MCMAD1 Chapter01 MaintenanceStrategies

Machine Condition Monitoring and Fault Diagnostics
Chris K Mechefske
September 4, 2008
Page 1
Course Overview
Introduction to Machine Condition Monitoring and Condition Based Maintenance Basics of Mechanical Vibrations Vibration Transducers Vibration Signal Measurement and Display Machine Vibration Standards and Acceptance Limits (Condition Monitoring) Vibration Signal Frequency Analysis (FFT)
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Course Overview
Machinery Vibration Trouble Shooting Fault Diagnostics Based on Forcing Functions Fault Diagnostics Based on Specific Machine Components Fault Diagnostics Based on Specific Machine Type Automatic Diagnostic Techniques Non-Vibration Based Machine Condition Monitoring and Fault Diagnosis Methods
Current Topic
Introduction
What is Machine Condition Monitoring and Fault Diagnostics? basically it is a maintenance tool also being applied in quality control, and process control, process monitoring
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Introduction
ISO definition: a field of technical activity in which selected physical parameters, associated with machinery operation, are observed for the purpose of determining machinery integrity not just vibration based
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Introduction
Also includes: oil analysis (oil quality, contamination) wear particle monitoring and analysis force sound pressure (intensity) temperature output (machine performance) product quality odour visual inspection and others
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Machinery Failure
To place Machine Condition Monitoring and Fault Diagnostics in context with the larger plant maintenance picture: Most machinery is required to operate within a close set of limits. operating speed (not variable speed machines) load (throughput) product quality standards Occasionally machinery is required to operate outside these limits for short times (electric generators).
Machinery Failure
The main reason for employing a Machine Condition Monitoring and Fault Diagnostics program is to find accurate, quantitative information on the present condition of the machinery. reasonable expectation of machine performance will a machine stand a required overload? should equipment be serviced now or later? what is the expected time to failure? what is the expected failure mode?
Machinery Failure
Machinery failure is the inability of the machine to perform its required function. Failure is machinery specific. Examples: conveyor belt drive-end pulley bearings failure = seized bearing (belt stops) computer disk drive failure = slow response, noisy
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Machinery Failure
Other considerations which may dictate machine performance: economics (obsolescence - run to failure) safety (minimize risk of failure trains, planes).
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Causes of Failures
design deficiencies material deficiencies processing deficiencies improper assembly practices improper service conditions inappropriate maintenance excessive demands
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Types of Failure
Catastrophic - sudden and complete. Incipient - partial, usually gradual. In most cases there is some advanced warning of the onset of failure. All failures pass through an incipient phase even if they do so quickly.
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The goal of Machine Condition Monitoring and Fault Diagnostics is to:

detect onset of equipment deterioration diagnose the condition trend its progression over time prognose (predict) when ultimate failure will occur allow time for maintenance planning This excludes failures caused by unforeseen and uncontrollable outside forces - earthquakes, etc.
Frequency of Failure
Bath-tub Curve (individual machine or population of machines)
Wear In Failure Rate Normal Wear Wear Out
Time In Service
Wear In Failures
Typically high frequency of failures early in the expected life of a machine due to: design errors manufacturing defects assembly mistakes installation problems commissioning errors
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Normal Wear (Random Failures)
Typically occur during the majority of the life of a machine. Relatively low failure rate when operating within design specifications.
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Wear Out Failures

Occur towards the end of a machines design life. Gradually increasing failure rate at the expected end of a machines useful life - primarily due to: fatigue wear mechanisms corrosion obsolescence
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Wear Out Failures

The slope of the wear-out part of the bath-tubcurve is machine and operational history dependent.
If the machine design is such that the operational life ends abruptly (due to fatigue for example) or the machine is under designed to meet the load expected or the machine has endured a severe operational life (experienced numerous over-loads) the slope of the curve in the wearout section will increase sharply with time. If the machinery is over designed or experiences a relatively light loading history the slope of this part of the bath-tub-curve will increase only gradually with time.
This curve shape is generally true for individual machines and populations of machines of the same type.
Wear In Failure Rate Normal Wear Wear Out
Time In Service
Wear In Failure Rate Normal Wear
Time In Service
Basic Maintenance Strategies

