PRESENTATION

CONDITION BASED MAINTENANCE

BY
ALEX APPIAH-FOKUOH

CONTENT
Part 1 Maintenance Management
Maintenance Systems
Introduction to:
a. Predictive Maintenance or (C B M)
b. Condition Monitoring
Part 2 Predictive or Condition Based
Maintenance
Wear Debris Analysis Techniques
Infra-red Thermography Techniques

Vibration
Analysis Techniques
Part
3
Balancing
Alignment
PREDICTIVE
MAINTENAN

 INTRODUCTION
IMPORTANCE OF MAINTENANCE
MAINTENANCE TYPES
PREDICTIVE MAINTENANCE
(Condition Based Maintenance)
TYPES OF CONDITION MONITORING

PREDICTIVE
MAINTENANC

INTRODUCTION
This program aims at giving some
understanding on the various techniques
used in monitoring the health of plant
equipment and machinery for the purpose of
Need-Based Maintenance of capitalintensive equipment used in modern
industries.
Maintenance personnel who are looking
towards minimizing the down-time of their
costly machinery.
PREDICTIVE
MAINTENANCE

INTRODUCTION cont.

The main thrust will be on improving overall

equipment effectiveness (O.E.E) through the
integration of various condition monitoring
techniques which the maintenance unit needs
to keep the plant working effectively.
Productivity can be achieved through
availability, and availability can be increased
through adopting the efficient maintenance
practices, by focusing on different types of
maintenance and strategies.
PREDICTIVE
MAINTENAN

WHAT IS
MAINTENANCE
? not have a
Maintenance
is a word which may
clear cut definition, but largely it is
appropriate to say it is the process of keeping
something in good condition.
OR

Maintenance is a set of organised activities that are

carried out in order to keep an item in its best
operational condition with minimum cost acquired.

PREDICTIVE
MAINTENANCE

MAINTENANCE

MAINTENANCE is a system by
which the Machinery Assets are kept
in GOOD working condition and
maintained in the same condition by
preventing from deterioration.
BUT

British Standard Glossary of terms

(3811:1993) defined maintenance as:
the combination of all technical and
administrative actions, including
supervision actions, intended to
retain an item in, or restore it to, a
state in which it can perform a
PREDICTIVE
required function.
MAINTENAN

MAINTENANCE

PREDICTIVE
MAINTENANCE

MACHINE
ALWAY
S
IN
NEW
TOPCLASS
EFFICIENT
NEAT
AND
NICE
CONDITION
EVERYWHER
E

Mechanical Device, Asset,

etc.

Production, Quality,
Performance/Availability
, Efficiency, etc.

Physical condition Cleanliness, Painting,

Rigidity, etc.

Unit parts, Entire plant

etc.

MAINTENANCE

IMPORTANTCE OF MAINTENANCE
LIFE CYCLE OF EQUIPMENT
Equipments when put to use goes through
various phases in its life from installation,
commissioning , usage period to ultimate
failure or disposal. In general, the life of
equipments has got a common pattern known as
the BATH TUB CURVE which is plotted failure
rate against time.
Basically it has three phases, i.e.
Infant mortality phase,
Useful life phase,
Wear out phase
PREDICTIVE
MAINTENANCE

MAINTENANCE

PREDICTIVE
MAINTENANCE

MAINTENANCE

1. Run or Infant phase: Is from installation,

commissioning with high failure rates which
gradually go on reducing to a stabilised
level. This may also be called running-in
period where the components exhibit high
failure rate due to manufacturing or material
defects, faulty assembly or faulty installation
etc. phase: Depicts a more or less
2. process
Useful life
constant
failure rate curve and failures
are
rare due to active preventive
maintenance
activities to increase the
active life span of
the equipment. This
phase has two types of
failures.
PREDICTIVE
MAINTENANC

MAINTENANCE

Useful life phase cont....

a) Functional failure which is an inability of an
asset to fulfil a function to a standard of
performance level that is acceptable. It does
not necessarily mean breakdown.
b) Potential failure which is an identifiable
condition that indicates that a functional
failure is either about to occur.

