Condition Monitoring Based Maintenance Management

CONDITION MONITORING BASED MAINTENANCE MANAGEMENT
JAGRUT PATEL
27-12-11 27 12 11
METHODS OF MAINTENANCE MANAGEMENT

METHODS CONDITION MONITORING EARTHING MV & LV CONDUCTORS MV AND LV PANEL BOARDS
[A] BREAKDOWN MAINTENANCE MANAGEMENT When: Simple When Machine Fails, Fix It Most Expensive Why Not: High value of spare parts inventory High overtime labour costs High machine downtime Loss of profit due to unscheduled partial or total stoppage of production production. Case: Example ? Everywhere Example?
CONDITION MONITORING BASED MAINTENANCE MANAGEME NT
JAGRUT PATEL

[B] PREVENTIVE MAINTENANCE MANAGEMENT When: Based on Elapsed Time or Hours of Operation Assumption : Machine Performance is Function of Time Outcome : Unnecessary Maintenance Why Not: Maintenance jobs same for type of equipment irrespective of duty Undue Costing No guarantee for failure of equipment in near future after maintenance Loss of production due to scheduled shutdown Example: Motor Bearing Replacement
JAGRUT PATEL

[C] PREDICTIVE MAINTENANCE MANAGEMENT When: Condition Driven Maintenance Conditions monitored Actual physical condition Operating parameters like efficiency Test results, whenever conducted Why Not: Inadequacy of electrical parameters observed to meet data requirements for proper and correct diagnosis of problem no co-relation with process parameters Condition monitoring of some portion or component of Co d t o o to g o so e po t o o co po e t o equipment entire system as a whole not monitored, hence true root-cause of problem not identified. Revenue Loss due to system down time and maintenance efforts i ff Case: Maintenance of transmission line Insulator Discs Gasket Replacements
CONDITION MONITORING BASED MAINTENANCE MANAGEME NT JAGRUT PATEL
INTRODUCTION
[D] CONDITION MONITORING BASED MAINTENANCE MANAGEMENT When: Dealing with entire system as entity holistic approach Concept of ignoring and extending maintenance period. Why: Possible to implement in relatively inexpensive stepby-step approach after giving due consideration to relevant factors Implementation to be approached in different way in working industry and new industry Easy to implement in new industry as part of project f Disadvantages of other maintenance programs.
11000
10800 10500 10000 9700 10700
MEGOHMS
Case: Insulation Trend Monitoring
10000
9000
8000
7500
7000
6000
5500
5000 Jan-06
Jul-06
Jan-07
Jul-07 MONTH & YEAR
Jan-08
Jul-08
Jan-09
JAGRUT PATEL
FACTORS AFFECTING CM IMPLEMENTATION

CRITICALITY OF EQUIPMENT FOR SUSTAINING PRODUCTION
COST OF NEW EQUIPMENT V/S CM COST
COST OF EQUIPMENT DOWNTIME
FACTORS FOR CONSIDERATION OF CONDITION MONITORING BASED MAINTENANCE MANAGEMENT
AVAILABILITY OF STANDBY REDUNDANCY
EQUIPMENT DUTY CYCLE
PRODUCTION LOSS DUE TO OUTAGE
JAGRUT PATEL
FACTORS AFFECTING CM IMPLEMENTATION

WEIGHTAGES : RANGE [1 TO 10]

CRITICAL -10/10 IMPORTANT 8/10 NOT IMPORTANT 5/10 % OF COST EQUIPMENT V/S CM COST 10% WEIGHTAGE- 10/10 EQUIPMENT DOWNTIME COST ONCE IN YEAR 1/10 ONCE IN MONTH 5/10
FACTORS FOR CONSIDERATION OF CONDITION MONITORING BASED MAINTENANCE MANAGEMENT
STAND BY AVAILABLE 5/10 NOT AVAILABLE 10/10
DUTY CYCLE CONTINUOUS 10/10 STAND BY 5/10
HEAVY LOSS 10/10 NO LOSS 0/10
Case: BFP of Power Plant M t of P Motor f Pumping St ti i Station

