Professional Documents
Culture Documents
4
Enterprise Asset Management Systems
%
2 Implementation
0
Jan Feb Mar April May June July Aug Sep Oct Nov
Maintenance Strategy review
2009 0.67 0.6 0.43 0.49 0.76 0.24 0.53 0.11 0.17 0.22 0.21 Spares Optimisation
2008 3.91 0.62 1.1 0 0 0.83 0.29 0.09 0.25 0.49 0.21 7UDLQLQJDQG&KDQJH0DQDJHPHQW
1.8 2.1 1.78 2.56 1.4 1.81 2.17 1.93 1.66 5.56 0.88
The result speaks for itself.
2007
7ROHDUQPRUHDERXW6.)$VVHW0DQDJHPHQW
With SKF AMS, Average unplanned downtime was clearly
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reduced from 2.15 % in 2007 to 0.4% in 2009
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AMMJ Contents
April 2011 Issue Vol 24 No 2
Asset Management and Maintenance Journal
Condition Monitoring. This paper of The latest maintenance news, products & services.
Operation
when 1.0 Bearing
bearings Oil 40°C too short
modified
even inspire.
To Subscribe to the AMMJ go to www.maintenancejournal.com to download the SUBSCRIPTION FORM. Annual Subscription is from $80.
Maintenance Engineering and
Engineering Economics
José Guilherme Pinheiro Côrtes1 jgcortes@terra.com.br; (Brazil)
Arthur Wellington is recognized as the founder of Engineering Economics (EE) for having written
the seminal work “The Economic Theory of the Location of Railways” in 1877. In it, he showed
his disgust with his fellow engineers who took no account of the economic aspects of investment
decisions regarding engineering assets. More than a century later, economics and engineering still
live like worlds apart. And yet, one needs the other. This must change.
One outstanding example of this long lived separation relates to the maintenance function. What
happens and why? Let us see next.
Vol 24 No 2
Return to Contents Page
AMMJ Maintenance Enginering and Engineering Economics
If I had to choose, I would pick the process view of the firm. Why? Because it adds processes to resources, it asks
us to look at how resources are used by the firm. Resources flow to or are consumed by cost objects through
processes. Not every cost object is also a revenue object: some are (for instance, saleable goods), some not (such
as support of community activities).
However, and possibly, accountancy influence upon activity based costing has resulted in replacing costs of
resources for resources properly. People often speak of depreciation instead of fixed assets, salaries but not
labour etc. I strongly argue in favour of starting from physical resources, to only later translate their use in terms of
money spent. This leaves me very comfortable with Engineering Asset Management, as regards physical assets.
Not every resource in taken into account, but a very respectful share of them is.
What is good news here? First, physical assets mean high cost, low decision reversibility and technology choice.
After you have decided to buy a particular equipment, a lot of money must have been spent, you will have to keep
the item for many years and the choice of technology will spread its effects over other resources – labour, specially.
I could have added that buying a new machine is a manly source of pleasure… EAM comes to rescue all involved
in these decisions and consequences from a lack of a sound framework to analyse every business case.
Second, EAM invites EE to assist in every step conducive to more effective management of resources. If this
invitation is not yet loud and clear, let us make it. Economic sense has to be made of any decision that costs money
to both private and public bodies. Take the case of public infrastructure. Official reports abound giving us notice
that infrastructure swallow huge budgets just to get maintenance and yet display a very unsatisfactory state.
Third, EAM is a multidisciplinary field, where different eyes (and minds behind them) look at the same problem:
how to do the best with our physical assets. I hope EAM will in the near future become an interdisciplinary field,
where eyes will see others and minds will strive to think together. Engineers are problem solvers by nature. As
problems rise and get ever more difficult to tackle, engineers must improve their preparedness. Before managing
physical assets, they are defied to manage intellectual assets. Time is now.
Notes:
1. J. G. P. Côrtes recently retired from the Universidade Federal do Rio de Janeiro (UFRJ) and is presently working
as a private researcher and consultant.
2. As far as I can see, engineering economists are not aware of the rapid advancement of EAM. They should.
Vol 24 No 2
Return to Contents Page
Locate electrical
problems
Check mechanical
devices
The Impact Of Reliability
Centred Maintenance
Daryl Mather Reliability Success P/L (Australia)
As a cornerstone of the maintenance discipline, Reliability Centred Maintenance - RCM can achieve
benefits in a vast number of areas depending on where and how it is applied.
When properly implemented, RCM provides companies with a tool for achieving lowest asset Net
Present Costs (NPC) for a given level of performance and risk.
This implies a cashable impact across a multitude of economic activities, covering both OPEX
(Operational Expenditure) and CAPEX (Capital Expenditure) .
However, RCM will also provide companies with a range of non-cashable advantages that will have a
positive impact throughout the enterprise.
This paper contains a brief description of potential areas of benefit; not the entire range of uses for
RCM. Along with these areas, the author has previously used RCM for capital submissions in regulated
industries,
• to reduce the risk of legal ramifications in management of environmental integrity,
• to establish a tool for contract negotiations related to outsourced maintenance,
• reduction of a company’s carbon footprint,
• and as a means of developing trouble shooting guides
The information in this paper helps alleviate some of the benefits anxiety that often surfaces in the
early implementation stages of large-scale RCM projects, and to provide guidelines for trainee RCM
Analysts.
INEFFECTIVE MAINTENANCE
One of the great misleading statistics in asset maintenance today is the calculation of average life for bearings. The
effect of this is to support the outdated and almost mystical belief of the link between age and failure. Based on
this way of thinking, it is still common to find maintenance departments carrying out hard-time bearing replacement
programs as a means of managing risk.
However, it has been the experience of the
author that hard time bearing replacement
policies can increase, rather than decrease,
the likelihood of failure while at the same
time increasing the direct maintenance
Advance
costs.
This flies in the face of popular beliefs and is your career
and company
an example of how RCM thinking can drive
reductions in routine maintenance levels.
The original Nowlan and Heap report2
specifically spoke about bearings when
addressing failure in complex assets.
A complex item, as opposed to a simple
item, is one that is subject to many failure
modes. As a result, the failure processes
may involve a dozen different stress and Equip yourself and your staff via our proven off-campus
resistance considerations. learning programs in Maintenance Management and
Even with complex items, failures related Reliability Engineering: masters, graduate diploma
to age will concentrate about an average and graduate certificates.
age for that mode. However, bearings have
many failure modes. ‘Our mill will save $US84,000 as an outcome from studying
Where there is no dominant failure mode just one Monash unit.’ Perry Pearman, Ponderay Newsprint,
(the most common cause of failure) , as is Washington State.
the case in complex items such as most ‘I was the Engineering Manager, and believe the Monash
bearings, then distribution of the average life
MRE studies helped me to be promoted to General Manager.’
of all the failure modes is widely dispersed
3
along the entire exposure axis . Therefore, Rob Howie, Chelopech Mining
failure will be unrelated to operating age. Mid-year entry 17 June 2011.
This is a unique feature of complex items.
When deciding maintenance policy for For details contact: mre@monash.edu call +61 3 5122 6453
bearings, this issue is further exacerbated by or visit www.gippsland.monash.edu/science/mre
the provision of the L10 life by manufacturers. CRICOS Provider: Monash University 00008C
This number represents the point at which
10% of the items may have failed, meaning
that 90% will have survived.
INAPPLICABLE MAINTENANCE
This mistaken belief that there is always a relationship between age and failure leads maintenance departments
to all sorts of policies that, in practice, are achieving nothing.
Often these occur during maintenance turnarounds. The opportunity to access items that are normally in a
running state drives people to inspect items just in case a life related failure mode has developed.
RELIABILITY TRAINING
In addition, opening the bearing housing and interfering with the bearing, which presumably is operating fine,
we again introduce the possibility of human error7.
It is difficult to categorize this maintenance practice directly; but the closest match in RCM is Predictive
Maintenance. (PTIVE)
In the RCM decision algorithm, this means the team needs to answer all of the following questions before this
task is applicable:
• Is there a clear potential failure condition? • What is it?
• What is the P-F interval?
• Is the interval long enough to take action to avoid or minimise the consequences of failure?
• Is the P-F interval reasonably consistent?
• Is it practical to do the task at intervals less than the P-F interval?
The team would be able to answer all of the above questions positively except for the last one. For the task of
dye penetrant, testing it is not practical to do the task at intervals less than the P-F Interval, therefore the task
is not applicable.
Inapplicable maintenance practices are widespread and, in the experience of the author, often reflect the
underlying belief of a consistent relationship between age and failure.
Figure 3
INCREASES IN REVENUE
Unplanned Shutdowns
There are two specific areas where an
RCM team can claim savings. Shutdown Overruns Downtime
Startup Failures
Where an asset, or system, has
a history of failures leading to lost Off Spec. Production
Under-performance Planned
production opportunities. Principally this Production Slow Down
refers unplanned shutdowns, overrun Capacity
turnarounds, and start up issues of an Uptime
asset or system. Best Achievable
Rate
Where an asset, or system, has a history
of failures leading to reduced production
output. This includes areas such as
utilization, quality, and reduced availability. For example:
• Reduced turnaround times • Increased yield (quality)
• Increased availability for full production rates
T
he PMO2000 ® (our unique approach) • Creates a closed loop system that makes
Process has always been a simple and investigations into losses very efficient and
effective means for you and your team highly effective
to understand the principles of reliability
International clients:
and how to deploy them. Our systems are built The Benefits
• Indonesia around simplicity, not complexity, but they work in
any capital intensive organisation. Our clients Put simply, successful implementation of our
• Malaysia
range from the current holder of the North program results in a reduction in maintenance
• Philippines American Maintenance Excellence awards to related downtime by one half. This can be
• Taiwan companies that are yet to install a computerised achieved site wide in 12 months.
maintenance management system.
• New Zealand • Reduced reactive or emergency
We help you create a culture of “Zero tolerance maintenance activities
• North America to unexpected failure”. We are not a company • Increased workforce productivity while
• Chile that just helps you write a maintenance strategy providing greater job satisfaction
- we assist you to deploy a reliability assurance
• South Africa • Reduced costs of spares and overall
program which is a living program.
maintenance activity
• Holland We will also assist you with a change of culture
• Saudi Arabia not only in your maintenance departments, but Our Strategy
within the production areas as well. This is
because we view reliability and maintenance as Our current strategy is to attract more local
processes not as departments. business than overseas business.
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How the process helps you Steve Turner
Director and Principal Consultant
• Defines what maintenance is value adding and
OMCS International
what is not and keeps this up to date
Email: steve@omcsinternational.com
• Trains and motivates your staff to build reliability Mobile 0419 397 035
concepts into their daily activities
• Groups all your results into practical schedules Or contact any of our local or global
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The RCM team can claim these savings only where they can prove they have isolated the cause of the lost, or
reduced, production and have recommended a strategy that will mitigate it or prevent it in the future.
These are potential because it will take a reasonable amount of time, nominally one year, before effective
measurement can prove reduced production losses.
However, it is often the case that there are noticeable increases in available uptime after implementing RCM
maintenance policies.
Calculating benefits in this case requires the estimation the value of additional uptime, throughput or yield, as
well as the reduced costs of labor and materials.
As these are historic failures, issues such as quantification of lost production, direct maintenance costs, and
the frequency of failure are relatively easy to find out.
However, an alternative is to use sophisticated forecasting techniques such as Crow-AMSAA. This is time
proven as an accurate method for forecasting failure rates; enabling the team to then calculate savings from
the changes to asset maintenance. This is also a valid method for forecasting savings in direct costs.
RISK MITIGATION
When the mitigated risk is economic, it is often termed cost avoidance.
Where the team has implemented a policy for a reasonably likely failure mode where there was an inadequate
New
it.
