Unscheduled downtime– Unscheduled downtime
– High cost for major failures– Personnel safety risk
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y
Preventive MaintenancePreventive MaintenanceScheduled/planned maintenance: calendar, hhoursConservative: based on historical estimates of expected life with additional safety factorof expected life with additional safety factor
Positive:– Prevents major failuresPrevents major failures– Extends machinery operating life
Negative:– Overhaul before useful life expended– Unnecessary tasks often performed
Induced failures© 1999-2013 IMPACT Engineering, Inc. TM
– Induced failures
Predictive Maintenance (PDM)Predictive Maintenance (PDM)Maintenance actions based on ConditionMaintenance actions based on Condition Monitoring data
Benefits:Benefits:– Detect faults– Predict failurePredict failure– Plan & schedule repairs– Eliminate unnecessary ‘Open/Inspect’ for y p p
Classification (ABS)
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Condition Monitoring Technologies
In Service Condition MonitoringIn-Service Condition Monitoring
Vibration Analysis Motor Current AnalysisVibration Analysis Motor Current Analysis
Ultrasound Detection Material Thickness
Thermographic Inspection Recip. Engine Analysis
Lube Oil Analysis Observationsy Observations
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PDM ProcessPDM ProcessGather valid data.– Vibration, Ultrasound, Thermography,
Maintenance History, Performance, InspectionsA l d t t t di tiAnalyze data; convert to diagnostic information.– Spectral Plots Alarm Levels Experience History– Spectral Plots, Alarm Levels, Experience, History
Perform corrective action.– Alignment Balancing Lubrication StructuralAlignment, Balancing, Lubrication, Structural
Evaluate results.– Trend, Assess, Communicate, Plan
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Trend, Assess, Communicate, Plan
What is Root Cause Failure at s oot Cause a u eAnalysis (RCFA)?
A systematic process of determining & eliminating fundamental problems which lead to failurep
It improves profitability through reduced cost of parts labor lost production and improved qualityparts, labor, lost production and improved quality
It is an essential part of a "world class" Reliability p yMaintenance program
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Pro-Active Maintenance (PAM)Pro Active Maintenance (PAM)
Extends machine life reduces maintenanceExtends machine life, reduces maintenance cost by:
P i i li t & b l i– Precision alignment & balancing– New equipment performance verification– Root Cause Failure Analysis
Results in immediate paybackResults in immediate payback
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Changing Maintenance PracticesChanging Maintenance Practices
Switching from “Reacting to Breakdowns”,
and changing to “Elimination of Breakdowns” g g
where Predictive Maintenance is the Plan
and Preventive or Scheduled is the
ExceptionException.
© 1999-2013 IMPACT Engineering, Inc. TM
Maintenance Costs for General Industrial Rotating Machinery
20
25
10
15
20
$/HP/Yr ReactivePreventive
0
5
10 Predictive
0
Maintenance MethodS & S
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Source: Hudachek & Dodd, ASME
Condition Monitoring with Vibration Spectral Analysis
Useful for all machinery
Spectral characteristics identify faultsSpectral characteristics identify faults
Detects a wide variety of faults:Mi li– Mis-alignment
– Imbalance– Looseness– Looseness– Wear, Damage, etc.
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Vibration Analysis MethodsVibration Analysis MethodsTime Waveform (amplitude vs. time)e a e o (a p ude s e)
Overall Level (vibration)
F S t ( li d f )Frequency Spectrum (amplitude vs. freq.)
– Fast Fourier Transform (FFT)
Selected Frequency Bands (1 x SS, 2 x SS, etc.)
Phase Comparison (relative position)p ( p )
Trend Comparison
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Spectral Plot (FFT)PISTON COOLING PUMP - #1
1C-10-1 -RP1 UPPER MOTOR BRN - RADIAL - PORT
ROUTE SPECTRUM 02-JUN-97 15:530.6
0.8
n/Se
cp ( )
02 JUN 97 15:53 OVRALL= .5611 V-DG PK = .5610 LOAD = 100.0 RPM = 1770. RPS = 29.50
0
0.2
0.4
PK V
el in
I
WAVEFORM DISPLAY 02 JUN 97 15:53
0.9
n/Se
c
CF ALARM PK ALARM
RPS 29.50 0 3 6 9 12 15 18 21 24 27
Frequency in Order
02-JUN-97 15:53 PK = .5415 PK(+) = .5738 PK(-) = .6107 CRESTF= 1.59
-1.5
-0.9
-0.3
0.3
Velo
city
in In
CF ALARM PK ALARM
0 100 200 300 400 500 600
Time in mSecs
Order: Freq: Spec:
1.0081783.9.550
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Imbalance: 1 X Shaft Speed (SS)Imbalance: 1 X Shaft Speed (SS)PISTON COOLING PUMP - #1
1C-10-1 -RP1 UPPER MOTOR BRN - RADIAL - PORT0 7
ROUTE SPECTRUM 18-NOV-97 10:10
OVRALL= .5019 V-DG PK = .5024 0.5
0.6
0.7
Sec
LOAD = 100.0 RPM = 1770. RPS = 29.50
0.3
0.4
PK V
eloc
ity in
In/S
0.1
0.2
P
0 3 6 9 12 15 18 21 24 27
0
Frequency in Order
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Looseness & Mis-alignment S t l Pl tSpectral Plot
BILGE PUMPBILGEPUMP -RS1 UPPER MOTOR BRN - RADIAL - STBD
0 16Route Spectrum 02-APR-98 16:21
OVRALL= .2306 V-DG PK = .2312 LOAD = 100 0
0.12
0.14
0.16
n/Se
c
LOAD = 100.0 RPM = 1750. RPS = 29.17
0.06
0.08
0.10
PK V
eloc
ity in
In
0.02
0.04
0 3 6 9 12 15 18 21 24 27
0
Frequency in Order
Order: Freq: Spec:
1.0391818.7.08320
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Ultrasound (UT) DetectionUltrasound (UT) Detection
Sound Energy above audible range: 40 kHzSound Energy above audible range: 40 kHz
Transmitted through structure or air
Mechanical friction and impacts produce UT
Measured via contact transducer or microphoneeasu ed a co tact t a sduce o c op o e
Sound is transformed to the audible range
Amplitude and ‘quality of sound’ is noted
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Major ApplicationsMajor Applications
Mechanical: Bearings, Couplings, Gears …
Leaks: Air Steam Vacuum GasLeaks: Air, Steam, Vacuum, Gas ...
