electrical - maintenance

NSTec Presentation Title

MAINTENANCE PROGRAMSMAINTENANCE PROGRAMS

Where are you?Where are you?

Vision – Service – Partnership


WHERE ARE YOU?WHERE ARE YOU?

MAINTENANCE PROGRAMS:MAINTENANCE PROGRAMS:

• Panic Maintenance: Maintenance performed only after a machine fails or experiences problems.Maintenance performed only after a machine fails or experiences problems.

• PM (Preventative Maintenance)Actions performed on a time- or machine-run-based schedule that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining oror mitigate degradation of a component or system with the aim of sustaining or extending its useful life and reduce the need for major repairs.

• PdM (Predictive Maintenance)Attempts to evaluate the condition of equipment by performing periodic or continuousAttempts to evaluate the condition of equipment by performing periodic or continuous (online) equipment condition monitoring. Basically, predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition of the machine rather than on some preset schedule.

• Proactive MaintenanceConcentrates on the monitoring and correction of root causes to equipment failures. RCM (part of which is root-cause-analysis), Laser Alignment, Precision Balancing are all part of proactive maintenance initiatives


all part of proactive maintenance initiatives.


P i M i tPanic Maintenance

C i i M i t / R ti M i t / RTF• Crisis Maintenance / Reactive Maintenance / RTF • Unplanned downtime• High parts and labor costs due to unplanned downtime and g p p

equipment damage• Inefficient use of staff resources• Maintenance and repair is controlled/set by machine failureMaintenance and repair is controlled/set by machine failure• Vague equipment status and reliability• Cannot predict equipment reliability



P v t tiv M i tPreventative Maintenance

• Histories of each machine type are analyzed and periodic overhauls are scheduled before “statically expected” problems occur. Potential for incidental damage to components in conducting unneededfor incidental damage to components in conducting unneeded maintenance.

• Catastrophic failures still likely to occur.Typically creates unwanted corrective maintenance• Typically creates unwanted corrective maintenance(in some companies over 50% of total CM’s)

• Includes performance of unneeded maintenance. • Expensive (Inefficient use of resources for most equipment)• Not taken seriously by most craft



P v tiv M i t RiskPreventive Maintenance RiskPreventive maintenance does involve risk. The risk here refers to the

t ti l f ti d f t f i t hil f i th PMpotential for creating defects of various types while performing the PM task. In other words, human errors committed during the PM task and infant mortality of newly installed components eventually lead to additional failures of the equipment on which the PM was performed. F tl th f il ft th PM i f dFrequently, these failures occur very soon after the PM is performed. Typical examples of human errors are shown on the following page.

Especially disturbing about these types of errors is the fact that theyEspecially disturbing about these types of errors is the fact that they go unnoticed - until they cause an unplanned shutdown. There is some published data that illustrates this point. It comes from the fossil-fuel power industry.

A review of the data from fossil-fueled power plants that examined the frequency and duration of forced outages after a planned or forced maintenance outage reinforces this concept. That data showed that of g p3146 maintenance outages, 1772 of them occurred in less than one week after a maintenance outage. Clearly, this is pretty strong evidence that suggests that in 56% of the cases, unplanned maintenance outages were caused by errors committed during a


maintenance outages were caused by errors committed during a recent maintenance outage.


SELF INDUCED FAILURESSELF INDUCED FAILURES

70 80 % f i t f il SELF INDUCED70-80 % of equipment failures are SELF-INDUCED • Putting hydraulic fluid into a reservoir without filtering it• Welding on equipment without grounding properlyg q p g g p p y• Running equipment to failure when it is not part of your maintenance

strategy• Aligning couplings without using a laserAligning couplings without using a laser• Improperly lubricating electric motors



P di tiv M i tPredictive Maintenance

B d hi diti hil it i i• Based on machine condition while it is running• Dependent on components providing early warning• Non-destructive testing (PdM tools: vibration analysis, oil analysis, IR, g ( y y

Ultrasound, Motor Analyzer Tester. Etc.)• Allows management to control machinery and maintenance• Allows for preemptive corrective actionsAllows for preemptive corrective actions• Increases plant readiness• Greater mainline reliability

R d di d l b• Reduces expenditure on spare parts and labor• Reduces the likelihood of catastrophic failure• Improvement in worker safetyp y



K T h ologi s fo PdM P og sKey Technologies for PdM Programs

P di ti M i t t lPredictive Maintenance tools:• Infra-Red Thermography• Ultrasound• Vibration Analysis • Motor/Transformer Tester Analyzer • Oil Lubricant and Wear Particle Analysis• Oil, Lubricant and Wear Particle Analysis

