Slides - Key Steps To Implementing Condition-Based Maintenance
Slides - Key Steps To Implementing Condition-Based Maintenance
Slides - Key Steps To Implementing Condition-Based Maintenance
uk
AV Technology Ltd
03.2011
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Introduction
Effective maintenance management depends
on applying the appropriate maintenance techniques Factors such as fault and failure modes, criticality and cost-effectiveness need to be considered Using the wrong maintenance technique can waste time, money and resources, often with no effect on improving or maintaining availability This seminar is based on ISO 17359: Condition Monitoring and Diagnostics General Guidelines
03.2011 CM39s Key Steps to Implementing CBM V2.0 Page 2
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03.2011
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Implementing CBM
1 2 3 4
5 6 7 8
Cost/Benefit analysis
Key steps to
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Phase
Routine KPI Optimise
Step
Detail
Return on investment analysis Life cycle cost Cost of failure / secondary damage What is the available budget
y y y y
y y y y
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Phase
Routine KPI Optimise
Phase
Routine KPI Optimise
Estimated availability & reliability FMECA, FMEA, FTA, Root cause failure analysis Maintenance history, pareto analysis, reliability databases
y y y
y y y
What Availability & Reliability does the business need? FMEA Failure Modes & Effects
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Improving Availability
Availability can be improved by optimising maintenance
Reliability
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Applicable Strategy
Onfailure Timebased CBM Design Out
Infant mortality
68% [Nowlan & Heap, 78] 29% [USN, 73]
Random
14% [Nowlan & Heap, 78] 42% [USN, 73]
Bathtub
4% [Nowlan & Heap, 78] 3% [USN, 73]
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Phase
Routine KPI Optimise
Step
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Maintenance Strategy
Failure Mode
OnFailure Fixed Time CBM Design Out
AHU Filter Pump Bearing Turbo-generator bearing Vehicle Engine Vehicle Wheel Vehicle Lamp
Filter blockage Misaligned on installation Plain bearing wear due to number of starts Degradation of oil due to adverse operating conditions Tyre tread wear Lamp element failure
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Phase
Routine KPI Optimise
Step
Detail
We can then select the best measurement technique and then select
the appropriate transducers and condition monitoring system
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Fault
Damaged impeller Damaged seals Eccentric impeller Bearing damage Bearing wear Mounting fault Unbalance Misalignment
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Phase
KPI Optimise
Step
Detail
Take measurements and trend readings Compare with alert/alarm criteria Diagnose, prognosis and assessment Identify root cause failure mode
y y y y
y y y y
Quality of Measurements OK? Possible errors come from If confidence in readings low:
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Resistance to Failure
Time
Vibration velocity (r.m.s.) Vibration acceleration (r.m.s.) Vibration acceleration (peak)
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Monitoring Frequency Q M 2W W D
On Line
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Phase
Routine KPI Optimise
Detail
Recommend appropriate maintenance action Carry out maintenance action Confirm diagnosis after maintenance actions Feedback to history records
y y y y
y y y y
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Typical Action/Advisory Priorities:Action Priority Description Immediate Urgent Routine None Comment Safety Related, Immediate Attention Urgent Attention Required At Next Routine Service No Action Continue Routine Monitoring
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Typical Response
1 2 3 4
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CONV-1 CONV-2
W
19/09/07
Chain impacts picked up on far end bearings Gear harmonics increasing indicating gearbox wear. Fan non drive end bearing noisy Drive belts broken Noted, alarms adjusted Fan bearings very noisy Fan unbalance increasing
3 2 3 1 4 1 2
A
19/09/07
Area:
AIR CON EXH FAN 1 EXH FAN 3 SUPP FAN 2 SUPP FAN 6 SUPP FAN 8
W
19/09/07
Lubricate fan bearings Replace drive belts No action recommended Continue monitoring Replace fan bearings Balance iaw ISO 1940 to balance grade G6.3
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N
19/09/07
W
19/09/07
A
19/09/07
A
19/09/07
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Measuring Effectiveness
Typical Condition-Based Maintenance Set-up Step
Set up
Phase
Routine KPI Optimise
Detail
Managing CBM is a continuous process Technology & Techniques change Periodic reviewing the process is an important step
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Pumps
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Conclusions
Benefits
Applies to all failure profiles Detect faults before failure Work can be planned Production rate can be modified Can avoid secondary damage
Remember
Review the cost benefits Target the failure mode Needs to be reasonable Lead Time to Failure
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References
ISO 17359, Condition monitoring and diagnostics of machines - General
guidelines
BINDT PCN CM Gen - Condition Monitoring Training & Certification Ball and Roller Bearings: Theory, design, and application. Brandlein, J.
and Eschmann, P. (1999). Wiley Simon Mills
Websites
British Standards web site http://www.bsi-global.com ISO web site http://www.iso.ch British Institute of Non-Destructive Testing http://www.bindt.org
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