DEVELOPMENT OF

MAINTENANCE PHILOSOFY
 Development
p of Maintenance Philosophy
p y
• Before WW II machineries were simple, heavy and “robust”
• Maintenance
M i t was simple
i l => >bbreakkd
down maintenance
i t
• Mass production systems require more reliable production
machineries. Machineryy break downs cause loss of revenue.
• Machineries have evolved to modern machineries
– Water wheels => water turbines
– Steam
St engines
i => steam
t turbines
t bi
– Mechanical control => electronice control
– Operating speed higher than crtical speed (10000 Rpm
and more) => machine dynamic behaviour become more
complex
• Need
N d new new strategy
t t
• Need speciallist within maintenance group
 FAILURE PATTERN
• Before 1960 it was beliefed thal all components failed
following “bathtub
bathtub curve”
curve failure rate pattern
• As a matter of fact only 4% of component population (eg:
bearings, connectors, switches, IC, PCB, etc) has
bathtub failure pattern.
e Rate

Start up Break down

cycle cycle
Failure

Useful life period

(wealth cycle)

Time
 FAILURE PATTERN
The meaning g of bath tube curve
• Start up cycle: failures are due to defective
material, manufacturing g defects, errors in
assembly, operator errors. Matting surface of
components are not smooth at the beginning of
running
i period.
i d
• Useful life: components fit to each other
• Break down cycle: failing due to fatigue,
excessive wear, erossion, abrasion etc.
Bath tube curve is good for modelling mechanical
components
 FAILURE PATTERN

4% 7%

14%
2%

68%
5%

Age related failure (1

(1, 2,
2 3) Age
g unrelated failure ((4,, 5,, 6))
FAILURE PATTERN POPULATION
PERCENTAGE

1
2
3
4
5
6
 CATEGORY OF PRODUCTION
EQUIPMENTS
• Production equipments can be classified based
on their complexity, cost, role in a production
chain as:
– Critical
– Essential
– General purpose
• This classification determines the appropriate
maintenance
 DEVELOPMENT OF
FAILURE PATTERN THEORY

1940 1950 1960 1970 1980 1990 2000

 DEVELOPMENT OF
MAINTENANCE STRATEGY

3rd Generation
-Better availability and reliability
-Better safety
-Btter
Btt product
d t quality
lit
2nd Generation
-Non environmentally harmfull
-Better availability
-Longer equipment life
1st Generation g equipment
-Longer q p life
-Better
Better cost effectiveness
-Fix when it breaks -Beter cost effectiveness

1940 1950 1960 1970 1980 1990 2000

 DEVELOPMENT OF
MAINTENANCE STRATEGY

3 rd generation
-Machinery
Machinery condition monitoring
-Design for reliability and
maintainability
2nd generation -Hazard
Hazard studies
-Scheduled overhaul -Small and high speed computer
-System for work planning and -FMEA
1st g
generation controlling -Expert
p systems
y
-Fix it when it breaks -Large and slow computer -Multi tasking and team works

1940 1950 1960 1970 1980 1990 2000

 DEVELOPMENT OF MAINTENANCE
STRATEGY
St t
Strategy Reactive,
R ti Preventive
P ti Predictive
P di ti Proactive
P ti
Run To Failure Maintenance Maintenance Maintenance
Definition Fix it when it Conduct Maintain based Redesign
g to
breaks, Run to maintenance at upon known eliminate root
Failure regular intervals condition/standard cause of failure
Advantages Cheap Can be planned Can spot potential Less
(when for or scheduled failure maintenance
implemented required
correctly)
y)
Disadvantages High spare Unnecessary Costly if Could be
(when stock level. replacement of implemented expensive
implemented Emergency parts Poor
parts. incorrectly
correctly) outages utilization of labor.
Component you Head light Oil change Automobile tires 2 year lease
would
ld maintain
i t i
 “Critical”
Critical Equipment