HURDLES
HURDLES IN CM IMPLEMENTATION IN WORKING INDUSTRIES:

Financial approval for capital investment. No technical feasibility to carry out modification in
installed equipment. No stoppage of production stream, if required, for marginal time duration to install devices required for the proposed condition monitoring Resistance of the shop floor people for introduction of shop-floor new system presuming consequent increase in their work load. Availability of good data and knowledge of problems in equipments and their nature, equipment failures, etc. And hence finding no need to introduce concept of CM.
JAGRUT PATEL
TYPES
[A] ON-LINE ON LINE Transformer Parameters Current, Voltage, Power Factor, KW, KVA, Oil/Winding Temp, Oil Level, Tap Position, Etc. Position Etc Generator Parameters Current, Voltage, Power Factor, KW, KVA, Winding Temp, Coolant Temp, Speed, Vibrations, Speed Vibrations Bearing Lube-oil Pressure/Temp Lube oil Pressure/Temp, Etc. High Rated HT/LT Motors - Current, Voltage, Power , , Winding Temp, Speed, Vibrations, g p, p , , Factor, KW, Bearing Lube-oil Pressure/Temp, Etc. [B] OFF-LINE Insulation Resistance Measurement Of Windings g BDV of Transformer Oil TAN / Power Factor / Capacitance Measurement Partial Discharge Testing Of HT Cables DC Resistance Measurement Of Windings Testing Of Protective Relays Testing And Calibration Of Instruments And Indicating/Recording Meters
IMPLEMENTATION
[A] PRELIMINARY PHASE Preparing database equipment data, past important operating data, maintenance data, testing data, etc. E i Equipment outage and f il t t d failure d t b database past records t d for cause of failure, action taken to set right breakdown, duration of outage with dates, spare parts used, cost incurred, etc. incurred etc Preparing preliminary CM implementation plan and estimated budget requirement modifications in plan p g g anticipated during actual execution along with consequent revision in budgeted cost [B] PRACTICAL PHASE Preparing detailed evaluation criteria & testing to be p g g carried out along with interval for equipment and/or system. Finalization of maintenance procedures and trouble shooting methods b h ti th d based on O&M manual, own d l experience, advice from technical expert. Finalization of report formats
JAGRUT PATEL
OPTIMIZING
[A] O Organization culture change bi i ti lt h biggest challenge. t h ll CM Considered as breakdown prevention tool Little or no knowledge of importance of maintenance Only maintenance Group responsible for breakdowns, unscheduled delays [B] CM program to be used as plant or process optimization tool to detect isolate and solve deviations detect, from desired level of performance Formation of special task group by selecting knowledgeable engineers from different departments to implement CM Group to be authorized to cross functional boundaries to implement changes under CM wherever required p e e t c a ges u de C e e e equ ed special task group to be imparted further training for specific aspects [ ] [C] Proper use of predictive techniques p p q Not only equipment alone, but system as a whole to be evaluated, process parameters to be noted and analyzed and arrive at conclusion System, instrumental for generating revenue, to be focused primarily along with individual component
MYTHS
Major M j cause of b kd f breakdown of electrical equipment - l k of f l ti l i t lack f maintenance or inadequate or improper maintenance - not true other causes of premature failure Incorrect design of equipment/system Incomplete purchase technical specification Use of sub-standard spare parts Inappropriate operating conditions MAINTENANCE IS A NECESSARY EVIL Any work carried out without proper understanding can be found only evil Nothing can be done to reduce the maintenance costs or optimization is impossible At the end of discussions held so far like process far, process, maintenance activity and cost can be optimized MAINTENANCE IS THANKLESS JOB True production people always appreciated for good results, but role of maintenance group hardly recognized
JAGRUT PATEL
EARTHING SYSTEMS
CONDITION MONITORING EARTHING SYSTEMS

