Applying Condition Based Monitoring Approach in Facility Management Services

by

Ismail Yusof

CONTENTS

Maintenance Strategies Condition Based Maintenance (CBM) Condition Based Maintenance Cycle Spectrum of CBM Detection Method in CBM Mortality of Machinery & Bathtub Type of CBM IR/VA/OA/PQA/US Benefits The Challenges

MAINTENANCE STRATEGIES
Maintenance

Reactive Maintenance Unplanned

Preventive Maintenance Planned

Condition Based Maintenance Condition Based

Condition Based Maintenance

A predictive approach can be applied to any equipment problem if,

A physical parameter like vibration, temperature, pressure, voltage, current, or resistance can be measured. An engineering limit for the measured physical parameter must be, established so a problem can be detected during routine monitoring. The limit should be low enough to detect the problem before excessive damage occurs. Correcting of the root problem is the key to most predictive efforts.

Condition Based Maintenance Cycle

Condition Based or Periodic Monitoring

Corrective Maintenance

(Schedule) yes
Open Corrective Work Order Analyze Problem

no

Spectrum of CBM

With CBM technology, a vast number of equipment failures can be predicted. Vibration measurement on rotating equipment & InfraRed Thermography is probably the best known of current CBM applications, but other categories of industrial equipment also benefit from a CBM approach.

Detection Method in CBM

Spectrum of CBM Equipment Category Rotating Machinery Equipment Types Pumps, Motors, Compressors, Blowers Failure Mode Failure Cause Detection Method Vibration and Lube Analysis

Premature Bearing Loss

Excessive Force

Lubrication Failure

Over, Under, or Improper Lube; Heat and Moisture

Spectrographic & Ferrographic Analysis

Electrical Equipment

Motors, Cable, Starters, Transformers

Insulation Failure

Heat, Moisture

Time I Resistance Tests, IR Scans and Oil Analysis Ultrasound

Corona Discharge

Moisture Splice Methods

Heat Transfer Equipment

Containment and Transfer Equipment

Exchangers, Condensers
Tanks, Piping, Reactors

Fouling

Sediment I Material Buildup

Chemical Attack Metal Fatigue

Heat Transfer Calculations

Corrosion Meters, Thickness Checks Acoustic Emission

Corrosion Stress cracks

The mortality of machinery

There is a definite pattern of life spans. In practice, this pattern manifests itself when a collection of machinery is subjected to rigorous operation. The plot of typical life spans is shown in the so-called bathtub curve. There is a rather high incidence of early failures, called infant mortalities. Most equipment that survives infancy will continue to perform with few failures occurring. In time, however, the failures begin to increase until the last of the group succumbs.

Bathtub Curve

Infant Mortalities

Normal Aging

Machine Failures Random Failures

Machine Life - Years

Type of Condition Based Maintenance

o o o o o Infra Red Thermography Vibration Analysis Oil Analysis Power Quality Analysis Ultrasound

InfraRed Thermography (IR)

Infrared thermography, thermal imaging, thermographic imaging, or thermal video, is a type of infrared imaging science. Thermographic cameras detect radiation in the infrared range of the electromagnetic spectrum (roughly 90014,000 nanometers or 0.9 14 m) and produce images of that radiation, called thermograms. Since infrared radiation is emitted by all objects near room temperature, according to the black body radiation law, thermography makes it possible to "see" one's environment with or without visible illumination. The amount of radiation emitted by an object increases with temperature, therefore thermography allows one to see variations in temperature. When viewed by thermographic camera, warm objects stand out well against cooler backgrounds; humans and other warmblooded animals become easily visible against the environment, day or night. As a result, thermography's extensive use can historically be ascribed to the military, security services and Condition Based Maintenance.

Sample of IR Images

Sample of IR Images
Infrared Image
AR01 LI01

Photo
151.5C 140 120 100 80

AR02 LI02

SP01

60
SP02

40 33.3C

Thermal Profile
C 150 IR01

100

50 Line li01 li02 li03 Min 37.6C 36.2C Max 125.9C 58.9C Cursor -

VIBRATION ANALYSIS (VA)

Vibration refers to mechanical oscillations about an equilibrium point. The oscillations may be periodic such as the motion of a pendulum or random such as the movement of a tire on a gravel road Rotating machinery has a characteristic vibration pattern depending on the location the vibration data is collected. Characteristic vibrations are produced at different frequencies for similar equipment. Any change to these vibration patterns will indicate the nature and severity of a defect such as misalignment of shafts, bearings and footing etc. In vibration analyses a transducer converts mechanical motion (vibration) to electrical signals. These electrical signals are then plotted on amplitude versus frequency plots, which then is analyzed to predict the source of vibration.

Defining VA Limits

Many engineered limits have already been established for equipment by manufacturers, professional societies and industrial groups. Vibration Institute, a not-for-profit professional organization, and other organizations have established levels of equipment health as a function of vibration velocity based on experiments. A simplification of this equipment health data for Rotating machinery ratings. This table is useful for categorizing vibration levels on most industrial equipment operating between 600 rpm and 3600 rpm.

Vibration Limits
Rotating Machinery Ratings Rating
Good Fair

Vibration Level
Less than .15 ips .15 ips to .30 ips

Necessary Action
Continue to trend Continue to trend

Poor

.30 ips & above

Analyze & Correct

Using Ultrasound & Vibration

In the past, ultrasound and vibration technologies have been used independently to monitor ball bearings in plant equipment. However, it is becoming more common to use ultrasonic inspection interfaced with vibration analysis to support CBM maintenance programs for periodic inspection of critical bearings to monitor wear and predict failure.

Using Ultrasound & Vibration

Oil Analysis

Oil analysis (OA) is the sampling and laboratory analysis of a lubricant's properties, suspended contaminants, and wear debris. OA is performed during routine preventive maintenance to provide meaningful and accurate information on lubricant and machine condition. By tracking oil analysis sample results over the life of a particular machine, trends can be established which can help eliminate costly repairs. The study of wear in an machinery is called tribology. Tribologists often perform or interpret oil analysis data. The sample sent to Accredited Lab for analysis.

Oil Analysis

OA can be divided into three categories:

Analysis of oil properties including those of the base oil and its additives. Analysis of contaminants. Analysis of wear debris from machinery.

Oil Analysis

Comparing the OA results of new and used oil, a tribologist can determine when an oil must be replaced.

Careful analysis might even allow the oil to be "sweetened" to its original additive levels by either adding fresh oil or replenishing additives that were depleted.

BENEFITS OF APPLYING CONDITION BASED MAINTENANCE

Increase Your Profitability by:

Reducing capital costs. Reducing maintenance costs. Reducing energy costs.

Reduces the risk of:

Costly business interruption. Fire/ life safety. Code violations.

The Challenges Ahead !!!!

First and most important of all, the initial cost of CBM is high. It requires improved instrumentation of the equipment. Often the cost of sufficient instruments can be quite large, especially on equipment that is already installed. Next introducing CBM will invoke a major change in how maintenance is performed, and potentially to the whole maintenance organization in a company. Organizational changes are in general very difficult. The technical side of it is not always as simple. Even if some types of equipment can easily be observed by measuring simple values as vibration (displacement or acceleration), temperature or pressure, it is not trivial to turn this measured data into actionable knowledge about health of the equipment. Also Limited Maintenance/resources budgets (insufficient manpower, tools, training and skilled staff). Lastly Obsolete systems & equipment.