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Condition Monitoring
Failed
Condition Parameter
Ideal
Startup Checks
Time
Diagnose
Plan
Schedule
Information produced from Australian South East IMRt Common Interest Work Group (CIWG) on Condition Monitoring (CM). The main issues dealt with include: Condition Monitoring systems used by members Organisational structures & management systems for CM Condition Monitoring techniques Skills Development, training and accreditation for CM Integration with Computerised Maint. Management Systems Condition Monitoring Reporting
Repair
Trend
Trend
Contents
Meeting Number 1. 15 July CUB Topic 1. Introductions, 2. Overview comparison of practices at the various sites, 3. Planning the forthcoming meetings. 1. Structures and management systems for condition monitoring 2. Plant technology and plant life cycle. 3. A focus on the following types of CM techniques; a. Thermography, b. Use of SCADA and DCS c. Energy Power usage, Air flow, load changes 1. Developing the people. Developing the skills, providing the training and defining and maintaining the standards. 2. A focus on engaging people in using the five senses to deliver condition monitoring. 1. Integrating the Computerised Maintenance Management System and the Condition Monitoring System. 2. A focus on NDT, on Ultrasonics and on Motor Circuit Analysis. 1. 2. 3. 4. Comparison of reporting systems. Reports from the contractors In-house reporting Bringing it all together.
Number 5.
CUB
Report by exception
1 monthly
CSI
MSC
Yallourn
Maximo
Report on line for routine. Report face to face for exceptions. Report by exception. One page maximum. Face to face for routine. Use RBMware and WAN
CSI
Murray Goulburn
CSI. Four Mostly in2120 house but analysers Mostly in house. refer to Use MSC for RBMware and assistance. WAN MSC CSI and Mostly inhouse. InBently Nevada for on house contractor line. CSI and Bently Mostly inNevada for on house. line. CSI Mostly inhouse.
Kraft
Avantis
Dependent on user.
Mostly in house.
PBS4
Mostly in house.
PPG
Maximo 5.2
6 on critical plant
Qenos
SAP
In house sampling
Mostly inCSI and house. Also On line = Bently MSC and 10, Portable Nevada for on Burdett =5 line. Engineering
Onesteel
SAP
Generally in-house
Mostly inhouse.
Shell
SAP
Pacer spreadsheet
10
CSI
Mostly inhouse.
Company
Loy Yang
Passport
Report on exceptions
Mostly inhouse.
Nufarm
Mex
By exception verbally
Bladett engineering
Australia Post
SAP
Not applicable
N/A
N/A
N/A
N/A
N/A
Orica
10
Monthly
SKF Microlog
10
ADI
BPIX Maximo
In-house
Pruftechnique
Bluescope Steel
MIMS
Report by exception Exception reporting for monthly management report and ability to view condition on all machines currently being put on intranet Monthly & by exception By exception Monthly
Typically monthly
In house
Edison Mission
MPAC
In house
3 monthly
WMC
SAP
Mostly CSI
Kodak Pilkington
7 2
Entek
Suggestions from the group for an output from the CIWG on Structures and Management Systems are listed below. Listing of elements to consider and options when deciding on structures and management systems for the support of CM. Information useful for Benchmarking of a CM practices within companies. An attempt was made in the meeting to setup a matrix to define good practice for CM structures and management systems but the group struggled with the complexities in this task because of the large range of variables involves. An updated version of the Condition Monitoring Practices Self Assessment initially reviewed by the WA IMRt in 2003 is included at the end of this report. Plant Technology & Plant Life Cycles Summary The concept of equipment and plant life cycles may not always be applicable as some equipment can be maintained indefinitely without replacement. There are plants and equipment that are promoted as maintenance free but this does not tend to work in practice. In most situations technology improvement drives major equipment replacement. Where equipment is subject of wear, usually from aggressive process mediums or fatigue, life cycle replacement is applicable LCC is a method used to justify these replacements (WMC). An analysis of different monitoring approaches was carried out for plant other than typical rotating equipment. This information is presented below
Hydraulic equipment
Thermography Summary Common in the group was the use of thermography for monitoring electrical equipment and was considered normal practice and did not require discussions. Other applications for thermography are many and varied and the technology is often used as a diagnostic and problem solving tool an much as a monitoring tool. Use of the technology is only limited by the imagination. Current high quality cameras cost between $25K to $50K with lower cost systems down to $3K. Simple non-contact temperature guns are widely used as a monitoring tool. Reports benefit from the including of digital photos with thermal images. SCADA & DCS Systems Summary Process computers are generally underutilised by maintenance as a monitoring tool. Applications such as monitoring motor amps, flow, pressure, temperatures and auto instrument calibration were mentioned. Recording equipment run hours was also mentioned. There are a number of advantages for monitoring batch processes where routine monitoring would be difficult to coordinate. Performance Monitoring Summary Two portable instrument liquid flow measurement technologies are very useful. o Transit time flow measurement for clean fluids o Doppler effect flow measurement for less clean fluids.