PREDICTIVE
MAINTENANC

MAINTENANCE

3. Wear out phase: is where the

equipment has reached its useful design
life and failure rate goes up. During the
wear out period, the failures in general are
caused due to factors such as:
Material wear
Ageing, end of design life,
Incipient stresses
Overloading
Fatigue, etc.
PREDICTIVE
MAINTENANC

MAINTENANCE

MAINTENANCE
OBJECTIVES

Machines are to be maintained in such a way

so
that it can be utilized to the fullest extent.
For maximizing profit run the equipment
efficiently which is possible if it is maintained
well. Maximum productivity with quality to be
achieved with out any accident.
Maintenance raises equipment performance
but adds to cost of production.
Maximum availability with minimum cost. etc
PREDICTIVE
MAINTENAN

MAINTENANCE OBJECTIVES

PLANT
Maximising
Production
Minimising
Energy Usage
Optimising
Useful Life of
Equipment
Providing
Budgetary
Control
Optimising
Resources
Utilisation
PREDICTIVE
MAINTENANC

M
A
I
N
T
E
N
A
N
C
E

Reduce
Breakdowns
Reduce
Downtime
Improving
Equipment
Efficiency
Improving
Inventory
Control
Implementing
Cost Reduction

WHY REDUCING DOWNTIME

AVAILABILIT

Plant uptime or availability is calculated as a

percentage figure of plant run time divided over
available production time:
Plant Uptime or availability = plant run time
(production) / Total available time to run or
produce
RUNNING TIME (RT)
AVAILABILITY (AV)

TOTAL TIME (TM)

TOTAL TIME (TM) = RUNNING TIME (RT) + DOWN TIME (DT)
DOWN TIME (DT)
=

PREDICTIVE
MAINTENANC

WAITING TIME (WT) + TIME TO REPAIR (TTR)

TYPICAL MACHINE MAINTENANCE:

DOWN TIME PERIOD

Find the
Diagnose Find the
person
the
spare
who can
M/C
fault
parts
repair
stops
the
fault

PREDICTIVE
MAINTENANC

Repair
the
fault

Test
the
M/C

M/C
restore
or
run

TYPICAL MACHINE MAINTENANCE:

A.

FIND THE PERSON WHO CAN REPAIR THE FAULT

Personnel training
Job specialization/skills
Sectionalisation of job skills
Reliability/availability

B.

DIAGOSE THE FAULT

Maintenance record /history
Immediate users report
Manufacturers mtce manual
Equipment familiarization

C. FIND THE SPARE PARTS

Inventory of parts
Coding/shelving
Proper parts storage/preservation
Decentralization of parts/stores
Training/supervision of store personnel
PREDICTIVE
MAINTENANC

TYPICAL MACHINE MAINTENANCE:

C. REPAIR OF FAULT
Personnel skillfulness on the job
Mobilization of proper tools
Proper work procedure ( best working/maintenance practices)
Safety of work personnel
Proper supervision of work personnel
D. TEST THE MACHINE
Proper test equipment
Proper test procedure/programme
Knowledge and skill for testing
Proper monitoring during test period
Well planned coordination procedure
Safety of equipment/personnel

PREDICTIVE
MAINTENANC

BASIC
EXAMPLE:
1
RT

DAYS
M/C STATUS
TT = 10 DAYS

TEAM
A

TEAM
B
PREDICTIVE
MAINTENANC

AV =

2
DT

3
RT

4
DT

RT = 4 DAYS

5
DT

6
RT

7
DT

8
DT

9
DT

10
RT

DT (WT +TTR) = 6 DAYS

4
= 0.4 (40 %) WAITING TIME OR
4+6

PREPARATORY WORKS
-Tools/Equipments, Personnel,
Materials etc.

(3+3)WT+TT
R
TIME TO REPAIR OR
6
(60
%)
0.6
=
AV =
WORKING PERIOD
6+4
(1+3 WT+TT
)
R

Planning, Techniques,
Skills/Experience, Safety etc.