• Can be dangerous when break down

• Production process stop when the
equipment break down cause.
• Power
P 5000 to
t 50000 HP
• Expensive
pe s e investment
est e t
• Expensive repair cost
• Long repair time
 “Essential”
Essential Equipment

• Smaller than critical equipments, usually

provided with standby
p y unit.
• Examples: Process pump, boiler feed
water pump
pump, cooling water pumppump.
 “General
General Purpose
Purpose” Equipment

• Does not endangered people and environment

• Does not affect p
production p
process when it
breaks down
• Inexpensive investment
• Inexpensive repair cost
• Does not cause secondary failureEquiped with
stand by unit
• Single unit equipment but not critical to
production process
 RTF PM
RTF, PM, PdM
PdM, Proactive Maintenance
• Break down (run to failure) maintenance : No
maintenance
i t until
til machine
hi b breaks.
k Primary
Pi ffailures
il
always cause secondary failures.
• Preventive maintenance (PM) or time base maintenance:
performed based on fixed schedule (or based on
operating hours)
• Predictive (on condition based) maintenance (PdM):
Health condition of machines is continuously monitored.
Only if abnormal condition is detected maintenance will
be performed.
• Proactive (prevention) maintenance: the cause of
premature failures are investigated using RCFA.
Findings are followed up by redesign.
 Preventive Maintenance
(Time Based Maintenance)
• P
Preventive
ti maintenance:
i t maintenance
i t activity
ti it to
t
prevent equipments from break down by
inspecting detecting and fixing
inspecting, fixing.
• Based on fixed schedule (weekly, monthly,
quarterly yearly
quarterly, yearly, 1000 hrs,
hrs 3000 hrs).
hrs)
• Implementation is easy, just follow the schedule:
cleaning painting
cleaning, painting, lubricating
lubricating, inspection
inspection, repair
repair.
• Budget planning is easier, done yearly.
 PM (TIME BASED)
Appropriate equipments to be treated with PM
• Equipments that can cause
– major shut down
– product quality degradation
– failure to related components
– danger people.
• Lighting, floor, ceiling that can cause poor
product quality or poor working condition
 PM (TIME BASED)

Equipments not to be treated with PM

q p
• Equipments with stand byy unit
• Equipments with investment cost less than their
repair cost
• Equiments with long life expectancy without PM
 Predictive Maintenance (PdM)
• Distribution of machine/components life
• Life of rolling bearing: L10 => mean life is 1 million
rotation when loaded at Cd
• There are some with shorter life and some with longer
life
ability
Proba

Life
Mean
 Predictive Maintenance (PdM)

• Distribution of load vs. distribution of strength

• There is pprobability
y of load > strength
g ((statics,
fatigue, wear etc) as shown bellow
ty
Probabilit
P

Beban Kekuatan

Rata2 Rata2 MPa

 PdM
• Predictive maintenance tries to predict machine
condition along “bathtub curve”, when critical wear
occurs
Failure Rate

Start up Break down

cycle cycle

Useful life period

((wealth cycle)
y )

Time
 PdM

Predictive Maintenance (PdM)

Machine is repaired Breakdown before

before it needs it scheduled PM

Time based preventive maintenance (PM)

 PdM
Technology needed for condition monitoring in
PdM tot detect
d t t whenh “critical
“ iti l wear”” occurs
• Oil analysis
• Ferrography
F h
• Chemical analysis
• Infrared
I f d
• Magna flux
• Vibration
Vib ti
• Ultrasonic imaging
• Ultrasonic
Ult i thickness
thi k gauging
i
• Advanced visual inspection
 PdM

• Need investment for instruments and specialist

y implemented
• If correctly p can reduce
miantenance cost
• Its advantages and disadvantages should be
carefully studied.
Investment for Reduction of
tools and specialist maintenance
cost
Cost Comparison of RTF,
RTF PM,
PM PdM
Comparison of RTF,
RTF PM,
PM PdM
 Comparison of RTF, PM, PdM
Predetermined Maintenance, Fix it
b f
before it b
breaks,
k PlPlanned
d
Maintenance, Historical
Maintenance, Calender Based
Rate

