4.5 g Maintenance Strategy by Deepak Sahoo

DN : BAL/DS/CBM/A1004 BAL - Internal Use Only. CBM – Part - I
4.5 Generation
Maintenance Strategy
Doc. No : BAL/DS/CBM/A1004 CBM – Part - I
An Introduction To Condition Based Maintenance (CBM)
Prepared By : DEEPAK SAHOO
Internal Use only. For Balasore Alloys Limited, Balasore.

 Agenda
Introduction
Maintenance Strategy
Types of Maintenance
More about CBM / CM
CBM/CM Tools
- i -
INDEX
Prepared By : DEEPAK SAHOO, Manager - TPM

 Introduction
Accident Rate in Aviation industry.
- 01 -
INDEX
The 2011 global accident rate (measured in hull losses per million flights) was 0.37, the equivalent of one accident every 2.7 million flights.
0.1
0.45
0.34
0.8
0.72
1.87
7.41
0
1
2
3
4
5
6
7
8
NORTH AMERICA
EUROPE
NORTH ASIA
ASIA- PACIFIC
MIDDLE EAST AND NORTH AFRICA
LATIN AMERICA
AFRICA
ACCIDENT RATE IN AVIATION INDUSTRY
Data collected from IATA. http://www.iata.org/pressroom/pr/pages/2011-02-23-01.aspx

 Introduction
Maintenance Strategy in Aviation industry.
- 02 -
INDEX
 CBM++
 RCM

 Maintenance Strategy
Reactive
Preventive
Predictive
Proactive.
RCM – Reliability Centered Maintenance
»Aviation Industry.
»Spacecraft Industry.
»Nuclear Industry.
»Petrochemicals.
»Oil & Gas
- 03 -
INDEX

 Maintenance Strategy
What is Maintenance and Its Objective ?
- 04 -
INDEX
Maintenance is a set of organised activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired.
PLANT
M A I N T E N A N C E
Reduce Breakdowns
Reduce Downtime
Improving Equipment Efficiency
Improving Inventory Control
Implementing Cost Reduction
Maximising Production
Optimising Resources Utilisation
Optimising Useful Life of Equipment
Minimising Energy Usage
Providing Budgetary Control

 Type of Maintenance
Run to Failure Maintenance (RTF)
Preventive Maintenance (PM)
Corrective Maintenance (CM)
Predictive Maintenance (PDM)
Improvement Maintenance (IM)
- 05 -
INDEX

- 06 -
INDEX
MAINTENANCE
UNPLANNED MAINTENANCE (REACTIVE)
BREAKDOWN
EMERGENCY
PLANNED MAINTENANCE (PROACTIVE)
CORRECTIVE MAINTENANCE
REMEDIAL
DEFERRED
PREDECTIVE MAINTENANCE
CONDITION - BASED
STATISTICAL - BASED
PREVENTIVE MAINTENANCE
ROUTINE
RUNNING
DESIGN - OUT
ENGINEERING SERVICES
WINDOW
IMPROVEMENT MAINTENANCE
SHUTDOWN CORRECTIVE
SHUTDOWN PREVENTIVE
SHUTDOWN IMPROVEMENT
OPPORTU-NITY

Run to Failure Maintenance (RTF)
–Emergency maintenance: It is carried out as fast as possible in order to bring a failed machine or facility to a safe and operationally efficient condition.
–Breakdown maintenance: It is performed after the occurrence of an advanced considered failure for which advanced provision has been made in the form of repair method, spares, materials, labour and equipment.
- 07 -
INDEX

Preventive Maintenance (PM)
- 08 -
INDEX
•Routine maintenance which includes those maintenance activities that are repetitive and periodic in nature such as lubrication, cleaning, and small adjustment.
•Running maintenance which includes those maintenance activities that are carried out while the machine or equipment is running and they represent those activities that are performed before the actual preventive maintenance activities take place.
•Opportunity maintenance which is a set of maintenance activities that are performed on a machine or a facility when an unplanned opportunity exists during the period of performing planned maintenance activities to other machines or facilities.
•Window maintenance which is a set of activities that are carried out when a machine or equipment is not required for a definite period of time.
•Shutdown preventive maintenance, which is a set of preventive maintenance activities that are carried out when the production line is in total stoppage situation.

Corrective Maintenance (CM)
- 09 -
INDEX
•Remedial maintenance, which is a set of activities that are performed to eliminate the source of failure without interrupting the continuity of the production process.
•Deferred maintenance, which is a set of corrective maintenance activities that are not immediately initiated after the occurrence of a failure but are delayed in such a way that will not affect the production process.
•Shutdown corrective maintenance, which is a set of corrective maintenance activities that are performed when the production line is in total stoppage situation.