MAINTENANCE
TYPES
MAINTENANC
E
PLANNED
MAINTENANC
E
(PROACTIVE)

UNPLANNED
MAINTENANC
E (REACTIVE)

BREAKDOWN

EMERGENCY

PREDICTIVE
MAINTENANC
E

STATISTICAL
- BASED

PREVENTIVE
MAINTENANC
E

CONDITION
-BASED

ENGINEERIN
G SERVICES

IMPROVEMEN
T
MAINTENANC
E

DESIGN OUT

Shutdown
WINDO
W

PREDICTIVE
MAINTENANC

RUNNIN
G

ROUTIN
E

OPPORT
U-NITY

SHUTDOWN
PREVENTIVE

CORRECTIVE
MAINTENANC
E

DEFERRED

REMEDIAL

Maintenance
SHUTDOWN
IMPROVEMEN
T

SHUTDOWN
CORRECTIVE

PREDICTIVE
MAINTENANC

Preventive Maintenance (PM)

Its maintenance repairs performed on

a regular schedule to minimize
component degradation and extend the
life of equipment. It is performed after
a set amount of elapsed calendar time
or machine run time, regardless of
whether
the repair is needed.

PREDICTIVE
MAINTENANCE

Preventive Maintenance (PM) Basics Condition Mon

L. T. C.

L. L. F.

I. A.L.

Lubricating

Listen

Inspect

Tightening

Look

Adjust

Cleaning

Feel

Lubricate

PREDICTIVE
MAINTENANCE

Preventive Maintenance
(PM) ...................????????

As the preventive maintenance is timebased and activities such as changing

lubricant, etc are based on time, like
calendar time or equipment run time.
Basically, predictive maintenance or
Condition Based Maintenance (CBM)
differs from preventive maintenance by
basing maintenance need on the actual
condition of the machine rather than on
some preset schedule.

PREDICTIVE
MAINTENANC

The main difference between preventive

maintenance and predictive maintenance is
that predictive maintenance uses monitoring
of machine/equipment conditions to determine
the actual time to failure whereas preventive
maintenance depends on industrial average
life or period statistics .

PREDICTIVE
MAINTENANC

Predictive Maintenance Condition Based

Maintenance

Predictive maintenance is a set of activities that

detect changes in the physical condition of
equipment (signs of failure) in order to carry out
the appropriate maintenance work for maximising
the service life of equipment without increasing
the risk of failure.
The determination of a machine's condition while
in operation. The technique is dependent on the fact
that most machine components will give some type of
warning before they fail.

PREDICTIVE
MAINTENANCE

Predictive Maintenance Condition Based

Maintenance
To sense the symptoms by which the machine is
warning us requires most cost effective tools and
several types of non-destructive testing, such as;
0il and wear particle analysis,
Vibration analysis,
Temperature measurements, etc.

PREDICTIVE
MAINTENANC

Predictive Maintenance
Use of these techniques to determine the machine
condition results in a much more efficient use of
maintenance effort compared to any earlier types of
maintenance.
Measure equipment on a regular basis, tracking
key indicators over time, and take corrective
action when measurements are about to go
outside the equipment operating limits thus
predicting repair time.
However, tracking the measurements requires new
tools,
training, and software to collect and analyze the
data and predict repair cycles.
PREDICTIVE
MAINTENAN

Predictive Maintenance

It is classified into two kinds according to the

methods of detecting the signs of failure:
Condition-based predictive maintenance
Statistical-based predictive maintenance

Condition-based predictive maintenance depends on

continuous or periodic condition monitoring equipment to
detect the signs of failure.

Statistical-based predictive maintenance depends on

statistical data from the meticulous recording of the
stoppages of the in-plant items and components in order to
develop models for predicting failures.

PREDICTIVE
MAINTENAN

Predictive maintenance (PdM)

This technique help determine the condition of inservice equipment in order to predict when
maintenance should be performed. This approach
offers cost savings over routine or time-based,
because tasks are performed only when
warranted.
The main value of Predicted Maintenance is to
allow convenient scheduling of corrective
maintenance, and to prevent unexpected
equipment failures. The key is "the right
information in the right time".

