NSTec Presentation Title

MAINTENANCE PROGRAMS Where are you?

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NSTec Presentation Title

WHERE ARE YOU?

MAINTENANCE PROGRAMS:
Panic Maintenance: Maintenance performed only after a machine fails or experiences problems. PM (Preventative Maintenance) Actions performed on a time- or machine-run-based schedule that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining or extending its useful life and reduce the need for major repairs. PdM (Predictive Maintenance) Attempts to evaluate the condition of equipment by performing periodic or continuous (online) equipment condition monitoring. Basically, predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition of the machine rather than on some preset schedule. Proactive Maintenance Concentrates on the monitoring and correction of root causes to equipment failures. RCM (part of which is root-cause-analysis), Laser Alignment, Precision Balancing are all part of proactive maintenance initiatives initiatives.
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NSTec Presentation Title

Panic Maintenance P i M i t
Crisis M i t C i i Maintenance / Reactive Maintenance / RTF R ti M i t Unplanned downtime g p p High parts and labor costs due to unplanned downtime and equipment damage Inefficient use of staff resources Maintenance and repair is controlled/set by machine failure Vague equipment status and reliability Cannot predict equipment reliability

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NSTec Presentation Title

Preventative Maintenance P v t tiv M i t

Histories of each machine type are analyzed and periodic overhauls are scheduled before statically expected problems occur. Potential for incidental damage to components in conducting unneeded maintenance. Catastrophic failures still likely to occur. Typically creates unwanted corrective maintenance (in some companies over 50% of total CMs) Includes performance of unneeded maintenance. Expensive (Inefficient use of resources for most equipment) Not taken seriously by most craft

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NSTec Presentation Title

Preventive Maintenance Risk P v tiv M i t

Preventive maintenance does involve risk. The risk here refers to the potential for creating defects of various types while performing the PM t ti l f ti d f t f i t hil f i th task. In other words, human errors committed during the PM task and infant mortality of newly installed components eventually lead to additional failures of the equipment on which the PM was performed. Frequently, these failures occur very soon after the PM is performed. F tl th f il ft th i f d Typical examples of human errors are shown on the following page. Especially disturbing about these types of errors is the fact that they go unnoticed - until they cause an unplanned shutdown. There is some published data that illustrates this point. It comes from the fossil-fuel power industry. A review of the data from fossil-fueled power plants that examined the frequency and duration of forced outages after a planned or forced g p maintenance outage reinforces this concept. That data showed that of 3146 maintenance outages, 1772 of them occurred in less than one week after a maintenance outage. Clearly, this is pretty strong evidence that suggests that in 56% of the cases, unplanned maintenance outages were caused by errors committed during a recent maintenance outage.
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NSTec Presentation Title

SELF INDUCED FAILURES

70-80 70 80 % of equipment f il f i t failures are SELF INDUCED SELF-INDUCED Putting hydraulic fluid into a reservoir without filtering it g q p g gp p y Welding on equipment without grounding properly Running equipment to failure when it is not part of your maintenance strategy Aligning couplings without using a laser Improperly lubricating electric motors

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NSTec Presentation Title

Predictive Maintenance P di tiv M i t

Based on machine condition while it is running B d hi diti hil i i Dependent on components providing early warning g( y y Non-destructive testing (PdM tools: vibration analysis, oil analysis, IR, Ultrasound, Motor Analyzer Tester. Etc.) Allows management to control machinery and maintenance Allows for preemptive corrective actions Increases plant readiness Greater mainline reliability Reduces expenditure on spare parts and labor R d di dl b Reduces the likelihood of catastrophic failure Improvement in worker safety p y

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NSTec Presentation Title

Key T h ologi s for K Technologies fo PdM P og Programs s

Predictive M i t P di ti Maintenance tools: t l Infra-Red Thermography Ultrasound Vibration Analysis Motor/Transformer Tester Analyzer Oil Lubricant and Wear Particle Analysis Oil, Proactive Maintenance tools: RCM Root Cause Analysis Laser Alignment Precision Balancing

