3-Condition Based Maintenance PDF

Advanced Building Services And Maintenance (BSGF 6103)
Venue: BK 3
Week 12:
Introduction to Condition-Based Maintenance
PROF. AZLAN SHAH ALI

PhD, MSc, B. Building Surveying (Hons), Prof. Dip., Dip
FRISM, FCIOB, FRICS
Chartered Building Surveyor
Building Surveying Department

Faculty of Built Environment
University of Malaya, Kuala Lumpur, Malaysia
 Lecture Outline
 Introduction to CBM/ Predictive Maintenance
 Introduction to Vibration Analysis
 Introduction to Infra-red Thermography
Saturday, 03 December 2016 2

1.0 Introduction to CBM
Current Scenario (Malaysia):

 Survey on maintenance strategy used
by building owners for office and L1 :Fundamental
commercial used buildings (n=53): Document
-Ad-hock/ corrective maintenance 37% Fundamental strategy and
-Schedule/Preventive maintenance 63% concept
 Government maintenance manual does L2: Manual

Practice and responsibility of
not stated clearly on condition-based PAM
maintenance strategy in L3 and L4

L3: Management
documents. Approach
Operational approach based on
 Conditioned-based conducted based L2
on individual requests for specific FM L4: Supporting

contracts Documents:
Specification, Code of Practice,
Standard and Guidelines
 Specialised scope mostly were carried
out by a specialist contractor on one-off
or case by case basis
Source: JKR
Malaysia
The building users’

dissatisfaction was mainly due to
issues such as: Maintenance
strategy
 lack of maintenance staff
 lack of expertise
 lack of tools and technology Planned Unplanned
 insufficient allocations
 inappropriate maintenance
strategies. Preventive Corrective Corrective
These issues are more evident Condition

Schedule
in medium-sized high-rise office Based
building, which is equipped with

more sophisticated systems
 Condition-based maintenance is defined as the maintenance initiated as a

result of knowledge of the condition or significant deterioration of an item or
component through continuous monitoring and routine inspection to
minimise the total cost of repairs [Seeley, 1987].
 This maintenance strategy is aimed to minimise the total maintenance cost

by collecting and gathering the condition data of the building systems,
especially those critical components.
 Condition-based maintenance (CBM) strategy leads to cost saving and high

system reliability
 It has been proven that payback for CBM would drastically cut down
maintenance cost and produced positive and good result
Advantage:
- Reduce maintenance cost in long run
-High accuracy
-Can perform while equipment in
operation
-Improve overall maintenance
performance
Disadvantage:
-High initial cost
-Requires staff training
-Applicable to limited equipment
especially to building components
There are a few types of

condition-based method Vibration
Analysis
available.
Most popular and widely used in Ultra Infrared

building maintenance: Sound Thermog
Airborne raphy
 Infrared thermography
CBM
 Vibration analysis
Oil
Acoustic
Analysis
CBA: Case Study: Malaysia
Building Information
 Type: Training Institute
 Built-up Area: 260,000 sqft
 Monitoring duration: 2.5 years
 System: Centralised HVAC System
Corrective/ Run to Fail Strategy

 HVAC supply to spaces that can generate income around RM8,000.00 per day.
 One of the cooling tower was out of service for 5 days
 5 days = RM40,000.00 loss of income
 Material cost (from invoice) = RM12,000.00
 Labour cost for replacement of fan and accessories = RM4,000.00
 Total captured cost = RM56,000.00
 Other cost that not captured:

 Lost of idle personnel
 Customer dissatisfaction due to uncomfortable room temperature/environment
 Noise pollution due to poor operating equipment
 Worker safety when the fan failed
CBA: Case Study Malaysia
 Preventive Maintenance Strategy
 Another cooling tower, fan overhaul are scheduled and performed on a timely basis
without regard to equipment condition.
 The fan was removed and balanced, all bearings were replaced, the drive motor was
removed and overhaul with bearing replacement, the motor was tested when
reassembled.
 Cost at previous rate were:

 4 days loss of income= RM24,000.00, However, since this was scheduled outage, the
booking space can be scheduled accordingly. Estimated 50% loss of income charged
to this maintenance work @ RM12,000.00.
 Material cost (from invoice) = RM12,000.00
 Labour cost for replacement of fan and accessories = RM4,000.00
 Total cost = RM 28,000.00
 However, in corrective maintenance strategy, the cooling tower had been operating
for 17 month since the last repair, given average monthly cost =RM3,295.00.
 With Preventive maintenance, the fan was overhauled on an annual basis far an
average cost of RM2,333.00
 There is still apparent cost saving in performing preventive maintenance. This is not
including intangible aspects such as safety and health, customer satisfaction and etc.
Condition-Based Maintenance Strategy
 After 15 months of running, the outboard bearing on the fan was determined to be
failing. This conclusion was reached based on a rise of temperature and by oil
analysis indicating the presence of bearing race metal.
 Trending of the vibration levels indicated that the fan rotor did not need to be
removed for balancing. There were no faults indicated on the motor bearings.
 Maintenance was scheduled for 24 hours outage. Cost:
 1 day = RM8,000.00 loss of income
 Material cost (from invoice) = RM4,000.00 for new fan bearing and belts,
examination of the motor showed loose connection in the motor control center
that only needed tightening.
 Labour cost for replacement of fan and accessories = RM4,000.00
 Total captured cost = RM16,000.00
 Condition-based maintenance cost:

 Monitoring equipment and personnel RM24,000.00 per year (to monitor over 30
equipment for the building). Prorated cost per equipment was =RM800.00.
 Monitoring equipment cost RM50,000.00 amortised over 10 years life at a cost of
RM5,000.00 per year, with calibration cost of RM300 per year.
 Total captured cost = RM23,550.00 ((averaged per month= RM1570.00)
Cost Benefit Analysis: US Case Study
2.0 Introduction to Vibration Analysis
• Vibration Analysis (VA), applied in maintenance environment aims to
reduce maintenance costs and equipment downtime by detecting equipment
faults.
• This technique is often referred to as Condition Based Maintenance
Example: Vibration Analysis Detects Inadequate Lubrication in Fan Bearing.
• Correcting this lubrication deficiency, a motor bearing failure due to this
condition was prevented
Source: Steven, D. (2004)

Static/Force Unbalance
Force Unbalance will be in-phase and steady. Amplitude

due to unbalance will increase by the square of speed
below first rotor critical (a 3X speed increase = 9X higher
vibration). 1X RPM is always present and normally
dominates spectrum. Can be corrected by placement of
only one balance correction weight in one plane at Rotor
center of gravity (CG). Approx. 0° phase difference should
exist between OB & IB horizontals, as well as between OB
& IB verticals. Also, approximately 90° phase difference
between horizontal & vertical readings usually occurs on 33
each bearing of unbalanced rotor (±30°).
2.0 Introduction to Vibration Analysis:
Vibration Diagnostic Chart
Couple
Unbalance
Couple Unbalance results in 180° out-of-phase motion on same shaft. 1X

RPM is always present and normally dominates spectrum. Amplitude
varies with square of increasing speed below first rotor critical speed.
May cause high axial vibration as well as radial. Correction requires
placement of balance weights in at least 2 planes. Note that approx. 180°
phase difference should exist between OB & IB horizontals, as well as
between OB & IB verticals. Also, approximately a 90° difference between
the horizontal & vertical phase readings on each bearing usually occurs
(±30°).
34
Parallel Misalignment
Offset Misalignment has similar vibration symptoms to Angular, but

shows high radial vibration which approaches 180°out-of-phase across
coupling. 2X often larger than 1X, but its height relative to 1X is often
dictated by coupling type and construction. When either Angular or
Radial Misalignment becomes severe, they can generate either high
amplitude peaks at much higher harmonics (4X-8X), or even a whole
series of high frequency harmonics similar in appearance to mechanical
looseness. Coupling type and material will often greatly influence the
entire spectrum when misalignment is severe. Does not typically have
raised noise floor.
Angular Misalignment
Angular Misalignment is characterized by high axial vibration,

180° out-of-phase across the coupling. Typically will have high
axial vibration with both 1X and 2X RPM. However, not unusual
for either 1X, 2X or 3X to dominate. These symptoms may also
indicate coupling problems as well. Severe angular misalignment
may excite many 1X RPM harmonics. Unlike Mechanical
Looseness Type 3, these multiple harmonics do not typically have
a raised noise floor on the spectra.
Cocked Bearing
Cocked Bearing will generate considerable axial vibration. Will

cause Twisting Motion with approximately 180° phase shift top
to bottom and/or side to side as measured in axial direction on
same bearing housing. Attempts to align coupling or balance the
rotor will not alleviate problem. Bearing unusually must be
removed and correctly installed.
Soft Foot
"Soft Foot" occurs when a machine's foot or frame deflects greatly when a hold-
down bolt is loosened to hand tightness, causing the foot to rise more than
approximately .002 - .003 inch. This does not always cause a great vibration
increase. However, it can do so if the soft foot affects alignment or motor air gap
concentricity. "Sprung Foot" can cause great frame distortion, resulting in
increased vibration, force and stress in the frame, bearing housing, etc. This can
occur when a hold-down bolt is forceably torqued down on the sprung foot in an
attempt to level the foot. "Foot-Related Resonance" can cause dramatic amplitude
increases from 5X to 15X or more, as compared with that when the bolt (or
combination of bolts) is loosened to hand tightness. When tight, this bolt can
notably change the natural frequency of the foot or machine frame itself. Soft Foot,
Sprung Foot or Foot-Related Resonance most often affects vibration at 1X RPM, but
can also do so at 2X RPM, 3X RPM, 2X line frequency, blade pass frequency, etc.
(particularly Foot-Related Resonance).
Mechanical
Looseness
Type C is normally generated by improper fit between component parts.