Getting the right culture of rigorous CM, inspections, PMs and planning is difficult as trades personnel tend to think of themselves as repairers which tends to support a breakdown culture. When the main additional financial reward is Overtime, this also support a breakdown culture. Annualised salaries if well managed can tend to support good CM and planning cultures. Where there is other effective systems of rewards that support good maintenance performance, this also support good CM and planning cultures. The greater the percentage of time a person is doing condition monitoring and inspection work the greater the skill level that can be achieved. Personnel who are only very occasionally required to do CM data collection work will probably not be very motivated or successful.
Training
Yallourn Energy has developed there own level 1 vibration training material Training involves classroom presentations and computer based modules Vibration training software system used is i Learn within the training process and there was suggested to be a good system. Available as a single user system or as a network system This vibration training has been set up as a special local TAFE accredited training module for Yallourn. The person who does the training is a local Yallourn person. Existing generic CM TAFE modules (18-10 & 18-16) do not fully cater for the training requirement. The technical side of CM is generally well catered for by the current condition monitoring equipment and service suppliers such as Rockwell, CSI and ALS. Noria oil analysis courses are recognised as excellent training. Some good examples of the effectiveness of peer to peer training were given. Where CM personnel are based in local teams there is increased difficulty in building and maintaining expertise. Having locally based personnel come to a central location, where technical support is available, to download and analyse data has advantages in ongoing training and support. Networked CM software has advantages for support of less experienced personnel especially if support personnel are some distance away from the user. It is important to have someone who is a CM coordinating role in a larger organisation to ensure standardisation of approach, manage skill development and to audit compliance to the current condition monitoring strategy. Process of regular monthly meetings of CM personnel is a good opportunity to present case studies and technical information as a part of an ongoing training process for CM personnel who are locally based. Systems where tradesmen are paid for completing training have not been as successful as where people are paid for using skills.
Accreditation
One issue with CM accreditation is if organisations can see the benefits they will get out of paying extra to get there personnel Certificated. This needs to be promoted. The individual benefits from completing accredited training by having recognised skills that are transportable. A major advantage of a well accepted training accreditation system is that a company can advertise for personnel of a certain level and have good confidence that the person they hire will have the required competencies. ISO Standards have a standard on Condition monitoring an diagnostics of machine Requirements for training and certification of personnel. There are several parts to the standard, most of which are still in draft form. They are: o 1 - Requirements for certifying bodies and the certification process o 2 Vibration condition monitoring and diagnostics o 3 Requirements for training bodies o 4 Lubrication management and analysis o 5 Thermography o 6 Diagnostics and prognostics o 7 Condition monitoring specialists Vibration CM and lubrication management will have 4 levels of certification with level 1 basic data collection and oil sampling respectively. Thermography will have 3 levels of certification. It is currently proposed that the accreditation body for training in Australia will be the AINDT. AINDT is already managing the thermography certification for CM personnel which should be similar under the ISO standard. The first new system of accreditation for CM training in Australia will likely be for Lubrication management and analysis. Accreditation for vibration condition monitoring training may be a considerable time before it is in operation
Operator and Maintenance Front Line Personnel Involvement, Communication and Processes
CUB has a system of coloured tags that operators attach to their equipment to identify faults and the colours define the priority that the maintenance personnel should apply to the repair and follow-up actions. Some organisations have white board systems to record issues and their priorities. Capturing and actioning the items that piss operators off with the equipment and getting things done is very important in building relationships and teamwork. This is especially so where there is large backlogs of uncompleted maintenance and improvement work. The process of carrying out lubrication on equipment and the motivation and ownership of the personnel involved are very important. Application of 5 senses inspection and simple CM during lubrication is strongly supported.
