Francis ConceminoAssociate Engineer (Reliability and Maintenance)Inland Empire Utilities Agency

What is Maintenance?

The performance of the task(s) necessary to preserve the function of an asset in its current environment.the function of an asset in its current environment.

Maintenance Progressiong

2000•Condition monitoring

2000

1990

•Design for reliability and maintainability•Hazard studies•Small, fast computers

il   d   ff   l i1980

1970

•Failure modes effects analysis•Expert systemsYear

1970

1960•Schedule overhauls•Systems for planning and controlling work•Big slow computers

3

19501940 •Fix it when it broke

Asset Condition Monitoring

The utilization of information obtained by  methodically collecting and analyzing vital data to determine the health, performance, and maintenance requirements for an asset This strategy reduces downtime and mitigatesan asset. This strategy reduces downtime and   mitigates the consequences of failure.

Machine Life Cycle‐ Bath Tub Curvera

teFa

ilure

r

Early life Useful life Wear out

F

Time in service

P‐F Curve*

*Courtesy of Vesta

Medical Analogy

7Source:

Condition Monitoring Techniques

Oil Analysis

Vibration Analysis

Motor Circuit Analysis

Thermography

Ultrasonic Monitoring

Performance Monitoring

Oil AnalysisOil AnalysisOil AnalysisOil Analysis

Function of Lubricants

Reduces wear by reducing friction between moving parts.

Cooling to reduce temperature

Power Transmission

Inhibits Corrosion

Total Lubrication Management Standards, Consolidation and Procurement

Lubricant Storage and Handling

Oil Sampling Techniques and Procedures

Contamination Control

Training, Skill Standards and Qualifications

Lubricant Analysis

Continuous Improvements

T t l L b i ti M tTotal Lubrication ManagementUndesirable Lube Oil Storage Condition Optimum Desired Stateg p

Oil Analysis

The process of collecting and testing new oil or used oilThe process of collecting and testing new oil or used oil samples, to determine the condition of the oil and the health of machines.

Oil Analysis Wear products andOil Analysis‐Wear products and Contaminants Analysis

Oil Analysis

Lubricant   Machine Lubricant  Condition

Machine Condition

Is oil up to spec? Is the oil contaminated? 

Wear particles present?

Does the particles signifies type of metals and wear 

patterns?

Oil A l i T tOil Analysis Tests Viscosity

Water Contamination

Neutralization Numbers

hSpectrography

Particle Counting and Analysis (Ferrography)

Lube Oil Analysis: Sample Report

Particle Count 

i i d l f lCase in point: Secondary Clarifier Drive FailureLube Oil Particle Analysis Report

High concentration of Iron indicates wear

Case in point: Secondary Clarifier Drive Failure

Consequences of Failure:• Equipment downtime

• Loss of Production

• Overtime labor hoursOvertime labor hours 

• Drive Unit Replacement

R l t L d ti• Replacement Lead time

Vib ti A l iVib ti A l iVibration AnalysisVibration Analysis

Vibration Analysis Vibration Causes andVibration Analysis‐Vibration Causes and TransmissionMachines and components vibrate in response to one or more pulsating forces, called excitation. 

l b lExample: mass unbalance.

The magnitude of vibration is dependent not only on th f b t l ti f th t b ththe force but also properties of the system, both may depend on speed.

Vibration can be used to identify defects that arise Vibration can be used to identify defects that arise from defective design, misalignments, and unbalance.

Vibration Analyzer 

Vibration Analyzer  Accelerometers

Vibration Analysis

How Bad?

Wh t C t?What Component?

26 - Aux. WasteHeat Loop Pump #326 Aux. WasteHeat Loop Pump #326J-140 -P1H Pump Inboard Horizontal

Trend Display Overall Value

0.20.30.40.5

K In

/Sec

ALERT FAULT

R t S t0.05

0 300 600 900 1200 1500

0 0.1

Days: Nov-18-01 To Oct-11-05

P

WARNING

Route Spectrum Dec-05-01 18:55:48 OVERALL= .0611 V-DG PK = .0609 LOAD = 100.0 RPM = 1800. (30.00 Hz)

00.010.020.030.040.05

PK In

/Sec

Route Waveform Dec-05-01 18:55:48 0.4

0.8

-s ALERT FAULT

0 10 20 30 40 50 60 70 80 90

0

Frequency in Orders

RMS = .1056 PK(+/-) = .2971/.3198 CRESTF= 3.03

0 40 80 120 160

-0.8

-0.4

0

Acc

in G

- ALERT

ALERT FAULT

Date: Dec-05-010 40 80 120 160Time in mSecs

Time: Ampl:

18:55:47 .06113

22 P2 SECONDARY TREATMENTPOINT: G6H - MORE THAN ONE EQUIPMENT

0.6

0.8

1.0Max Amp .91

Sec

0

0.2

0.4

0.6

K V

eloc

ity in

In/S 0

02-Oct-02G3 -G6H

12-Sep-02H3 -G6H

PK

09-Jul-02F3 -G6H

0 10 20 30 40 50 60 70 80 9009-Jul-02E3 -G6H

RPM= 55.43 11:36:28 02-Oct-02 Point= G6H G3

Ordr: Freq:

64.193557 8

Frequency in OrdersFreq: Sp 3:

3557.8 .701

Motor Circuit Motor Circuit AnalysisAnalysisAnalysisAnalysis

Motor Circuit Analysis

Motor Circuit Analysis

A computerized evaluation that combines several tests to determine the overall condition of an Electric Motor.

