introduction to predictive maintenance for forging
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PREDICTIVEMETHODSANDTOOLS
A Quick Overview
for
Forging Industry
Association
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PRAIRIEPREDICTIVESERVICESSPP
Purpose
Overview of Predictive Maintenance - PdM(condition based maintenance)
What
Why
How
Introduce three useful technologies
Thermography
Vibration measurement Ultrasound
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Outline
Bathtub curve
Maintenance strategies
Three technologies for Predictive
Maintenance
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Bathtub curve components
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Bathtub curve
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No cost until failure
Unpredictable
Expensive if misapplied
Reactive Run to failure
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SPP
More reliable than Reactive
Higher cost & more errors then necessary
Preventive service before theres a chance to fail
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SPP
More reliable than preventive
Cut unexpected failures
Predictive detect onset of failure, then service
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More reliable than predictive
Increase uptime, lifetime
Proactive control failure root causes
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SPP
Predictive Maintenance - Why
Cut unexpected failures
Eliminate unnecessary service
Maximize runtime
Reduce introduced faults
Improve Overall Equipment Effectiveness
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Predictive Maintenance - How
How to start
Identify equipment that yields greatest benefit
Select technology(ies)
Build plan
Equipment routes and schedules
Aquire and learn to use tools
Develop benchmarks for trending
Develop information flow
Data for trending
Actionable reporting
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Potential Pitfalls
Lack of planning
No training
Poor data and diagnosis
False alarms, missed early warnings
Early warnings ignored
All lead to a Failed Program
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Technologies for Predictive Maint.
Common Thermography
Ultrasound
Vibration Analysis (Tribology - not part of presentation)
Overview for each
Description
Application
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Subset of electromagnetic spectrum
All objects radiate according to
temperature (freq
temp) IR invisible so IR camera is used
Thermography Infrared (IR)
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Thermography Infrared (IR)
area of interest
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Early Warning
Increased friction
Abnormal resistance or current
Non-contact
Realtime display
Useful for electrical and mechanical
Thermography
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Thermography Electrical
Typical Items Inspected
Power distribution
Fuse boxes
Motor Controllers
Switchgear
Capacitors
Transformers
Motor leads
Common Problems Found
Unbalanced loads
Excessive draw
Faulty connections
Component failure
Harmonics
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Thermography Electrical
Fuse at main disconnect was open
Left phase at 92 F
Center phase at 116 F
Right phase at 119 F
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Thermography Mechanical
Typical Items Inspected
Bearings
Gearboxes
Drive Belts Motors (check cooling)
Common Problems Found
Inadequate lubrication
Misalignment
Blocked cooling
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Thermography Mechanical
Motor
misaligned
Motor running hotVent clogged
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Ultrasound
Above audible range (20~100kHz)
Travels through all matter
Excellent for lubrication Electrical and mechanical
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Earliest indicator of fatigue
When to grease, how much
With FFT can determine failure mode
Ultrasound Bearings
good
bearing
bad
bearing
adding
grease
3 minutes
later
sound files copyright of UE Systems
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Arcing and tracking
Corona over 1000V
Used BEFORE opening panels
Ultrasound Electrical
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Easy to detect and locate
Estimate 20% (+) of compressed air is lost
100hp compressor costs $35k~$50k yearly
$7k~$15k savings in energy cost
Help pay for PdM expenditures
Ultrasound Compressed Air Leaks
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Monitor bearing wear (Predictive)
Rotating machine condition (Proactive)
Alignment
Balance
Mounting problems (softfoot, etc.)
Vibration Monitoring
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Vibration Monitoring
Types
High frequency narrow band
Broadband
Hybrid (attributes of other two)
Configurations
Portable (walk-around)
On-line (permanently mounted and networked)
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SPP PRAIRIEPREDICTIVESERVICES
Predictive Maintenance
What monitor assets plan service after early detection of problem
verify repair
Why cut unexpected failure
reduce costs and faults
extend runtime
How select assets to monitor choose monitoring technology(ies); train
establish and maintain schedule
develop concise reporting