CONDITION BASED MONITORING

A PROJECT ABOUT PLANT PREVENTIVE MAINTENANCE IMPLEMENTED

AT

BARNES REINFORCING INDUSTRIES (PTY) LTD

1.WHAT IS CONDITION BASED MONITORING(CBM)?

•DEFINITION :

Condition-based monitoring (CBM) is maintenance that is regularly performed on a machine to lessen the likelihood of the machine to breakdown.

BACKGROUND/HISTORY :

2.WHY IMPLEMENT CBM at BRI?

•ADVANTAGES :

REDUCES MAINTENANCE LABOR COSTS.

MINIMIZE THE COST OF SPARE PARTS.

ELIMINATES MANUFACTURING INTERRUPTIONS.

PRODUCES MAXIMUM QUALITY OF PRODUCTS.

INCREASES MACHINE LIFE SPAN.

2.WHY NOT IMPLEMENT CBM AT BRI?

•DISADVANTAGES :

CONSUMES TOO MANY RESOURCES.

MAINTENANCE DEPARTMENT MAY FIND IT DIFFICULT TO MANAGE CBM AND BREAKDOWNS AT SAME TIME.

THERE IS NOT ENOUGH TIME AND MANPOWER TO MANAGE CBM AND OTHER IMPORTANT DAILY MAINTENANCE TASKS.

IT TAKES LONG TO SEE THE RESULTS.

•Project aim:

To monitor the condition of rotating and heating equipment in machines by means of condition-based monitoring and preventive maintenance.

To identify equipment failure which causes the machines to experience frequent breakdowns.

3.METHODOLOGY AND OBJECTIVE FOLLOWED :

• SPECIFIC TOOLS USED:

TOPTRONIC T306 INFRARED THERMOMETER.

3.METHODOLOGY AND OBJECTIVE FOLLOWED :

• SPECIFIC TOOLS USED:

Brit IR THERMOGRAPHIC CAMERA.

3.METHODOLOGY AND OBJECTIVE FOLLOWED :

• SPECIFIC TOOLS USED:

SKF MACHINE CONDITION ADVISOR.

3.METHODOLOGY AND OBJECTIVE FOLLOWED :

•Project Objective:

1. Engineering trainees will determine the components to be monitored.

2. The project manager together with engineering trainees will determine the monitoring schedules for the equipment to be monitored.

3.METHODOLOGY AND OBJECTIVE FOLLOWED :

•Project Objective:

3. A monitoring procedure will be determined, which will demonstrate the methodology of conducting the project.

4. Tools for monitoring such as infrared thermometer, thermography camera, vibration analyser and other technologies will be determined and used by engineering trainees for monitoring equipment.

3.METHODOLOGY AND OBJECTIVE FOLLOWED :

4.LIMITATIONS OF PROJECT:

CBM took much time and sometimes produced little results.

an urgency of continuation of production by management, whilst machines were scheduled for maintenance.

routine tasks were done too often than required.

5.BUDGET FORECAST:ACTIVITY COST

REGISTRATION FOR P2 EXPERIENTIAL LEARNING R 1 750

STUDENT STIPENDS * X 12 MONTHS R 67 956

PROPOSAL PREPARATION AND SUBMISSION PRINTING COSTS R 200

LITERATURE STUDY AND INTERNET PROVISION R 1 000

OFFICE EQUIPMENT R 10 000

INSTRUMENTS/TOOLS FOR TESTING PURPOSES R 20 000

ELECTRONIC/MECHANICAL COMPONENTS NEEDED R 10 000

MACHINE INSTALLATION AND COMMISSION R 57 000

LANGUAGE EDITING, ADVISE AND BINDING R 0

OTHER R 10 000

TOTAL ± R169 656

6.PROPOSED TIMETABLE:

TO DO LIST….

