Maintenance Management ( EM 664 )

Predictive Maintenance (Predictive Testing and Inspection).

Predictive testing and inspections (PTI) is sometimes called
condition based monitoring (CBM) or predictive maintenance.
Predictive maintenance is : a management technique that uses
regular evaluation of the actual operating condition of plant
equipment, production systems, and plant management
functions to optimize total plant operation. (Higgins, 1995).
Predictive maintenance is the application of advance technology
to detect when failures will occur. (Levitt, 1997).

The aim of predictive maintenance or (CBM) is:

To predict when equipment failure might occur,
To prevent occurrence of the failure by performing
maintenance.
Monitoring for future failure allows maintenance to be
planned before the failure occurs.

Predictive maintenance or (CBM) advantages is:

Better planning of repairers is possible , out of production
time.
Inconvenient breakdowns and expensive consequential
damage are avoided.
The failure rate is reduced, thus improving plant availability
and reliability
The spares inventory is reduced and parts are ordered when
needed.
Unnecessary work is avoided and equipment life is extended.

Predictive maintenance or (CBM) disadvantages is:

High investment costs
Additional skills required

Conventional CM Techniques :
There are a host of techniques that can be used for direct
(requiring access to the machine) or indirect
measurement each having its own advantages and
disadvantages.

Maintenance Management ( EM 664 )

Visual Inspection:
This simple qualitative technique makes use of human senses such
as sight, hearing and touch.
Most useful for detection of cracks, sub-surface defects, corrosion,
excessive noise and/or vibration, loss of V-belt drive and leakage.

Portable instruments inspections:

Use of portable instruments tends to increase the consistency of

the results of different operators.
The problem is that different conclusions may
be drawn for the same machine by different
inspectors due to individual personal skills
.and experience

Maintenance Management ( EM 664 )

Condition monitoring techniques
Different predictive maintenance methods and techniques
such as:
Vibration analysis,
Temperature monitoring,
Acoustic analysis,
Performance monitoring (Process Parameters),
Dynamic cylinder pressure monitoring,
Instantaneous angular speed (IAS) analysis,
Infrared analysis,
Lubricant analysis (oil analysis),
Electrical condition monitoring.

Maintenance Management ( EM 664 )

Vibration and Acoustics : The most common problems that
produce vibration and acoustics are:
Unbalance of rotating parts
Misalignment of couplings and bearings
Bent shafts
Worn, eccentric, or damaged parts
Bad drive belts and drive chains
Bad bearings
Torque variations
Electromagnetic forces
Aerodynamic forces
Hydraulic forces
Looseness
Resonance.

Maintenance Management ( EM 664 )

Parameter Measurement, Transducers and
Instrumentations
Vibration Measurement using (Accelerometers)
Figures show online vibration data collection and analysis
typical of that used in industry to detect and diagnose faults in
machines.

Maintenance Management ( EM 664 )

Acoustic Measurements Using (Microphones) :

Airborne sound normally using high-bandwidth free-field microphone

operate in the frequency range up to 100kHz.

Typical sample of the online raw data

. from the microphone

High-bandwidth microphone

.Time domain analysis of airborne acoustic signal

Spectrum of airborne acoustic signal

Maintenance Management ( EM 664 )

Dynamic Cylinder Pressure Monitoring using (pressure

transducer )

Previously the use of dynamic cylinder pressure as a diagnostic aid has often been seen
as being the concern of the specialist consultant, a specialist diagnostic tool,

However, dynamic pressure as a condition-monitoring tool is extremely powerful,

Online pressure measurements and pressure data collectors used in industry today.

Measured internal cylinder pressure signal is plotted against the crank angle.

Pressure
signals

Pressure
signal

from crank
end

from head
end

Online cylinder pressure data readings

Maintenance Management ( EM 664 )

Instantaneous Angular Speed (IAS) Monitoring Using (Shaft
Encoder)
Small changes in shaft speed to be recorded.
The device produced a square pulse output for every angular degree
(thus the term 360 line encoder) for every complete revolution.

Encoder set up

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Maintenance Management ( EM 664 )

Temperature Measurement using (Thermocouples &
Infrared cameras)
2nd
1st
stage stage

Online thermocouple digital

output

ThermaCAM P60 Infrared Camera

(Courtesy of FLIR Systems Ltd, Kent,
UK) [66]

Thermal image of pulley-bearing

(Courtesy of FLIR Systems Ltd, Kent,
UK

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Maintenance Management ( EM 664 )

Measurement Practice and Data Management in the Lab.
Accelerometer

Thermocouple

Pressure sensor
Microphone

Encoder

Tank pressure
sensor
Amplifier

filter

Tank

Kemo filter

Amplifier

One pulse & 360

pulses

CED 1401plus

Schematic diagram of the compressor test system

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Maintenance Management ( EM 664 )

Measurement Practice and Data Management in the
Lab.
Signal processing: to handle the data or signals
collected for better understanding and interpretation
of the data using .
The main methods for data analysis are:
Time-domain analysis
Frequency- domain analysis (Spectrum Analysis)
Time-frequency analysis.

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Maintenance Management ( EM 664 )

Time-domain analysis
Discharge pressure (0 psi)

Amplitude

Discharge pressure (40 psi)

Discharge pressure (80 psi)

Discharge pressure (120 psi)

DVOH

DVCH

DVOH

DVCH

DVOH

DVOH

DVCH

DVCH

Crank Angle (Deg)

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Maintenance Management ( EM 664 )

Frequency-domain analysis

Time Frequency analysis

(c)
leakage 0.8%
DVCL

DVOL

SVCL

SVOL

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