EARTHING SYSTEM DEFINATION

IS:3043-1987 CL.2.7 IS 3043 1987 CL 2 7 [ CODE OF PRACTICE FOR EARTHING] Earthing or earth - the conductive mass of the earth whose electrical potential at an point is con enientl hose any conveniently taken as zero. IEEE:142-2007 IEEE:142 2007 [ GROUNDING OF INDUSTRIAL AND COMMERCIAL POEWR SYSTEMS IEEE GREEN BOOK] A conducting connection whether intentional or connection, accidental, by which electric circuit or equipment is connected to the earth or some conducting body of e at e y a ge e te t t at se es p ace o t e ea t relatively large extent that serves in place of the earth. OTHER STANDARDS IEEE-80-2000 - [IEEE GUIDE FOR SAFETY IN AC SUBSTATION GROUNDING] EARTHING PRACTICE CDA PUBLICATION 1191997
EARTHING & GROUNDING

GROUNDING means connection of current carrying ti f t i
parts to ground, like transformer or generator neutral EARTHING means connection of non-current carrying parts to ground like metallic enclosures parts to ground, ground, like metallic enclosures ACTUAL AS PER STANDARDS To quote from IS:3043, CL.0.7 the terms Earthing and Grounding are synonymous. To quote from IEC:60050 The terms Earth as well as Earth Ground have both been in general use to describe the common power/signal reference point interchangeably around the world in the Electro-technical terminology. To quote from Earthing Practice CDA Publication 119 1997 (vide BS 7430:1991 Code of Practice for Earthing) It is worth noting that in Europe tend to use the term earthing whilst in North America the term earthing, America, grounding is more common.
JAGRUT PATEL
STATUTORY REQUIREMENTS
AS PER IE RULES 1956 RULES:1956 All medium voltage equipment to be earthed by two separate and distinct connections with earth. Neutral Ne tral points of high and e tra high voltage s stems to extra oltage systems be earthed by not less than two separate and distinct connections with earth at generating stations and substations, each having its own earth electrode, to be earthed at any other point, if required, ensuring no interference caused by such multiple earth connections. In case of direct earthing proving harmful rather than providing safety, as in case of high frequency coreless furnaces, relief to be obtained. Earthing to be provided at substations generating substations, stations and consumer premises as per IS:3043. To provide facility (test link) for testing of individual earth electrode and all earth connections to be visible for inspection as far as possible. To calculate prospective fault current for any addition of p plant load, electrical equipment, etc. Vis--vis , q p , comparing with capability of exIsting earthing system and to strengthen, if required, along with system modification. CONDITION MONITORING BASED MAINTENANCE MANAGEME NT JAGRUT PATEL
FACTORS EFFECTING EARTHING

TYPE OF SOIL BLACK COTTON, YELLOW SAND, ROCKS, SALINE
SOIL RESISTIVITY
MOISTURE CONTENT IN SOIL, AFFECTING UP TO SOME EXTENT SOIL TEMPERATURE AFFECTING IN AREA HAVING FREEZING TEMPERATURES
FACTORS TO BE CONSIDERED FOR DESIGN OF EARTHING
RESISTANCE OF EARTH ELECTRODE NEGLECTED DUE TO VERY LOW RESISTANCE
MATERIAL OF CONSTRUCTION OF EARTH ELECTRODE AFFECTIN CASE OF PROTECTIVE CONDUCTOR
JAGRUT PATEL
METHODS AS PER IEC

TT Earthfaultloop impedance RCDRequired Needearth electrodeat site? Conductorcost Riskofbroken neutral l Safety Electromagneti cinterference High Yes
IT Highest No
TNS Low Yes
TNC Low No
TNCS Low AfterNandPE After N and PE separates
Yes Low No Safe Least
Yes Low No LessSafe Least
No Highest No Safest Low
No Least Highest h LeastSafe High
No LeastCost. No Subjectto consumerend Low
Advantages
Safeand reliable
Continuityof operation, cost Safest
Cost
Inexpensive.
JAGRUT PATEL
MYTHS AND FACTS

