Francis Concemino Associate Engineer (Reliability and Maintenance) Inland Empire Utilities Agency

Transcription

1 Francis Concemino Associate Engineer (Reliability and Maintenance) Inland Empire Utilities Agency

2 What is Maintenance? The performance of the task(s) necessary to preserve the function of an asset in its current environment.

3 Maintenance Progression Year Condition monitoring Design for reliability and maintainability Hazard studies Small, fast computers Failure modes effects analysis Expert systems Schedule overhauls Systems for planning and controlling work Big slow computers Fix it when it broke 3

4 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 mitigates the consequences of failure.

5 Machine Life Cycle Bath Tub Curve Failure rate Early life Useful life Wear out Time in service

6 P F Curve* *Courtesy of Vesta

7 Medical Analogy Source: 7

8 Condition Monitoring Techniques Oil Analysis Vibration Analysis Motor Circuit Analysis Thermography Ultrasonic Monitoring Performance Monitoring

9 Oil Analysis

10 Function of Lubricants Reduces wear by reducing friction between moving parts. Cooling to reduce temperature Power Transmission Inhibits Corrosion

11 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

12 TtlL Total Lubrication Management Undesirable Lube Oil Storage Condition Optimum Desired State

13 Oil Analysis The process of collecting and testing new oil orused oil The process of collecting and testing new oil or used oil samples, to determine the condition of the oil and the health of machines.

14 Oil Analysis Wear products and Contaminants Analysis Oil Analysis 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?

15 Oil Analysis Tests Viscosity Water Contamination Neutralization Numbers Spectrographyh Particle Counting and Analysis (Ferrography)

16 Lube Oil Analysis: Sample Report Particle Count

17 Case in point: Secondary Clarifier Drive Failure Lube Oil Particle Analysis Report High concentration of Iron indicates wear

18 Case in point: Secondary Clarifier Drive Failure Consequences of Failure: Equipment downtime Loss of Production Overtime labor hours Drive Unit Replacement Replacement tlead dtime

19 Vibration Analysis

20 Vibration Analysis Vibration Causes and Transmission Machines and components vibrate in response to one or more pulsating forces, called excitation. Example: mass unbalance. bl The magnitude of vibration is dependent not only on the force but also properties of the system, both may depend on speed. Vibration can be used to identify defects that arise from defective design, misalignments, and unbalance.

21 Vibration Analyzer Vibration Analyzer Accelerometers

22 Vibration Analysis How Bad? What Component?

23 PK In/Sec P K In/Sec Acc in G- -s Aux. WasteHeat Loop Pump #3 26J-140 -P1H Pump Inboard Horizontal FAULT ALERT WARNING Days: Nov To Oct Trend Display Overall Value Route Spectrum Dec :55:48 OVERALL=.0611 V-DG PK =.0609 LOAD = RPM = (30.00 Hz) Frequency in Orders 0.8 FAULT Route Waveform 0.4 Dec :55:48 ALERT RMS = PK(+/-) =.2971/.3198 CRESTF= ALERT -0.8 FAULT Time in msecs Date: Dec Time: 18:55:47 Ampl:.06113

24 Max Amp P2 SECONDARY TREATMENT POINT: G6H - MORE THAN ONE EQUIPMENT PK Velocity in In/S Sec 0 H3 -G6H 12-Sep-02 G3 -G6H 02-Oct Frequency in Orders E3 -G6H 09-Jul-02 F3 -G6H 09-Jul-02 G3 Point= G6H 02-Oct-02 11:36:28 RPM= Ordr: Freq: Sp 3:.701

25 Motor Circuit Analysis

26 Motor Circuit Analysis

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

28 Motor Circuit Analysis Power Quality Insulation Power Circuit Stator Rotor Air Gap Fault Zones

29 Motor Circuit Analysis Summary of Electric Motor Failures Fil Bearing, Stator, 37% 41% Other, 12% Source: Combined EPRI and GE Study Rotor, 10%

30 Infrared Thermography

31 Infrared Thermography Based on the principle that all objects above absolute zero ( 273 o 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 o F or less Source- RCM II by John Moubray

32 *>233.7 F R VFD#3 SLATER PS E90105 Spot *<27.9 F

33 Infrared Thermography Electrical Applications Relays and circuit breaker Bus and fuse connections Disconnects Thermal overloads Generator and motor windings Motor control centers

34 Infrared Thermography Mechanical Applications Boilers and refractories Heat texchangers Bearings Couplings Steam traps Wall and roof insulation

35 Ultrasonic Analysis

36 Ultrasonic Operation ti 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

37 Ultrasonics Instruments Modulate ultrasonic frequencies to the range of human hearing. Output of the device is provided by earphones, smallspeaker speaker or a screen.

38 Ultrasonic Applications Leak detections Valve seat integrity Pump Cavitation SteamTraps Blow by Detecting High Frequency Defects

39 Performance Analysis

40 Performance Analysis The analysis of a machine to determine its performance by using pressure, temperature, flow or other readily available process parameter(s).

41 Performance Analysis The tools needed are in most cases already available, hence capital cost is low. Repeatability of measurement is essential rather than absolute accuracy It may be possible to find one parameter that indicates theoverall condition of themachineor a distinct part of it.

42 Performance Analysis Pumps Heat exchangers Steam Turbines Analyzers Compressors

43 Case in Point: Tertiary Filter Turbidity Analyzer Issue

44 Implementation Cost Technique Hardware Software Training/ Certification Vibration $15,0000 $20,000 Infrared $10,000 $50,000 Oil Analysis $10,000 $80,000 Ultrasonics $3,000 $8,000 $2,000 $20,000 $5,000 $10,000 $5,000 $10,000 $2,000 $5,000 $10,000 $6,000 $10,000 $2,000 MCA $4,000 $5,000 $8,000 $70,000 $10,000

45 Benefits of Asset Condition Monitoring Warning of most problems in time to minimize unexpected failures. Increase awareness of equipment condition. Allows for the esafe elimination ato of a significant sg tamount tof preventive maintenance. Reduces requirements for spare parts.

46 How to start a Condition Monitoring Program Don 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.

47 How to start a Condition Monitoring Program Get the necessary training when in doubt seek advice from experts. Document successes and failures (i.e. KPI s). Provide management with frequent updates. Train others when confidence level increase.

48 How 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.

49 Questions?