Maintenance policies

Maintenance Policies/Tactics/Methodologies
(1) (5)
Failure-Based Total-Based
Reactive (ReM): Global (GM):
(3)
- RTF - Optimization Approach
Condition-Based
- CM
Predictive (PdM):
- BD (2) - TPM
- Oil analysis
:: Time-Based ::
- Vibration analysis
Preventive (PM): - Temperature analysis (4)
- Calendar: - Pressure analysis Risk-Based
Weekly - Wear analysis Proactive (PaM):
Monthly - Efficiency analysis - RCFA
:: :: - FMEA \ FMECA
- Running: - HAZOP
1000 R.H. - RCM \ RCM2
1000 K.M. - RBI :: ????
::
Classification of maintenance policies.
[Venkatesh 2003, Waeyenberg and
ME091301 PintelonManagement
Maintenance 2004, and Gomaa et al. 2005] 1
 Predictive maintenance
Vibration
Visual analysis Oil
Inspection analysis

Efficiency Condition based Temperature

analysis management analysis

Pressure
Wear
analysis
analysis
Ultrasonic

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 Condition-based maintenance
 Condition-based maintenance is usually most
effective because it almost always can warn of
a failure before it occurs.
 The warning may be subtle and give little time
to react.
 Good candidates for components that fail in a
progressive manner, rather than without
warning.
 Typical components that benefit are large
rotating units.
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 Selecting appropriate method
 Factors should be considered for selection:
 The failure mechanism itself
 The reliability of the method chosen

 The warning time it gives

 The cost, both initial and ongoing
 The skill level required to monitor and interpret
the measure

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 Condition monitoring techniques
 Oil Analysis
 Vibration Analysis
 Laser Alignment & Shaft Balancing
 Thermography (Infrared Camera)
 Ultrasonic Evaluation
 Electronic Signature Analysis
(Motor Current Analysis)

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 Oil/lubricants analysis
 Also known as tribology.(Tribology is the science and
engineering of interacting surfaces in relative motion. It
includes the study and application of the principles of
friction, lubrication and wear).
 Take periodic samples of oil from equipment and send
out for laboratory analysis
 Check for viscosity and acidity for example
 Periodically compared to baseline to check for
deterioration
 Tests condition and wear of components
 The size and shape, chemical analysis, wear particles
 Will warn of impending problems and reduce chance of
premature failures
 Will possibly point out root causes of failure
 Costs
 Experts, laboratory checks, testing equipments

Oil analysis  http://www.wearcheck.com/info/about.asp

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 Vibration Analysis
 Vibration analysis monitors the mechanical
movement of a machine.
 Based on regular schedule, watching for
vibration levels outside the predetermined
range or baseline.
 The vibration signal is used to diagnose the
location of problem.
 Common vibration sources:
 Misalignment, imbalance

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 Vibration Analysis
 All equipment vibrates, but if this vibration
becomes too severe, it indicates problems. Use
vibration levels to prioritize repairs.
 What to measure?
 Amplitude  how much movement
 Frequency  how fast

 Phase  how a machine is vibrating

 Vibration is measurement of the periodic motion

of equipment (I.e. the ‘shaking’). Vibration is
measured in units of inches/second (in/sec, IPS).
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 Vibration analysis
 Some Rules of Thumb to judge the condition of
your equipment:
 lessthan 0.050 IPS Excellent
 0.050 - 0.100 IPS Good
 0.100 - 0.200 IPS Acceptable
 0.200 - 0.400 IPS Unacceptable
 greater than 0.400 IPS Failure Likely

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 Vibration Analysis
 The technician takes a simple hand held
instrument out each piece of equipment to be
tested.
 He then attaches a magnetic accelerometer to
several specific places and records readings
electronically.
 These readings are then downloaded to a
computer and analyzed with a software program
purchased with the hand held instrument.