Run to failure (Breakdown) Maintenance has failed. Example: Burnt out light bulb.
Machine Capacity (Est.) Estimated Capacity and Load Machine Duty (Load) Time In Service
September 4, 2008
maintenance performed only when machinery
Failures
Maintenance
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Scheduled (Preventative) Maintenance specific maintenance tasks performed at set time intervals (or duty cycles) significant margin between machine capacity and actual duty maintained. Example: Oil changes on your car.
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Scheduled Maintenance
Machine Capacity (Est.) Estimated Capacity and Load Margin Machine Duty (Load) Time In Service
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Margin
Maintenance
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Condition Based (on-condition, predictive, pro-active, reliability centred) Maintenance
actual condition of the machinery is assessed
data used to optimally schedule maintenance maximum production and avoidance of catastrophic failures is achieved Example: Tire changes on your car.
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Condition Based Maintenance
Machine Capacity (Est.) Estimated Capacity and Load Reduced Load Minimum Margin Machine Duty (Load) Time In Service
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Maintenance
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Condition Based Maintenance Note: margin between duty and capacity is never allowed to reach zero - breakdown avoidance. Results: longer time between maintenance tasks than for scheduled maintenance.
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Advantages and disadvantages do exist. Situations exist where one or the other would be appropriate. The maintenance engineer must decide and justify action. Combinations of strategies may also be required. Examples: - increased frequency of monitoring as the age of a machine increases - maximum time between overhauls with monitoring looking for random failures

Philosophy: Fix it when it breaks
Reactive
Benefit: Zero initial investment
Cost: Costly catastrophic breakdowns
Philosophy: Change it out every ____ hours
Scheduled
Benefit: Reduced catastrophic breakdowns
Cost: Premature work
Philosophy: Does it need to be fixed?
Condition Based (CBM)
Benefit: Maintenance done when needed
Cost: Requires effective use of information Upfront cost
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Factors which Influence Maintenance Strategy

classification of machine - critical to production? - high cost of replacement? - long lead time for replacement? manufacturers recommendations failure data (history), MTTF, MTBF, failure modes redundancy safety (plant personnel, community, environment) parts cost/availability costs (personnel, administrative, equipment) running costs

In general the following rules apply. Breakdown Maintenance if equipment is redundant low cost spares available interruptible process, stockpiled product safe failure modes long MTTF/MTBF low cost secondary damage quick repair or replacement (low cost of interruption to production)

In general the following rules apply. Preventive Maintenance statistical failure rate available narrow failure distribution (predictable MTBF) maintenance restores full integrity single failure mode (known) low cost of regular overhaul/replacement unexpected interruptions to production expensive (scheduled interruptions not so bad) low cost spares available reduced number of breakdowns required costly secondary damage from failure

In general the following rules apply. Condition Based Maintenance expensive/critical machinery long lead time for replacement (no spares) uninterruptable process (both regular and unexpected) - costly large/complex machinery overhaul expensive/needs highly trained people reduced numbers of highly skilled maintenance people

In general the following rules apply. Condition Based Maintenance (contd) costs of monitoring program acceptable. safety is a priority (failures dangerous) remote, mobile equipment failure not indicated by operation degeneration costly secondary damage.
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Finally: Each case must be evaluated individually. Principal considerations defined in economic terms. Company policy considerations.
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Potential advantages increased machine availability and reliability improved operating efficiency improved risk management (less down time) reduced maintenance costs (better planning) reduced spare parts inventories improved safety improved knowledge of machine condition (safe overloading of machine possible)