AS PER IE RULES 1956 RULES:1956 Copper Earth Electrodes are better than GI or Steel Earth Electrodes Plate Earthing is better than Pipe Earthing More water, less resistance More salt, less resistance Deeper the earth pit and longer the earth pipe/rod, lesser will be the resistance Maintenance Free Earthing Install and forget For Conductor Electrodes Resistance as per IS:3043 100 2l2 R = ------- loge ----- Ohms 2l wt where, = Resistivity of the soil in Ohm-m L = Length of the CONDUCTOR in cm w = Depth f burial f the l t d in D th of b i l of th electrode i cm t = Width of strip conductor
CONDITION MONITORING
WHY: WHY HIGHLY NEGLECTED : in many plants, commercial establishments, electricity supply utility companies, domestic establishments agriculture establishments, HOW: Instruments required for condition monitoring 1. Earth resistance tester 2. Resistance measuring instrument Different concepts for designing of earthing for outdoor switchyard applications and plant areas Digital techniques 1. Digital type earth leakage (C C principle) relays (CBCT ) 2. Earth loop impedance measurement through short circuit analysis (smart meters)
JAGRUT PATEL
EARTH LOOP IMPEDANCE TESTER
EARTH LEAKAGE RELAY
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MV & LV CONDUCTORS
MV & LV CONDUCTORS
INTRODUCTION
WHY: WHY VITAL PARTS: Feeders, Distributor, Loop cable, Link carrying current specially when to cater heavy demand. In the Form of Ins lated Cable B s d cts B sbar of: Insulated Cable, Bus ducts, Busbar Trunks, Overhead conductors, Indoor & Outdoor Panel Busbar etc. To Fight Against: Unbalance Loading Condition Temperature Rise Harmonics Electro Magnetic Interference Moisture & Dust Ambient Temperature Conditions Mechanical Strength Method of Installation Joints
JAGRUT PATEL
CONDITION MONITORING TECHNIQUES

TEMPERATURE MONITORING 1. Thermograph
2.
Infrared temperature monitor
DISTINCT BENEFITS: 1. Maintains Records 2. L d t R t Leads to Route-cause of 70 80% problems f 70~80% bl


INSULATION MONITORING 1. HV Test
2.
Harmonic Measurement
3. 3
Differential Protection
JAGRUT PATEL

ELECTRICAL
PARAMETER MONITORING THROUGH ENERGY MANAGEMENT SYSTEM (SMART GRID CONCEPT) : 1. 1 By Use of Communicable Breakers 2. By Use of Communicable releases/relays 3. Necessary Control Wiring & DAS devices
JAGRUT PATEL
MV & LV PANEL BOARDS

PANEL BOARDS
INTRODUCTION
WHY: WHY VITAL PARTS: Handling Bulk Power, heart of any distribution network. To Fight Against: Unbalance Loading Condition Temperature Rise Harmonics Electro Magnetic Interference Electro Static Problems Moisture & Dust Ambient Temperature Conditions b e t e pe atu e Co d t o s Connections to switchgears & Component failure problems Mechanical Breakages (Reptile problems) g ( p p ) Vibrations Control Wiring
JAGRUT PATEL

TEMPERATURE MONITORING 1. Thermograph 2. 2 Infrared temperature monitor INSULATION MONITORING 1. 1 HV Test 2. Harmonic Measurement 3. 3 4.
CONTROL WIRING MONITORING VIBRATION MONITORING
JAGRUT PATEL
CASE STUDIES
11 KV HT CABLE FREQUENT FAILURE OF XYZ
MAKE CABLE AT SUZLON FACTORY BARODA
- REASON : VOLTAGE SPIKE - CULPRIT : NON-HOMOGENEOUS INSULATION

FREQUENT TRIPPING OF MAIN LT BREAKER OF
TRANSFORMER
- REASON : OVERLOADING NEUTRAL - CULPRIT : HARMONICS GENERATION BY MOTOR DRIVE. DRIVE

UNABLE TO LOAD GENERATOR BEYONG 50% OF
RATED CAPACITY AT JCT BARODA
- REASON : UNBALANCED LOADING - CULPRIT : FLOATING NEUTRAL CONNECTION TO GROUND.