Improvement Maintenance (IM)
- 10 -
INDEX
Design-out maintenance which is a set of activities that are used to eliminate the cause of maintenance, simplify maintenance tasks, or raise machine performance from the maintenance point of view by redesigning those machines and facilities which are vulnerable to frequent occurrence of failure and their long term repair or replacement cost is very expensive.
Engineering services which includes construction and construction modification, removal and installation, and rearrangement of facilities.
Shutdown improvement maintenance, which is a set of improvement maintenance activities that are performed while the production line is in a complete stoppage situation.

Predictive Maintenance (PDM)
Condition-based predictive maintenance depends on continuous or periodic condition monitoring equipment to detect the signs of failure.
Statistical-based predictive maintenance depends on statistical data from the meticulous recording of the stoppages of the in-plant items and components in order to develop models for predicting failures.
- 11 -
INDEX

 CBM
What is CBM ?
Definition
–CBM is a set of maintenance actions based on real-time or near-real time assessment of equipment condition which is obtained from embedded sensors and/or external tests & measurements taken by portable equipment.
Purpose
–The purpose of CBM strategy is to perform maintenance only when there is objective evidence of need, while ensuring safety, equipment reliability and reduction of total ownership cost.
- 12 -
INDEX

 CBM
3 Levels of CBM?
Human Senses.
–See, hear, Touch, Smell etc.
Asset Performance Indicator.
–BMS, DCS incorporating statistics.
Applied Technologies.
–Vibration Analysis, IR Thermography, MCSA, WDA, NDT etc.
- 13 -
INDEX

 CBM – How it Works.
- 14 -
INDEX
Ethernet
Data-base
Network Data Server
LAN
Trend Data
Workstation
LAN- connected Maintenance Workstation
Junction Box
Temperature
Pressure
RPM
CFP
A
V
Vibration
Vibration
Junction Box
Voltage
Current
Embedded Sensors
Data Bus
Computer
Low Speed DAQ
High Speed DAQ
(At System)
(Off System)
Portable Maint Aid
Workstation
Workstation
Workstation
(On System)
Computerized Maintenance Management System

 CBM – How it Works.
Identify Equipment & CBM Technique
Schedule & Planning
Measurement
Unscheduled Jobs
Scheduled 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
- 15 -
INDEX

 CBM
- 16 -
INDEX

 CBM
Formulate CBM Strategy
- 17 -
INDEX
PLAN
Management formulate CBM strategy and provides the vision and mission.
SHARE
Share with employees in Engg. Functions.
UNDERSTAND
Employees understand the vision of Management and benefits of CBM Activities.
Process
of CBM Activities
start

 CBM - Applied Technologies Tools
Vibration Analysis
IR – Thermography
WDA – Wear Debris Analysis
Motor Current Signature Analysis
Rotor balancing
NDT
Radiography (RT)
Magnetic Particle Testing (MT)
Ultrasonic Testing (UT)
Penetrant Testing (PT)
Acoustic Emission Testing (AE)
- 18 -
INDEX

- 19 -
INDEX
Condition based management
Visual
Inspection
Vibration
analysis
Ultrasonic
Pressure
analysis
Temperature analysis
Oil
analysis
Efficiency
analysis
Wear
analysis

Thermal Techniques
Contact Sensors, Paints, Thermocouples, Liquid expansion
Infra-red Cameras
Application
Pipe work
Insulation breakdown
leaks
Electrical
High resistance joints
- 20 -
INDEX
Overheating components
Hot motors /Blocked cooling filters
Mechanical
Bearings
Coolant
Gear Box etc.

- 21 -
INDEX

Vibration Analysis
Vibration Analyser
Vibration Meter / Tester
Probe
Application
All Rotating Equipment - Fans, Compressors, Pumps, high speed Gear boxes, Motors etc
- 22 -
INDEX

 CBM – Vibration Analysis
What is vibration?
Oscillatory / repetitive motion of a body about its equilibrium is called vibration.
Simple Harmonic Motion
- 23 -
INDEX

Vibration Monitoring Devices
Online Vibration Monitoring
 E.g.: CSI Online monitoring system, Bentley Nevada, Shinkawa etc.
Offline / Portable Vibration Monitoring
Handheld Vibration Meter.
Handheld Vibration Analyzer ( A single channel / dual channel analyzer)
- 24 -
INDEX

Vibration Monitoring Sensor
Proxy Probes ( measures only Displacement)
Velocity Pick Up (measures Displacement & Velocity)
Accelerometer ( measures Displacement / Velocity / Acceleration.
- 25 -
INDEX

Methods of Communication from Sensor to Device
Traditional : Wired System
The Future : Wireless System
- 26 -
INDEX
CSI 9420 Vibration Transmitter.

 Thank you.
END
INDEX

4.5 g Maintenance Strategy by Deepak Sahoo

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