Causes a truncation of time waveform and a raised noise floor in the
spectrum. Type C is often caused by a bearing liner loose in its cap, a
bearing loose turning on its shaft, excessive clearance in either a sleeve or
rolling element bearing, or a loose impeller on a shaft, etc. Type C Phase is
often unstable and may vary widely from one measurement to next,
particularly if rotor shifts position on shaft from one startup to next.
Mechanical Looseness is often highly directional and may cause noticeably
different readings comparing levels at 30° increments in radial direction all
the way around one bearing housing. Also, note that looseness will often
cause subharmonic multiples at exactly 1/2 or 1/3 RPM (.5X, 1.5X, 2.5X,
etc.).
Mechanical Looseness
Type B is generally caused by loose pillow

block bolts, cracks in frame structure or in
bearing pedestal.
Mechanical Looseness
Type A is caused by Structural looseness/weakness of

machine feet, baseplate or foundation; also by deteriorated
grouting, loose hold-down bolts at the base; and distortion of
the frame or base (i.e., soft foot). Phase analysis may reveal
approximately 90° - 180° phase difference between vertical
measurements on bolt, machine foot, baseplate, or base itself.
Normal Spectrum shows Gear & Pinion Speeds, along with

Gear Mesh Frequency (GMF) and very small GMF harmonics.
GMF harmonics commonly will have running speed sidebands
around them. All peaks are of low amplitude, and no natural
frequencies of gears are excited. FMAX recommended at 3.25X
GMF (minimum) when # teeth are known. If tooth count is not
known, set FMAX at 200X RPM on each shaft.
3.0 Introduction to Infrared Thermography
Infrared Thermography- Theory
• Simple calibration before starts to use IR camera

Infrared Thermography- Application (CBA)
• The initial cost of a camera may be high, but cost justification is

evident when the cost of downtime is realised.
• Predictive maintenance can save more cost over reactive
maintenance.
• Facilities failure could have been prevented with a routine inspection
and condition-based maintenance program.
• Increased lead time for maintenance technicians.
• Decrease in equipment failures.
• Higher production efficiency, better quality, and lower maintenance
costs.
Infrared Thermography- Application (Benefit)
• Early indication of faults and undesirable conditions.

• Enable a proactive work-flow model.
• More efficient planning and scheduling.
• Increased lead time for maintenance technicians.
• Decrease in equipment failures.
• Higher production efficiency, better quality, and
lower maintenance costs.
Infrared Thermography- Application
Observe with Observe with

naked eyes infrared camera
Inspection on
Inspection on
air-conditioning
electrical
system
system
Inspection on
Inspection on
moisture intrusion
plumbing
system
The hot spot indicates a probable problem with

the disconnect.
Poor connection to common buss bar in

circuit breaker panel.
Poor fuse to fuse clip connection.

Probable loose or corroded connections.

THANK YOU
“Introduction to Condition Based Maintenance”
For enquiries, please contact:

Prof Dr. Sr Azlan Shah Ali
PhD, MSc, B(Hons), Prof. Dip. Dip, FRISM, FCIOB, FRICS
Department of Building Surveying
Faculty of Built Environment
University of Malaya
50603 Kuala Lumpur
Email: asafab@um.edu.my;
H/p: 012-7570936; 03-7967 4494

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Advanced Building Services And Maintenance (BSGF 6103)

PROF. AZLAN SHAH ALI

Chartered Building Surveyor

Building Surveying Department

Saturday, 03 December 2016 2

Current Scenario (Malaysia):

 Government maintenance manual does L2: Manual

maintenance strategy in L3 and L4

on individual requests for specific FM L4: Supporting

The building users’

These issues are more evident Condition

building, which is equipped with

 Condition-based maintenance is defined as the maintenance initiated as a

 This maintenance strategy is aimed to minimise the total maintenance cost

 Condition-based maintenance (CBM) strategy leads to cost saving and high

There are a few types of

Most popular and widely used in Ultra Infrared

Corrective/ Run to Fail Strategy

 Other cost that not captured:

 Cost at previous rate were:

 Condition-based maintenance cost:

Source: Steven, D. (2004)

Force Unbalance will be in-phase and steady. Amplitude

Couple Unbalance results in 180° out-of-phase motion on same shaft. 1X

Offset Misalignment has similar vibration symptoms to Angular, but

Angular Misalignment is characterized by high axial vibration,

Cocked Bearing will generate considerable axial vibration. Will

Type C is normally generated by improper fit between component parts.

Type B is generally caused by loose pillow

Type A is caused by Structural looseness/weakness of

Normal Spectrum shows Gear & Pinion Speeds, along with

• Simple calibration before starts to use IR camera

• The initial cost of a camera may be high, but cost justification is

• Early indication of faults and undesirable conditions.

Observe with Observe with

The hot spot indicates a probable problem with

Poor connection to common buss bar in

Poor fuse to fuse clip connection.

Probable loose or corroded connections.

“Introduction to Condition Based Maintenance”

For enquiries, please contact:

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