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NSTec Presentation Title

Infra-Red Thermography I f R d Th og ph
Thermography is the measurement of surface temperature through remote means to indicate equipment health and assigning a color based on the temperature. Uses include: Equipment startup acceptance and commissioning Temperature survey of low voltage, 600 volts and less nominal, electrical Temperature survey of medium voltage, 600 to 47kV, electrical distribution di t ib ti Temperature survey of high voltage, greater than 47kV, electrical transmission and distribution Electro-Mechanical equipment condition monitoring (HVAC (HVAC, Pumps, Motors, Bearings, Gearboxes, Belt-Drives, etc.) Building envelope inspection Heat loss and gain evaluation g Cooling loss and gain evaluation Roofing inspection for wet insulation Inspection of insulation characteristics
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NSTec Presentation Title

Infra-Red Thermography I f R d Th og ph

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NSTec Presentation Title

Ultrasound Ult so d
Equipment startup acceptance and commissioning E i t t t t d i i i Pressure and vacuum leaks detection Bearing inspection and monitoring High speed gearbox defect detection Steam trap leakage inspection Check valve functional verification Pump cavitation Electrical arcing y g Electrical system corona discharge Heat exchanger and condenser tube and tube sheet leakage Boiler monitoring Boiler tube leakage Tank and pressure vessel leakage Enclosure leakage inspection

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NSTec Presentation Title

Ultrasound Ult so d

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NSTec Presentation Title

Vibration Analysis Vib tio A l sis

E i Equipment startup acceptance and commissioning t t t t d i i i Rotating equipment analysis on HVAC, Pumps, Motors, Bearings, Gearboxes, Belt-Drives, etc. High speed, >600 RPM component vibration analysis speed RPM, ibration anal sis Low speed, <600 RPM, component vibration analysis Shock pulse analysis (bearing lubrication issues) Structural analysis Looseness of transformer coils Misalignment Belt tension and alignment Unbalance condition Lubrication issues Bad bearings Mechanical looseness Worn gears Electrical problems (rotor & stator issues)
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NSTec Presentation Title

Vibration Analyzer Vib tio A l

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NSTec Presentation Title

Off-Line Moto /T Off Li Motor/Transformer Tester A sfo T st Analyzer l

Detects any type of motor electrical fault: Turn-to-turn, coil-to-coil, and phase-to-phase faults Shorted windings Open phases Burned or contamination windings Insulation breakdown Poor connections Ground faults Phase unbalances Cable faults Cab e au ts All types of rotor faults. Example: Broken/cracked rotor bars and rotor casting voids & Rotor eccentricity Good for testing spare motors to confirm their status and insures against installing a faulty motor i t i t lli f lt t NOTE: It tests virtually any size or type of motor, generator or transformer, transformer even from a remote locations locations.
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NSTec Presentation Title

On-Line Moto /T O Li Motor/Transformer Tester A sfo T st Analyzer l

Motor Current Si M t C t Signature A l i Evaluate, Detect, and Monitor: t Analysis E l t D t t d M it Stator electrical and mechanical health Rotor bar health Air gap/eccentricity issues Mechanical component health including bearings, balance and alignment, alignment and driven equipment Adaptors for external equipment plug in

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NSTec Presentation Title

All Test Pro Off Line Motor/Transformer Tester Off-Line Analyzer

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NSTec Presentation Title

Oil, L b i Oil Lubricant and W t d Wear P ti l A Particle Analysis l sis

Choose the tests that are appropriate for your piece of equipment and pp p y p q p oil type! Example of Various Transformer Oil Tests: Dissolved gas analysis (DGA or TOGA) (ASTM D 3612) Water Content (D 1533) Acid Number (TAN-E) (D 664) Interfacial Tension (D 971) y Myers Index = IFT/TAN Color (D 1500) Dielectric Breakdown (D 1816) Polychlorinated Biphenyls (D 4059) Furanic Compounds (D 5837)

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NSTec Presentation Title

Oil, L b i Oil Lubricant and W t d Wear P ti l A Particle Analysis l sis

Trace Elements (D5185) T El t Particle Counts (ASTM draft method) y (RBOT) ( 2112) ) (D ) Oxidation Stability ( Oxidation Inhibitor Content (D 2668) Power Factor (D 924) Specific Gravity (D 1298) Viscosity (D 445) Static Charge Density Halogens (D5384 and D808) Flash Point (D 92)