Corrective maintenance, Maintenance

Predictive Maintenance,
Failure R

R to
Run t Failure
F il
Machines are repaired when there are If it is not break don’t fix
Maintenance, Breakdown
no faults it, Condition based
Maintenance
maintenance
Repair often causes more harm than
g risk of secondaryy failure
High
goodd Hi h iinvestment
High t t costt
High down time
There are still unscheduled breakdown Additional skills required
High cost of spare parts
Miantenance is performed in controlled Unexpected breakdowns
Over time labor manner are reduced
d d
Safety hazardous Fewer catasthropic failures Parts are ordered when
needed
Machines are not over Greater control over stored parts and
maintained cost Maintenance
M i t iis performed
f d
when convenient
No condition monitoring Unexpected machinery failures should
related cost be reduced Equipment life is extended

Maintenance Strategy
Cycle of PdM Implementation
 Advantages of PdM
• Maximize
M i i machine
hi productivity
d ti it
• Reduce maintenance cost
• Red ce prod
Reduce production
ction cost
• Minimize unscheduled down time
• Safely extend overall intervals
• Enhance plant safety
• Improve repair time
• Increase MTBF
• Improve product quality
• Extends machine components service life
 Proactive Maintenance
(Prevention Maintenance)
• P
Premature
t f il
failures can h
happen on equipments
i t
• To prevent premature failure from reoccuring
• The cause of failure is analyzed using Root
Cause Failure Analysis (RCFA)
• Improvement / redesign is performed based on
the results of RCFA
VIBRATION AND MACHINE
CONDITION
 Vibration and machine condition

When a machine g
gets older its vibration
level becomes higher. This is due to:
–Wear
Wear on machine elements
–Foundation settlement causing deformation
on machine housing resulting in
missalignment of shaft
–Change
Ch iin d
dynamici bbehaviour
h i off th
the machine
hi
such that its natural frequency shifted
Maintenance Cost vs
vs. Vibration Level
 Vibration and Machine Condition

• Machine vibration
– Not dangerous if the machine is designed to generate
vibration
– Dangerous if the machine is not designend to
generatet vibration
ib ti
• Forced vibration (frequency = rotational speed) => remedy:
replace defective elements, balancing, alignment
• Resonance (frequency = fixed) => remedy: change
operational speed, increase stiffness, increase damping,
reduce vibration input
input, utilize dynamic dampers)
 Vibration and Machine Condition
• Vibration as measured: it is an effect,, in p
practice it can
only be measured on the outside part of the machine
• Abnormality, faults: it is cause (ex: unbalance, gear
defects dll), occurs on the inside parts of the machine,
practically can not be measured
• How can we know the cause from the effect?
 Vibration and Machine Condition
FORCING
FUNCTION: MACHINE
Unbalanced, bent STRUCTURE: Gear
shaft, misalignment, wheel, rotor disks, RESPONSE
b i d
bearing defect,
f shaft,
h ft bearings,
b i
rubs, gear mesh coupling, housing
problems
Forcing function

Response
 Vibration and Machine Condition

• Frequecy as vibration signature

Synchronous

Harmonics
Subharmonics
1X
¼ X, 1/3 X, ½ X 2X 3X 4X

Subsynchronous S
Supersynchronous
h
 Vibration and Machine Condition

• What are needed to reconstruct the

cause from the effect
• Cause effect relationship (can be
modeled and verified by measurements)

Fault Vibration Signature

U b l
Unbalanced d 1 x, etc
t
Misalignment 1 x, 2 x, etc
Bent shaft 1 x, 2 x, etc
Bearing defect BPFO, BPFI, BPS, etc
 Vibration and Machine Condition

