Predictive Maintainance

©2009 Fluke Corporation Vibration testing 1

“Predictive Maintenance

Workshop”

An Introduction to

Maintenance

Practices


Before We Begin…

• Ask questions at any time!

• Please turn your cell phone to vibrate.

• If you must take a call, please feel free but we ask

that you take it outside the seminar room.


IMPORTANCE OF MAINTENANCE STRATEGY

Technology / Solution

Maintenance Strategy

Improved Business Performance

Plant Owner Business Objectives

Business objectives drive

the maintenance strategy,

which in turn drives the

technologies and

solutions applied.

Maintenance strategy

definition and development

is a critical success factor in

the customer’s value chain.


• Reactive Maintenance: Often called “run to failure.” No repair or

maintenance actions are taken on machinery until the designed

life span is reached…or other variables cause the machinery to

fail.

– Upside:

• Lower upfront maintenance costs

• Lower maintenance staff costs

– Downside:

• Unplanned, sometimes catastrophic, downtime and overtime

hours

• Secondary damage to machines impacted by the failed

machine

• Potentially higher capital costs as entire components may need

to be replaced

• Machines control maintenance department

Maintenance Practices


• Preventive Maintenance (Proactive – Calendar Based )

Also called “Historical or calendar-based maintenance”

– Upside:

• Increased equipment life

• Reduced equipment or process failure

• Flexibility with maintenance scheduling

– Downside:

• Fault free machines maintained unnecessarily – could lead

to incidental problems with components

• Overhaul reduces reliability of the machine (see the

bathtub curve)

• More labor intensive than Reactive Maintenance




• Predictive Maintenance (Proactive – Condition Based): Use of different

testing (vibration, thermography, oil analysis, ultrasound are the most

common) to understand machine condition and prevent failure

– Upside

• Allows preemptive action to increase equipment life

• Increased equipment life

• Reduced equipment or process failure

• Reduced repair parts and labor costs

• Increased safety

• Reduced likelihood of catastrophic failures

– Downside

• Increased investment in diagnostic / test equipment

• Increased investment in training and staff

• Cost benefits not readily seen by management

• May require top-down cultural change in maintenance approach


CONDITION MONITORING

Condition Based Maintenance is the

maintenance initiated as a result of

knowledge of the condition of an

item from performing inspections

with condition monitoring

technologies.


Semi Critical Machines

General Purpose Machines

CR

ITIC

ALI

TY

Number of Rotating Machines

1

2

Critical Machines

1

PLANT ASSET CLASSIFICATION

3


Asset Criticality Ranking

On the Asset Criticality Pareto Chart, natural “break points” appear to

segregate the assets into identifiable criticality classifications

For the most critical assets (typically 10-15% of assets), a

Reliability Centered Maintenance (RCM) approach is used

to determine the appropriate maintenance strategy.

Critical assets are assessed using Failure

Modes & Effects Analysis (FMEA) process.

Less Critical assets are assigned a

strategy using standard Templates

Non-Critical assets

Run-to-failure

Distribution of Assets

15%

Cri

tica

lity

Ra

nk

ing

30% (typical) 50% (typical)5%


• Highly Critical- Continuous online vibration,

Thermography, Lube oil Analysis, Ultrasonic

Technology, Process Variable Analysis.

• Critical- Continuous online vibration measurement,

protection & Analysis, Thermography.

• Mid Level Criticality- Periodic Vibration online

Scanning

• Low Level Criticality- Periodic Vibration Scanning

• Non critical- Run to failure.

TECHNOLOGY


Advantages of a CM Program

• Find the problem before it finds you!

• Improved less expensive maintenance

• Consistent and improved availability

• Increase in production rate

• Reduced maintenance costs

• Extend asset life (less need for capitol

expenditure)

• Reduce asset base i.e. spare parts

• Increased product quality and consistency


Potential cost savings

• Cost of failure / poor efficiency– Lost revenue (downtime, lost customer confidence)

– Energy cost

– Replacement cost

– Repair costs (especially labour)

– Cost of scrap

– Cost of cleanup and restart

– Insurance premium


The Maintenance Strategy defines how the asset’s failure modes will be managed. This requires identifying the failure modes, probability of failure and appropriate mitigation plan.

The three alternative tools that can be applied for maintenance Strategy Development are:

•RCM ( Relibility Centred Maintainance) – carried by teams on only the most critical systems. An individual RCM analysis may take 8 to 10 person-weeks to complete.

•FMEA (Faliure Mode Effect Analysis) – developed by single analyst on critical systems and equipment. The use of FMEA libraries helps fastrack this process.

•Templates – consist of standard maintenance strategies for low criticality assets

Develop the Maintenance Strategy


PM Optimization

This is a systematic review of routine Preventive Maintenance (PM)

tasks with reference to the ideal maintenance strategy .

Work plans are strengthened with improved procedures, fully

developed Bill-of-Materials, tools and parts kits

By optimizing existing PM tasks, the cost of the maintenance program

is reduced, while reliability remains high

Savings from the PM Optimization process can fully fund the

introduction of a Predictive Maintenance program

Typical results from PM Optimization:

30% of PM tasks can replaced by more cost effective Predictive Maintenance tasks

30% of PM tasks can be deleted (no value)

30% of PM tasks need strengthening.


Testing for PdM

Condition Monitoring

Machine watch

keeping & Etc..

Temperature

Vibration

Electrical / Power

monitoring

Process Parameters

Acoustic

Oil analysis


Thank You

Predictive Maintainance

Documents

Transcript of Predictive Maintainance