PREDICTIVE
MAINTENANC

Predictive maintenance (PdM)

By knowing which equipment that needs

maintenance, the maintenance work can be better
planned (spare parts, people etc.) and what would
had been "unplanned stops" are transformed to
shorter and less "planned stops" thus increasing
plant availability. Other values are increased
equipment life time, increased plant safety, less
accidents with negative impact on environment,
an optimised spare parts handling, etc

PREDICTIVE
MAINTENANC

Predictive Maintenance - Summary

Tracking key indicators over time to predict when equipment
needs repair; that is actions based on actual condition obtained
from operating and condition measurement.
Time assessment of equipment condition which is obtained from
embedded sensors and/or external tests & measurements taken by
portable equipment.
Performing maintenance programs when measurements are
about to go outside the equipment operating limits.
Repairing equipment as-needed, requires fewer man-hours and
parts than preventive maintenance.
However, tracking the measurements requires new tools, training,
and software to collect and analyze the data and predict repair
cycles.
PREDICTIVE
MAINTENANC

PREDICTIVE MAINTENANCE -SOME

DRAWBACKS

a) It depends heavily on accurate and the

correct interpretation of the
information/data.
b)Condition monitoring equipments/tools
can be very expensive.
c) High cost of training of personnel.
(knowledgeable and skilled personnel)
PREDICTIVE
MAINTENANC

CONDITION MONITORING (C.M)

It is the process of monitoring a parameter of

condition in machinery, such that a significant change
is indicative of a developing failure.
OR
It can also be defined as a method of surveillance
(observation) designed to recognise change in norms and
give warning when the change exceeds safe or limiting
values.

PREDICTIVE
MAINTENANC

CONDITION MONITORING (C.M)

It is a major component of predictive

maintenance.
The use of conditional monitoring allows
maintenance to be scheduled, or other actions to
be taken to avoid the consequences of failure,
before the failure occurs. Nevertheless, a deviation
from a reference value (e.g. temperature, vibration
behaviour, etc.) must occur to identify impending
damages.

PREDICTIVE
MAINTENANC

CONDITION MONITORING (C.M)

Machines with defects are more at risk

of failure than defect free machines.
Once a defect has been identified, the
failure process has already commenced
and CM systems can only measure the
deterioration of the condition.
Intervention in the early stages of
deterioration is usually much more cost
effective than allowing the machinery
to fail.
PREDICTIVE
MAINTENANC

CONDITION MONITORING (C.M)

Early Uses of CM
Early Bearing Condition Analyzer

Wheel Tappers on Railroads

PREDICTIVE
MAINTENANC

CONDITION MONITORING

1850 :
1945 :
1970 :
1978
1983
1990
2000

:
:
:
:

Condition Monitoring History

Railroad Wheel Tappers
Oil Analysis, Canadian Pacific Railways
Established use of vibration, oil and thermal
monitoring
First major textbooks on PdM
First PC based CM system
Well established CM sub-industry
Condition Monitoring well ensconced in
Indian industries

The techniques are very wide from simple visual

surface inspections Look, Listen, Feel, Smell, by
human senses to more modern instruments detecting
changes (data trending) in the machine operating
conditions.
PREDICTIVE
MAINTENANCE

CONDITION MONITORING

Data Trending : is when periodic measurement is taken

to allow easy analysis of progressive changes. Periodic
measurements are more useful than single
measurements.

Normal Operating.
Condition
Max. Allowable Limit.
Trending Parameters which indicate
condition
PREDICTIVE
MAINTENANCE

CONDITION MONITORING

C.M also helps the following:

Identify critical machines in terms of safety and cost
Find most sensitive parameters to monitor
Identify equipment failure mode (seizure, breakage,
high vibration etc)
Decide on new monitoring instrument use.
Decide on method of monitoring, e.g. L.L.F.S
(Look, Listen, Feel, Smell), manual & portable
instruments or online monitoring.

PREDICTIVE
MAINTENANCE

CONDITION MONITORING
TECHNIQUES

CONDITIONE
D
MONITORING
TECHNIQUES

WDA
THERMOGRAPH
Y
VIBRATION
MOTOR
CURRENT
SIGNATURE
ANALYSIS
SLOW MOTION
STUDIES
ULTRASONIC
MONITORING

PREDICTIVE
MAINTENANC

ETC.