Potential advantages (contd) extended operational life of machine improved customer relations (less planned / unplanned downtime) elimination of chronic failures (root cause analysis and redesign) reduction of post overhaul failures due to improperly performed maintenance or reassembly

Potential disadvantages monitoring equipment costs (high) operational costs (running the program) skilled personnel needed needs strong management commitment long run-in time to collect machine histories and set trends reduced costs are harder to sell as direct benefits to management than increased profits
MCMAD Philosophy
Get useful information on the condition of equipment to the people who need it. - operators, maintenance, managers, etc. - these groups need different information at different time This means: - collect useful data - change data into information in a form required by and useful to others - timely reporting
MCMAD Philosophy
Types of data collected: - vibration severity, frequency analysis, temperature, oil analysis, etc. Types of information gleaned: - existing condition - trends - expected time to failure at a given load - type of fault existing or developing - type of fault which caused failure
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MCMAD Tasks
Detection Diagnosis Prognosis Post Mortem Prescription
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MCMAD Tasks
Detection data gathering comparison to standards comparison to limits set in-plant for specific equipment trending over time
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MCMAD Tasks
Diagnosis recognising the type of fault developing (different fault types may be more or less serious and require different action) severity of fault
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MCMAD Tasks
Prognosis expected time to failure trending forecasting maintenance planning/timing
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MCMAD Tasks
Post Mortem root cause failure analysis research, laboratory / field tests modeling of system and analysis
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MCMAD Tasks
Prescription (activity dictated by information collected) may be applied at any stage alter operating conditions alter monitoring strategy (frequency, type) redesign process or equipment
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MCMAD Strategies
How much data to collect? How much time to spend at data analysis? These things dictate the MCMAD strategy (cost will always be a factor) Consider: equipment class, size, importance within process, replacement cost and availability safety different pieces of equipment or processes may require different monitoring strategies.
MCMAD Strategies
No Monitoring inexpensive, non-critical equipment in stock equipment (or readily accessible) low load equipment low failure rate known failure modes well understood
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MCMAD Strategies
Periodic Monitoring non-critical equipment failure modes known historically dependable equipment trending and severity levels checks only problems trigger more rigorous investigations
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MCMAD Strategies
Continuous Monitoring permanently installed monitoring system samples and analyses data automatically critical equipment (expensive to replace with downtime (loss of production) being expensive) changes in condition trigger more detailed investigation or possibly automatic shutdown
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What to Measure
vibration levels (displacement, velocity, acceleration). oil analysis (lubricating quality contamination) wear particle monitoring and analysis (number, size, shape, composition) force measurements sound level odour temperature output quantity product quality visual inspection, etc.
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Machine Condition Monitoring and Fault Diagnostics

The goal of Machine Condition Monitoring and Fault Diagnostics is to:

Normal Wear (Random Failures)

Wear Out Failures

Wear Out Failures

Basic Maintenance Strategies

maintenance performed only when machinery

Basic Maintenance Strategies

Basic Maintenance Strategies

Basic Maintenance Strategies

Basic Maintenance Strategies

Basic Maintenance Strategies

Basic Maintenance Strategies

Basic Maintenance Strategies

Benefit: Zero initial investment

Cost: Costly catastrophic breakdowns

Philosophy: Change it out every ____ hours

Benefit: Reduced catastrophic breakdowns

Cost: Premature work

Philosophy: Does it need to be fixed?

Condition Based (CBM)

Benefit: Maintenance done when needed

Cost: Requires effective use of information Upfront cost

Factors which Influence Maintenance Strategy

Factors which Influence Maintenance Strategy

Factors which Influence Maintenance Strategy

Factors which Influence Maintenance Strategy

Factors which Influence Maintenance Strategy

Factors which Influence Maintenance Strategy

Machine Condition Monitoring and Fault Diagnostics

Machine Condition Monitoring and Fault Diagnostics

Machine Condition Monitoring and Fault Diagnostics

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