CM Techniques
Timely systems that monitor water in oil with direct feedback to cleaning crews on the job has been successful in reducing water entry into oil compartments.
List of IMRt member participants involved with CIWG. (Will be completed after
next meeting)
8 Records are formalised and trend analysis Is routinely used to monitor equipment condition. 9 A system of inspections have been developed for; 1. Noise level 2. Leaks or emissions 3. Hot spots 4. Physical condition (paint- corrosion, loose parts, missing nuts or bolts, deteriorated insulation- etc) 10 11 12 13 A system is in place to ensure that inspection occurs. Equipment specifications are maintained and are easily retrieved when needed. There is always a follow up on observations made by personnel carrying out inspections. Service providers carry out work to an agreed and appropriate standard and are audited.
14 A methodical process, based on recognized principles, has been used to customize asset management strategies, alarm limits and frequencies. The process includes review of the cost effectiveness of condition monitoring. 15 Steps are taken to ensure readings are taken in a repeatable way. For example the accelerometer is placed in exactly the same way and the pump is operated under the same process conditions. 16 The system provides appropriate feedback. For example (1) Inspectors are able to see what actions are taken on their observations, (2) Appropriate "post mortems" are carried out on failed parts. 17 Formal roles, responsibilities and range are defined for condition monitoring and follow up action and personnel have appropriate skills. 18 Failure Mode Effects and Criticality Analysis (FMECA) or Root Cause Analysis (RCA) is used to assess critical failure modes and appropriate precautions are in place. Planning systems, history archives and the use of arc appropriately integrated. 19 Trades people and operators believe that leadership promotes and provides appropriate ownership and management of condition monitoring. 20 A system is in place for the calibration of instrumentation, both process instrumentation and instrumentation used in condition monitoring.
Deleted: 20
Introduction:
Main Points:
how the different maintenance approaches can be used at Yallourn Energy. Conclusion: This unit covers the underpinning knowledge required to recognize all types maintenance and how condition monitoring is used to support maintenance. PC projector, White board, Work Book. Interactive (common maint practice introduction). - (cond mon-why do we do it)
Resources:
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Main Points:
- Smell Condition monitoring using portable test equipment. Training Methods: Assessment: Discussion, work book, overheads, demonstration, I Learn Participants will: By way of multiple choice question exam demonstrate knowledge of the machinery failure Bath Tub curve. Define the human senses that can be used for CM and the electronic technologies that can be used to enhance these senses. This unit covers the underpinning knowledge needed to identify the modes of machinery failure and methods used for condition monitoring. PC projector, White board, Work Book. I Learn (cond mon - introduction) - (cond mon technologies vibration analysis)
Conclusion:
Resources:
Introduction:
Explain vibration in simplest form and how it is able to provide in comparison to other technologies the most information regarding a machines condition. Defining vibration Relationships of different ways of measuring vibration Methods for measuring vibration (frequency/amplitude Vibration unit relationships Vibration waveform and spectrum Basic machinery fault identification Alarm trending Discussion, notes, overheads, demonstration, I Learn Interactive. Participants will: By multiple choice question exam give evidence of understanding, in the definition of vibration and of 3 main units it can be measured, the difference between waveform/spectrum and the knowledge of basic machine faults and frequencies at which they occur. This unit covers the underpinning knowledge that will enable participants to take vibration measurements on rotating plant to Standard Operating Procedures and make Exception Analysis Reports from collected data. PC projector, White board, Work Book. I Learn (Vibration Fundamentals complete list)
Main Points:
Conclusion:
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Danny Shine Maintenance Fitters Learning Center This session will provide students with the knowledge and skills to be able to demonstrate the correct use CSI 2120 vibration data collector to take machinery vibration data. It will also cover the use of CSI RBMWare software PC program used to record and analyse vibration data. (Performance Criteria 18.10A.1.3) Broadly explain the difference between the CSI 2120 data collector (Hardware) and RBMWare PC (Software) in the CM program and the role each plays as part of the CM program. Operation of CSI 2120 data collector:Taking route based data Reviewing measurement alarms Basic spectrum analysis Using Note Codes Taking exception data Measurement errors Reporting measurement point alarms Operation of CSI RBMWare:Demonstration of RBMWare program
Introduction:
Main Points:
Demonstration, discussion, notes, overheads. Participants will: Confirm via workshop demonstration and limited field examples that students can print previous condition reports from 80/20, Upload vibration measurement point route into CSI 2120 data collector, operate function keys of CSI 2120 data collector to take vibration readings, make field observations of plant condition & assess alarms and record Note Codes, down load measurement point readings into PC, print an Exception Analysis report and report findings.