Motor Circuit AnalysisFault Zones

Power QualityQ y

Insulation 

Power Circuit

Stator

Rotor

Air Gap

Motor Circuit AnalysisS f El t i M t F il

Bearing, 41%

Summary of Electric Motor Failures

Stator, 37% 41%

Rotor 10%

Other, 12%

Rotor, 10%Source: Combined EPRI and GE Study

Infrared Infrared ThermographyThermographyThermographyThermography

Infrared Thermography Based on the principle that all objects above absolute 

zero (‐273 o C) emit infrared radiationzero (‐273  C) emit infrared radiation

Images are captured on electronic cameras that make the 

radiation optically visible in an image of different colors

Can see temperature differences as small as 0 1 oF or lessCan see temperature differences as small as 0.1  F or less

Source- RCM II by John Moubray

RVFD#3 SLATER PS E90105 Spot 2

168.4*>233.7°F

R

199.1200.0

100.0

*<27.9°F

Infrared Thermography ElectricalInfrared Thermography‐ Electrical Applications

Relays and circuit breaker 

B d f tiBus and fuse connections

Disconnects

Thermal overloads

Generator and motor windings

Motor control centers

Infrared Thermography MechanicalInfrared Thermography‐Mechanical Applications

Boilers and refractories

H t E hHeat Exchangers

Bearings

Couplings

Steam traps

Wall and roof insulation

l ll lUltrasonic AnalysisUltrasonic Analysis

Ult i O tiUltrasonic‐Operation Ultrasound technology is concerned with high Ultrasound technology is concerned with high 

frequency sound waves above human perception (20 Hz to 20kHz) ranging between 20kHz to 100kHz.

High frequency sound waves are extremely short and tend to be fairly directional.

Ultrasound equipment filters out surrounding noise and other unwanted frequencies.

Readings displayed visually or as an audible signal on headphones.

Source- RCM II by John Moubray

Ultrasonics Instruments Modulate ultrasonic frequencies to the  range of human hearing.

Output of the device is provided by earphones small speaker Output of the device is provided by earphones, small speaker or a screen.

Ultrasonic Applications Leak detections

Valve seat integrity Valve seat integrity

Pump Cavitation

Steam Traps Blow‐by Steam Traps Blow‐by

Detecting High Frequency Defects

Performance Performance AnalysisAnalysisAnalysisAnalysis

Performance Analysis

The analysis of a machine to determine its performance by using pressure, temperature, flow or other readily 

available process parameter(s).

Performance Analysis  The tools needed are in most cases already available, hence capital cost is low.

Repeatability of measurement is essential rather than absolute accuracyabsolute accuracy

It may be possible to find one parameter that indicates the overall condition of the machine or a distinct part ofthe overall condition of the machine or a distinct part of it. 

Performance Analysis

Pumps

Heat exchangers

Steam Turbines

AnalyzersAnalyzers

Compressors

C i P i T i Fil T bidi A l ICase in Point: Tertiary Filter Turbidity Analyzer Issue

Implementation CostImplementation CostTechnique Hardware Software Training/

Certification

Vibration $15,0000‐

$20,000

$2,000‐

$20,000

$10,000

Infrared $10,000‐

$50,000

$5,000‐

$10,000

$6,000

Oil Analysis $10,000‐

$80,000

$5,000‐

$10,000

$10,000

Ultrasonics $3,000‐

$8,000

$2,000‐

$5,000

$2,000

MCA $4 000 $5 000 $8 000MCA $4,000‐

$70,000

$5,000‐

$10,000

$8,000

f f dBenefits of Asset Condition Monitoring

Warning of most problems in time to minimize unexpected failures.

Increase awareness of equipment condition.

Allows for the safe elimination of a significant amount of o s o t e sa e e at o o a s g ca t a ou t opreventive maintenance.

Reduces requirements for spare parts.q p p

How to start a Condition MonitoringHow to start a Condition Monitoring ProgramDon’t apply technology to all assets.

Be selective! Attack the critical assets first.

Carefully select suitable technology and monitoring frequency for each asset.

Budget appropriately for program and include ongoing software, hardware, and training cost.g

How to start a Condition MonitoringHow to start a Condition Monitoring ProgramGet the necessary training – when in doubt seek advice from expertsexperts.

Document successes and failures (i.e. KPI’s).

Provide management with frequent updates.

Train others when confidence level increase.

How to start a Condition MonitoringHow to start a Condition Monitoring Program

Keep the program transparent‐ share analysis results with all stakeholders. 

Be open‐minded and listen to your customers.

Pride and arrogance will kill the program.

Questions?Q