Predictive

Predictive Maintenance
(With in-depth explanation of Thermography and Tribology)
Speaker : M.Aqeel Asharf (NUST-SMME)

Maintenance engineering

Mechanical Engineering

Objective:
Know what maintenance is and why it is important

Know different maintenance management systems

Know why predictive maintenance has an edge over other maintenance management systems

Know different predictive maintenance techniques

Know in-depth details of Thermography and Tribology A total-Plant predictive maintenance program Know what is World-Class Maintenance
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CONTENTS
1.1 Maintenance and its importance 1.2 Maintenance Management Systems 1.2.1 Breakdown Maintenance 1.2.2 Preventive Maintenance 1.2.3 Predictive Maintenance 1.2.4 Proactive Maintenance 1.3 Predictive Maintenance Techniques 1.4 Thermography 1.5 Tribology 1.6 A Total-Plant Predictive Maintenance Program 1.7 What is World Class Maintenance?

1.1 Why Maintenance !!!

Maintenance Engineering is applying of engineering concepts for the optimization of equipment, procedures, and departmental budgets to achieve better maintainability, reliability, and availability of equipment

Facts and Figures .

Each year over $300 billion are spent on plant maintenance and operations by U.S. industry. The typical size of a plant maintenance group in a manufacturing organization varied from 5 to 10% of the total operating force.
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1.2 Maintenance Management systems

Breakdown Maintenance
The basic philosophy behind breakdown maintenance is to allow the machinery to run to failure and only repair or replace damaged components just before or when the equipment comes to a complete stop.

Preventive Maintenance
The philosophy behind preventive maintenance is to schedule maintenance activities at predetermined time intervals, based on calendar days or runtime hours of machines.

1.2 Maintenance Management systems cont'd Predictive Maintenance

This philosophy consists of scheduling maintenance activities only when a functional failure is detected.

Proactive Maintenance
This philosophy lays primary emphasis on tracing all failures to their root cause. Each failure is analyzed and proactive measures are taken to ensure that they are not repeated. It utilizes all of the predictive/preventive maintenance techniques discussed above in conjunction with root cause failure analysis (RCFA).
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1.3 Predictive Maintenance Techniques

Vibration monitoring

Thermography

Tribology

Ultrasonic
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Others : process parameters, visual inspection and nondestructive testing techniques (NDTs)

1.4 Thermography Overview: A predictive maintenance technique that can be used to monitor the condition of plant machinery, structures, and systems. It uses instrumentation designed to monitor the emission of infrared energy (i.e., temperature) to determine operating condition. By detecting thermal anomalies (i.e., areas that are hotter or colder than they should be), an experienced surveyor can locate and define incipient problems within the plant.
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1.4.1 Infrared Basics:

It is based on the fact that all objects with a temperature above absolute zero emit energy or radiation. The intensity of infrared radiation from an object is a function of its surface temperature. Three sources of thermal energy can be detected from any object: energy emitted from the object itself, energy reflected from the object, and energy transmitted by the object . Only the emitted energy is important in a predictive maintenance program. A perfect emitting surface, is called a blackbody and has an emissivity equal to 1.0. These surfaces do not reflect. Instead, they absorb all external energy and re-emit it as infrared energy. Surfaces that reflect infrared energy are called gray bodies
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1.4.3 INFRARED THERMOGRAPHY SAFETY

Equipment included in an infrared thermography inspection is almost always energized. Therefore, a lot of attention must be given to safety. The following are basic rules for safety while performing an infrared inspection: Plant safety rules must be followed at all times. Notify area personnel before entering the area for scanning. A qualified electrician from the area should be assigned to open and close all panels. Where safe and possible, all equipment to be scanned will be online and under normal load with a clear line of sight to the item.
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1.5 Tribology
It refers to design and operating dynamics of the bearing-lubrication-rotor support structure of machinery. Several tribology techniques can be used for predictive maintenance: Oil Analysis tests, ferrography, and wear particle analysis.
Oil Analysis Tests

Typically, the following tests are conducted on lube oil samples: 01: Viscosity 02: Contamination 03: Fuel Dilution 04:Fuel Soot 05: Oxidation 06:Nitration 06: Total Acid Number (TAN)
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Wear Particle Analysis

Wear particle analysis provides direct information about the wearing condition of the machine-train.

Types of Wear
Five basic types of wear can be identified according to the classification of particles: 01: Rubbing wear 02: Cutting wear, 03: Rolling fatigue wear 04: Combined rolling and sliding wear 05: Severe sliding wear.

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Ferrography
First, ferrography separates particulate contamination by using a magnetic field. Because a magnetic field is used to separate contaminants, this technique is primarily limited to ferrous or magnetic particles.

The second is that particulate contamination larger than 10 microns can be separated and analyzed. Normal ferrographic analysis will capture particles up to 100 microns in size and provides a better representation of the total oil contamination.

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1.6 A Total-Plant Predictive Maintenance Program It would be convenient if a single system existed that would provide all of the monitoring and analysis techniques required to routinely monitor every critical piece of equipment. Unfortunately, this is not the case !!!!!!!! How do you decide which techniques will provide a cost-effective method of controlling the maintenance activities in your plant? The answer lies in determining the type of plant equipment that needs to be monitored. Example: Plants with a large population of electrical equipment should use thermographic or infrared scanning as their primary tool. Plants with a large population of mechanical machines and systems should rely on vibration techniques.
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( a) Predictive Maintenance Techniques Most plants have large populations of mechanical systems, vibration techniques will be the primary method required to implement a total-plant program. Secondary methods must be used to gain this additional information. At a minimum, a comprehensive predictive maintenance program should include: Visual inspection Ultrasonic Thermography Tribology
( b) Predictive is not enough !!!

At a minimum, the overall maintenance management methods must include effective planning and scheduling, preventive maintenance tasks, motivations, and record keeping.

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1.7 World Class Maintenance OR: Total Productive Maintenance (TPM) Moving from a breakdown maintenance mindset toward a concept of proactive maintenance organized around a well-trained staff, within a carefully defined plan, and with meaningful participation of employees.

Developing partnership among the manufacturing or production people, maintenance, engineering, and technical services to improve what is called overall equipment effectiveness (OEE). Equipment breakdowns Setup and adjustment slowdowns Idling and short-term stoppages Reduced capacity Quality-related losses Startup/restart losses
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Calculating OEE ( overall equipment effectiveness)

Availability = Operating time/planned production Performance = Ideal Cycle Time / Total Pieces or (total pieces / Operating time)/Ideal Run time

Quality = (Total Pieces-Defective pieces) / Total Pieces

OEE = Availability X Performance X Quality

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Involving Operators in Daily Maintenance Improving Equipment Effectiveness

Designing and Managing Equipment for Maintenance Prevention

Fundamental of
World-Class performance Improving Maintenance Efficiency and Effectiveness Educating and Training

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Thanks for your patience listening !!

Acknowledgement:
I here acknowledge the support of my teachers and friends during preparation of this presentation Reference book: Introduction to Predictive Maintenance (2nd Edition) Author: R. Keith Mobley Publisher: Plant Engineering

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