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NSTec Presentation Title

Proactive Maintenance P o tiv M i t

What i Wh t is proactive maintenance? While preventive and predictive ti i t ? Whil ti d di ti maintenance seek to catch and prevent symptoms before they result in breakdowns, proactive programs seek to lessen or eliminate the root causes. Proactive maintenance is a maintenance strategy for causes stabilizing the reliability of machines or equipment. Its central theme involves directing corrective actions aimed at failure root causes, not active failure symptoms, faults, or machine wear conditions. A typical proactive maintenance regiment involves three steps: (1) setting a quantifiable target or standard relating to a root cause of concern (e.g., a target fluid cleanliness level for a lubricant), (2) implementing a maintenance program to control the root cause property to within the target level (e.g., routine exclusion or removal of contaminants), and (3) routine monitoring of the root cause property using a measurement technique (e.g., particle counting) to verify the current level is within the target.

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NSTec Presentation Title

Proactive Maintenance P o tiv M i t

According to major industries throughout the world, its time to A di j i d i h h h ld i i throw out your old ideas on machine maintenance. The costsaving trend is toward a maintenance program that targets the root causes of machine wear and failure. Preventive methods are out: proactive maintenance are in. Why? Because proactive maintenance methods are currently saving industries of all y g sizes thousands, even millions, of dollars on machine maintenance every year. According to DuPont, maintenance is the largest single controllable expenditure in a plant. In many plant companies it often exceeds annual net profit. The problem of costly maintenance has truly reached a serious level, but as some companies have found out, and more come to realize out every day, their maintenance costs can be cut drastically by establishing a proactive line of defense.
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NSTec Presentation Title

Proactive Maintenance P o tiv M i t

Proactive maintenance uses the following basic techniques to P i i h f ll i b i h i extend machinery life:
Proper installation and precision rebuild Failed-parts analysis Root-cause f il R t failure analysis l i Reliability engineering Rebuild certification/verification Age exploration Recurrence control Continuous monitoring of things such as lubricants, hydraulic lubricants fluids and coolants Developing strict contamination control program for: lubrication fluids, fluids hydraulic fluids, gear oils, and transmission fluids fluids oils
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NSTec Presentation Title

RCM
Reliability-Centered M i R li bili C d Maintenance, often known as RCM i an f k RCM, is industrial improvement approach focused on identifying and establishing the operational, maintenance, and capital improvement policies that will manage the risks of equipment failure most effectively. Reliability Centered Maintenance can be used to create a cost-effective maintenance strategy to address dominant causes gy of equipment failure. It is a systematic approach to defining a routine maintenance program composed of cost-effective tasks that preserve important functions It is defined by the technical standard functions. SAE JA1011.

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NSTec Presentation Title

The Th RCM P o ss Process

Phase 1 consists of identifying the functions of the equipment, Ph i t f id tif i th f ti f th i t identifying the functional failures, identify the different failure modes, identify the effects of the failure modes (at the plant level), identify the consequences conseq ences to the facility as a result of the failure effects This is facilit res lt fail re effects. the COFA (Consequence of failure analysis) evaluation analysis process. Phase 2 consist of specifying the appropriate maintenance task (PM, PdM, Proactive, or simply RTF) for the equipment identified in Phase 1. These tasks must be both applicable and effective. This phase also Th k b b h li bl d ff i Thi h l includes a very prescriptive method for identifying default actions if an applicable and effective preventive task cannot be found. Phase 3 consists of properly executing the tasks specified in phase 2 and includes the sustainment process.
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NSTec Presentation Title

Conclusion Co l sio
A proactive maintenance program is the capstone of an RCM ti i t i th t f philosophy. From the RCM program you can develop the appropriate maintenance philosophy to use for a particular piece of equipment whether it is run-to-fail, pre entati e predicti e or proacti e hether is: r n to fail preventative, predictive, proactive.

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