predictive maintainance
TRANSCRIPT
©2009 Fluke Corporation Vibration testing 1
“Predictive Maintenance
Workshop”
An Introduction to
Maintenance
Practices
©2009 Fluke Corporation Vibration testing 2
Before We Begin…
• Ask questions at any time!
• Please turn your cell phone to vibrate.
• If you must take a call, please feel free but we ask
that you take it outside the seminar room.
©2009 Fluke Corporation Vibration testing 3
IMPORTANCE OF MAINTENANCE STRATEGY
Technology / Solution
Maintenance Strategy
Improved Business Performance
Plant Owner Business Objectives
Business objectives drive
the maintenance strategy,
which in turn drives the
technologies and
solutions applied.
Maintenance strategy
definition and development
is a critical success factor in
the customer’s value chain.
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• Reactive Maintenance: Often called “run to failure.” No repair or
maintenance actions are taken on machinery until the designed
life span is reached…or other variables cause the machinery to
fail.
– Upside:
• Lower upfront maintenance costs
• Lower maintenance staff costs
– Downside:
• Unplanned, sometimes catastrophic, downtime and overtime
hours
• Secondary damage to machines impacted by the failed
machine
• Potentially higher capital costs as entire components may need
to be replaced
• Machines control maintenance department
Maintenance Practices
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• Preventive Maintenance (Proactive – Calendar Based )
Also called “Historical or calendar-based maintenance”
– Upside:
• Increased equipment life
• Reduced equipment or process failure
• Flexibility with maintenance scheduling
– Downside:
• Fault free machines maintained unnecessarily – could lead
to incidental problems with components
• Overhaul reduces reliability of the machine (see the
bathtub curve)
• More labor intensive than Reactive Maintenance
Maintenance Practices
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Maintenance Practices
• Predictive Maintenance (Proactive – Condition Based): Use of different
testing (vibration, thermography, oil analysis, ultrasound are the most
common) to understand machine condition and prevent failure
– Upside
• Allows preemptive action to increase equipment life
• Increased equipment life
• Reduced equipment or process failure
• Reduced repair parts and labor costs
• Increased safety
• Reduced likelihood of catastrophic failures
– Downside
• Increased investment in diagnostic / test equipment
• Increased investment in training and staff
• Cost benefits not readily seen by management
• May require top-down cultural change in maintenance approach
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CONDITION MONITORING
Condition Based Maintenance is the
maintenance initiated as a result of
knowledge of the condition of an
item from performing inspections
with condition monitoring
technologies.
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Semi Critical Machines
General Purpose Machines
CR
ITIC
ALI
TY
Number of Rotating Machines
1
2
Critical Machines
1
PLANT ASSET CLASSIFICATION
3
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Asset Criticality Ranking
On the Asset Criticality Pareto Chart, natural “break points” appear to
segregate the assets into identifiable criticality classifications
For the most critical assets (typically 10-15% of assets), a
Reliability Centered Maintenance (RCM) approach is used
to determine the appropriate maintenance strategy.
Critical assets are assessed using Failure
Modes & Effects Analysis (FMEA) process.
Less Critical assets are assigned a
strategy using standard Templates
Non-Critical assets
Run-to-failure
Distribution of Assets
15%
Cri
tica
lity
Ra
nk
ing
30% (typical) 50% (typical)5%
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• Highly Critical- Continuous online vibration,
Thermography, Lube oil Analysis, Ultrasonic
Technology, Process Variable Analysis.
• Critical- Continuous online vibration measurement,
protection & Analysis, Thermography.
• Mid Level Criticality- Periodic Vibration online
Scanning
• Low Level Criticality- Periodic Vibration Scanning
• Non critical- Run to failure.
TECHNOLOGY
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Advantages of a CM Program
• Find the problem before it finds you!
• Improved less expensive maintenance
• Consistent and improved availability
• Increase in production rate
• Reduced maintenance costs
• Extend asset life (less need for capitol
expenditure)
• Reduce asset base i.e. spare parts
• Increased product quality and consistency
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Potential cost savings
• Cost of failure / poor efficiency– Lost revenue (downtime, lost customer confidence)
– Energy cost
– Replacement cost
– Repair costs (especially labour)
– Cost of scrap
– Cost of cleanup and restart
– Insurance premium
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The Maintenance Strategy defines how the asset’s failure modes will be managed. This requires identifying the failure modes, probability of failure and appropriate mitigation plan.
The three alternative tools that can be applied for maintenance Strategy Development are:
•RCM ( Relibility Centred Maintainance) – carried by teams on only the most critical systems. An individual RCM analysis may take 8 to 10 person-weeks to complete.
•FMEA (Faliure Mode Effect Analysis) – developed by single analyst on critical systems and equipment. The use of FMEA libraries helps fastrack this process.
•Templates – consist of standard maintenance strategies for low criticality assets
Develop the Maintenance Strategy
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PM Optimization
This is a systematic review of routine Preventive Maintenance (PM)
tasks with reference to the ideal maintenance strategy .
Work plans are strengthened with improved procedures, fully
developed Bill-of-Materials, tools and parts kits
By optimizing existing PM tasks, the cost of the maintenance program
is reduced, while reliability remains high
Savings from the PM Optimization process can fully fund the
introduction of a Predictive Maintenance program
Typical results from PM Optimization:
30% of PM tasks can replaced by more cost effective Predictive Maintenance tasks
30% of PM tasks can be deleted (no value)
30% of PM tasks need strengthening.
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Testing for PdM
Condition Monitoring
Machine watch
keeping & Etc..
Temperature
Vibration
Electrical / Power
monitoring
Process Parameters
Acoustic
Oil analysis
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Thank You