Condition Based monitoring

By,Priyesh Nair

Contents:1. Maintenance Objectives

2. Maintenance Classification

3. Predictive Maintenance & CBM

4. Comparison of Machine to Human

5. Advantages & Necessity of CBM

6. Techniques & Frequency of CBM

7. Flow Chart of Implementation

8. Implementation

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1. Maintenance Objectives:

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2. Maintenance Classification:Entire maintenance can be broken down into sub categories which is as follows:

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3. Predictive Maintenance: As the name implies it involves the prediction of the failure

before it occurs, identifying the root cause for those failure symptoms and eliminating those causes before the y result in extensive damage of equipment.

Type of maintenance performed continuously or at regular intervals according to the requirements to diagnose a condition and monitor a condition or system. Also known as Condition Based Monitoring.

Condition Based Monitoring: The ultimate objective of CBM program is to ensure the

availability of the equipment for safe and reliable operation during its useful life at optimum maintenance cost.

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oPredictive Of M/C Is As Doctor Care Human FOR HUMAN:HEARTBEAT READING----TEMPRATURE-----BLOOD TEST---------CARDIOGRAPH

FOR M/C:VIBRATION-----------------THERMOGRAPHY--------M/C OIL TEST------FFT SIGNATURE

4. Comparison of Machine to Human

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An approach to best Condition Monitoring Practices

Factors Affecting Industrial Appliances:◦ Where downtime cost is predominantly high.◦ Where a safety risk is particularly likely to arise from the breakdown of

machinery.◦ Where accurate and advanced planning of maintenance is essential.◦ Where plant/equipment is of recent design and may have residual

development problems◦ Where operators cannot be expected to detect faults in expensive

equipment whose breakdown may result in serious damage.◦ Where instruments or other equipments required for condition

monitoring can be used or is already being used◦ Where the manufacturer can offer a condition monitoring service to

users of its equipment Priyesh Nair

5. Advantages of CBM: Allows planned maintenance rather than breakdown

maintenance. Production can be modified to extend unit life. Cause of failure can be analyzed. Permits for maintenance can be planned. Manpower/Spares can be arranged well in advance. Modifications can be planned.

Necessity for CBM:Cost Benefits Time Benefits

Minimum equipment damage/repairs

Reduced downtime of equipment through scheduled vs unscheduled repairsMinimal oil use and disposal

Less use of inventory items through reliability enhancement

Reduced Mean Time To Repair

Indirect cost-less part loading due to equipment outage

High Mean Time Between Failures differences.Priyesh Nair

6. Techniques for monitoring CBM: Vibration Analysis Thermography Motor Current Signature Analysis Oil Analysis Wear Debris Analysis

Frequency of implementation:S.No. Method Frequency

1. Vibration Analysis Monthly2. Thermography Quarterly3. Motor Current Signature

AnalysisQuarterly

4. Oil Analysis Monthly5. Wear Debris Analysis On need basisPriyesh Nair

7. Flow Chart of Implementation:

Identify equipment and CBM technique

Scheduling and Planning

Measurement• Scheduled• Unschedule

d

Data Entry

Abnormal

Reading

Normal Reading

Report Generation and

circulation

AnalysisException Report for corrective

actionCorrective Action by

Department

Feedback from Department

Re-measurement

Data Entry to History

Sheets/SoftwaresPriyesh Nair

8. Implementation:

The CBM methods are implemented based on the equipments that needs assessment.

S.No. Technique Equipment1. Vibration Analysis Rotating and reciprocating equipments

2. Thermography All Electrical PCC, MCC, switchyards etc.

3. Motor Current Signature Analysis All Terminal Boxes

4. Oil Analysis All type of Hydraulic and lubricating oils

5. Wear Debris Analysis All type of Hydraulic and lubricating oils

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Thank You