COURTSEY:
1. Mr. 1 Mr Ashok Parikh Vadodara 2. Mr. S. Sivakumar L & T, Conoor.
JAGRUT PATEL

Condition Monitoring Based Maintenance Management

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Condition Monitoring Based Maintenance Management

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CONDITION MONITORING BASED MAINTENANCE MANAGEMENT

METHODS OF MAINTENANCE MANAGEMENT

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

METHODS OF MAINTENANCE MANAGEMENT

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

METHODS OF MAINTENANCE MANAGEMENT

Case: Insulation Trend Monitoring

Jul-07 MONTH & YEAR

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

FACTORS AFFECTING CM IMPLEMENTATION

CRITICALITY OF EQUIPMENT FOR SUSTAINING PRODUCTION

COST OF NEW EQUIPMENT V/S CM COST

COST OF EQUIPMENT DOWNTIME

FACTORS FOR CONSIDERATION OF CONDITION MONITORING BASED MAINTENANCE MANAGEMENT

AVAILABILITY OF STANDBY REDUNDANCY

EQUIPMENT DUTY CYCLE

PRODUCTION LOSS DUE TO OUTAGE

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

FACTORS AFFECTING CM IMPLEMENTATION

WEIGHTAGES : RANGE [1 TO 10]

FACTORS FOR CONSIDERATION OF CONDITION MONITORING BASED MAINTENANCE MANAGEMENT

STAND BY AVAILABLE 5/10 NOT AVAILABLE 10/10

DUTY CYCLE CONTINUOUS 10/10 STAND BY 5/10

HEAVY LOSS 10/10 NO LOSS 0/10

Case: BFP of Power Plant M t of P Motor f Pumping St ti i Station

HURDLES IN CM IMPLEMENTATION IN WORKING INDUSTRIES:

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

CONDITION MONITORING EARTHING SYSTEMS

EARTHING SYSTEM DEFINATION

EARTHING & GROUNDING

GROUNDING means connection of current carrying ti f t i

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

FACTORS EFFECTING EARTHING

TYPE OF SOIL BLACK COTTON, YELLOW SAND, ROCKS, SALINE

FACTORS TO BE CONSIDERED FOR DESIGN OF EARTHING

RESISTANCE OF EARTH ELECTRODE NEGLECTED DUE TO VERY LOW RESISTANCE

MATERIAL OF CONSTRUCTION OF EARTH ELECTRODE AFFECTIN CASE OF PROTECTIVE CONDUCTOR

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

METHODS AS PER IEC

TNS Low Yes

TNCS Low AfterNandPE After N and PE separates

Yes Low No Safe Least

Yes Low No LessSafe Least

No Highest No Safest Low

No Least Highest h LeastSafe High

No LeastCost. No Subjectto consumerend Low

Continuityof operation, cost Safest

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

MYTHS AND FACTS

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

EARTH LOOP IMPEDANCE TESTER

EARTH LEAKAGE RELAY

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

CONDITION MONITORING TECHNIQUES

TEMPERATURE MONITORING 1. Thermograph

Infrared temperature monitor

DISTINCT BENEFITS: 1. Maintains Records 2. L d t R t Leads to Route-cause of 70 80% problems f 70~80% bl

CONDITION MONITORING TECHNIQUES

INSULATION MONITORING 1. HV Test

CONDITION MONITORING BASED MAINTENANCE MANAGEME NT

CONDITION MONITORING TECHNIQUES