Energy Management Teleworkshops March Workshop Objectives

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1 Operations and Maintenance Management Workshop Ray Pugh Pacific Northwest National Laboratory OPERATIONS MAINTENANCE ENGINEERING O & M INTEGRATION TRAINING ADMINISTRATION Workshop Objectives Appreciate O&M and its importance Understand the key elements of an effective O&M program Describe tools and technologies that can be used in a predictive maintenance approach Describe some immediate O&M implementation ideas to generate energy and cost savings Operations and Maintenance Management Page 1

2 Maintenance Practices Maintenance The aggregate of direct and supporting actions that detect, preclude or mitigate the degradation of a system or component functionality, or restore that function to an acceptable level of performance following failure. See if its breaking, try and stop it from breaking, and if you can t, fix it after its broken. Maintenance Practices A Closer Look Reactive maintenance (corrective) Preventive maintenance (PM) Predictive maintenance (PDM) Reliability centered maintenance (RCM) Operations and Maintenance Management Page 2

3 Predictive Maintenance - PDM Measurements that detect the onset of a degradation mechanism thereby allowing casual stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability. Predictive Maintenance A Third Life-Cycle Alternative Measuring component stress levels before they can cause a problem. Measure component stresses (Vibration, Thermography, Oil Analysis) Measure the degradation mechanism (Allignment/Balance) Evaluate component performance (Power consumption) Operations and Maintenance Management Page 3

4 Predictive Maintenance Advantages Increased component operational life/availability Allows for preemptive corrective actions Decrease in equipment or process downtime Decrease in costs for parts and labor Improved worker and environmental safety Improved worker morale Energy Savings EPRI study showed a 8-12% savings over preventive maintenance programs Predictive Maintenance Other Benefits Eliminate most tear-down events Provides information to perform a root cause analysis Eliminate brush fire maintenance Operations and Maintenance Management Page 4

5 Predictive Maintenance Disadvantages Increased investment in diagnostic equipment Increased investment in training of staff Savings potentials not readily seen by management Predictive Maintenance Technologies Operations and Maintenance Management Page 5

6 Predictive Maintenance Savings Reduction in maintenance costs Elimination of breakdowns Reduction in downtime Increase in production Decreased spare parts inventory Predictive Maintenance Technologies (PDM) Thermographic analysis Vibration analysis Oil analysis Ultrasonic analysis Operations and Maintenance Management Page 6

7 Thermography - What is it? Detection of the Infrared Electromagnetic Radiation emitted by any object at a temperature greater than absolute O. Insert Applicable section of CSI Thermography Video Operations and Maintenance Management Page 7

8 Thermographic Analysis Foundation of electrical component predictive maintenance Can be used on mechanical and structural components Based on the principle that frictional and resistive changes result in changes in temperature Detection of infrared emissions Can be used to analyze patterns of heat loss or gain Non-intrusive Non-contact Thermography Uses - Electrical Components Electrical switches High voltage lines Motor control centers Electrical substations Transformers Operations and Maintenance Management Page 8

9 Thermography Uses - Mechanical Components Bearings Drive belts Steam lines and traps Piping insulation Valves Refractories Heat Exchangers Operations and Maintenance Management Page 9

10 Thermography Uses - Structural Components Roofs Building Insulation Storage Tanks Operations and Maintenance Management Page 10

11 Thermographic Analysis Infrared Camera or Gun Software program route description and tracking data collector field analysis What s Needed Report generator and data storage Operations and Maintenance Management Page 11

12 Thermographic Analysis Limitations Fairly expensive (50K and up) Limited mechanical troubleshooting Cannot read through glass or metal covers Data affected by reflective nature of surface Thermographic Analysis Advantages and Pay Backs Particularly good for large, distant, or hazardous applications Camera operations relatively easy Only a moderate amount of training needed Service companies readily available 12 month or less cost recovery Operations and Maintenance Management Page 12

13 IR Web Page Resources Academy of Infrared Thermography (www. Level I, II, and III certification information and training schedule. Online store (books, software, videos) Online resources (links, image gallery, message board) Communication (classifieds, news, industry related information Company profile and contact information Operations and Maintenance Management Page 13

14 Snell Infrared (www. Training and course information Industry Links IR Library News Letter Classifieds IR Application Information FLIR Systems (www. Product Information Image Gallery Application Overview with Images Used Camera Source Operations and Maintenance Management Page 14

15 Vibration Analysis Foundation of rotating machinery predictive maintenance Involves measuring the forces created from vibrations Non-intrusive Most widely known PDM technology Insert Applicable section of CSI Video Operations and Maintenance Management Page 15

