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Maintenance Management Of Electrical Equipment (Condition

Monitoring Based) – Part 5

Maintenance Management Of Electrical Equipment – Condition Monitoring Based, Part 5 (photo credit: irisys.co.uk)

Read previous parts of this serie – Part 1 | Part 2 | Part 3 | Part 4

Preliminary preparation phase for CDM in the working industry

In case of new industry, it would be easy to implement Condition Monitoring based Maintenance Management
(CDM) as apart of respective equipment or system itself after evaluating various factors discussed in previous part
4 of article. The new industry may also take into account various technical and financial aspects of CDM discussed
in this paper.

Considering the difficulties in introducing CDM in the working plant as discussed in previous part 4, it is
appropriate to discuss issues relevant to incorporation of CDM program in the working plant.

One of the very attractive aspects of CDM is the fact that it can be implemented in a relatively inexpensive, step-
by-step approach without much difficulty. Because CBM is based on the equipment oriented concepts of PDM, it
can be applied gradually – one system at a time. Eventually the entire power system is included in the program
and cost savings would begin to multiply thereafter.

Whenever any major revision in the maintenance management is made, it is essential to include review the safety
procedures relevant to that specific electrical equipment or system for consequences of CDM.
Data Collection and Storage Procedures

Possible Preventive Maintenance schedule for Electrical Apparatus in a Petrochemical Process Plant

The major difference between PMM/PDM and modern CDM is the use of maintenance data collected . In the
past, maintenance data obtained at fixed interval under the maintenance program was reviewed and filed in most
of the industries. Hardly any attention was paid to comparison of data or plotting of trend of results obtained.

As described in this paper, trend plotting and statistical analysis are the fundamental building
blocks of CDM.

Comparison of absolute values, and perhaps more importantly, comparing data deviations via statistical analysis
provide information never before available. Obviously, a statistically relevant database is required to be maintained
for getting advantages of CDM.

As mentioned, many industries have at least maintained good records of operating data, maintenance data and
test results over the years for the equipments and systems. This data is to be converted to a computerized
database, which one may find time consuming, but simple.

The table structure for database should be as general as possible and it can be developed as per suitability of the
maintenance organization created in the industry. The structure should allow create database for various types of
electrical equipment as well as incorporate future modifications.

Each maintenance and testing result record should be correctly dated to allow identifying the specific test
interval.

Along with maintenance database, it is necessary todevelop the equipment database. If desired, the equipment
database may be linked to the master maintenance database. It may also be incorporated in the master
maintenance database; however, more flexibility is realized if they are kept separate.

Equipment failure and outage information

A compilation of equipment’s unscheduled outage data is a must to help assessment of risk of failure under
CDM program.

This information may include such data items as type of outage, cause of failure, outage duration with dates,
work carried out in brief, spares used (if any), cost incurred and other such data.

Outage information can be used to prioritize the implementation sequence of the CDM program. Obviously, the
equipment or system with a high failure rate and/or a high value to the production should be enrolled in the
program first.

Preliminary budget and plan

The final and most important step of preliminary preparation is the estimation of preliminary plan and a budget for
implementing CDM program.

It may be noted that as the plan for implementing CDM would be preliminary, one should expect modifications as
the actual program implementation begins and consequently the actual cost may also revise.

For example, the equipment such as low and medium voltage circuit breakers are not as readily
predicted as the transformers, the concept of detailed statistical analysis may be dropped in favor of
a less rigorous approach.

Practical implementation phase of CDM program in the working industry

Once preliminary strategy and budget costing for the proposed program is approved, the database and other
information gathered in preliminary phase will be put to work as an active Condition Monitoring Based
Maintenance Management Program.

Development of detailed evaluation criteria and methods

Based on the database gathered in preliminary phase, the maintenance management team should decide the
statistical evaluation techniques to be used as an analytical tool and control strategies. The exact nature of
strategies, to be used, may become known with passage of time.

If desired, the services of qualified and experienced CDM consultant can be engaged to assist the selection and
implementation of appropriate strategies.

Finalisation of
recommended
maintenance procedures
and intervals

Initial source of normal

maintenance and trouble shooting
is the O&M Manual supplied by
the equipment manufacturer. As
the details provided in the manual
would be general, the
maintenance procedures can be
added as needed based on the
opinions and observations of the
engineers and skilled technicians.

The ambient environmental

conditions are also extremely
important in the overall
evaluation.

