1. TRAINING PROGRAM ONTRAINING PROGRAM ON
PREDICTIVE MAINTENANCEPREDICTIVE MAINTENANCE
(CONDITION B(CONDITION BASED MAINTENANCE)ASED MAINTENANCE)

2. MAINTENANCE STRATEGIES

3. FOUR MAINTENANCE STRATEGIES
On-Failure (B/D)
Fix it when it fails
Fixed Time
Maintain based
Upon calendar
or running time
Condition Based
Maintain based upon
known condition
Design Out
Design out cause of
failure
Maintenance
Plan
• Applicable to plant that exhibits wear out -
but must be used in conjunction with other
strategies
• Only effective if correctly implemented

4. CONDITION BASED MAINTENANCE
(CBM)
• Advantages
Allows shutdown before severe
damage occurs
Allows run to failure
Production can be modified to
extend unit life
Cause of failure can be analysed

5. • Advantages
Permits maintenance to be planned
Labour to be organised
Spares to be assembled
Modifications can be planned
CONDITION BASED MAINTENANCE
(CBM)

6. What is Condition Monitoring?
CM depends on the trending of parameters
which are indicators of the condition of key
equipment failure modes
0
10
20
30
40
50
60
Life Units

7. Failure Characteristic
B < 1
Wear out Random
dominated
Early life
Failure Probability graph
B > 3
Difficult
Expensive
Easy Cheap Difficult
Expensive
Easy Cheap
High Low High Low High Low
Condition Monitoring
Mean time between failure
Strategy in order of preference
 Fixed – time
Operate-to-
failure
Condition
based
Design out
Condition-
based
Fixed-time
Operate-
to-failure
Design-
out
Condition
based
Operate-
to failure
Design-
out
Condition
-based
Operate-
to failure
Design-
out
Operate-
to failure
Condition
based
Design-out
Condition-
based
Operate-to
failure
Analysis of Maintenance records permits an effective strategy to be chosen
1 < B < 3

8. HUMAN VS MACHINE

9. NDT/CBM
HUMAN VS MACHINE
SYSTEM
/MONITORING
HUMAN MACHINE / PROCESS
TEMPERATURE FEVER /
OTHER HOT SPOT
 MECHANICAL
 ELECTRICAL
 PROCESS SYSTEM
INTERNAL TESTS  PATHOLOGICAL TESTS
 X- RAYS
 CT SCAN, MRE
 ULTRASOUND
 ANGIOGRAPHY
 DEBRIS ANALYSIS
 OIL QUALITY
 NDT FLAWS
 RADIOGRAPHS
EXTERNAL TESTS  BLOOD PRESSURE
 ECG
 OVERALL VIBRATION
 VIBRATION SIGNATURES

10. NDT/CBM
HUMAN VS MACHINE
TYPE OF
MAINTENANCE
HUMAN MACHINE / PROCESS
CONDITION BASED
MAINTENANCE
MONITORING OF
 BLOOD PRESSURE
 CHLOROSTROL LEVEL
 SUGAR
 FEVER
 CANCER CELLS
 PATHOLOGICAL
TESTS
 ULTRASOUND
 ANGIOGRAPHY
 X- RAYS
 CT SCAN, MRE
 VIBRATION MONITORING
 THERMOGRAPHY
 QUALITY / DEBRIS
PARTICLES TRENDS
 THICKNESS / CRACK
MEASUREMENT
 PERFORMANCE / VISUAL
MONITORING
 OTHER CBM
TECHNIQUES
(CORROSION, AEM ETC)

11. NDT/CBM
HUMAN VS MACHINE
TYPE OF
MAINTENANCE
HUMAN MACHINE / PROCESS
PREVENTIVE
MAINTENANCE
PREVENTIVE REMEDIAL
MEASURES / CARE AS
PER CBM MONITORING
 DIET CONTROL
 WEIGHT MONITORING
 MEDICINE MEASURES
 CHECKS AT REGULAR
INTERVAL
 ADVANCED TESTS –
ECG / SCANS
 CHECKS / MEASURES
AGAINST DETERIORATION
 PREPARATION OF S/D AS
PER MONITORING
 CONTROL ON DEBRIS BY
FILTRATION
 VIBRATION CONTROL BY
ALIGNMENT, BALANCE
 PM /PI SCHEDULE AS PER
EQUIPMENT COMPONENT
LIFE / DETERIORATION
TRENDS

12. NDT/CBM
HUMAN VS MACHINE
TYPE OF
MAINTENANCE
HUMAN MACHINE / PROCESS
BREAKDOWN
MAINTENANCE
(WITH OUT ANY CARE)
 HEART ATTACK /
BY - PASS SURGERY
 INSULINE DROPS –
UNCONSCIOUS
 KIDNEY PROBLEM
 CRONIC TYPHOID
 TUMOUR / ULCER
 BEARING SEIZED
 SYSTEM BREAKDOWN
DUE TO PROCESS/
MECHANICAL /
ELECTRICAL FAILURES
 PANEL BURNOUT

13. CONDITION BASEDCONDITION BASED
MAINTENANCEMAINTENANCE
TECHNIQUESTECHNIQUES

14. Human Senses
VISUAL MONITORING
 Touch
 Sight
 Smell
 Hearing
 The simplest techniques are often the best - but to
be effective any evaluation must be quantifiable

15. Thermal Techniques
Contact Sensors
(Cheap but have limitations)
 Paints
Thermocouples
Liquid expansion
Infra-red Cameras & Videos
(Expensive but very powerful)

16. Thermal Techniques
Applications :
Pipe work
Insulation breakdown
leaks
Electrical
High resistance joints
Overheating components
Hot motors /Blocked cooling filters
Mechanical
Bearings
Coolant
 Gear Box etc.