They are nevertheless valid and important benefits
for the RCM team to claim.
Note the emphasis on “an inadequate existing
strategy”. RCM did not invent maintenance, and often
there are adequate existing failure management
New
policies in place.
As an output, the team will find that some maintenance
regimes will disappear, some will remain, and they Figure 4
will add some new, more sophisticated, regimes Pre-RCM Post-RCM
(see Figure 4).
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The benefits of RCM are obvious to anybody who has studied it or to Cashable Non-Cashable
any maintenance practitioner who can relate to the concepts espoused
in the method.
All levels within the corporation generally see different advantages to Increased Risk
RCM and there is rarely a lack of motivation for improvement. Revenue Mitigation
Implementation problems commence due to fundamental
misunderstandings about maintenance and the functions of physical
asset management9 . This leads maintenance departments to see Reduced Knowledge
increased risk where it does not exist. Costs Increases
For example, a maintenance manager could face any of the following
recommendations: (Among others)
Elimination hard-time replacement policies where applicable and effective,
Elimination of invasive inspection while we have the opportunity on planned turnarounds.
This reluctance to change comes from the perception that this is risky, and instead of implementing the policy
changes, things stay as they are.
The result is more of the same.
• Risk of unplanned failure stays provably higher, and
• the effectiveness of maintenance stays provably lower.
Moreover, resources remain tight performing maintenance that is not required, or repairing problems caused
by the activities that are supposed to prevent them.
It is clear that before we can successfully implement the strategy outcomes of RCM, we first need to make sure
that there is a deep understanding within the company of modern reliability principles.
to the nominal voltage and other reflected waves. The SPD will aid in reducing the voltage peaks of the reflected
waves. More importantly, if the connection between the drive and the motor extends outdoors, along a path that
is exposed to the environment or close to the building’s steel structure, protection at this location is important to
diminish the effects of direct lightning or induced voltage surges due to nearby lightning. These surges can cause
damage to the drive, even if protection is provided at the motor input. At this location, a parallel connected, voltage
responsive circuitry device is appropriate (one without frequency responsive circuitry). Frequency responsive
circuitry is not recommended for this location due to the high harmonic content of the signal due to the normal
operation of the drive. Installation of frequency responsive circuitry devices at this location will lead to failure of the
SPD. Utilizing a voltage responsive circuitry device at this location will eliminate this possibility.
5. Motor Input.
Protecting the motor input is an essential step in protecting the drive system. Providing protection at this location
prevents surge damage due to events propagated from the drive output to the motor input. Providing protection
at this location aids in extending the life of the motor as the SPD helps to prevent damage to the windings and
bearings of the motor due to surges. Further, if the connection between the drive and the motor extends outdoors,
along a path that is exposed to the environment or close to the building’s steel structure, protection at this location
is important to diminish the effects of direct lightning or induced voltage surges due to nearby lightning. These
surges can cause damage to the motor, even if protection is provided at the drive output.At this location, a parallel
connected, a voltage responsive circuitry device is appropriate (one without frequency responsive circuitry).
Frequency responsive circuitry is not recommended for this location due to the high harmonic content of the signal
due to the normal operation of the drive. Installation of frequency responsive circuitry devices at this location
will lead to failure of the SPD. Utilizing a voltage responsive circuitry device at this location will eliminate this
possibility.
Overall, properly installed surge protective devices reduce the magnitude of random, high energy, short
duration electrical power anomalies. These occurrences are typically caused by atmospheric phenomena
(such as lightning strikes), utility switching, inductive loads, and internally generated overvoltages. The
ultimate goal of our approach is to keep sites and systems operating safely and reliably. PowerTrip®
Surge Protection Devices incorporate “Frequency Responsive Circuitry” technology years ahead of any
other devices on the market today. Utilizing proprietary electro-chemical encapsulation, PowerTrip® SPDs
dissipate large amounts of surge energy to prolong service life.
The author was inspired by the concept of condition monitoring to help prevent unnecessary overhauls when
he started as a young engineer in power generation in 1964. In parallel with a general engineering and middle
management career in several power plants in Australia and the UK, he developed and applied vibration and
performance analysis for pumps, steam turbines, boilers and heat exchangers. His experience and passion for
sharing knowledge led to presentation of many in-house and public courses and his first book. That in turn led
him to Monash University in 1992 and a second award-winning book in 2003. In that role, he reflected on his
experiences and has written 70+ papers, many of which have been chosen for conferences and technical journals
around the world. The lessons learnt stand forever, but not all are well-known. This paper of brief case studies in
narrative style is intended to entertain, inform and even inspire.
Lesson #2 When a plant is new and/or the major asset makes it easier to get proposals
for monitoring etc. accepted.
After further training attachments, I was assigned to Hazelwood Power Station in 1966. It had three 200MW units in
service, but would grow by a unit each year to reach eight, its current size. The boilers were essentially identical,
but there were two makes of steam turbines and boiler feed pumps.
The vibration measurement program was as at Yallourn, but more use was made of the balancing instrument to
find relative phase angles of the 1X vibration to give a crude operation deflection shape. For routine monitoring of
the steam turbines, permanent numbers were painted around the rotor line at a visible section.
Case study 1
A strange vibration was experienced on the newest machine at the generator drive end bearing. When runup
following a shutdown, the machine vibration was unacceptably high. The operators tripped it and ran for some
hours on turning gear (low speed rotation at 30 r/min). Back on line, the vibration was now acceptable. This
happened repeatedly: sometimes all would be OK after a shutdown, sometimes not. Vibration measurements
with our crude instruments on line in both states showed that the vibration amplitude and phase angle differed on
every run! All I could say was “these symptoms indicate that there is something loose inside the generator rotor
around that end”.
Stripdown was arranged and the generator rotor examined closely. Nothing was found. Eventually, a message
came from the OEM saying that one of the rotors – this one - was non-standard. At the end of manufacture, the
rotor centres were bored out to about 100mm diameter, and the hole packed tightly with rubber bungs. Flaws
were found in one of the rotors and a length was bored to a bigger diameter…. but bungs of the same size were
inserted – see Figure 1. You can guess the effect of these masses moving around! They were removed -“no
longer our practice” - and after an expensive 38 weeks off line, all ran well.
Vol 24 No 2
Return to Contents Page
AMMJ Lessons Learnt In 45 Years of Condition Monitoring 23
Figure 1 Cross-section of 200MW generator that proved to have loose bore plugs
Lesson #3 Correct and confident diagnosis is often possible without complex instruments.
Lesson #4 Persist with the “5 Whys” until every possibility for a cause has been exhausted -
right back to the intimate detail of a component’s manufacture.
Case study 2
The coal mills (64 of them!) are essentially a large
heavy single-stage fan, driven through a fluid
coupling, The coal flow eroded the blades unevenly,
causing unbalance. Unlike the older much smaller
mills at the older Yallourn Power Station, timed-
oscillation balancing was not workable and the
phase angle method is used.
A rough mill would be detected on routine vibration
checks, and arranged to be taken from service.
Next day, it was cold and isolated to be safe
for phase marks to be chalked around the drive
shaft. De-isolation was followed by an “original
run”. Shutdown and isolated, a trial weight was
attached, and a calibrating run made. Shutdown
and isolated, the balance correction could be made
at the blade chosen. De-isolated, a final check run
was made. Provided operators were available,
this took a day.
I decided to make permanent shaft marks, and
from records of our experience came the rule: “Cut
off 1 pound per thou of vibration 2 blades behind
the indicated high spot”. A table giving size of cut
and mass was provided. Balancing now took an
hour or so, as the initial reading was made on-
line when the high vibration was detected. The
next day with the mill isolated, open and cold, the
correction could be made and the machine closed
up for return to service. Figure 2 Large lignite coal mill (8 per boiler)
Vol 24 No 2
Return to Contents Page
AMMJ Lessons Learnt In 45 Years of Condition Monitoring 24
The UK experience
Based on my proposal to learn more about condition
monitoring, I was successful in getting a 2-year
travelling scholarship to work in the UK. (500MW boiler
commissioning (Babcock), turbine design and dynamics
(Parsons), and tests and investigations with the then CEGB). Unlike my home situation with the world’s cheapest
fuel, thermal efficiency was the priority, but its engineering effort shares much with condition monitoring. Following
a shaft crack in a 500MW unit, vibration monitoring had been further developed.
I returned full of ideas, and wrote 11 reports. Only one had a specific recommendation to spend money: to enhance
our vibration analysis capability by obtaining a real-time analyser, accelerometers, vector filer phase meter, plotter,
tape recorders, etc. The Power Generation Manager approved the largest expenditure on test equipment that
the technical heads in the power stations had ever seen. He did so on the condition that each station proved an
engineer to work with me in applying the equipment. This proved to be very wise, and gained “buy-in” at each
place that a superstar would not have gained working alone!
Lesson #6 If you find that worthwhile learning for your organization can only be obtained
outside it (whether in another country or not), make the proposal, but ensure that it is only you
that can be selected to go!
Lesson #7 To get buy-in, involve locals deeply in any development.
In the meantime
It took some months to write specs, call for bids and then analyse them and place orders. In my absence, the
Yallourn (old station) people had bought a replacement balancing instrument. It had a significant advance on
the old ones – it had a frequency scale! Without them realising this capability, we had a way of finding vibration
signatures (spectra). Several intractable vibration problems were solved. (Beebe, 2001)
I recall the stores manager raising his eyebrows when asked to locate a large mill bearing and count the number
of rollers in it!
Lesson # 11 Check your cupboards – you may have under-utilised equipment with as yet
unknown capability! See again Lesson #3.
Figure 4 Front panel of the analyser showing how to set it up (from the operating handbook we wrote).
We designed a special graph paper so that plots could be compared by holding sheets up to the light. Our intent
was to eventually have this comparison done by a computer, but in the pre-PC days….
As the equipment was to be shared around five power stations, we set up clearly labelled carry cases to facilitate
collection by any driver. Each case had the required connecting cables. Unfortunately, after some time cables got
lost. Locating the cases also took time.
In the ensuring years, more advanced FFT analysers, multi-channel tape recorders, later versions of other
instruments were obtained. A major re-organisation set up a central specialist group.
Lesson #12 Specialist test equipment needs to have a regular owner and full-time skilled
operator
Hand-portable analyser/collectors and associated computer packages have become commonplace, so our dream
was realised.
Vol 24 No 2
Return to Contents Page
AMMJ Lessons Learnt In 45 Years of Condition Monitoring 26
Case study 4
The new graduate engineer hooked up the accelerometer via the long cable reel to the signal conditioning/
readout instrument. He reported that turbine vibration was 55mm/s rms – over 10 times greater than what might
be expected! Before panic set in, we found that he had used the cable to connect the accelerometer to the
instrument. It was an ordinary shielded co-axial type, intended to be used from the instrument to an analyser. Low
noise cables are required from charge output accelerometers to avoid tribo-electric boosting of the output to give
a spurious high vibration reading.
Lesson #13 Check, and recheck, critical data values if any look to be unusual.
Case study 5
Using an innovative approach, site trim balancing Fig 5 Bearing stability chart showing effect of oil viscosity
was conducted on a 120MW generator rotor. and bearing length
The coupling between turbine and generator
was unbolted, and faces held apart. The exciter
was connected to run as a motor, with the rolling Lines of Recommended
torque provided using the overhead crane and Load parameter W’
increasing area
a rope wrapped around the rotor. (Appropriate constant b/d
design checks had been made).
After reassembly, run-up proceeded as normal, 10
until when nearing normal service speed Oil 71°C
generator bearing vibration suddenly jumped Original
operation
so much that the floor shook and dust fell from
the rafters! The operator tripped the machine.
