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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) ?

© 1999-2013 IMPACT Engineering, Inc. TM

Maintenance MethodsMaintenance MethodsTotal ReliabilityTotal Reliability

ManagementMaintenance Methods

Reactive(RM)

Preventive(PM)

Predictive(PDM)

Pro-Active(PAM)


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


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)


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


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


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


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


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.


Maintenance Costs for General Industrial Rotating Machinery

20

25

10

15

20

$/HP/Yr ReactivePreventive

0

5

10 Predictive

0

Maintenance MethodS & S


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.


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


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


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


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


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


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 ...


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


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)


UT Sound ClipsUT Sound ClipsGood Brg. -- Bad Coupling Bad Spindle Brg.

Bad Brg. Clicking / Rubs HFO Purifier


Thermographic Infrared ImageThermographic Infrared ImageDigital Camera Infrared Camera


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.


Sensor SetupSensor SetupUltrasonicDynamic

Cylinder PressurePressure

Vibration • Data manipulation• Calculating power• Trending

C i ti• Communication

Encoder Output


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


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).


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


Reverse Dial Indicator MethodShaft Alignment

Vertical Pump Horizontal PumpVertical Pump Horizontal Pump


Alignment SoftwareAlignment Software


Vertical Machine AlignmentVertical Machine Alignment


Vertical Move & Shim DiagramVertical Move & Shim Diagram


Laser/Optical Shaft AlignmentLudeca Optalign™


Dynamic BalancingDynamic Balancing


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


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


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


Establishing an Effective TRMCondition Monitoring Program

Strategic Plan: Tactical Plan:Purpose

Objective

Procedure

Trainingj

Methods

g

Resources


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