Proactive Maintenance tools:• RCM• Root Cause Analysis• Laser AlignmentLaser Alignment• Precision Balancing



I f R d Th og phInfra-Red Thermography

Thermography is the measurement of surface temperature throughThermography is the measurement of surface temperature throughremote means to indicate equipment health and assigning a color based on the temperature. Uses include:• Equipment startup acceptance and commissioningEquipment startup acceptance and commissioning• Temperature survey of low voltage, 600 volts and less nominal,

electrical • Temperature survey of medium voltage, 600 to 47kV, electrical

di t ib tidistribution • Temperature survey of high voltage, greater than 47kV, electrical

transmission and distribution • Electro-Mechanical equipment condition monitoring (HVACElectro-Mechanical equipment condition monitoring (HVAC,

Pumps, Motors, Bearings, Gearboxes, Belt-Drives, etc.)• Building envelope inspection • Heat loss and gain evaluation g• Cooling loss and gain evaluation • Roofing inspection for wet insulation • Inspection of insulation characteristics



I f R d Th og phInfra-Red Thermography



Ult so dUltrasound

E i t t t t d i i i• Equipment startup acceptance and commissioning• Pressure and vacuum leaks detection• Bearing inspection and monitoring • High speed gearbox defect detection • Steam trap leakage inspection • Check valve functional verification • Pump cavitation • Electrical arcing • Electrical system corona discharge y g• Heat exchanger and condenser tube and tube sheet leakage • Boiler monitoring • Boiler tube leakageBoiler tube leakage • Tank and pressure vessel leakage • Enclosure leakage inspection



Ult so dUltrasound



Vib tio A l sisVibration Analysis

E i t t t t d i i i• Equipment startup acceptance and commissioning • Rotating equipment analysis on HVAC, Pumps, Motors, Bearings,

Gearboxes, Belt-Drives, etc.High speed >600 RPM component ibration anal sis• High speed, >600 RPM, component vibration analysis

• Low speed, <600 RPM, component vibration analysis • Shock pulse analysis (bearing lubrication issues) • Structural analysis • Looseness of transformer coils• Misalignment • Belt tension and alignment• Unbalance condition• Lubrication issues• Bad bearings• Mechanical looseness• Worn gears


Worn gears• Electrical problems (rotor & stator issues)


Vib tio A lVibration Analyzer



Off Li Moto /T sfo T st A lOff-Line Motor/Transformer Tester Analyzer

Detects any type of motor electrical fault:Detects any type of motor electrical fault: • Turn-to-turn, coil-to-coil, and phase-to-phase faults• Shorted windings • Open phases• Open phases• Burned or contamination windings• Insulation breakdown• Poor connectionsPoor connections• Ground faults• Phase unbalances• Cable faultsCab e au ts• All types of rotor faults. Example: Broken/cracked rotor bars and rotor

casting voids & Rotor eccentricity • Good for testing spare motors to confirm their status and insures

i t i t lli f lt tagainst installing a faulty motor

NOTE: It tests virtually any size or type of motor, generator or transformer even from a remote locations


transformer, even from a remote locations.


O Li Moto /T sfo T st A lOn-Line Motor/Transformer Tester Analyzer

M t C t Si t A l i E l t D t t d M itMotor Current Signature Analysis Evaluate, Detect, and Monitor:• Stator electrical and mechanical health • Rotor bar health • Air gap/eccentricity issues • Mechanical component health including bearings, balance and

alignment and driven equipmentalignment, and driven equipment • Adaptors for external equipment plug in



All Test Pro Off Line Motor/Transformer Tester All – Test Pro Off-Line Motor/Transformer Tester Analyzer



Oil L b i t d W P ti l A l sisOil, Lubricant and Wear Particle Analysis

Choose the tests that are appropriate for your piece of equipment and pp p y p q poil type!