PROPOSED CONDITION MONITORING

REQUIREMENTS SHOULD BE COMMENCED BY BEGINNING

OF SEPTEMBER 2016

COMPONENTS TO BE MONITORED MUST BE DETERMINED BY THE END OF SEPTEMBER

2016

THE REPORT SHOULD BE SENT IN FOR

LANGUAGE EDITING AROUND THE ENDING

OF NOVEMBER

MONITORING SCHEDULES AND

PROCEDURES SHOULD BE COMPILED AND APPROVED IN MID

OCTOBER 2016

IDENTIFIED COMPONENTS SHOULD BE TESTED USING

SPECIALIZED TOOLS BY END OF OCTOBER 2016

PRIORITY MACHINES MONITORED

1) EURA 16

2) EVG (LML)

3) HEAVY MESH LINE(HML)

4) STRAIGHT AND CUT MACHINES

5) WIREDRAW

Procedure:

Monitoring an electric motor for temperature and vibration analysis

Bearing temperature

(fan side)

Coil temperature

Bearing temperature (drive side)Gearbox (overall vibration)

Procedure:Monitoring an electric motor for temperature and vibration analysis

• Step 1: Mark the points of monitoring as shown in picture above

• Step 2: Using a condition advisor tool place the tool on the green mark-ups to take reading of velocity(mm/s)

• Step 3: Using an infrared thermometer aim the red light from the tool to the orange mark-up for readings of temperature in degrees (ºc)

Procedure:

Monitoring an electric motor for temperature and vibration analysis

• Step 4: Capture the readings in table form in accordance to the colour sequence

• Step5 : Repeat step 1 to 5 until you have 3 tables for each machine monitoring.

• Step 6:Draw a temperature VS velocity graph to analyse the results.

7.PROJECT OUTCOME:

VIBRATION ANALYSIS OF RESULTS

As the results were analysed this was the outcome:

Envelope acceleration classification 1= bearing bore diameter of 200mm-500mm = Shaft speed of 500 RPM = ALERT

Envelope acceleration classification 2= bearing bore diameter of 300mm-400mm = Shaft speed of 1800 RMP = DANGER

7.PROJECT OUTCOME:

VIBRATION ANALYSIS OF RESULTS

As the results were analysed this was the outcome:

ALERT MEANS :

1) IT ‘S A WARNING THAT MONITORED COMPONENT NEEDS TO BE CHECK IMMEDIATELY FOR FAULTS

2) WARNS THAT IT MIGHT CAUSE BREAKDOWN LATER IF NOT ATTENDED SOONER

7.PROJECT OUTCOME:

VIBRATION ANALYSIS OF RESULTS

As the results were analysed this was the outcome:

DANGER MEANS :

1) THE COMPONENT MONITORED IS BEYOND REPAIR AND NEEDS TO BE REPLACED

2) IT IS A DANGER TO THE MACHINE , BREAKDOWN IS ABOUT TO OCCUR

7.PROJECT OUTCOME:

THE GRAPH OF ELECTRIC MOTOR PERFORMANCE

7.PROJECT OUTCOME:

EVG(LML)

THE GRAPH OF ELECTRIC MOTOR PERFORMANCE

7.PROJECT OUTCOME:

WIRE DRAW LINE

THE GRAPH OF ELECTRIC CONTACTOR PERFORMANCE

8.SUMMARY OF OUTCOME

As a result of completing the CBM procedure we found that most neglected mechanical faults were the main causes of major breakdowns compared to electrical faults.

Bearings of motor posed as fault to the overall of machine due to overheating, fatigue failure, lubricant failure, misalignment and corrosion.

8.SUMMARY (Let’s Recap!)

BRI, a manufacturing organization is faced with the problem of experiencing maximized breakdowns.

These breakdowns are caused by lack of proper maintenance and mechanical faults causing major breakdowns compared to electrical faults.

The aim was to monitor the condition of the identified heating and rotating equipment using condition-based monitoring.

The practice of CBM is necessary to achieve reducing spare parts cost, maintenance labour costs, maximum machine life span, etc.

8.SUMMARY (Let’s Recap!)

Specialised tools such as infrared thermometer, thermography camera and vibration analyser were used to test for temperature and vibration.

Condition-based monitoring is focused on correction of failure modes found in equipment of machines.

It preserves, protects and extends the life of machine equipment.

Condition-based monitoring reduces overall maintenance cost.

REFERENCE

1) Andrew K.S. Jardine , Daming Lin, Dragan Banjevic,

“A review on machinery diagnostics and prognostics

implementing condition-based maintenance” Mechanical

Systems and Signal Processing 20 (2006) 1483–1510.

2)Y. Han and Y. H. Song, “Condition Monitoring

Techniques for Electrical Equipment—A Literature Survey”,

IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 18,

NO. 1, JAN 2003

10. ANY QUESTIONS ? ? ?