Conclusion:
This unit covers the underpinning knowledge required to operate the CSI 2120 data collector and take vibration measurements. CSI 2120 data collector, CSI RBMWare, Work Book.
Resources:
Introduction:
Main Points:
Discussion, notes, overheads, demonstration. Participants will: Confirm via On Job demonstration that students can operate function keys of CSI 2120 data collector to take vibration readings, assess alarms, record Note Codes and take Exception Based vibration data. Upload and download vibration data from CSI RBMWare and produce an Exception Report to highlight faults for further analysis and follow-up by key personnel. This unit covers the underpinning knowledge required to achieve successful soft foot correction and identify Rotalign faults. CSI 2120 data collector, Networked PC with CSI RBMWare, Operational machinery, System Engineer.
Conclusion:
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Conclusion:
This unit covers the underpinning knowledge required to recognize all types of mis-alignment and the tools used to measure and correct alignment. Pruftechnik Rotalign Set, Overhead projector, White board, Handouts, Training rig, Dial indicator Bar Sag rig, Tool kit.
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Conclusion:
This unit covers the underpinning knowledge needed to identify Lasers used in alignment and their safe use. Pruftechnik Rotalign Set, Overhead projector, White board, Handouts, Training manual.
Resources:
Introduction:`
Main Points:
Provide written evidence of knowledge to correct tooling, cleaning and permit procedures required for machinery alignment. Provide a practical demonstration of shaft run-out, bearing clearance and soft-foot measurement and correction. Conclusion: This unit covers the underpinning knowledge that will enable Fitters to select the tooling required for alignment tasks and identifies checks and corrections before alignment. Pruftechnik Rotalign Set, Overhead projector, Handouts, Training rig, Tool kit
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Main Points:
Saving measurements to history. Saving alignment files. Training Methods: Assessment: Discussion, notes, overheads, demonstration. Participants will: Confirm via demonstration that students can select the appropriate leveling and aligning procedure. That measurements can be taken effectively and consistently and can be interpreted so the machine can moved to tolerance. Demonstrate file saving and recording on PC system. This unit covers the underpinning knowledge required to achieve accurate alignment with the use of Rotalign. Pruftechnik Rotalign Set, Overhead projector, Handouts, Training rig, Tool kit
Conclusion:
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Introduction:
Main Points:
What is soft foot? How to measure and correct different soft foot types. Trouble shooting Rotalign faults. Techniques to obtain consistent measurements. Limitation of lasers and environmental factors. Discussion, notes, overheads, demonstration. Participants will: Confirm through practical demonstration that student can effectively measure 3 different soft foot examples, create soft foot maps and correct soft foot error. Via written test identify 4 most common causes of Rotalign error and suggest remedies. This unit covers the underpinning knowledge required to achieve successful soft foot correction and identify Rotalign faults.
Conclusion:
Resources: Pruftechnik Rotalign Set, Overhead projector, White board, Handouts, Training rig, Tool kit