Subsequent attempts at run-up were no different. Operation
A challenge for the vibration team! The gear when 1.0 Bearing
was set up with the analyser set to PEAK HOLD bearings Oil 40°C too short
modified
mode. The extreme vibration was revealed as at
19 Hz – the first critical speed of the rotor. It Increased risk of half-
was noticed that the vibration started soon after frequency whirl
the auxiliary oil pump was stopped, so it was
0.1
left running and the unit was eventually put into 0.1 0.5 0.9
service. The 19Hz vibration was still evident, and
Eccentricity ratio
could be varied in amplitude by changing the oil
temperature.
Bearing dimensions and clearances were found, and the bearing wedge pressures (giving shaft loading) and oil
temperatures noted to calculate the Load Parameter. The resulting plot on a bearing stability assessment chart
showed that the operating range was well outside the “recommended” area (ESDU 1966), as shown in Figure 5.
The only variable that could be changed permanently was the length of the bearings (to increase the specific
loading). Surprisingly, the spares in the store were found to be shorter, as were those on the adjacent “identical”
machine! Bearing changeover was the cure. This was a strange case, as this machine had operated 17 years
without this problem. The vibration team gained superhero status for this success. (Beebe, 2002).
Lesson #15 Assess whether the plant instruments can be used to give a usable trend for CM.
If a DCS exists, then try data extraction and utilisation.
Case study 8
The superheater tubes in a series of large coal boilers of the same natural circulation drum type design leave the
furnace through spaces between roof tubes, and connect to later sections, often via headers. There are several
superheater sections in series. The platen superheater at the top of the furnace has 30 sections, each with 16
tubes in a U-shaped pendant loop, hanging through the roof tubes of the furnace. Unlike other designs where the
leading tube down has a kink so that it becomes an inner tube in the up direction, these pendants are laid out such
that the assembly would be flat, i.e the inner tubes are progressively shorter than the outer tube. The platen is
heated mainly by radiation, so the longest tubes on the outside of the array take up more heat than those on the
inner side.
The
Manufacturing Game R
RCA Rt facilitators are expert www.rcart.com.au +61 3 9697 1100 Copyright Want to play the game?
incident investigators available to lead your team onsite contact: melissa@sirfrt.com.a
These tubes are then led Figure 7 Boiler cross-section above furnace.
out of the furnace space
through gaps in the roof
tubes into the dead space,
where they connect to
primary superheater inlet
tubes. There are 80 of these
superheater sections across
the gas path, so each has 6
tubes.
Excessive metal
temperatures lead to
considerable reduction in
creep rupture life. At these
temperatures, an increase of
only 11 C° can halve the life,
so operational monitoring is
important. Manufacturers
use thermocouples installed
in tube walls, sometimes in
special sections (BEI) to try
and measure the maximum
metal temperature. Such
sophistication was not
available when these boilers
were built, so at several
sections, 5 thermocouples
were fixed across the gas path
to primary superheater outlet
tubes in the dead space,
and the limits for operation
derived by calculation.
Two boilers built almost at
the same time exhibited quite different temperature behaviour at otherwise similar operating conditions. One
was often close to alarm limits, and operation was adjusted to keep within them. The other showed no such high
temperatures. After some years of service the “good” boiler suffered a spate of superheater tube failures due
to overheating and creep rupture, and the complete superheater had to be replaced. Why should two identical
boilers be so different?
Close investigation and painstaking tracing of tube path layouts showed that the hottest tubes from the outside of
the platen array led mostly to leading tubes, but sometimes to the tube behind it in the primary superheater, as the
number of platen tube banks is less than the number in the primary superheater. The monitoring thermocouples
were installed on leading tubes. Unfortunately, in the “good” boiler, the thermocouples were installed on leading
tubes that did not come from the hottest tubes out of the platen. Presumably, the installer was given set distances
in from the furnace wall rather than specific tube numbers. The lesson here is to check such points in detail if two
“identical” plant items show quite different behaviours.
Lesson #16 In critical cases, do not believe everything you read in the control room without
verification of labels and actuality at and inside the plant.
References
ASME (1970) Simplified procedures for routine performance tests of steam turbines ASME PTC 6S Report
(reaffirmed and revised 2003)
Beebe, Ray (1978) Recent Experience with Condition Monitoring of Steam Turbines by Performance Analysis -
IEAust Mechanical Engineering Transactions, 1978 pp 42 – 49
Beebe, Ray (2001) Machine condition monitoring MCM Consultants, Hazelwood
Beebe, Ray (2002) Diagnosis and solution of resonant whirl on a steam turbine generator Proceedings
ICOMS2002, Brisbane.
Beebe, Ray (2003) Predictive maintenance of pumps using condition monitoring Elsevier, London
Beebe, Ray (2008) Is your control room data telling you what you think it is? Proceedings MARCON2008 (and
several journals)
BEI (British Electricity International) Modern power station practice: incorporating modern power system practice.
3rd ed. Oxford Pergamon Press, 1990-1992
ESDU 66023 (1966) Calculation methods for steadily loaded pressure fed hydrodynamic journal bearings
Engineering Sciences Data Unit, IMechE London
Systems Structure: API Pro is powered by Progress providing multi- • Identifies and optimizes insurance spares and projected Inventory
tier client/server technology. Its query tools allow for advanced reporting demand;
and statistical analysis. • Creates dynamic OPEX and CAPEX budgets based on production,
revenue,
CMMS/EAM RELATED SERVICES financial, taxation and asset management scenarios;
• Life cycle costing;
API Pro is used within 500 leading companies worldwide in a variety • Carbon, Water, Energy Accounting;
of industries maintaining high-value capital assets, plant, facilities, • Fully Integrated with PBS8
building & equipment.
API Pro is designed to generate continuous management improvements PDA’s software development and Asset Management experience
within your company by optimising production output, utilisation of and competencies assure boutique services to clients that have high
human & financial resources. expectations. We also assure our certified 3rd party Asset Management
Example of Modules: professionals who are fully supported by Paradigm.
• Plant Documentation & Information Searching CMMS/EAM RELATED SERVICES:
• Maintenance, Inspection
• Stock Control • Strategy Coaching
• Purchase Management • High level implementation and Customisation services
• Job Ordering • Training and Online training systems
• Internal Purchase Requests
• Drawing and Documents and Graphical Navigator Other related services: Product is delivered as a hosted service
• Production Calendar
• Project Management
• Resource Planning Bigfoot CMMS
• WEB
• Analysis & Performance Smartware Group, Inc
• Palm Pilot USA
• Condition Monitoring Interface, SKF @ptitude www.bigfootcmms.com
• Documentation validation (FDA)
• Standard interface to SAP, MFG/Pro + others IN-COUNTRY SUPPORT FOR THIS CMMS/EAM:
Bigfoot is available and supported in North America, with resellers in
API Pro is supported with Professional Services – Implementation Australia, Qatar, and Saudi Arabia.
(porting data & seamless integration), Training, Software Maintenance
Agreements. IS THIS CMMS/EAM DESIGNED FOR A PARTICULAR INDUSTRY:
Bigfoot CMMS is designed for Manufacturers, Education, Financial
Services, Food/Beverage Processors, Government, Healthcare,
AssetMetric™ Hospitality, Retail, Stadiums, Arenas, Convention Centers, Property
Management, Construction, Transportation, Distribution, and Utilities
Paradigm Designs Australia P/L with single or multiple plant facilities.
Australia
TYPICAL COST OF THE CMMS/EAM SOFTWARE: Pricing can be
www.Parasoft.com.au as low as $33 USD/user/month for Bigfoot CMMS. Services include
training, customization, hosting, and data conversion.
IN-COUNTRY SUPPORT FOR THIS CMMS/EAM:
Australia and China IS THIS CMMS/EAM available as a stand-alone system: Yes
IS THIS CMMS/EAM DESIGNED FOR A PARTICULAR INDUSTRY IS THIS CMMS/EAM part of or able to be integrated with a larger
GROUP: Manufacturing, Pulp and Paper, Mining, Engineering and management system: Yes, it can be integrated with third-party
Asset management consulting service providers. applications, such as ERP and Accounting Systems.
TYPICAL COST OF THE CMMS/EAM SOFTWARE:
DESCRIPTION
As low as AUD$1,000 per user per month, price varies depending on
total number of uses and setup fees With over 1,400 customers worldwide, Bigfoot Computerized
Maintenance Management Software (CMMS) has a proven track record
IS THIS CMMS/EAM available as a stand-alone system: NO of managing the maintenance needs of organizations. Bigfoot CMMS’s
IS THIS CMMS/EAM part of or able to be integrated with a larger full functionality paired with its intuitive design allows you to implement
management system: YES, PBS8, the solution and get results quickly, often in a matter of weeks. Native
Bigfoot functionality includes preventive/predictive maintenance, work
CMMS/EAM DESCRIPTION: orders, inventory, maintenance requests, tool crib management, and
AssetMetric is the next generation “whole of business” optimization reporting, allowing you to:
system that dynamically models and optimizes PMs and related - Maintain detailed security, site, and user management control
Tasks, Spares, Risk, Lifecycles, Replacement Intervals, Budgets and access throughout your enterprise
Resource Allocations based on production, reliability, management risk - Utilize the same CMMS for an unlimited number of facilities
profiles, business life, taxation and financial inputs. Scenarios can then - Access Bigfoot CMMS worldwide, in real-time, with multi-language
be tested based on various inputs to provide economic and engineering capabilities
management decision support, which can then be easily implemented - Predict your IT budget
within EAM/ERP. - Undergo a minimal & quick implementation, often in a matter of
AssetMetric addresses Board level objectives as it insures Corporate weeks
Governance and Compliance because it provides a comprehensive risk - No need for software upgrades or server backup/maintenance
identification methodology within a Risk Mitigation Strategy Change - Schedule unlimited preventive maintenance tasks and procedures
Management System that then can be downloaded to the ERP/CMMS. with automatic reminders
Carbon, resources and energy usages modeling is provided and can be - Create, manage, and analyze work orders
used to model improvement or measurements for ”Triple Bottom-line” - Track and analyze equipment information and history
accounting variables. AssetMetric is the ultimate economic, engineering - Request maintenance from anywhere in your company
and environment continuous improvement tool for business and - Manage and track asset and parts inventory
shareholders. - Analyze historical maintenance issues and help predict future
events
Key Features: - Notify people of maintenance events with the automated e-mail
• Dimensional Plant reference and risk model (Asset registers); system
• Risk mitigation strategies (PAS55, AS4360); - Locate maintenance “hot spots” in your facility
• PM optimization based on production, reliability, risk and resourcing
levels; Bigfoot Benefits
• Lean PMs can be exported to CCMS/ERP; - Minimize equipment and repair costs
The eMaint X3 system is fully configurable – from screen layouts to provides our customers many options, but what keeps them committed
field selections to workflows to reports and dashboards – so that it can to Maintenance Connection is the relationship and the level of attention
match your precise business requirements. each of our customers receives. Just ask them!
Emaint has been providing CMMS and EAM software solutions to Key features include: Work Order Tracking, Asset Management,
customers world-wide for over 25 years through both on-demand (web- Preventative Maintenance, Spare Parts Inventory, Service Requests,
hosted) and on-site deployment. Calendar Scheduling, Security Access Groups, Mobile Workflow, KPI
Dashboards, and Custom Report Writer.