Example of Various Transformer Oil Tests:Example of Various Transformer Oil Tests:• Dissolved gas analysis (DGA or TOGA) (ASTM D 3612)• Water Content (D 1533)• Acid Number (TAN-E) (D 664)• Interfacial Tension (D 971)• Myers Index = IFT/TANy• Color (D 1500)• Dielectric Breakdown (D 1816)• Polychlorinated Biphenyls (D 4059)• Polychlorinated Biphenyls (D 4059)• Furanic Compounds (D 5837)



Oil L b i t d W P ti l A l sisOil, Lubricant and Wear Particle Analysis

T El t (D5185)• Trace Elements (D5185)• Particle Counts (ASTM draft method)• Oxidation Stability (RBOT) (D 2112)y ( ) ( )• Oxidation Inhibitor Content (D 2668)• Power Factor (D 924)• Specific Gravity (D 1298)• Specific Gravity (D 1298)• Viscosity (D 445)• Static Charge Density• Halogens (D5384 and D808)• Flash Point (D 92)



P o tiv M i tProactive Maintenance

Wh t i ti i t ? Whil ti d di tiWhat is proactive maintenance? While preventive and predictive maintenance seek to catch and prevent symptoms before they result in breakdowns, proactive programs seek to lessen or eliminate the root causes Proactive maintenance is a maintenance strategy forroot causes. Proactive maintenance is a maintenance strategy for stabilizing the reliability of machines or equipment. Its central theme involves directing corrective actions aimed at failure root causes, not active failure symptoms, faults, or machine wear conditions. A typical proactive maintenance regiment involves three steps: (1) setting a quantifiable target or standard relating to a root cause of concern (e.g., a target fluid cleanliness level for a lubricant), (2) implementing a maintenance program to control the root cause property to within themaintenance program to control the root cause property to within the target level (e.g., routine exclusion or removal of contaminants), and (3) routine monitoring of the root cause property using a measurement technique (e.g., particle counting) to verify the current level is within the target.




A di j i d i h h h ld i ’ iAccording to major industries throughout the world, it’s time to throw out your old ideas on machine maintenance. The cost-saving trend is toward a maintenance program that targets the root causes of machine wear and failure. Preventive methods are out: proactive maintenance are in. Why? Because proactive maintenance methods are currently saving industries of all y gsizes thousands, even millions, of dollars on machine maintenance every year. According to DuPont, maintenance is the largest single controllable expenditure in a plant In manythe largest single controllable expenditure in a plant. In many companies it often exceeds annual net profit. The problem of costly maintenance has truly reached a serious level, but as some companies have found out and more come to realizesome companies have found out, and more come to realize every day, their maintenance costs can be cut drastically by establishing a “proactive” line of defense.




P i i h f ll i b i h iProactive maintenance uses the following basic techniques to extend machinery life:

• Proper installation and precision rebuild• Failed-parts analysis

R t f il l i• Root-cause failure analysis• Reliability engineering• Rebuild certification/verification• Age exploration• Recurrence control• Continuous monitoring of things such as lubricants hydraulic• Continuous monitoring of things such as lubricants, hydraulic

fluids and coolants• Developing strict contamination control program for: lubrication

fluids hydraulic fluids gear oils and transmission fluids


fluids, hydraulic fluids, gear oils, and transmission fluids


RCMRCM

R li bili C d M i f k RCM iReliability-Centered Maintenance, often known as RCM, is an industrial improvement approach focused on identifying and establishing the operational, maintenance, and capital improvement policies that will manage the risks of equipment failure most effectively. Reliability Centered Maintenance can be used to create a cost-effective maintenance strategy to address dominant causes gyof equipment failure. It is a systematic approach to defining a routine maintenance program composed of cost-effective tasks that preserve important functions It is defined by the technical standardpreserve important functions. It is defined by the technical standard SAE JA1011.



Th RCM P o ssThe RCM Process

Ph 1 i t f id tif i th f ti f th i t• Phase 1 consists of identifying the functions of the equipment, identifying the functional failures, identify the different failure modes, identify the effects of the failure modes (at the plant level), identify the conseq ences to the facilit as a res lt of the fail re effects This isconsequences to the facility as a result of the failure effects. This is the COFA (Consequence of failure analysis) evaluation analysis process.

• Phase 2 consist of specifying the appropriate maintenance task (PM, PdM, Proactive, or simply RTF) for the equipment identified in Phase 1. Th k b b h li bl d ff i Thi h lThese tasks must be both applicable and effective. This phase also includes a very prescriptive method for identifying default actions if an applicable and effective preventive task cannot be found.

• Phase 3 consists of properly executing the tasks specified in phase 2 and includes the sustainment process.



Co l sioConclusion

A ti i t i th t f RCMA proactive maintenance program is the capstone of an RCM philosophy. From the RCM program you can develop the appropriate maintenance philosophy to use for a particular piece of equipment

hether it is r n to fail pre entati e predicti e or proacti ewhether it is: run-to-fail, preventative, predictive, or proactive.


electrical - maintenance

Documents

nstec presentation

equipment

predictive

maintenance

preventative

panic maintenance

unplanned

red thermography