Plant Maintenance & Condition Monitoring

Dr Mohd Salman Leong

Institute of Noise & Vibration Universiti Teknologi Malaysia Kuala Lumpur

salman@citycampus.utm.my

Institute Noise and Vibration, Universiti Teknologi Malaysia

Maintenance

The Lecturer
Qualifications Experience
Vibrations in Rotating Machines Condition Monitoring Structural Vibrations Vibration Control Research Teaching
Institute Noise and Vibration, Universiti Teknologi Malaysia

Maintenance

Machine Condition Monitoring

Institute Noise and Vibration, Universiti Teknologi Malaysia

Maintenance

Where Applicable.
Petrochemical Power Generation Water Treatment Engineering Plants
(Steel, Paper Mills, Cement, etc.)

Palm Oil Mills, etc. Buildings Ships..

Institute Noise and Vibration, Universiti Teknologi Malaysia

Maintenance

What Youll Learn

..Nothing? Some things. A lot of things

. Matter of Context and Content

Institute Noise and Vibration, Universiti Teknologi Malaysia

Maintenance

Topics To Be Covered
Introduction Maintenance Strategy and CM Overview Vibration Analysis Basic Machinery Faults Diagnosis Wear and Oil Debris Analysis Thermography Performance Monitoring
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Reference Materials
ATLs Guide HP Application Notes SKF Vibration Diagnostics Institute Notes Mitchells Blochs

Institute Noise and Vibration, Universiti Teknologi Malaysia

Maintenance

Maintenance Concepts

An overview of Maintenance Strategies, and how Condition Monitoring is used in Maintenance

Institute Noise and Vibration, Universiti Teknologi Malaysia

Maintenance

Some Definitions
Availability is the average percentage of the time that a device is available to give satisfactory performance during its required operating period. The availability depends on its reliability and maintainability. Reliability is the average time that devices of a particular design will operate without failure.

Maintainability is measured by the average time that devices of a particular design take to repair after a failure.
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Relationships between Availability, Reliability.

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Failures
The likely cause..

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Occurrence of Failures
Failures tend to occur in the following stages

Institute Noise and Vibration, Universiti Teknologi Malaysia

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MaintenanceStatus Quo

Significant % of Operating Costs Continue to rise Desire to over-maintain

Institute Noise and Vibration, Universiti Teknologi Malaysia

Maintenance

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Type of Maintenance
Production Production Run to Breakdown Time

Maintenance

Production

Production

Time-based Preventive Maintenance Time

Production

Production

Time

Condition Based Predictive Maintenance

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Run To Breakdown
Failure rate

Maintenance upon break down

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Time Based Preventive Maintenance

Failure rate

If is not broken, don't fix it !

Time Maintenance at regular intervals

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Condition Based Prediction Maintenance

Failure rate

Maintenance upon fault detection

If is not broken, don't fix it !

Time

Measurement value

Intermittent or continuous measurements

Alarm Alert Time

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Maintenance Efforts
Effort

Run to Breakdown Maintenance

Months Effort
The Regular maintenance shut down Short shut downs for minor repairs

Effort

Problem anticipated and caught in time

Months

Months

Time Based Maintenance

Institute Noise and Vibration, Universiti Teknologi Malaysia Maintenance

Condition Based Maintenance

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Protection Systems
For avoiding sudden catastrophic breakdown Continuous measurements Simple measurements Relays for automatically tripping.

Shutdown Relay

Annunciation Relay

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Determining Acceptable Operating Conditions

Manufacturing Process Utility : Product Quality : Process Performance (Quantity & Quality) : Availability

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Maintenance Strategies
Maintenance Strategies

Breakdown

Preventive

Predictive

Repair on breakdown

Calendar or hours run routine maintenance schedule

Maintenance On-condition of machine

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Maintenance Management Plan

Maintenance Management Plan Business Plan

Objectives
Strategies Tactics
Institute Noise and Vibration, Universiti Teknologi Malaysia Maintenance

Financial
Maintenance Philosophy Specific Maintenance Engineering Techniques
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3 Steps in Determining Maintenance Strategy

Budgets Manpower Spares

Financial Objectives

Maintenance Audit

Planned Predictive Breakdown Planned Maintenance Software Condition Monitoring System

Strategy

Machine Criticality Assessment Machine Audit Defect Matrices

Tactics

CM System Specification
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Integrated Maintenance Management

MANAGEMENT
Development of Tactics On-going Implementation Strategic Issues Development of Tactics Setting Financial Objectives Financial Monitoring and Control

Overall Maintenance Objectives

Strategic Issues

Current Situation

Setting Financial Objectives

ENGINEERING

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Machine Critically Assessment

Evaluate each machine with grading system under the following headings:
- Process Critically - Capital Cost - Operating Point - Safety - Operational Reliability (Historic or Generic) - Condition Monitoring Viability
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Criticality Assessment Interpretation