Key components include:
• Asset Management - including warranty tracking and multi-location CMMS/EAM RELATED SERVICES
support Maintenance Connection can provide additional services including
• Inventory Management – includes FIFO/LIFO and mobile support data collection, consultation, implementation and training to help you
implement Maintenance Connection to produce yet another Maintenance
• Preventive Maintenance – calendar-based, meter-based or condition Connection Success Story. Our CMMS community service allows you
monitoring and auto-generation options to learn from the best practices of other users and share reports and
• Work Scheduling – easily manage work schedules through drag-and- KPIs with individuals or the Maintenance Connection community.
drop calendar views
• Reporting & Dashboards – over 95 pre-loaded reports and fully OTHER RELATED SERVICES
customizable KPIs and dashboards in graphical format Maintenance Connection offers its customers a fully managed option
• Fluid Analysis Integration – Integration available with selected fluid to host their software online in a Secure Data Centre. This allows our
analysis/lab systems customers to focus on the business of maintaining their assets rather
than worrying if their server has the latest software or if the backups
CMMS/EAM RELATED SERVICES have been performed. This service comes with an SLA to guarantee
eMaint offers the following Professional Services: network and server uptime.
• Implementation and Project Management
• Configuration and Customization
• Data Conversion and Data Integration MaintiMizerBlackBox™
• On-site and On-Demand Training Ashcom Technologies Inc.
• CMRP Consulting USA
www.ashcomtech.com
Maintenance Connection IN-COUNTRY SUPPORT FOR THIS CMMS/EAM:
Maintenance Connection United States, United Kingdom, Canada, Malaysia
Australia TYPICAL COST OF THE CMMS/EAM SOFTWARE: $2995USD for a
3 user system, $4995USD for a 5 user system.
www.mcaus.com.au
IS THIS CMMS/EAM available as a stand-alone system: Yes
IN-COUNTRY SUPPORT FOR THIS CMMS/EAM: IS THIS CMMS/EAM part of or able to be integrated with a larger
Australia, America, Canada, UK management system: Yes
IS THIS CMMS/EAM DESIGNED FOR A PARTICULAR INDUSTRY
GROUP: Maintenance Connection is able to adapt to almost any CMMS/EAM DESCRIPTION
industry. Our current customer industries include; Manufacturing, MaintiMizer BlackBox™ is the first self-contained CMMS network
Schools & Universities, Oil & Gas, Hotels & Resorts, Distribution & appliance on the market. MaintiMizer BlackBox™ is perfect for
Warehousing, Buildings & Facilities to name a few. companies with small or non-existent IT departments because Ashcom
provides technical support so you can focus on what’s most important,
TYPICAL COST OF THE CMMS/EAM SOFTWARE: Starting from your business. Simply plug it in and gain access to MaintiMizer™’s 5
AUD$9995 (includes all modules and 3 concurrent user licenses). modules, including:
Pricing is also dependant on implementation and support agreements.
• Work Order—Allowing you to submit and approve work orde requests,
IS THIS CMMS/EAM available as a stand-alone system: Yes track everything associated with that WO from costs to time loss/
IS THIS CMMS/EAM part of or able to be integrated with a larger spent, and delegate WO’s to specific employees or
management system: Yes, Maintenance Connection’s web-based departments.
open architecture allows the system to be very easily integrated within • Preventative Maintenance/Equipment—Know what’s going on with
ERP systems. your equipment & make sure your scheduled maintenance is done in
a timely manner. Keep tabs on the amount of time down, the upkeep
CMMS/EAM DESCRIPTION costs, warranties, and location of your equipment.
Maintenance Connection has been developing and delivering quality • Inventory—Know what you have and where it’s at!
Computerised Maintenance Management Software (CMMS/EAM • Vendor/PO—Maintain supplier records and easily create purchase
Software) to organisations around the world for over 10 years. Our orders.
Facility Maintenance and Asset Management Software (Browser-
Based CMMS/EAM) is designed to help your organisation manage • Timecard—Keep track of employee hours and rates.
maintenance, not software. Packaged in a simple, user-friendly, yet CMMS/EAM RELATED SERVICES
powerful application, Maintenance Connection connects maintenance
professionals to their operations with a unique style that continues to Training, Coaching & Mentoring:
revolutionise the way maintenance is performed. Ashcom knows making a CMMS implantation successful is directly
The technology framework Maintenance Connection is built upon affected by the quality of practical training a user receives. Ashcom offers
remains to be cutting edge – a full featured and entirely browser-based a broad range of tested training methods to fit your needs. Choose to
application without the need for plug-ins or propriety code, and without be trained on-site at your facility, at our state-of-the-art training facility
having to install anything on client machines. This means you can get or web training. Ashcom offers tried & true basic software training or
up and running quickly, and allows you to manage maintenance, not customized training tailored to your specific needs. Ashcom also offers
software. Combine that with software uniquely built for all the various coaching & mentoring services where an industry expert visits your
roles within a maintenance operation, and you have a powerful solution facility, observes your current practices and use of MaintiMizer™, and
that is easy to use, whether the end user is a Manager, Technician, or make suggestions to improving your current processes.
Requester. OTHER RELATED SERVICES
Maintenance Connection places a priority on providing customers with Technical Support, Customization, Data Integration, & Analysis:
the service, support and a product second-to-none all combined to deliver
a package unique to your individual needs. Ask our customers – service • Every purchase comes standard with a maintenance agreement;
excellence is the foundation on which all of Maintenance Connection’s giving you access to skilled support technicians when you need them
customer relationships are built. The maintenance software industry most. Ashcom’s support technicians are reliable, knowledgeable
and friendly.
• MaintiMizer™ is fully customizable; screens can be edited to provide TYPICAL COST OF THE CMMS/EAM SOFTWARE:
only the information you want and fields can be named with the terms MaintiMizer™ Web Edition pricing is based on number of users, on
your work-force use & know. average a 3 user system runs $6500USD. Please contact Ashcom for
• Data specialists help move your old data into MaintiMizer™ as more specific pricing based on your needs.
painlessly as possible. Your data can be analyzed, giving you expert IS THIS CMMS/EAM available as a stand-alone system: Yes
opinions on changes that will push your business forward. IS THIS CMMS/EAM part of or able to be integrated with a larger
management system: Yes
MaintiMizer™.com CMMS/EAM DESCRIPTION
Ashcom Technologies Inc. MaintiMizer™ Web Edition—hosted on the internet or your intranet, making
USA upgrades and technical support virtually hassle free. MaintiMizer™ Web
www.ashcomtech.com Edition is fluid and has the ability to change and grow with you. Ideal for
companies that have multiple locations or for those that need access
IN-COUNTRY SUPPORT FOR THIS CMMS/EAM: to the system when they are away from the facility, MaintiMizer™ Web
United States, United Kingdom, Canada, Malaysia Edition comes standard with 5 user-friendly modules to get things done
including:
TYPICAL COST OF THE CMMS/EAM SOFTWARE:
As low as $30USD per month with a year contract. • Work Order—Allowing you to submit and approve work order requests,
track everything associated with that WO from costs to time loss/spent,
IS THIS CMMS/EAM available as a stand-alone system: Yes
and delegate WO’s to specific employees or departments.
IS THIS CMMS/EAM part of or able to be integrated with a larger
• Preventative Maintenance/Equipment—Know what’s going on with
management system: Yes
your equipment & make sure your scheduled maintenance is done in
CMMS/EAM DESCRIPTION a timely manner. Keep tabs on the amount of time down, the upkeep
costs, warranties, and location of your equipment.
MaintiMizer™.com—The SaaS, Software as a Service, version of
• Inventory - Know what you have and where it’s at!
MaintiMizer™ is an online edition that allows you to minimize the capital
• Timecard - Keep track of employee hours and rates.
investment of implementing new software and utilize MaintiMizer™
• Vendor/PO - Maintain supplier records and easily create purchase
for a low monthly fee. MaintiMizer™.com is great for companies that
orders.
are unsure if CMMS software is right for them or for small companies
just getting started with CMMS software. MaintiMizer™.com comes CMMS/EAM RELATED SERVICES
complete with 5 modules including: Training, Coaching & Mentoring:
Ashcom knows making a CMMS implantation successful is directly
• Work Order Allowing you to submit and approve work order
affected by the quality of practical training a user receives. Ashcom offers
requests, track everything associated with that WO from costs
a broad range of tested training methods to fit your needs. Choose to be
to time loss/spent, and delegate WO’s to specific employees or
trained on-site at your facility, at our state-of-the-art training facility or web
departments.
training. Ashcom offers tried & true basic software training or customized
• Preventative Maintenance/Equipment—Know what’s going on wit
your equipment & make sure you scheduled maintenance is
done in a timely manner. Keep tabs on the amount of time down,
the upkeep costs, warranties,and location of your equipment.
• Inventory—Know what you have and where it’s at!
• Vendor/PO—Maintain supplier records and easily create purchase
orders.
• Timecard—Keep track of employee hours and rates.
CMMS/EAM RELATED SERVICES
Training, Coaching & Mentoring:
Ashcom knows making a CMMS implantation successful is directly
affected by the quality of practical training a user receives. Ashcom Maintenance Management Solutions
offers a broad range of tested training methods to fit your needs.
Choose to be trained on-site at your facility, at our state-of-the-
art training facility or web training. Ashcom offers tried & true basic
software training or customized training tailored to your specific
needs. Ashcom also offers coaching & mentoring services where an
industry expert visits your facility, observes your current practices and
use of MaintiMizer™, and make suggestions to improving your current Reducing Costs
processes. Increasing Productivity
OTHER RELATED SERVICES
Technical Support, Customization, Data Integration, & Analysis:
Improving Quality
• Every purchase comes standard with a maintenance agreement;
giving you access to skilled support technicians when you need
them most. Ashcom’s support technicians are reliable, • Work Order We’ve been in this business for
knowledgeable and friendly.
• PM/Equipment over 25 years. We know what you
• MaintiMizer™ is fully customizable; screens can be edited to provid
only the information you want and fields can be named with the • Inventory need and want in a CMMS/EAM
terms your work-force use & know. system. MaintiMizer™ comes
• Data specialists help move your old data into MaintiMizer™ as • Vendor/PO standard with 6 user-friendly
painlessly as possible. Your data can be analyzed, giving you expert • Timecard modules to get the job done on
opinions on changes that will push your business fo
• Utility time, on task & on budget.
MaintiMizer™ Web Edition
Ashcom Technologies Inc. Contact us for more information—
USA
www.ashcomtech.com web: www.ashcomtech.com
email: info@ashcomtech.com
IN-COUNTRY SUPPORT FOR THIS CMMS/EAM: United States, phone: +1 734 665 1780
United Kingdom, Canada, Malaysia
fax: +1 734 665 6074
training tailored to your specific needs. Ashcom also offers coaching & professionals across all sectors of industry so it is a near, dovetail-fit
mentoring services where an industry expert visits your facility, observes with the real world needs of maintenance management practitioners.
your current practices and use of MaintiMizer™, and make suggestions
to improving your current processes. TYPICAL COST OF THE CMMS/EAM SOFTWARE:
Single user maintenance system Aud$3,250. A six user system running
OTHER RELATED SERVICES maintenance, stores less than Aud$10,000.
Technical Support, Customization, Data Integration, & Analysis: IS THIS CMMS/EAM available as a stand-alone system: YES
• Every purchase comes standard with a maintenance agreement; IS THIS CMMS/EAM part of or able to be integrated with a larger
giving you access to skilled support technicians when you need management system: YES
them most. Ashcom’s support technicians are reliable, knowledgeable
and friendly. CMMS/EAM DESCRIPTION
• MaintiMizer™ is fully customizable; screens can be edited to provide With over 10,000 customers, Shire Systems is the UK’s No.1 provider
only the information you want and fields can be named with the terms of CMMS solutions. Locally supported in Australia and NZ by Shire
your work-force use & know. Systems (South Pacific) the new Pirana system raises the bar for ease
• Data specialists help move your old data into MaintiMizer™ as of use and affordability.
painlessly as possible. Your data can be analyzed, giving you expert Pirana is the revolutionary browser-based system for the integrated
opinions on changes that will push your business forward. management of maintenance, materials, services and more. Streets
ahead of the rest, Pirana sets new benchmark standards for CMMS
simplicity, usability and affordability. Whatever the size of your
PBS8 Paradigm Business System ver 8 organisation - micro-small to mega-multinational - Pirana can fit your
needs like a glove. Pirana schedules, tracks and reports on any type
Paradigm Designs Australia P/L of task, supporting the real world need for getting things done in an
www.Parasoft.com.au organised, fast and effective way. Internet, intranet and mobile phone
deployment means you can access your system from anywhere.