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 Vibration Analysis - Two Options
 Costs to set up on-site program
 Costs for software and hardware
 One to several weeks training for technician

 Technician must work on vibration monitoring at

least 3 days/month to stay fluent in the
technology and analysis
 Costs to contract out
 Costsmainly depend on number of pieces of
equipment and accessibility

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Parameters used for detection of machine faults

12
Parameters used for detection of pump faults

13
Vibration severity

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Condition monitoring options for turbocharger

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Vibration sources

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Accelerometer location

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Vibration spectrum analysis

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Vibration analysis  Standard measurement
ISO 2372-Vibration Severity Range Limits (Velocity)

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 Laser Alignment
 Provides quicker and more accurate means of
shaft alignment than dial gauges.
 There are many sources of error in dial gauge
readings:
 sagging indicator brackets
 sticking/jumping dial hands
 low resolution means rounding losses
 play in mechanical linkages
 tilted dial indicator leads to offset errors
 axial shaft play leads to gap error

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 Infrared Imaging
 A handheld camera is used in a way that enables you to
‘see’ temperature differences. The camera is a lot like a
video camera in size and weight.
 The hotter the temperature, the more yellow the
equipment
 Not all temperature differences are indicative of
problems
 You must be trained to recognize those temperature
differences that are significant
 Some Infrared Imaging Costs:
 Thermal imaging system
 Technician training & fluency education

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 Infrared Imaging
 Here is a transformer as seen
through a short wave
infrared camera.

 The yellow coloring does not

indicate a problem. It is the
reflection of sunlight.

 The maintenance technician

must be trained to recognize
this. Otherwise he will
report ‘false’ hot spots that
will lead to wasted corrective
action.
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 Infrared Imaging
 Here, the same transformer
is seen through a long wave
infrared camera.

 The ‘false’ hot spots seen

through the short wave
camera do not show up here
but maintenance technician
must be trained to recognize
significant yellow areas.

 Maintenance programs that

require outdoor surveys are
best served by long wave
cameras.

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 Ultrasonic Evaluation
 Ultrasonic testing is used to check for: arcing, tracking, corona
discharge and vibration.
 In certain instances it is easier to ‘listen’ for problems from a
distance when it is difficult to get right next to the equipment
in question.
 Ultrasound is an effective, low cost means of evaluating the
condition of insulation components on high-voltage
transmission and distribution equipment.
 Initial Equipment Cost
 Training Costs

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 Ultrasonic Evaluation
 Ultrasound should be used in conjunction with Infrared
Imaging when Infrared Imaging is not practical.
 Ultrasound can often detect potential insulation faults that do
not show up in an infrared survey.
 A combination of infrared and ultrasound is often used on
high-voltage electrical equipment, particularly enclosed
switchgear.
 Infrared locates resistive faults (e.g. dirty switch
contacts or loose joints)
 Ultrasound locates developing insulation faults
 Ultrasound instrument can be used on enclosed
switchgear that cannot be ‘viewed’ with an infrared
instrument. Removing a few bolts allows ultrasound
to penetrate into the inside of the gear.

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 Ultrasonic Evaluation
 Ultrasound used here to test for vibration
problems in hard-to-reach bearing

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 Electronic Signature Analysis
 Electronic signature analysis (ESA) is a developing
predictive maintenance technology that can supplement
other technologies.
 ESA instrument acquires voltage and current supplied to
an electric motor. Associated software helps
maintenance technician analyze that data and determine
the ‘health’ of the motor, distortion of the incoming
power, and vibration characteristics of the driven
equipment.
 Initial & training costs.

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 References
 John Dixon Campbell, Uptime: Strategies for
Excellence in Maintenance Management,
Productivity Press, 1995
 GMM or CMS, Slides prepared by Dr. Attia
Hussien Gomaa, Engineering service -
American University in Cairo (AUC).
 Anthony Kelly, Maintenance Systems and
Documentation, Elsevier, 1st Edition 2006.

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