• Cause => effect, direct problem, deteministic

• Effect => cause, invers p
problem, can be
complicated due to:
– Similarityy of vibration signature
g from different faults
– Measured vibration is combination of vibrations from
many different sources plus noise
– Two vibration with different frequencies can produce
another vibration
– Machine structure are “non linear” (to make it simple,
it is assumed to be linear)
 Vibration and Machine Condition
Direct Problems
CAUSE EFFECT
Cause is given, 1x
Unbalance
Determine the effect,
CAUSE 1
Unique answer
Unbalance

Invers Problems EFFECT CAUSE 2

1x Missalignment
Effect
ec is
s known,
o ,
Determine the cause, CAUSE 3
Answer is not unique, Bent shaft
 Vibration and Machine Condition

• How to solve this type of invers problems

Machine Calculate
anatomy theoretical
frequencies
Corelate Causes Normal?

Vibration Reduce into

measureme vibration
nt (effect) components
 Machine Anatomy

•Working principle
•Main components
• Kinematic
relationship
between
components
Machine Anatomy
Machine Anatomy
 Corelation

• Corelate between measured frequencies

with theoretical ones
mm/sec

RPM = 2950
?
m

? Unbalance = 49 Hz
?
BPFO = 255 Hz
Gear mesh = 735
Hz
Hz
MACHINERY VIBRATION
 Major Axis of Machine Vibration
Measurement
Y

Z
X

Z
X
 How Machine Vibrates?
Shaft on journal bearing: Relative Displacement.
Y

X
Bearing clearance
with lube oil Rotation, low speed,
Rotor no vibration

Bearing Y

Shaft
Base plate X

Precession, higher
speed vibration
speed,
 How Machine Vibrates?
Shaft on rolling bearing: No relative displacement.

Y
Rolling bearing

Rotor
X

Shaft Rotation, high speed,

Base plate no vibration
 Absolute (left) vs. Relative (right)
Vibration Measurement
Abs (100%) Abs (100%) Abs (100%) Abs (10%) Rel (90%)

= - =

Bearing clearance
with
ith llube
b oilil
Rolling bearing Rotor
Rotor B i
Bearing
Shaft
Shaft
Base plate Base plate
 Simple Vibration
d
0.05 sec
• Precession = circular
D=2.5
movement mm

• Projection:
P j ti i ωt
d = D sin
t
• d=instantenous displ
(relative between haft
and sensor), Sensor
Shaft
• D=amplitude
• Example: ωt
d = 2.5 sin 2π (1 / 0.05)t
 Phase of Vibration
Phase represents “timing” relationship between 2 signal.
IIn vibration,
ib ti 2 signal
i l can b
be cause (stimulus)
( ti l ) and
d effect
ff t (response),
( )
as seen in mass spring system with input at A and response at B.
Displacement at A is ahead of displacement at B
B. This is called
relative phase.

Response Input Respons

d e
B m

Input t
k
A Phase different, in
degree or time
 Phase of Vibration
Keyphasor event: output voltage from keyphasor
t
transducer
d b
becomes more negative
ti when
h kkeyway pass
keyphasor.
Apphase measured relative to keyphasor
yp event is defined
as absolut phase.

Shaft
ω Keyphasor event

Volttage
Transducer signal

Trigger level

Keyphasor
K h
transducer
t
 Phase of Vibration
Phase
d
Top: signal
T i l ffrom a
vibration sensor
t

Middle: Signal from Keyphasor event

keyphasor
yp

ge
Transducer signal

Voltag
transducer Trigger level

Bottom: Combined t
signal d

Keyphasor event t
 Phase of Vibration

Y X Y

t
Trajectory
j y
of shaft
X
center Precession
center

Keyphasor t
transducer
X ahead
h d off Y 90
deg
 Phase of Vibration
Most vibration Unfiltered signal
signals are not
sinusoide. Phase
measurementt can
be done if the
signals are Filtered 1 X
dominated by their
harmonics ( 1X,
2X,, 3X,, dst).
)