Product Supported: Australia and China
With ferocious power, supreme ease-of-use and an unbeatable price,
Industry Groups: Manufacturing, Pulp and Paper, Mining, Engineering Pirana is set to tear shreds off its inferior rivals.
and Asset management consulting service providers.
Don’t ask us why Pirana is so affordable – ask the other CMMS providers
Now with 20 years of history in CMMS software, PBS8 operates as a why their software is not!
core system providing clients with proven technology that operates within Full functional maintenance software like this can only come from Shire
corporate landscape and requirements. PBS8 is a product for Clients – since 1982 the leaders in CMMS systems.
that require an Industrial strength system whose life cycle continues
Ask for your free evaluation system today and try for yourself the power
well into the future and that delivers expected core functionality and
and full functionality of Pirana.
meets the challenging user acceptance requirements but with a cost
of ownership. With Thousands of users PBS is a proven system that CMMS/EAM RELATED SERVICES
requires minimal training.
Shire is not just an IT company like other CMMS providers. We’re about
Strategies and Standards are critical success factors that any CMMS much more than software supply and support.
system must support if the business is to achieve worlds best practice. Shire offers a comprehensive range of multidisciplinary professional
So whether you adopt “On Condition”, “Risk Based”, “Operator Driven”, services to help time-poor organisations and maintenance professionals
“Six Sigma”, etc or all of these strategies it is of great benefit if the achieve their CMMS implementation and performance aspirations
CMMS system support the delivery of these strategies. – FAST.
Mature, Strategic Clients need a solution that serves the business, We customize our services to respond exactly to your pinpointed
leverages efforts and delivers competitive advantage, at a reasonable needs including system training, system implementation, System
cost. PBS is a unique to quickly and reliably generate forms, interoperate performance review, asset policy and maintenance strategy formulation,
with other SOA products and is architected to manage core and custom compliance and preventative maintenance plan development, asset
code. What this means is Clients can throw away those unsupported registration, asset identification labelling, and software installation and
access databases and build from a proven base system that provides customization.
95% of business functions and then add functionality that will seamlessly
integrate other core systems to secure business process through robust OTHER RELATED SERVICES
technology. Pirana On-TapTM is Software-as-a-Service and with it you can be up
A special note for Global organizations which will benefit from a unique and running with professional CMMS in a flash. For a small monthly
“trans-Lingual’ capabilities which enable the system to be used in fee Shire will host Pirana for you in a secure data centre, managing
multiple languages concurrently in a single data silo. All forms are the whole service, not least data preservation and disaster avoidance.
generated to support this mode which is a built in feature that is fully Shire also automatically upgrades the system-in-use. To get going at
Unicode compliant supporting for example Chinese character set. your end, you only need an Internet-connnectable computer with a web
browser.
Finally, Clients are supported by our experienced system architects
that have extensive experience in Asset management, Business
requirements, System Integration (Including SAP) and System PRONTO-Xi Maintenance Management
development. To be able to truly assess this opportunity you need to
organize a consultant with specific details. Pronto Software
CMMS/EAM RELATED SERVICES: Australia
• Strategy Coaching • High level implementation and Customisation www.pronto.com.au
services • Training and Online training systems
Other related services: Product is delivered as a hosted service or IN-COUNTRY SUPPORT FOR THIS CMMS/EAM:
Managed service or Supported onsite system Australia, New Zealand, South-East Asia, Africa, Europe and North
America.
IS THIS CMMS/EAM DESIGNED FOR A PARTICULAR INDUSTRY
Pirana GROUP:
Shire Systems (South Pacific) Ltd PRONTO-Xi is designed for Companies requiring an ERP solution with
Maintenance Management functionalities , such as the mining and
New Zealand facilities managementorganisations.
www.shiresystems.com IS THIS CMMS/EAM available as a stand-alone system: No
IN-COUNTRY SUPPORT FOR THIS CMMS/EAM: Australia, New IS THIS CMMS/EAM part of or able to be integrated with a larger
Zealand, United Kingdom management system:
IS THIS CMMS/EAM DESIGNED FOR A PARTICULAR INDUSTRY PRONTO-Xi Maintenance Management is a module of Pronto Software’s
GROUP: Pirana’s functionality was specified by maintenance flagship ERP solution, PRONTO-Xi.
Healthy For Longer becoming critical for their survival, and for
the survival of the operating companies.
Thomas Westman, Pierre Lorin and Paul A. Ammann ABB Power Products (Switzerland)
Vol 24 No 2
Return to Contents Page
AMMJ Fit at 50 39
The enormous costs of power transformer failures Figure 3 Cost estimates of an unplanned replacement
provide ample incentive for electric companies to of a typical generator step-up transformer
ensure reliability and availability throughout the
life cycle of these key assets. Transformers cost
anywhere from $2 million to $4 million, and on the Environmental cleanup $500,000
rare occasions they do fail, the financial impact can Lost revenue ($500,000/day) $10 million
be even more significant – in extreme cases, they Installation labor and processing $100,000 – $300,000
can leave a company facing financial ruin (Figure Additional modifications and site work $300,000
3). In addition, as most countries have strict laws in New transformer unit $2 million – $4 million
place that control and regulate power supply, non-
delivery penalties can be as high as 100 times the Transformer failures can cost up to $15 million, in addition to an
price of the energy itself. operator’s reputation. Source: Doble Life of a Transformer Seminar.
Clearwater, FL, United States
An Aging Fleet
Although transformers are regarded as highly
dependable equipment, the world’s current
transformer fleet is quite old. The average age for
those in industrial plants is 30 years, and 40 years
for those used by utilities. While aging transformers
are generally not “ticking time bombs,” their failure
rates as well as their replacement and repair costs
are steadily – albeit slowly – increasing.
Figure 4 shows the development of the failure
rate of transformers installed in industrial plants
(dark orange), generation plants (light orange) and
transmission networks (gray). The risk development
curves are steeper for industrial and power generation
plants as the transformers in these installations
tend to be used more intensively. While age alone
does not increase the risk of unexpected failures, it
generally is an indication of this risk. Risk of failure
is heightened by other factors, including type of
application and the tendency to load transformers to Figure 4 Development of the transformer failure rate in
their maximum to meet the economic needs of the three different applications
deregulated environment and competitive markets.
Figure 5 shows the investment Figure 5 Transformer investment then and now
peak in the 1960s and 70s for
many companies in Europe and
the United States.
The cost burden when replacing
aging equipment has forced
many companies to keep
transformers operating beyond
their recommended life span in
order to smooth the investment
peak. This is only possible by
optimizing the maintenance
of the transformers and by
implementing measures that
extend their use.
9a Step 1: Transformer fleet screening (of the 9b Step 2: Transformer design and condition assessment (of a subset of high-risk
whole transformer fleet) provides a risk assessment. transformers) suggests concrete actions for each transformer.
Condition assessment
ABB is the pioneer in highly customized condition assessment
offerings. Its MTMP (Mature Transformer Management Program)
is a state-of-the-art minimally invasive condition assessment
process used to evaluate the power transformers in a customer’s
fleet and to identify which units need to be replaced or refurbished
and when.
This process is implemented in three steps (Figure 9). It starts with
a high-level fleet assessment based on easily accessible data,
such as unit nameplate data, oil and dissolved-gas-in-oil data,
load profile and history of the unit (transformer fleet screening)
(Figure 9a). Next, a subset of the transformers identified in step
9c Step 3: Life assessment/profiling (of a few transformers
one is examined in more detail (transformer design and condition that had unusual results in steps 1 and 2) uses in-depth
assessment) (Figure 9b). Modern design rules and tools are analysis to show the status of the transformers. The circled
area indicates the need for immediate action.
used to evaluate the original design, and advanced diagnostic tests are performed to assess each of the principal
properties of the transformer in a structured way. These include mechanical status, thermal status (aging of the
insulation), electrical status of the active part and the condition of the accessories, such as tap changers, bushings,
overpressure valves, air-dryer system, pumps and relays. The number of units identified for further analysis is
typically limited to two or three out of a population of 100. At this stage (life assessment/profiling) (Figure 9c), highly
specialized experts analyze the units using simulation tools. Detailed data is then sent to the end users’ operational
managers, providing concrete information about whether a transformer can be overloaded, its nominal power or
voltage rating increased or its lifetime extended[4].
Risk assessment
The risk assessment (Figure 6) is based on two variables. The first, risk of failure, is estimated using the input from
the analysis phase, ie, age or time in service, transformer’s nameplate data (kV, MVA, etc.), application and loading
practices, operational problems or issues, latest field-test data (eg, dissolved gas and oil analyses), availability of a
spare transformer and spare parts. The second variable is the importance of a transformer in a network, indicating
how much of the operator’s system will be out of service if a particular transformer fails. By comparing these two
variables, different levels of urgency for maintenance actions can be defined (Figure 9a). The asset manager can
then ensure that maintenance of high-risk transformers is prioritized.
Asset management scenarios
The risks for a transformer operator include not only the inherent technical risks but also the economic consequences
of a possible fault, eg, the cost of non-delivered energy. With this in mind, ABB and a large operator co-developed
an economical model that evaluates the life-cycle costs of a transformer fleet over a given period (Figure 6). The
model takes into account four categories of costs related to the cost of ownership over the lifetime: investment,
maintenance, operational and consequential costs. Comparative investment scenarios and sensitivity studies can
be run by varying the replacement year or maintenance of the unit. For each scenario, the process shows the
associated net present value. An optimization routine can also be used to automatically minimize the life-cycle
costs of the population. The process outputs a list presenting the optimum time to maintain or replace the individual
transformers or transformer groups. The net present value of the whole population of transformers is determined
by looking at the condition of each unit and the maintenance actions selected to improve their condition. The
operational manager can then evaluate different maintenance scenarios and obtain a summary of the payback of
planned maintenance actions. The novel aspect of the method is that not only are maintenance costs considered
but economical benefits related to the impact of maintenance on reliability are considered as well[5].
Maintenance packages
ABB provides personalized recommendations and support using available data and state-of-the-art tools and
maintenance packages, as shown in Figure 6. These include regular asset services, early-life inspection, midlife
refurbishment and remanufacturing. For many operators midlife refurbishment has become very important as their
transformers are aging. Midlife refurbishment is an extensive overhaul of a transformer to extend the remaining
lifetime and increase reliability, and is typically performed after half of the expected lifetime. It involves several
maintenance steps, including advanced diagnostics to check mechanical, thermal and electrical conditions. New or
refurbished accessories such as on-load tap changers, bushings, pumps, temperature sensors, valves, gaskets and
water coolers might be used. Refurbishment of the active part through, for example, cleaning, winding reclamping,
connection retightening and installation of new parts, is often an aspect of a midlife refurbishment.
The benefits
Not knowing the risk structure of its fleet, a company tends to overspend on the maintenance of its low-risk transformers
and underspend on the high-risk transformer (Figure10). Overspending on low-risk transformers is a “high-risk
activity,” as approximately 30 to 50 percent of maintenance actions are unnecessary[6]. But needless maintenance
work can be avoided by implementing regular fleet assessments. The use of preventive or predictive maintenance
is improving the transformer economy, which has been challenged by the limited maintenance resources associated
with utility deregulation. Focusing the personnel and capital resources to the prioritized needs – with the priority
based on the condition assessment ranking – can provide improved reliability at a fraction of the cost of traditional
time-based maintenance programs.