Flow: Steam Traps, Valves, Fuel Injectors ..Flow: Steam Traps, Valves, Fuel Injectors ..
Electrical: Motor Controls, Switch Gear ...
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Bearing & Coupling UT Monitoring Benefits
Monitor bearing lubrication qualityMonitor bearing lubrication quality.– Under-lubrication causes many bearing failures
El t d UT ill b d t t d b fElevated UT will be detected before significant increases in vibration
Identify early stages of bearing faults– Eliminate unexpected failure and damage
Excellent correlation with vibration data for advanced bearing fault detection
© 1999-2013 IMPACT Engineering, Inc. TM
UT Sound QualityUT Sound QualityGood bearings & couplings produce smooth sound without distinct popping/clickingwithout distinct popping/clickingFaulty bearings produce popping/clicking soundsDynamic loading increases amplitude valuesDynamic loading increases amplitude values
Typical Operating Speeds (rpm)
Typical or Normal UT Levels
High Friction (Lubrication Required)
Bearing Fault Present (Extreme Clicking/Popping)p ( p ) ( q ) ( g pp g)
500 - 1,200 1 - 15 dB 15 - 25 dB > 25 dB (clicking) 1,800 10 - 25 dB 25 - 35 dB > 30 dB (clicking) 3 600 20 30 dB 30 45 dB 40 dB ( li ki )3,600 20 - 30 dB 30 - 45 dB > 40 dB (clicking)
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UT Sound ClipsUT Sound ClipsGood Brg. -- Bad Coupling Bad Spindle Brg.
Bad Brg. Clicking / Rubs HFO Purifier
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Thermographic Infrared ImageThermographic Infrared ImageDigital Camera Infrared Camera
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CARMA ®
Diesel Engine Condition MonitoringReal Time monitoring of:Real Time monitoring of:– Cylinder Pressure
Vibration– Vibration – Ultrasound– Position of crank angle & rotation– Position of crank angle & rotation
Data saved for later analysis and trending
Cylinder performance and condition of components analyzed immediately.
© 1999-2013 IMPACT Engineering, Inc. TM
Sensor SetupSensor SetupUltrasonicDynamic
Cylinder PressurePressure
Vibration • Data manipulation• Calculating power• Trending
C i ti• Communication
Encoder Output
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p
Analysis ProcessyThe Result..
P Vib ti...Pressure, Vibration and Ultrasonic signals are displayed in reference to crankin reference to crank angle.
ConsequentlyConsequently......pattern events can be correlated to piston, con-rod and crank position. Intake Compression Power Exhaust
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Corrective MaintenanceCorrective MaintenanceShaft Alignment– Mis-alignment is the ‘Root Cause’ for 50% of
vibration/machinery problems
Dynamic BalancingStructural Resonance Testing & CorrectionsImmediate Payback– Reducing vibration levels by 50% will increase g y
bearing L10 life by a factor of 8 ($3).
© 1999-2013 IMPACT Engineering, Inc. TM
Shaft AlignmentShaft AlignmentMisalignment causes vibration - reduces machinery component life.Alignment is often assumed, not obtained.Quality equipment and training essential!– Alignment investment pays for itself g p y
(Immediate Payback)
Methods– Dial Indicators (Reverse Indicator Method)– Laser/Optical
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Reverse Dial Indicator MethodShaft Alignment
Vertical Pump Horizontal PumpVertical Pump Horizontal Pump
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Alignment SoftwareAlignment Software
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Vertical Machine AlignmentVertical Machine Alignment
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Vertical Move & Shim DiagramVertical Move & Shim Diagram
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Laser/Optical Shaft AlignmentLudeca Optalign™
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Dynamic BalancingDynamic Balancing
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Total Reliability Management (TRM) Program Strategy
M i h ff i l b lMaintenance strategy that effectively balances:
Reactive - On Demand / Run to FailureReactive On Demand / Run to Failure
Preventive - Interval Repairs
Predictive - Condition Monitoring
Proactive - Corrective & Root Cause Analysis
© 1999-2013 IMPACT Engineering, Inc. TM
TRM Program ImplementationTRM Program ImplementationPhase I
– Baseline Diagnostic EvaluationPhase II
ABS Cl ifi ti S b itt l D t ti– ABS Classification Submittal, Documentation– ABS Program Training
Phase IIIPhase III– Perform Proactive (Corrective) Maintenance
Phase IV– Vessel purchases PDM tools for onboard analysis
& Corrective Maintenance
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PDM Investment ‘Pay-Back’yNote: for Phase IV Program Implementation
Source: W. Woyshner, EPRI M&D Centery ,
Relative$
CostBenefitNet
1st Year 2nd Year 3rd Year 4th Year 5th Year
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Establishing an Effective TRMCondition Monitoring Program
Strategic Plan: Tactical Plan:Purpose
Objective
Procedure
Trainingj
Methods
g
Resources
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