Francis Concemino

Associate 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.
Maintenance Progression
g
•Condition monitoring
2000 •Design for reliability and maintainability
•Hazard studies
1990 •Small, fast computers
il   d   ff   l i
•Failure modes effects analysis
Year 1980 •Expert systems
1970
•Schedule overhauls
1960 •Systems for planning and controlling work
•Big slow computers
1950
1940 •Fix it when it broke
3
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
an asset. This strategy reduces downtime and   mitigates 
the consequences of failure.
Machine Life Cycle‐ Bath Tub Curve
Failure rrate

Early life Useful life Wear out

F

Time in service
P‐F Curve*

*Courtesy of Vesta
Medical Analogy

Source: 7
Condition Monitoring Techniques
 Oil Analysis
 Vibration Analysis
 Motor Circuit Analysis
 Thermography
 Ultrasonic Monitoring
 Performance Monitoring
Oil Analysis
Oil 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 t
Total Lubrication Management
Undesirable Lube Oil Storage Condition
g Optimum Desired State
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Oil Analysis
The process of collecting and testing new oil or used 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.
Oil Analysis Wear products and 
Oil Analysis‐ Wear products and
Contaminants Analysis
Oil 
Analysis

Lubricant   Machine 
Condition Condition

Does the particles 
Is the oil  Wear particles  signifies type of 
Is oil up to spec?
contaminated?  present? metals and wear 
patterns?
Oil A l i T t
Oil Analysis Tests
 Viscosity
Water Contamination
Neutralization Numbers
Spectrography
h
Particle Counting and Analysis (Ferrography)
Lube Oil Analysis: Sample Report

Particle Count 
 i i d l f l
Case in point: Secondary Clarifier Drive Failure
Lube 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 hours 
Overtime labor hours
• Drive Unit Replacement
• Replacement Lead time
R l t L d ti
Vib ti A l i
Vibration Analysis
Vibration Analysis Vibration Causes and
Vibration Analysis‐Vibration Causes and 
Transmission
 Machines and components vibrate in response to 
one or more pulsating forces, called excitation. 
Example: mass unbalance.
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The magnitude of vibration is dependent not only on 
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the force but also properties of the system, both may 
b t l ti f th t b th
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
What Component?
t?
 26 - Aux. WasteHeat Loop Pump #3
26J-140 -P1H Pump Inboard Horizontal
0.5
Trend Display
0.4
FAULT Overall Value
PK In/Sec

0.3
ALERT
0.2
0.1
WARNING
0
0 300 600 900 1200 1500
Days: Nov-18-01 To Oct-11-05
0.05
0.04 Route
R t SSpectrum
t
Dec-05-01 18:55:48
PK In/Sec

0.03 OVERALL= .0611 V-DG

0.02 PK = .0609
LOAD = 100.0
0.01 RPM = 1800. (30.00 Hz)
0
0 10 20 30 40 50 60 70 80 90
Frequency in Orders
0.8
FAULT Route Waveform
0.4 Dec-05-01 18:55:48
Acc in G--s

ALERT RMS = .1056

0 PK(+/-) = .2971/.3198
CRESTF= 3.03
-0.4 ALERT
-0.8 FAULT
Date: Dec-05-01
0 40 80 120 160 Time: 18:55:47
Time in mSecs Ampl: .06113
 22 P2 SECONDARY TREATMENT
POINT: G6H - MORE THAN ONE EQUIPMENT
1.0
Max Amp
0.8
.91
0.6

0.4

0.2
Sec
K Velocity in In/S

0
H3 -G6H
12-Sep-02

G3 -G6H
02-Oct-02
PK

F3 -G6H
09-Jul-02
G3
Point= G6H
02-Oct-02
E3 -G6H 11:36:28
09-Jul-02 RPM= 55.43
Ordr: 64.19
0 10 20 30 40 50 60 70 80 90
Freq: 3557.8
3557 8
Frequency in Orders Sp 3: .701
Motor Circuit 
Analysis
Motor Circuit Analysis
Motor Circuit Analysis

A computerized evaluation that combines several tests to 
determine the overall condition of an Electric Motor.
Motor Circuit Analysis
Fault Zones
 Power Quality
Q y
 Insulation 
 Power Circuit
 Stator
 Rotor
 Air Gap
Motor Circuit Analysis
S
Summary of Electric Motor Failures
f El t i M t F il
Bearing, 
Stator, 37% 41%

Other, 12%

Source: Combined EPRI and GE Study

Rotor 10%
Rotor, 10%
 Infrared 
Thermography
Infrared Thermography
 Based on the principle that all objects above absolute 
zero (‐273 o C) emit infrared radiation
zero (‐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 
Can see temperature differences as small as 0 1 oF or less
or less

Source- RCM II by John Moubray

 R
*>233.7°F VFD#3 SLATER PS E90105 Spot 2
168.4

200.0
199.1

100.0

*<27.9°F
Infrared Thermography Electrical 
Infrared Thermography‐ Electrical
Applications
 Relays and circuit breaker 

Bus and fuse connections
B df ti

Disconnects

Thermal overloads

Generator and motor windings

Motor control centers
Infrared Thermography Mechanical 
Infrared Thermography‐ Mechanical
Applications
 Boilers and refractories

Heat Exchangers
H tE h

Bearings

Couplings

Steam traps

Wall and roof insulation
Ultrasonic Analysis
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 Ult i O ti
Ultrasonic‐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 
Analysis
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 accuracy
absolute accuracy

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

Heat exchangers

Steam Turbines

Analyzers

Compressors
C i P i T i Fil T bidi A l I
Case in Point: Tertiary Filter Turbidity Analyzer Issue
Implementation Cost
Implementation Cost
Technique Hardware Software Training/
Certification

Vibration $15,0000‐ $2,000‐ $10,000

$20,000 $20,000

Infrared $10,000‐ $5,000‐ $6,000

$50,000 $10,000

Oil Analysis $10,000‐ $5,000‐ $10,000

$80,000 $10,000

Ultrasonics $3,000‐ $2,000‐ $2,000

$8,000 $5,000

MCA $4,000‐
$4 000 $5,000‐
$5 000 $8 000
$8,000
$70,000 $10,000
 f f d
Benefits 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 o
preventive maintenance.

 Reduces requirements for spare parts.
q p p
How to start a Condition Monitoring
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 
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software, hardware, and training cost.
How to start a Condition Monitoring
How to start a Condition Monitoring 
Program
 Get the necessary training – when in doubt seek advice from 
experts.
experts

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

 Provide management with frequent updates.

 Train others when confidence level increase.
How to start a Condition Monitoring
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.
Q
Questions?