It is estimated that life extension of five to 15 years can be achieved with properly focused preventive maintenance
programs. The economic advantage related to preventive maintenance work and corrective actions can also be
expressed in terms of extended life of the transformer assets – this is achieved by eliminating failures that might
have occurred due to the lack of timely critical maintenance.
A proactive approach
ABB TrafoAsset Management provides operators with the information, expertise and maintenance tools they need
to face the challenge of managing their transformer fleets. The result is improved asset management and lower risk
of unexpected failures. In addition, the comprehensive range of data collected, from design to condition assessment,
helps reduce the impact of a failure by enabling the transformer to quickly return to normal operating conditions. By
performing proactive maintenance based on the TrafoAsset Management method, operators benefit from a lower
risk of unexpected failures as well as fewer penalties (for utilities) and loss of revenue (for industry) (Figure 10).
Vol 24 No 2
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AMMJ Fit at 50 43
One of ABB’s customers, a major transformer operator, had been using a time-based maintenance strategy,
which meant that it did not know whether the maintenance done on each transformer was adequate for its risk
profile. In addition, the maintenance budget was under pressure due to market liberalization and it was unclear
whether it would be sufficient for the risk structure of the transformer fleet.
ABB thus undertook a fleet assessment study of 128 individual transformers at 54 different substations to
determine the risk of failure of each of the transformers in the entire fleet. The result was a prioritization of the
fleet based on corrective measures, such as detailed design or condition assessment, diagnostic evaluation,
inspection, repair, or replacement. With this information, the customer could then reallocate its resources to
the high-risk transformers and reduce costs in the process.
The benefit of a condition-based maintenance approach is shown clearly in this example. The customer
benefits from an optimized use of time and resources, which results in increased fleet reliability. Much more
of the maintenance budget is now concentrated on the transformers that show a high risk of failure or are of
high importance in the network. These transformers are maintained proactively in order to lower the risk of an
unexpected failure.
Unit Budget prior to fleet assessment Budget after fleet assessment
11 high-risk transformers $110,000 (9% of budget) $245,500 (25% of budget)
47 medium-risk transformers $470,000 (37% of budget) $434,000 (45% of budget)
70 low-risk transformers $700,000 (54% of budget) $294,500 (30% of budget)
Total: 128 transformers $1.28 million maintenance budget $974,000 maintenance budget
Distribution of maintenance budget before and after ABB fleet assessment.
The result of the optimized maintenance solution is a savings of 24 percent of the customer’s maintenance
budget ($306,000 annually) as well as having better maintained high-risk transformers.
The importance of asset management and proactive services based on condition assessments of transformers is
paramount due to the increasing average age of the worldwide transformer fleet and the more demanding conditions
regarding quality of uninterrupted energy delivery. ABB’s integrated modular asset-management approach provides
a clear picture of the risk structure and the maintenance required to deliver needed asset reliability and availability.
This allows operation managers to make the best use of maintenance and replacement budgets, allocating funds
to high-risk units.
By reducing the risk of failure within given financial constraints and by minimizing the impact of a failure when it does
occur, ABB’s TrafoAsset Management is providing a powerful service.
For more information on ABB’s transformer offerings, please visit www.abb.com/transformers.
Thomas Westman ABB Power Products Zurich, Switzerland
Pierre Lorin ABB Power Products Geneva, Switzerland
Paul A. Ammann ABB Power Products Baden, Switzerland
References
[1] Institute of Nuclear Power Operations (INPO). (2002, Sept 18). Significant Operating Experience Report, Ref. SOER02-3.
[2] CIGRE Technical Brochure 248. (2004, June). Economics of transformer management.
[3] Boss P., Lorin P., Viscardi A., et al. (2000). Economical aspects and experiences of power transformer on-line
monitoring. CIGRE Session.
[4] Boss P., Horst T., Lorin P., et al. (2002). Life assessment of power transformers to prepare rehabilitation based on technical-
economical analysis. CIGRE Session.
[5] Lorin P. (2004). Lifetime decisions: Optimizing lifetime costs for transformers through informed decisions.
ABB Review Special Report Power Services, 10–15.
[6] IEEE PES Transformers Committee. (2007, March). Tutorial: Transformer fleet health and risk assessment, Dallas, TX.
Further reading
– Eklund L,. Lorin P., Koestinger P., et al. On-site transformation: TrafoSiteRepairTM combines the old with the new
to improve power transformer availability. ABB Review 4/2007, 45–48.
– Jonsson L. Transforming Transforming: Advanced transformer control and monitoring with TEC.
ABB Review 4/2002, 50–54.
– Lorin P. (2005, April/May). Forever young (long-lasting transformers). IET Power Engineer, 19(2), 18–21.
– Lorin P., Fazlagic A., Pettersson L. F., Fantana N. Dedicated solutions for managing an aging transformer
population. ABB Review 3/2002, 41–47.
– Potsada S., Marcondes R., Mendes J.-C. (2004). Extreme maintenance: No location too challenging for an
on-site repair! ABB Review Special Report Power Services, 59–62.
– Westman T. (2009). ABB Transformer Service Marketing and Sales Presentation Pack.
– ABB Transformer Experts. (2006). Transformer Service Handbook.
Vol 24 No 2
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The Role of Vibration Monitoring In
Predictive Maintenance
Steve Lacey Schaeffler UK steve.lacey@schaeffler.com
1 - Electric Motor
Vol 24 No 2
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AMMJ Role of Vibration Monitoring in Predictive Maintenance 45
Vol 24 No 2
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AMMJ Role of Vibration Monitoring in Predictive Maintenance 47
Figure 6 Envelope spectrum obtained from the DE Figure 7 Envelope spectrum obtained from the DE end
end cap of a 2MW generator with rattling noise present cap of a 2MW generator when the rattling noise was absent
While the base spectrum shows evidence of cage vibration, on closer examination vibration at the cage speed
is readily seen in the envelope spectrum at 10.9Hz along with the BPFO, which was not evident in the base
spectrum, Figure 6. The envelope spectrum was obtained by using a higher sampling frequency giving a
frequency resolution of 1.56Hz and the cage frequency of 10,9Hz is within the measurement accuracy.
Vibration measurements
were also obtained when the Figure 8 Radial vibration acceleration spectrum on the
housing of a vertical impact crusher
rattling noise was absent and
vibration at both the cage
rotational frequency and BPFO
(Ball Pass Frequency Outer
Ring) were not evident in the
envelope spectrum, Figure 7.
The presence of vibration at
the cage speed and BPFO
does not necessarily mean the
bearing is in distress. Even a
geometrically perfect bearing
will generate vibration1.
Cage noise, which can be
loosely described as rattling, is
not uncommon in ball bearings
fitted with pressed steel cages.
This is particularly true under
minimal lubrication conditions,
where the lubricant cannot
provide sufficient damping
as the cage interacts with the
rolling elements and, in the
case of ring guided cages, with
the cage guiding surface as
the rolling elements speed up
and slow down when entering
and leaving the load zone.
The cage motion is often
erratic; the cage may rise and
fall in slow running bearings
while it may run eccentrically
in high speed bearings due to
the effects of centrifugal force.
The first bending mode of
the cage may also be excited
giving rise to a squeal or
squeak which may be in the
low kilohertz range for a 25mm
bore bearing.
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AMMJ Role of Vibration Monitoring in Predictive Maintenance 48
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AMMJ Role of Vibration Monitoring in Predictive Maintenance 49
4 - Wind Turbines
Wind power is a rapidly growing form of renewable energy in many parts of the world. As an established
source of renewable electricity generation, they are set to play an important role in future energy supply around
the world. In the UK, there is increasing interest in placing wind turbines offshore, which offers a number of
advantages including improved wind conditions and reduced planning restrictions. However, the environment
in which offshore wind turbines must operate is more demanding and often extreme, demanding a higher
degree of integrity and reliability if costs are to be minimised.
Due to the remote location and poor accessibility of wind turbines, it is important that faults are detected
early and consequential damage reduced or avoided and repair costs minimised. This will lead to shorter
downtimes and reduced loss of revenue. Detecting bearing damage early could mean the difference between
replacing the gearbox at a cost of around €250000 and replacing the bearing at a cost of €5000.
Wind turbine gearboxes are subject to high dynamic
loads and, due to changing wind conditions, the
load spectrum varies greatly and includes high
peak loads and low load operating conditions. The
high static safety required for maximum load means
that bearings with high load carrying capacity are
required. When there is little wind, however, loads
are low and this can lead to damage due to sliding
of the rolling element set. As a result, many field
operating failures are a consequence of gearbox
bearing failure. Misalignment, poor lubrication and
maintenance also contribute towards this trend.
Figure 12 shows the spectrum from a gearbox
output shaft where the BPFO, 183Hz, and the
harmonics are clearly evident. Sidebands at the Figure 12 Frequency spectrum from gearbox output shaft
rotational speed, 18.7Hz, are also present.
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AMMJ Role of Vibration Monitoring in Predictive Maintenance 50
The gearbox was taken out of Figure 13 Damage on the bearing inner ring raceway of a gearbox output shaft
service for inspection and a
photograph of the damaged inner
ring raceway of the cylindrical roller
bearing located on the high speed
shaft is shown in Figure 13.
An example of an envelope
spectrum obtained from a wind
turbine gearbox is shown in Figure
14. Vibration at 227.1Hz, which
corresponded to the BPFI of type
NU2326 cylindrical roller bearing
located on the gearbox output
shaft, is clearly evident along with
sidebands at the shaft rotational
speed. Inspection of the bearing
revealed an inner ring raceway
defect. This data was obtained
from the FAG WiPro online
Condition Monitoring system
which was monitoring a VESTAS
V90 turbine.
Figure 14 Envelope spectrum obtained from the gearbox output shaft of a wind turbine
Summary
In some industries, maintenance is the second largest or even the largest element of operating costs and as
such as becomes a cost control priority. Equipment failure not only affects plant availability but also safety, the
environment and product quality. It can also impact on customer service in terms of missed deadlines and loss
of confidence.
The complexity and cost of modern day plant and equipment means that plant condition monitoring is now
becoming a much more cost-effective option. Although many industries have and still do take a reactive approach
to maintenance, since there are no upfront costs, they pay the price in terms of increased plant downtime or lost
production.
Vibration monitoring is still probably the most widely used predictive maintenance technique and, with few
exceptions, can be applied to a wide variety of rotating equipment. Vibration monitoring allows the condition of
machinery to be determined as it operates and detects those elements which start to show signs of deterioration
before they actually fail, sometimes catastrophically. With this type of approach, unplanned downtime is reduced
or eliminated, thereby increasing plant availability and efficiency and reducing costs.
Rolling bearings are a critical element in many rotating machines and generate characteristic vibration frequencies
which can combine to give complex vibration spectra which at times may be difficult to interpret other than by
an experienced vibration analyst. In the case of rolling bearings, however, characteristic vibration signatures
are often generated in the form of modulation of the fundamental bearing frequencies. This can be used to
advantage and vibration condition monitoring software is often designed to identify these characteristic features
and provide early warning of an impending problem. This usually takes the form of signal demodulation and the
envelope spectrum which indicates early deterioration of the rolling/sliding contact surfaces.
References
1. Lacey S J. An Overview of Bearing Vibration Analysis, Schaeffler (UK) Technical Publication.
First Published in the Maintenance and Engineering Magazine (2010)
Vol 24 No 2
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Technical Short Feature:
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Maintenance News
Dr Gunawan Joins Monash University to Lead MRE Thermal Cameras Play Their Part In
Dr Indra Gunawan has joined Monash University to lead and Flood Recovery
teach in the postgraduate programs in maintenance and reliability Deadly floods on Australia’s eastern seaboard have left a trail
engineering. He joins following 5 years at New Zealand’s of destruction with thousands of properties in need of damage
Auckland University of Technology. assessment and repair in coming months.