CDM Report Formats

Since long, the printed formats or

handwritten registers have been
around in almost all the industries
to record the maintenance work
carried out and test results. The
major limitation of printed formats
is the need for modification and
manual transfer of handwritten
data into the various computer Damage to inside of coil winding stack of oil-filled transformer (photo credit: forensic.cc)
databases.

With the advent of computers, specifically laptops, the data for all the activities can be directly entered into the
computer at the site of maintenance. The information can then be downloaded into the main maintenance PC
and/or acompany local area network. As another option, if the testing equipment has in-built memory to store the
test results, the data so stored may be transferred into the maintenance PC from the test equipment.

This approach is especially effective when the testis actually performed under computer control.

OPTIMIZING CDM PROGRAM

Large numbers of industries have sincerely implemented CDM programs, however all the industries have not been
able to generate measurable benefits. Technology limitation is not the principle cause of these failures, but it is
their failure to make the necessary changes in the workplace that would permit maximum utilization of these
predictive tools.

Some of the proactive steps, which can eliminate these restrictions, are narrated hereunder to help gain
maximum benefits from CDM program.

Organisation culture change

There is a perception in the minds of corporate-level managers that CDM technologies are exclusively a
maintenance management or breakdown prevention tool, which must be drastically changed at the corporate level
and permeate throughout the plant organisation.

Though sound simple, it is daunting task to change this corporate attitude toward perception of CDM, as most of
the corporate-level managers have rather limited or no knowledge or understanding of maintenance – or
even the need for maintenance-convincing them that a broader use of CDM technologies is extremely difficult. In
their view, the maintenance group is solely responsible for the breakdowns and unscheduled delays. They cannot
understand that most of these failures are the result of issues not related to maintenance.

If the data regarding equipment reliability in various industries are judiciously reviewed, the maintenance relevant
production interruptions and quality problems would be found to the tune of around 15 – 20%. Remaining 80 –
85% problems would be found totally out of purview of the traditional maintenance function’s responsibility.

Industrial processes often involve expensive equipment for producing expensive products (photo credit: rtcmagazine.com)

Other nonmaintenance causes are incorrect design of equipment/system, inappropriate operating practices, sub-
standard spare parts and numbers of other non-maintenance causes are the major contributors to production and
product-quality problems, not maintenance.

CDM program should be used as a plant or process optimization tool to detect, isolate, and
provide solutions for the deviations from desired performance, which may result in lost capacity,
poor product quality, increased costs, or a threat to employee safety.
CDM program has the capability to perform this critical role, but that is simply not being used to optimum. To
accomplish this task either of following approaches can be considered.

First approach

The first approach would be to select engineers having knowledge of one or more of these requirements. For
example, the group might consist of the best operations, maintenance, and technical personnel available from the
current workforce. Care must be taken to ensure that each group member has some real knowledge of his
specialty area. This group may be made accountable for total plant optimisation.

This group must have the authority to cross all functional boundaries and to implement changes under
CDM to correct the problems observed with analysis.

Second approach

The second approach is to hire services of professional reliability consultants. This approach may be found easier
at first glance, but not so because there are very few qualified and experienced reliability professionals available at
very high cost. Most of these professionals would prefer to offer their services as short-term consultants.

Hence, extreme caution is required to be exercised in selecting the consultant.

This new group must have a thorough knowledge of machine and process design, and be able to implement best
practices in both operation and maintenance of all critical production systems in the plant. In addition, they must
fully understand procurement and plant engineering methods that would provide best life-cycle cost for these
systems.

Finally, the group must understand the proper use of CDM program. Few plants have existing employees who
have knowledge of these fundamental requirements.

After formation of new team, necessary training forthe reliability team must be the first priority. The team member
having maximum knowledge and skills to carry out the assigned function may impart training especially regarding
application of CDM based on concept of reliability. Sufficient training is a must to ensure maximum return on the
investment made for the new team and system.

This training should focus on process or operating dynamics for each of the critical production systems
in the plant.

All the plants have few superstars who do not have a real, in-depth knowledge of their perceived specialty. In other
words, the best operator may in fact be the worst contributor to reliability or performance problems. Although he
may get more capacity through the unit than anyone else, the practices followed by him may be the root-cause of
chronic problems experienced in the plant.

As the suggested approach is a radical departure from the traditional organisation culture found in most industries,
the resistance would be met to change from all levels of the organisation. With few exceptional
employeeswho understand the absolute need for a change for betterment of plant, most of the workforce would not
voluntarily accept this new functional group; however, the formation of a dedicated group of professionals that is
absolutely and solely responsible for reliability function and production optimisation of total plant operation is
essential.

It is the only way any industry can achieve and sustain optimum performance.
Will be continued very soon…