Machine Critical Assessment Interpretation: -Not Viable - Marginal - Viable - Highest Return

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Example
Machine Critically Assessment
Machine Description
Carbon Water Pump 11 kW 2930 rpm 15 m3/hr Mixed Hydrogen Recip Compressor 950 kW 421 rpm 2487 m3/hr 20 bar
Criticality Assessment A. Process critically B. Capital cost C. Operating point D. Safety E. Operational reliability
Institute Noise and Vibration, Universiti Teknologi Malaysia

A
1 5

B
2 5

C
3 5

D
1 5

E
1 4

Assessment Value

8 24

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Economic Loss
Power Generation Example

Gas Turbine Generator Base Load Plant

100 MW 12 hours Daily Operation

Revenue Loss for 1 week Revenue Loss for 12 weeks

= RM 2 M = RM 24 M

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Economic Loss
Engineering Industry

Annual Throughput 4 Process Lines

= RM 500 M per year

Loss 10 days unscheduled downtime For 1 Process Line Revenue Loss = RM 3.4 M Actual Loss = RM 2.6 M
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Profits Loss
Unscheduled Downtime eats into Profits

Can easily escalate into significant percentage of Profits

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Potential Savings
Condition Based Maintenance Increased Machine Availability

Savings - Reduced maintenance expenditure - Increased production uptime - Increased product quality - Increased operator safety - Decreased spare parts inventory

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Why Make Condition Monitoring

Initial investigations, selection of monitoring points, establishment of limits Selection and purchase of instrumentation Training

Yes

No

Longer time between overhauls

Condition Monitoring

Reduced repair duration

Reduction of spare-part stock

Less unexpected breakdowns

Elimination of secondary damage Reduction in business interruption and damage insurance premiums

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Benefit Cost Analysis

Example of Benefit Cost Analysis Return of Investment Areas of Savings
Refer to Notes and 1990 American Industry Survey.
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A graphical method of selecting industries which are likely to achieve savings from the condition monitoring of their plant
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Defect Analysis Matrix

Budgets Manpower Spares

Financial Objectives

Maintenance Audit

Planned Predictive Breakdown Planned Maintenance Software Condition Monitoring System

Strategy

Machine Criticality Assessment Machine Audit Defect Matrices

Tactics

CM System Specification
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Example 1
Motor Fan Installation: Industrial ventilation system, air handling units, draft fans, etc. Vibration 1.0 1.1 1.2 1.3 Fan (Blower) Section Fan Blades Unbalances, cracked, loose, etc. Shaft Misalignment, bent, crack, etc. Bearings Damaged, cracks, overloaded, etc. Motor Armature Cracked rotor bars, damaged windings, etc Shaft Misalignment, bent, crack, etc. Bearings Damaged, cracks, overloaded, etc. Score Dn = Down 0 2 2 Up Up 1 0 2 Up Up Up 2 0 1 Up Up 1 0 1 Up Dn 2 2 2 Up Up Up 0 0 2 Up Up 0 0 1 Up 2 0 1 Dn Dn Thermal AC Current Flow

2.0 2.1 2.2 2.3

10

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Example 2
Pump Installation: Water treatment plants, Power station pumps, Process installations Vibration 1.0 1.1 1.2 1.3 1.4 Pump Impeller Unbalances, cracked, loose, corroded,etc. Shaft Misalignment, bent, crack, etc. Bearings Damaged, cracks, overloaded, etc. Seals Broken, leaking,etc Motor Armature Cracked rotor bars, damaged windings, etc Shaft Misalignment, bent, crack, etc. Bearings Damaged, cracks, overloaded, etc. Gear Box Coupling Misaligned, cracked, etc. Gears Cracked tooth, eccentric, etc. Bearings Damaged, cracks, overloaded, etc. Score Dn = Down 2 2 2 Up Up Up 0 0 0 0 0 1 Up 0 0 0 0 1 1 Up Up 1 1 Up Up 0 2 2 Up Up 1 0 0 Dn 1 0 1 Up Up 1 0 0 Dn 2 0 1 Up 1 Up Up 2 2 2 0 Up Up Up 2 0 0 2 Dn Dn 0 0 1 0 Up 2 0 0 2 Dn Dn 1 0 1 0 Up 1 Up Up Flow Thermal Pressure Current Noise

2.0 2.1 2.2 2.3

3.0 3.1 3.2 3.3

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Past and Now

Manual Monitoring

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Maintenance

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Now and Future

Integrated Monitoring, Telemonitoring

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Now and Future

Telemonitoring & Reporting

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Teleconsulting
Now and The Near Future..

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Lectures Schedule

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Contact Details
Lecture Hours 2 x 1.5 hours Monday afternoon Waktu Perjumpaan every Monday morning11.00 - 12.30, also 1st Wednesday of every Month (afternoon). Room C24-336 E mail salman@citycampus.utm.my UTM KL telephone 03-2615 4924/ 4925
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