QUICK SCAN THROUGH SOME OF

THE CONDITION MONITORING
TECHNIQUES
AND THEIR APPLICATIONS.

PREDICTIVE
MAINTENANCE

CONDITION MONITORING
TECHNIQUES

analysis (e.g., Ferrography, particle

WDA -(OIL ANALYSIS) Oil
counter testing) can be performed on
different types of oils such as lubrication,
hydraulic or insulation oils. It can indicate
problems such as machine degradation (e.g.,
wear), oil contamination, improper oil
consistency (e.g., incorrect or improper
amount of additives) and oil deterioration

VISGAGE

OXIDATION APPARATUS

PARTICLE COUNTER
PREDICTIVE
MAINTENANC

OIL ANALYSER

DIGITAL
VISCOMETER

CONDITION MONITORING
TECHNIQUES
INFRARED

THERMOGRAPHY

Thermal cameras scan thermal radiation of the objects

and
that thermal mapping reveals a lot about the failure.

Temperature measurement (e.g.,

temperature-indicating paint,
thermography) helps detect potential
failures related to a temperature change in
equipment.
PREDICTIVE
MAINTENANC

CONDITION MONITORING
TECHNIQUES
VIBRATION

INSTRUMENT

MONITORING

SPECTRUM

Spectral vibration signature analysis for rotating and

reciprocating equipments. It allows detection many faults
such as UNBALANCE, MISALIGNMENT and LOOSENESS.
PREDICTIVE
MAINTENANC

CONDITION MONITORING
TECHNIQUES

MOTOR CURRENT SIGNATURE

ANALYSIS
Electrical condition-monitoring
techniques (e.g., high potential
testing, power signature analysis)
involve measuring changes in
system properties such as
resistance, conductivity, dielectric
strength and potential. Some of
the problems that these
techniques will help detect are
electrical insulation deterioration,
broken motor rotor bars and a
shorted motor stator lamination.

PREDICTIVE
MAINTENAN

CONDITION MONITORING
TECHNIQUES

ULTRASONIC MONITORING

Thickness Measurement
Flaw Detection
Flow Measurement
PREDICTIVE
MAINTENANC

CONDITION MONITORING
TECHNIQUES

SLOW MOTION STUDIES

Rotating component is inspected/ examined in detail by

making it still with the help of a strobe light.
If the stroboscope is not quite synchronized with the object's
motion, the object will appear to move slowly either
backward or forward, depending upon whether the
stroboscope's rotation is too fast or too slow. Can be used on
Gear box, Impellers, Rotors etc. and measure
the
speed of rotation or frequency.
PREDICTIVE
MAINTENANC

CONDITION MONITORING
TECHNIQUES

SELECTING A CONDITION MONITORING

TECHNIQUE:
Does it give us the information about the
mode of
failure we have
identified?
Is it practical to apply?
Is it Cost Effective?
Is it the simplest method available?

PREDICTIVE
MAINTENANC

Some Key Points

CM has been around for

generations.
Parameters must be fault indicative.
Periodic measurements more useful
than single measurements.
Repeatability more important than
absolute accuracy.
Use trending to ease interpretation.
Simplest techniques often the most
cost effective.

PREDICTIVE
MAINTENANCE

CONDITION MONITORING
TECHNIQUES

HUMAN
BODY TEMPERATURE

EQUIPMENT
THERMOGRAPHY

PREDICTIVE
MAINTENAN

HEALTH
BLOOD TEST

HEALTH
WDA

MONITORING
ECG

MONITORING
VIBRATION

CONDITION MONITORING
TECHNIQUES
WEAR DEBRIS
ANAYSIS

INFRARED
THERMOGRAPH
Y

VIBRATION
MONITORING

PREDICTIVE
MAINTENANC

THANK
S

FOR
YOUR
ATTENTION !

GOD BLESS YOU!

PREDICTIVE
MAINTENANC

appifok