Filtered 2 X
 Simple Vibration

• Vibration theory in general is explained by the

use of mathematical formulation => it can be
difficult and not interesting
• Can it be studied in a more easier and
interesting way?
• Yes, mainly from practitioners through
– Graphs and pictures Î can be easily understood
– Know the phenomena then understang the formula
 Pendulum

Pendulum movement =
Harmonic movement, with
frequency of

ω = g
L ...... rad / det

ω= 1
2π
g
L .......Hertz
 Pendulum
• Pendulum movement can be used to help p
in understanding vibration theory, for
examplep relationship
p between
displacement, velocity and acceleration
• All of us might have played with pendulum
• What can we observeYang dapat diamati
– At lowest
l t position:
iti displacement
di l t zero, velocity
l it
maximum, acceleration zero (in this position
gravity does not have lateral component)
– At farthest position: displacement maximum,
velocity zero
zero, acceleration maximum
 Simple Vibration

• Vibration: displacement, velocity and

acceleration
• Phase relationship between d, v and a
 Phase Relationship ϕ

Displ phase = Accel phase

+ 180 (displacement lag
180 relative to accel))
Displ phase = Velocity
phase + 90
Velocity phase = Accel
phase + 90
 Phase Relationship

• R
Relationship
l ti hi
between displ,
vel and accel
at constant freq
 Free Vibration without Damping

• Vibration system consisting of mass and spring

• Vibration will sustain
 Natural Frequency

• Natural
N t l ffrequency in
i rad/det
d/d t
m

ωn = k
m ω n = g
y
k
• Natural frekuencyy in Hz
ωn
fn = 2π
• m=mass, k=spring constant, g=gravity, y= static
deflection
 Critical Speed

• Si
Simplyl supported
t d shaft
h ft
1 g
• Critical speed in Hz, nc =
• where 2π Y

Wrotor L3
Y=
48 EI
πd 4
I=
32 L/2 L/2
 Critical Speed

• Overhung shaft
1 g
p
• Critical speed in Hz nc =
2π Y
• where

Wrotor L3 (1 + c / L)
Y=
3EI
c L
 Dynamic Absorber

• Slidi
Sliding overhung
h
mass supported
by cantilevered
spring is ”tuned” to
have natural
frequency same
with frequency of
pipe vibration
• Pipe vibration
energy will be
absorbed by
overhung mass
 Damped Free Vibration

• Vibration system consisting of mass and spring

• Vibration will die out
 Damped Free Vibration

• Vibration will die out

g the damping
• The larger p g the faster vibration die
out.
• Underdamped, over damped, critically damped
 Forced Vibration

• Excitation in the form of sinusoidal force with

constant amplitude

F = Fo sin πft

k
 Forced Vibration
• An engine
g and compressor
p with a mass of 1000 kgg
supported by 4 springs as isolator, each with k = 10 k
N/mm. Detemine natural frequency fn.
• Are
A spring
i constants
t t effectively
ff ti l attenuate
tt t vibration
ib ti when
h
operated at 3000 Rpm?

Compressor Engine
Vibration
isolator
 Vibration of
Rotating Unbalanced Mass
• Excitation: sinusoidal force
with amplitude of mω e
2
 Vibration of
Rotating Unbalanced Mass
• Polar plot
 Vibration of
Rotating Unbalanced Mass
• Measurement results
 Vibration of
Rotating Unbalanced Mass
 Torsional Vibration

• Beside lateral vibration, torsional vibration also

occur on shaft
 Expression of Vibration Level

Peak to peak: for displacement of shaft relative to bearing

bearing.
Peak to zero: for velocity dan acceleration
F sinusoide
For i id
RMS = 0.707 A
A = peak Average = 0.637 A

t
2A = peak to
peak

V
Crest factor =Peak/Rms