17. Vibration Monitoring
Versatile tool for condition monitoring of
rotating & reciprocating plant
Wide range of techniques and instrumentations
Careful selection and application of technique is
essential for success

18. Vibration Monitoring:
Techniques
Overall Acceleration, Velocity &
Displacement
Vibration Spectral Monitoring
Run-up/down tests
Phase plots
Time Signature Analysis

19. Vibration Monitoring:
Rolling Element Bearing MonitoringRolling Element Bearing Monitoring
 Spike Energy/HFD
 High Frequency Velocity
 Overall Acceleration
 Shock Pulse

20. Performance Monitoring
Involves the use of existing data,
 Current
 Temp
 Pressure
 Flow rate

21. Performance Monitoring
Any variable which is indicative of a failure mode
Thermal efficiency
Wear rate
Compressor loading / unloading time
Product Accuracy

22. Wear Debris Monitoring
Techniques
Spectrographic Oil Analysis (SOA)
Ferrography (direct & analytical)
Particle Quantifier
Microscopic optical assessment
Choice of technique is critical to success

23. Non Destructive Testing
 Ultrasonic Methods
 Radiography
 Dye Penetrant
 Magnetic Particle

24. Corrosion Monitoring
 Visual Inspection
 Ultrasonic Leak Detection
 Coupons
 Electrical Resistance Probe

25. CRITERIA FOR SELECTION OF CBM TECHNIQUE
CBM TECHNIQUE TYPE OF EQUIPMENT
VIBRATION ANALYSIS All Rotating Equipment - Fans,
SPM Compressors, Pumps, high
LASER ALIGNMENT speed Gear boxes, Motors etc.
THERMOGRAPHY & All Electrical PCC, MCC,
THERMAL IMAGING High Tension Switch yards
Motors, Mech. Drives etc.
NDT THICKNESS/ FLAW All type of Tubes, Pipes &
DETECTION Vessels, Plates, Shaft etc.
LUBRICANT & WEAR All Type of Lubricating &
DEBRIS MONITORING Hydraulic Oils
DISSOLVED GAS All Transformer Oils
ANALYSIS

26. EQUIPMENT CAUSES OF
FAILURE
TECHNIQUES COMMENTS
Fan  Out of balance
 Misalignment
 Bearing
damage
 Aerodynamic
forces
 Belt problems
 Overall acceleration
 Spike energy
measurement
 Overall vibration
 Vibration analysis
 Flow measurement
 Motor current
measurement
Simple application
using windowed
spectra to trend
deterioration in
specific faults.
Equipment
performance is
monitored by
measuring process
parameters
SAMPLE APPLICATION OF MONITORING TECHNIQUES

27. EQUIPMENT CAUSES OF
FAILURE
TECHNIQUES COMMENTS
Pumps  Misalignment
 Bearing
damage
 Cavitation
 Impeller
damage
 Hydraulic
forces
 Overall vibration
 Vibration analysis
 Overall acceleration
 Spike energy
measurement
 Flow measurement
 Motor current
measurement
Windowed spectra to
trend deterioration in
specific failure
modes. Cavitation
can be detected
using frequency
analysis. Often blade
pass frequency
indicates hydraulic
problems
SAMPLE APPLICATION OF MONITORING TECHNIQUES

28. Identify Equipment & CBM Technique
Schedule & Planning Measurement
Unscheduled JobsScheduled Jobs
Data Entry
Analysis Abnormal Reading Normal Reading
Exception Report for Corrective Action Report Generation
Corrective Action by
DEPT.
.
Abnormal Reading
Feedback
from DEPT. Re Measurement
Normal
Reading
Trend for
History
and
Analysis
Re circulation
of Report
FUNCTION AND FLOW OF CBM SYSTEM

29. VIBRATION INSTRUMENTS
IRD Model - 306 M
Model PL-31 ANALYZER SPM A 30

30. INFRARED THERMOMETERSCONTACT THERMOMETERS
THERMAL IMAGER Model IRISYS
THERMOGRAPHY INSTRUMENTS

31. LUBRICANT OIL TESTING
WEAR DEBRIS /PARTICLE ANALYSIS
- SEPARATE INFRASTRUCTRUE /LAB

32. ULTRASONIC THICKNESS GAUGE
make - MODSONIC
ULTRASONIC FLAW DETECTECTORS
ULTRASONIC FLAW DETECTOR
MODEL GAILLILO-100

33. Condition Based Maintenance
Pump Vibration Measurement Non contact temperature Measurement
Thermography of switch Yard Wear debris analysis ( External)