Introduction to cbm

Condition Based Maintenance (CBM) and Condition Monitoring

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CBM is about utilizing the condition monitoring technologies to predict the failure pattern (s) of a machine.

CBM will not be scheduled based on the time.

CBM will allow the maintenance to be scheduled based on the condition of the machine.

Vision of CBM:

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Attain meaningful set of maintenance schedules (Technical Basis of Maintenance – TBoM)

Attain improved operating performance

Ensure safety and environmental protection

Introduction to cbm (continued)

Attain reduced maintenance costs

Attain comprehensive maintenance database (centralized)

Attain clearer view of resource requirements

Attain lasting benefits and can be applied across all or just selected machine

Methodology of CBM:

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The strategy of CBM uses a two level approach by overlaying techniques and technologies on monitored components

Level One (Short term):

Introduction to cbm (continued)

• Identify and reduce machine failures across site

• Use technologies to troubleshoot and examine poor performing assets

• Energy usage examinations

Methodology of CBM:

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The strategy of CBM uses a two level approach by overlaying techniques and technologies on monitored components

Level Two (Medium term to Long term):

Introduction to cbm (continued)

• Reduce maintenance exam tasks, extend maintenance exam and overhaul periodicities (TBoM integration)

• Use technologies to reduce maintenance costs

• Effective utilization of work force

• Increased knowledge of machine performance and condition

• Feedback into TBoM

Portable Vibration Analysis

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What does it monitor?

Introduction to cbm (continued)

• Imbalance problems

• Misalignment problems

• Bearing problems

• Electrical defects

Portable Vibration Analysis

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Where does it monitor?

Introduction to cbm (continued)

• Cranes• Air Compressor motors• Brake resistor/Traction cooling fans• Alternators• Turbocharger• Gearboxes• Electrical motors• Cooling system pumps• Lubrication oil system pumps• Fuel pumps• Diesel engine• Axle boxes

Portable Ultrasonic Analysis

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What does it monitor?

Introduction to cbm (continued)

• Air leak problems

• Electrical problems

• Mechanical problems

Portable Ultrasonic Analysis

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Where does it monitor? Leak detection in

Introduction to cbm (continued)

• Valves• Air supply lines• Brake resistor/Traction cooling fans• Flexible hoses• Pneumatic systems• Pressurized systems• Vacuum system problems• Compressor• Steam traps• Electrical – Arcing detection• Mechanical – Bearing defects, lack of lubrication and over lubricatoin

Portable Thermography Analysis

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What does it monitor?

Introduction to cbm (continued)

• Electrical problems

• Mechanical problems

• Pipework problems

Portable Thermography Analysis

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What kind of problems?

Introduction to cbm (continued)

• Electrical• High resistance connection• Corroded/hot connections• Earths returns – higher loading• Relay problems• Internal fuse damage• Internal breaker fault• Cracking insulation• Overload or unbalanced load• Busbar faults• Couplings• Cooling jackets

Oil and Grease Analysis

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Three dimension analysis:

Introduction to cbm (continued)

• Wear – Ferrous and Nonferrous

• Contamination – Dust, Water and Fuel

• Chemistry – Oil and Additive