Indra graduated in Civil Engineering from Parahyangan At the forefront of the road back to recovery will be an army of
University, Indonesia, and gained his master’s degree in building inspectors and professional thermographers armed with
Construction Management and a PhD in Industrial Engineering no more than an infrared camera.
from Northeastern University, USA. His research interests These hi-tech cameras can detect, spot and measure temperature
include project management, reliability engineering and differences over entire surfaces.
operations management.
Residual moisture, mould or dampness problems can be easily
He replaces Ray Beebe, who has led these off-campus programs identified by thermal imaging cameras. For many flood victims,
since 1996 and seen them grow to reach students in many IR images will be required as buildings and property are able
continents. Ray retired from tenure in 2010, but continues part- to be assessed by thermal image without the need for further
time with teaching in condition monitoring. He continues to be damage or demolition.
available for speaking engagements and is writing his third book, Newly released FLIR E-Series handheld thermal imagers from
provisionally titled “Condition monitoring of steam turbines”. FLIR Systems, have further refined the skill in ‘moisture-spotting’
www.gippsland.monash.edu/science/mre through the use of MeterLiNK which frees the thermographer
from the manual process of collecting field data.
Using WI-FI and Bluetooth® technologies, MeterLiNK enables
Bermuda Electric Light Company Selects Oniqua the thermographer to wirelessly transmit diagnostic data from
clamp and moisture meters directly to the camera and associate
Oniqua Enterprise Analytics, the leading provider of MRO these readings with the corresponding targets stored in an
(maintenance, repair and operations) analytics software infrared image for accurate, coordinated documentation.
solutions for asset-intensive organizations, has announced that Voice comments can be added via Bluetooth headset and text
Bermuda Electric Light Company Limited (BELCO) has selected notes from the touch-screen keypad.
Oniqua Analytics Solution (OAS) to optimize its inventory levels,
increase operational efficiency and ensure reliable delivery of For building-related professionals concerned with tracking
electric service to the residents and businesses of Bermuda. moisture and water entry, MeterLiNK works with the Extech
InspectorPro MO297 multi-function moisture meter and
BELCO is Bermuda’s sole supplier of electricity, operating a psychrometer. Using Wi-Fi, images and data can be sent to an
generating plant and transmission and distribution system. iPhone(R) or iPad(R) to share reports and critical information
OAS will help ensure the right MRO materials are available quickly.
when needed to perform planned and corrective maintenance Roger Christiansz, General Manager FLIR Systems Australia
for BELCO’s power supply team. said: ‘MeterLiNK enables FLIR customers to integrate valuable
readings from advanced, multifunction Extech meters into one
“Our analysis indicated that by maintaining its current material format, infrared image.
management processes without taking any corrective actions,
BELCO would continue to increase inventory value and costs ‘MeterLink and the related connectivity features we are
without making any positive service level impact on the critical introducing represent FLIR’s commitment to driving innovation
spares necessary for the maintenance operation,” stated Lindsay and leadership in the infrared camera industry.’
Clarke, President of Oniqua Americas. FLIR SYSTEMS Australia P/L www.flir.com
“OAS, supported by Oniqua professional services, will help
BELCO eliminate unnecessary inventory; improve and maintain
the data integrity of its parts catalog; generate accurate, VAM Handheld Vibration Analyzer
business-critical reporting; and rapidly develop critical inventory
analyst expertise.” Datastick Systems, Inc., has announced the immediate
OAS is an advanced and comprehensive analytics solution for availability of its VAM Vibration Acoustic Monitoring package
inbound MRO optimization. OAS provides the unique capability for its VSA(TM) line of handheld Vibration Spectrum Analyzers,
to perform end-to-end analyses of MRO inventory, maintenance which are used in the maintenance of machinery, such as pumps,
and procurement activities, and then transform raw data into fans, motors, and compressors.
actionable information for smarter decision making. The package includes industrial noise-canceling headphones
with safety earmuffs and both Passive and Active Noise
In a recent research report entitled, Utilities Improve Financial Cancelation. The package also includes an in-line amplifier for
Performance for MRO Inventory, Maintenance, and Procurement: adjusting the sound level, as well as cabling and connector.
Ralph Rio, Research Director Enterprise Software, ARC Advisory
Group, stated, “With a utility’s sizable and widely distributed “Many vibration experts will use headphones as electronic
MRO inventory, the investment in OAS can provide significant stethoscopes in the normal signal acquisition process, so they
returns... OAS provides utilities with a comprehensive solution can simultaneously ‘listen’ to the sensor output while observing
for optimizing MRO inventory, maintenance and procurement the time or frequency spectrum displays,” said John Visotsky,
activities. It uses analytical tools to determine what materials Chairman of the Atlanta Chapter of the Vibration Institute. “This
are needed, when they should be ordered, how much stock to additional capability helps distinguish between bearing faults,
maintain, and what suppliers to use. This provides an opportunity race defects, lubrication requirements, gear mesh faults, rubbing
to improve asset availability and materials costs... and improve and other defects. Vibration novices will learn the sounds of
the P&L statement and balance sheet.” the problems they are finding, and gain greater certainty with
their tools. Audio signal output adds one more perception to a
www.oniqua.com vibration analyst’s toolset.”
Vol 24 No 2
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Maintenance News 53
Penny Melrose, Datastick CEO, said that the new accessory recurring jobs; and many others. All software enhancements
package was the direct result of requests from customers. and new functionalities in mespas R5 come free of charge to
“Analysis of the waveforms and frequency spectra of the vibration MESPAS customers. Two major innovations are the mespas
from machines with problems can prevent costly, unpredicted, Cube and mespas Reporting Engine:
and sometimes dangerous breakdowns. The VAM Vibration The mespas Cube, installed on board the ships, is a small
Acoustic Monitoring package gives maintenance and reliability offshore server (see attached picture). It acts as the hub between
managers and technicians an extra dimension in their analysis the vessel’s PCs and the central database ashore.
of vibration signals.” www.datastick.com
With the Cube, the vessel
client architecture was
Simple Tools Are Often The Best changed from a “single
user/single PC” to a
Mounting larger rolling element bearings is a technical job that “client/server” architecture,
can be frustrating without the proper tools. In one case, the which is fully network and
mechanics on a job were attempting to mount two 22244 spherical multi-user capable. This
roller bearings on a vertical pinion gear shaft. The bearings had means, the software can
to be driven up a tapered adapter sleeve to properly reduce the be run on multiple PCs on board the ship, without impinging on
clearance. The problem? They didn’t have the right tool for the the software’s ability to synchronize and work with the central
job. This bearing was to be mounted on a SNW44 series Sleeve/ database ashore. Since everything is pre-installed and pre-
Nut/Washer. The AN44 size nut is approximately 8.5” (216 mm) configured on the mespas Cube, there is no IT knowledge or
in diameter at the threads. intervention needed on board the ships to ensure the safe and
The workers had been trying for robust running of the software. In addition, the mespas Cube
three days to advance the nut allows automating certain processes.
on the threaded adapter sleeve. Ship owners and ship managers require accurate and timely
When they finally called for help, information on the performance of their fleet as the basis for
the problem was obvious. They informed decisions. The new mespas Reporting Engine was
were trying to advance the nut developed with this need in mind. “Those responsible for the
using a home-made piece of cost-efficient running of a whole fleet need a tool that gives them,
key stock! The existing nuts at the push of a button, the ability to review critical performance
were quite bashed up and had indicators, purchasing analyses, budgeting information as well
to be replaced. A quick visit to as a variety of technical overviews“, says Daniel Gsponer,
the trunk of the local SKF Field Chief Technology Officer of MESPAS AG. “All this information is
rep produced the proper tool: an available within the Reporting Engine.”
Impact Spanner. Both bearings
were properly mounted within The overviews, comparisons and analyses can be run on
an hour after the right tool was single vessel level as well as across products or even the entire
applied. fleet, thanks to the centralized database. With the mespas
Reporting Engine, the huge amount of data that is recorded and
The impact spanner is the “big brother” to the standard hook documented every day can be analysed and made available to
spanner. It’s made of special iron that takes a solid hit and relevant internal and external stakeholders.
doesn’t chip. The most important item to remember is that this www.mespas.com
spanner is designed to be hammered right on the head of the
tool, NOT on the handle. Hitting the handle usually breaks it off.
The TMFN series is available in several sizes to fit nuts from
about 5” - 30” (125mm - 750mm.) FLIR E-Series Creates New Class
Contents and pictures courtesy of SKF @ptitude Exchange.For For IR Handheld Cameras
assistance with mounting procedures, go to:
FLIR Systems has unveiled its new-generation E-Series range
www.skf.com/mount.
of compact thermal imaging cameras - packed with new features
like WiFi and Bluetooth®. connectivity, Touch-Screen and
iPhone App – to maintain its leadership status in the predictive
MESPAS launches Release R5.13 of its Fleet maintenance and building inspection IR markets.
Management Software mespas R5 Available in three different ‘point and shoot’ models – E40, E50
or E60 for electrical and industrial and a bx range for building
MESPAS AG has released version 5.13 of its fleet management - the totally re-designed handheld cameras are lightweight and,
software mespasR5. With morethan 80 new functionalities and according to FLIR, ‘very competitively priced.’
modifications, this software upgrade is the most complex and FLIR is describing the new range as ‘the best performing
largest ever released by MESPAS. It contains enhancements and value for money compact thermal imaging cameras ever
and innovations to benefit the operational as well as the produced that are designed to fit both your IR inspection program
management side of a shipping company’s business. The and neatly in the palm of your hand.’
most important innovations relate to the mespas Cube and
mespas Reporting Engine. Over 80 new functionalities and Designed for those looking for high quality resolution, FLIR E-
enhancements MESPAS announced that it has released in its Series has more user-friendly features like MeterLiNK, large 3.5”
new software upgrade mespasR5.13 on January 15, 2011. LCD screen and the ability to communicate findings efficiently
and easily using Bluetooth®.
New features include a complete redesign of the Planned
Maintenance System (PMS) – now called Asset Management Weighing in at 800g (lightest in class) and tested to survive and
System – which is further improving the system’s architecture as maintain accuracy after a 2m fall to concrete, FLIR says the ‘E-
well as the functionality and look & feel of the user interface. Series range is the best performing value-for-money IR cameras
available, made ‘tough’ to stand the rigors, shocks and vibrations
Additional enhancements were implemented in part of daily use’.
management, procurement, and maintenance. For example:
simplified recording of jobs; enhanced part management Roger Christiansz, Managing Director FLIR Systems Australia:
functionalities including location history; easy categorization of ‘ The E-Series are new-generation IR cameras with all the mod-
Vol 24 No 2
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Maintenance News 54
cons and class-leading features you would expect from FLIR.’ amounts of money. That is why Mr. Zhou Weihua, Deputy General
E-Series is a successful combination of strong industrial Manager of the Production Department, took a decision in 2008
design and lightweight materials. The result is a camera that is to evaluate his maintenance strategy and the technology to be
ergonomically a pleasure to use and one that will not weigh you applied within that strategy. A critical decision was to look for the
down as you go about your business, whatever the application. most reliable and experienced way to determine the health of his
turbines in the fastest and most effective way.
‘We expect demand for the E-Series to come from a wide With a few different turbine designs and sizes out in the field
spectrum of sectors including manufacturing, R & D, automotive, he needed the best possible way to get reliable and regular
electronics, logistics, renewable energy, construction and HVAC information about the general condition of selected turbines of
all looking for value for money, user-friendly thermal imager these designs and types. At the same time he wanted identify
rugged enough to take it and still deliver superior image quality.’ any typical negative trends that might occur in the various, but
FLIR E-Series boasts a host of new differing, field operating conditions that the turbines would be
features including: deployed to.