16 Vibration Analysis Uses Pumps Motors Compressors Gear Boxes Diesel Engines Gasoline Engines Vibration Analysis Failures Detected Defective bearings Mechanical looseness Worn/Broken gears Shaft misalignments Out of balance conditions Operations and Maintenance Management Page 16

17 Vibration Analysis Vibration Sensor Accelerometer Velocity Probe What s Needed Vibration Analysis System Displacement Probe (permanent installations) Signal Acquisition Unit Signal recording device Signal analyzer Analysis software Computer Vibration Analysis Limitations Fairly expensive (20K - 50K) Fairly complex: Training is required Limited application (Rotating Machinery) Requires additional staff resources Operations and Maintenance Management Page 17

18 Vibration Analysis Advantages and Pay Backs Measurements easy to take Considerable cost reductions due to... Reduction in machine overhauls Extended operations Increased availability month cost recovery Vibration Analysis Web Page References Operations and Maintenance Management Page 18

19 reliabilityweb.com free stuff free on-line vibration training Training Material Industry Links Free Software FFT/CMMS/Inventory Control Technical Articles Maintenance Related Articles Operations and Maintenance Management Page 19

20 Products Industry Articles Links skfusa.com References and Links Articles Products Training Classes/schedule/prices Operations and Maintenance Management Page 20

21 Ultrasonic Analysis Ultrasounds are detected utilizing an ultrasound scanning device. Changes to a component s ultrasonic signature are easily recognized as the component begin to wear and deteriorate. Ultrasonic Analysis Uses Steam systems Compressed air/pneumatic systems Hydraulic systems Vacuum systems Bearings Operations and Maintenance Management Page 21

22 Ultrasonic Analysis What s Needed Ultrasound scanning device. Handheld device usually with two modes: Scanning Contact Ultrasounds are processed into the audible range for monitoring by the technician. Most effective when scanned close to the equipment being inspected. Increasing the sensitivity can allow scanning from a longer distance. Ultrasonic Analysis Advantages and Pay Backs Moderate cost.(1k to 10K) Simple to use Savings potential is great Air leak identification Steam trap leaks ($2000 per year can be lost from a single trap) Pay back in one year or less Operations and Maintenance Management Page 22

23 Ultrasonic Web Page Resources CSI at compsys.com Sound library Application papers Fundamentals of Ultrasonics Products Operations and Maintenance Management Page 23

24 uesystems.com Technology Overview Training Links **** Sound Demos Bearings Traps Air Leaks Arcing Corona Oil Analysis Oldest predictive maintenance technology 50% of bearing failures are lubricant related Can detect machine faults up to two months before vibration analysis Operations and Maintenance Management Page 24

25 Oil Analysis Monitors three conditions Lubricant condition Lubricant/Oil system condition Machine condition Oil Analysis Advantages and Pay Backs Simple Fairly Inexpensive Ease of trending Extremely effective 12 month or less cost recovery Operations and Maintenance Management Page 25

26 Oil Analysis Web Page Resources Insite Services at testoil.com Free sample kit Free oil analysis Test type overview On-line sample results Operations and Maintenance Management Page 26

27 compsys.com Oil analysis products Training Library Other Benefits of Using PDM Technologies Identification of improper maintenance practices Identification of improper operating practices Identification of poor equipment design Identification of excessive operating conditions Operations and Maintenance Management Page 27

28 DSOM Another Tool Play DSOM CD Operations and Maintenance Management Page 28

29 PDM Web Page References Maintenance Technology mt-online.com Maintenance related articles for past three years Product supplier information: CMMS Predictive Maintenance Technologies Operations and Maintenance Management Page 29

30 Training Material Industry Links Reference Material Free Software Technical Articles Links reliabilityweb.com Articles Links References On-line chat and bulletin board Free Stuff! Audits / Training/ Software/ Oil Analysis Maintenance surveys, etc. Operations and Maintenance Management Page 30

31 Summary Predictive maintenance Predictive maintenance technologies Thermography Vibration Analysis Oil Analysis Ultrasonic Analysis DSOM Workshop Outline (Post-Work) O&M Ideas Steam systems Chillers Cooling Towers HVAC systems Air Compressors Pumps Drives Operations and Maintenance Management Page 31

32 Contact Information Ray Pugh Pacific Northwest National Laboratory P.O. Box 999 MS K5-20 Richland, WA (509) fax (509) Greg Sullivan Pacific Northwest National Laboratory P.O. Box 999 MS K8-17 Richland, WA (509) fax (509) Operations and Maintenance Management Page 32