Not being satisfied with his previous assessment process of
• Thumbnail JPEG image gallery
only using temperature readings of gearbox oil and generator
• High thermal sensitivity Accuracy
bearing housings, he wanted to investigate on-line monitoring,
± 2% and 0.1°C
where vibration signals from critical components are collected
• Long life battery 4 hours
24 hours a day and analysed to determine exactly if and where
• Fusion Picture-in-Picture (P-I-P)
problems are developing, and how severe any problems were.
• Copy images to USB
This type of monitoring would also provide valuable knowledge
• Thermal fusion (E40/E50)
that could allow critical maintenance to be planned and avoid
• Instant reports (E60)
unexpected and very costly breakdowns.
• Text and voice annotations
• Transmit images to smart iphone His first step was to make a deep investigation of what technology
or tablet PC was available and the quality and knowledge of the suppliers.
These investigations covered all the key suppliers of such
www.flir.com technology but contacts with other wind farm operators in China
quickly brought him to consider SKF and their turbine monitoring
system for further discussions. After direct contact with SKF, I
heard that they had recently been successful with remote on-
Marine Software’s PM Job Lock line monitoring, where data from the monitored turbine in the
U.K. based Marine Software Ltd have successfully supplied their wind farm were transmitted by Internet to their specialists for
MPM - Marine Planned Maintenance solution to Swedish based analysis.
Rederi AB Uman. These PMS systems will be installed on three In order to get first hand experience of their remote on-line
Gibraltar flagged self-discharging general cargo vessels, which capability he visited their Intelligence Centre Wind (ICW), their
operate mainly in the Baltic and North Sea regions. major wind turbine diagnostic centre in Hamburg, Germany”.
Marine Software also delivered a central OPM – Office Planned “In Hamburg I saw examples of almost all the capabilities
Maintenance system for Rederi AB Uman’s Karlshamn office. of a SKF WinCon system, because there were so many
This provides all shore side technical staff the ability to monitor systems deployed in so many wind farms. The level of detail
fleet maintenance status ashore. that the system could give was clearly demonstrated, and the
Reederei AB Uman were very interested in the “PM Job Lock” explanations by the people making the analysis clearly indicated
module, to ensure once the MPM database was operational on- that they knew all about wind turbines and the critical machinery.
board, that no crew member would be able to make Job Card The Hamburg visit gave me the confidence to set up a field trial
amendments to job instructions or interval periods, even as the on some turbines in Guohua wind farms in 2009”.
system administrator. The field trial involved 11 SKF WindCon systems to be deployed
The central office OPM users could then control these changes across 3 wind farms; one in Jiangsu province, one in Shadong
ashore and submit simple job card update files to the vessels province and one in Inner Mongolia. Around the time SKF were
for the reflective changes to be made. This type of control is installing their systems in the Guohua turbines SKF had opened
becoming increasingly popular throughout Marine Software’s a Remote Condition Monitoring Centre in Shanghai. Having SKF
client base, as it ensures on-going database integrity especially experts so close was an added benefit to Mr. Zhou and he was
for same class sister vessels. anxious to get the systems operating and see what the results
Mr Björn Holm, Fleet Manager Comments: would be.
“For us the choice of planned maintenance system was simple; The data was collected on
a user-friendly program with a lot of module functions that can be a local server at each wind
built on to fit just our organisation, and a great support function farm and transmitted to an
as well.“ www.marinesoftware.co.uk SKF server in Shanghai for
analysis. Any immediate
emergency situation would
be reported at once but an
Guohua Wind Turbines Choose SKF Remote ‘emergency situation’ was
Monitoring not detected at start up of
When the fourth biggest wind farm operator in China increases the monitoring, and a report was issued once per month to the
their installed capacity by 50% within one year, that indicates wind farm site managers and Mr Zhou.
a company that knows its business. And one of the business The reports contained the detailed vibration spectra for the key
aspects that all wind farm operators need to take care of is “turbine components being monitored, together with a brief statement that
reliability” – keeping the turbines turning as much as possible summarised the analysis of the data in terms of the condition of
and keeping maintenance activities down to a minimum. the component. But there was also a “report grid” that indicated
Reduced or controlled maintenance is always a valuable the components being monitored and each one had one of 3
contribution to bottom line profitability, but when you’ve got colours; green, yellow or red to give immediate indication of the
2000 MW of installed capacity then you are talking about huge condition, with green being OK, yellow being a slight to major
Vol 24 No 2
Return to Contents Page
Maintenance News 55
deviation from the “acceptable levels or trends”, and red being Management. “We have been working closely with our clients
something requiring immediate attention. over the past 20 years to design, build and manage enterprise
The first results were good, because Mr Zhou could “see” for the asset management solutions that help them gain maximum
first time what was really happening with his critical machinery. value from their asset life cycles.”
The SKF WindCon systems delivered the vibration spectra, “Our clients will now be able to procure this best of breed asset
similar to those he saw in Hamburg, and the SKF experts in management software directly from Logica, packaged with
Shanghai interpreted the data in terms of the condition of the certified professionals who understand the core benefits and
bearings, potential misalignment, gear damage etc. challenges of integrating Maximo with exiting systems to simplify
During the six months to January 2010, the SKF WindCons their processes,” added Sargeant.
provided good information on the turbines allowing Mr. Zhou to Maximo is asset management software that provides lifecycle
determine if and what maintenance would be required. In that and maintenance management for all asset types to help
period one of the installed SKF WindCons identified a severely companies gain maximum value from their investment, business
damaged generator gearbox bearing at the Inner Mongolia wind and IT assets within their lifecycle. The software provides a
farm. single platform to track enterprise assets, ICT assets, and
“The SKF WindCons did their job, said Mr. Zhou, they kept mobility assets, and is a critical application for Logica’s clients
me informed and the early identification of the severity of the in the energy and utilities, transport and logistics, engineering
damaged bearing in Inner Mongolia was enough to allow us to services, retail and public sectors.
plan for replacement at minimum cost and disturbance to the Logica is one of the few organisations that has IBM Maximo
planned electricity supply from the turbine”. certified professionals working across both its sales and delivery
Since the tests Guohua have installed another 58 SKF WindCons teams. Logica’s skilled team supports clients with planning,
and a further 280 have been ordered. implementation and the ongoing management of Maximo to
www.skf.com remove the complexity and ensure a smooth transition.
“The most effective asset management solutions are those that
track assets across the whole enterprise, rather than taking a
Logica Australia Partners With IBM siloed approach for individual departments. We help our clients
take this philosophy one step further by showing them where
Logica Australia, a leading IT and business services provider, they can achieve additional benefits by integrating Maximo with
has announced it has expanded its asset management offering other critical business systems and supporting this rollout,” said
by signing a new agreement with IBM to resell, deliver and Sargeant.
support Maximo® Asset Management.
For more information on Maximo please visit: http://www-01.ibm.
“Logica already has a very strong asset management practice com/software/tivoli/products/maximo-asset-mgmt/
in Australia,” said Paul Sargeant, Director, Enterprise Asset www.logica.com
Seminar 1 (1 Day)
Workshop (1 Day)
Organised By Engineering Information Transfer P/L and the Asset Management and Maintenance Journal
Seminar 1 Duration - 1 Day Seminar 2 Duration - 1 Day
• The different activities performed in maintenance. • Equipment coding, inventory and asset registers.
• Emergency, corrective, preventive, predictive, Asset technical databases. Rotables.
condition based, and Proactive maintenance. • Asset and task priority or criticallity.
• Possible problems associated with fixed time • Maintenance requests. Quick work request.
replacement of components. • A PM becoming a Corrective task. The small job.
• Understanding what are failures in maintenance. • Backlog and frontlog files.Opportunity
• The different failure types and how they affect what maintenance. Backlog file management.
maintenance should be used. • Planning PM routines and corrective work.
• What maintenance is needed. Basic rules in setting • Determining the weekly work. How much work?
inspection and PM frequencies. • Maintenance planning coordination meeting.
• Work order issue, work in progress.
3. Improving Maintenance Activities • Feedback and history.
• Performance measures for plant,
• Introduction to maintenance plan development. maintenance, people and planning.
PM’s and repair proceedures.
• Moving through Preventive / Predictive to Proactive 3. Maintenance Stores
Maintenance.
• Store objectives and stock control.
4. Inspections & Condition Based Maintenance • Impact of maintenance type on stock held.
• Who owns the stores? Who owns the parts?
• What inspection and preventive/predictive techniques • Maintenance of parts in the store.
are now available in maintenance. • Vendor and user alliances. Consignment stock.
• A look at the wide range of inspection and condition • Monitoring service levels from your store.
monitoring techniques • Location of the stores.
• Visual inspections, oil analysis, vibration monitoring, • Internet spares, parts optimisation,
thermography, acoustic emission, boroscopes, fibre
optics, alignment techniques, residual current.
4. Maintenance Management
5. The People and Structures In Maintenance • Using downtime data to minimise the impact of
downtime.
• The different organisational structures used for • Examples of how to collect, use, and understand
maintenance activities. maintenance data.
• Restructured maintenance, flexibility, multiskilling • Maintenance - Using MTBF? Histograms, Pareto
and team based structures. Analysis, Simulation.
• What motivates people to work with the company
rather than against it.
• Maintenance Outsourcing/Contracting - for and 5. Asset Management
against. • Introduction to Asset Management and
• Introduction to what the best do: Leadership, Maintenance Excellence.
recruitment, training, flexibility, motivation, • Introduction to life cycle costing of assets.
teams, TPM, performance, rewards, core skills • Introduction to Setting Strategies: Audits,
and outsourcing. Benchmarking, and KPI,s
3. Proactive Work
• Proactive Work Flow Model Attributes
• The Roles of a Planner
• The Roles of a Maintenance Supervisor RICKY SMITH - Workshop
• Planning Proactive Work Process
• Kitting Parts Ricky Smith is renowned in the world of
• Managing the Backlog Overview reliability and maintenance. He has more
• Feedback on the Plan once it has been executed than 30 years of experience working in
hundreds of plants world wide in reliabil-
4. Maintenance Scheduling ity, maintenance management and train-
• Daily and Weekly Scheduling ing.
• Wrench Time Ricky has worked in maintenance at some
• Measuring Wrench Time of the World’s great companies including
• What to do about a low wrench time?
Alumax Mt Holly (now Alcoa Mt holly).
• Scheduling one week of work load for your crew
Ricky spent one year in Kuwait and Iraq as
5. Maintenance Execution a maintenance company commander for
• Maintenance Planning effect on Work Execution the US Army Reserve, where he provided
• Maintenance Scheduling effect on Work Execution maintenance to US and Coalition Forces.
• Lack of / use of Effective Work Procedures
Ricky has developed an insight applicable
effect on Work Execution
• Feedback to the planner and schedulers to every maintenance facet.
• Work Order Close Out Ricky is also a well-respected author
• Rework – how to eliminate it with his published books, “Lean
Maintenance” and “Industrial Repair, Best
6. Maintenance Program Metrics Maintenance Repair Practices” with his
• Metrics and Key Performance Indicators latest book, “Rules of Thumb in Reliability
• Department Level Measures Engineering”.
• Equipment or System Level Measures
Phone Email
____________________________________________________________________________________________________________________________________________________________
Expiry Date_______________
Mail this form to: EIT P/L, PO Box 703, Mornington, VIC 3931 Australia or email: mail@maintenancejournal.com
ABN: 67 330 738 613 Phone: 03 59750083 Fax: 03 59755735 For Australia prices are inclusive of GST taxes.
Prices are in Australian Dollars and are valid until 1 December 2011. This form may be photocopied.
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May be used by one person and stored on a single computer.
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