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M8. Condition Monitoring

M8. Condition Monitoring

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MINGGU VIII

LABORATORIUM SISTEM MANUFAKTUR TEKNIK INDUSTRI ITS SURABAYA 2010
1

Maintenance Strategy, CM v/s PM
1.

Corrective maintenance (CM)  The actions carried out (because of failure) to repair component, equipment, or a system to a stated condition  All actions performed as a result of failure, to restore an item to a specified condition. Preventive Maintenance (PM)  All actions performed in an attempt to retain an item in specified condition by providing systematic inspection, detection, and prevention of incipient failure  Scheduled maintenance : Preventive maintenance performed at prescribed points in the item’s life Which one will be held ???

2.

Maintenance Strategy, stat v/s condt based
1.

Statistical based / reliability based  The components must be replace/repair at the certain age  Objective : minimize total cost, fixed statistically optimal PM interval Condition based / censored based  Feedback censor information used to perform maintenance planning decision
Which one will be held ???

2.

Condition Based Maintenance (CBM) = Condition Monitoring = Predictive Maintenance (PdM)

Based on known condition

Action / activity in maintenance
While for every strategy, we can choose action / activity to maintain the system :
 Repair, retaining or restoring the system to specified

condition. There are 3 types of repair : minimal repair, perfect repair, imperfect repair  Replace, change failed item with the new one

DEFINITION 6 .

is the art of monitoring your equipments health by taking simple measurements of the machines performance. .Condition Based Maintenance Maintenance based on the condition of an asset. 4 Asset: An item of value. 4 Condition: The state of an item.

on scientific research. 4 Thankfully the medical profession has a good understanding of what is normal and what is not. blood pressure etc 4 If these measures are abnormal the doctor may suggest that they continue to take measurements but maybe more often. 4 He bases his decisions on known values or a standard.Much the same way a Doctor will check (measure) your health by checking your pulse. temperature. more rest etc. 4 Or based on the first set of readings he may recommend some process changes such as. or experience from training. 8 . better diet.

impending failure or other deterioration without disrupting the normal operation of those systems Condition Based Maintenance Maintenance requirements based on the performance or physical state of the system 9 . to distinguish wear.Condition Monitoring : The non-invasive monitoring of systems to obtain knowledge of their condition.

Predictive Maintenance Measurements that detect the onset of a degradation mechanism thereby allowing causal stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Schedule maintenance activities when mechanical or operational conditions warrant to repair or replace deteriorated equipment before obvious problems occur. Results indicate current and future functional capability. 10 .

non-invasive tests. 1980) 11 . and condition measurements.Predictive Maintenance 4 Maintenance action based on actual condition (objective evidence of need) obtained from in-site. operating. 4 kegiatan perawatan yang berhubungan dengan memonitor kondisi program perawatan preventif dimana metode memonitor secara langsung digunakan untuk menentukan kondisi peralatan secara teliti (Blanchard.

viskositas minyak pelumas.  Parameter-parameter terukur ini secara periodik dimonitor. tingkat keretakan.Predictive Maintenance  PdM adalah pemeliharaan berdasarkan penilaian atau analisa kondisi (Condition Base) komponen atau peralatan  Kondisi itu harus dapat terukur (parameter terukur) seperti temperatur. tingkat keausan.  Apabila suatu komponen peralatan atau peralatan tidak memberikan parameter terukur. Apabila ada parameter yang mengalami gejala memburuk. tekanan. konduktivitas air pendingin. maka Predictifve Maintenanace tidak dapat dilaksanakan. daya mampu. efisiensi dan lain sebagainya. maka monitoring harus lebih diintensifkan dan diprediksi kapan kerusakan sesungguhnya akan terjadi. tingkat korosi (corrosion rate). (Prajitno. sisa umur kekuatan logam. vibrasi. 2005) .

12% savings over a good preventive maintenance program .Predictive Maintenance Timeline to Failure Stressor Applied Noticeable Performance Degradation Failure Preventive Maintenance Zone Predictive Maintenance Zone 48 Months Additional 8% .

Degradation Zone FAILURE Preventive Maintenance Zone Stressor Applied Predictive Maintenance Zone No Failure Proactive Operations and Maintenance Zone Prediction and Planning Mitigation and Repair Fix What Broke .

Interval waktu antar pemeliharaan diperpanjang (sesuai prediksi kondisi peralatan) dan volume pekerjaan pada setiap pemeliharaan bisa terukur (efektif) sesuai kebutuhan .Predictive Maintenance  Ada yang memandang     PdM dimasukkan dalam PM karena keduanya saling berkaitan Namun ada yang melihat PM dan PdM sebagai dua hal yang berbeda PdM tidak menghilangkan PM.

Advantages and Disadvantage Advantage 4 Increased component operational life/availability 4 Allows for preemptive corrective actions 4 Decrease in equipment or process downtime 4 Decrease in costs for parts and labor 4 Better product quality 4 Improved worker and environmental safety 4 Improved worker morale 4 Energy Savings 4 Field study showed a 8-12% savings over preventive maintenance programs Disadvantage 4 Increased investment in diagnostic equipment 4 Increased investment in training of staff 4 Savings potentials not readily seen by management .

insurance and class  Technical complexity  Lack of independent advise  Overworked crew 17 .Barriers to adoption  Lack of management commitment  Failure to change traditional maintenance practices  Concern about acceptance by OEMs.

health. the environment. appropriate to the equipment's HSE and performance criticality. Criticality analysis Focuses attention on equipment items (or systems).Key elements for successful implementation 1. condition monitoring techniques will be applied with a view to optimising equipment availability and eliminating cause of failures" 2. Clear maintenance policy “ Maintenance plans will be developed using best available techniques. failure of which will significantly affect safety. For rotating equipment . or business performance Considers 4 Likelihood of failure 4 Consequence of failure 18 . “A risk-based approach to extent and timing of maintenance activities will be used.

re-design of a radar mast to reduce vibration-induced failures of a19 radar antenna ...g. not to undertake preventive maintenance E.g. oncondition Run-to-failure A decision. based on a systematic analysis.– overhaul fuel valves and replace nozzles every 8000 hours Condition-based maintenance Maintenance carried out according to the need indicated by condition monitoring E.g. Select appropriate maintenance task – reactive..3.overhaul inert gas fan when vibration readings exceed limiting values Re-design A decision.allowing a domestic fresh water pump to operate until it either ceases to pump Scheduled maintenance Maintenance carried out in accordance with an established time schedule E. planned. to reduce the probability of failure by modification of the item E. based on a systematic analysis.g.

    Identify failure modes Identify physical characteristics associated with each failure mode Determine a non-intrusive method of measuring each physical characteristic Set limiting values 5. Establish training programme 6. For on-condition tasks. measurement intervals and limits. choose appropriate techniques. Measure performance of cm programme 20 .4.

jika perlu dilakukan perbaikan  Menentukan panjang waktu sebelum kegagalan terjadi Repair Inspection schedule  Perbaikan jadwal terjadi kerusakan  Menggunakan leadtime dengan baik .Tahapan PdM Setup Monitoring  Mengidentifikasikan peralatan dan prioritas item berdasar dampak kerusakan  Menentukan bagaimana peralatan akan rusak menggunakan pengetahuan operator dan sejarah perawatan  Menyusun jadwal inspeksi  Mengumpulkan informasi peralatan  Uji peralatan yang sesuai dan memasukkan data dalam database PdM  Menganalisa dan memonitor pengukuran  Menyelidiki adanya kerusakan.

P-F INTERVAL 22 .

23 .

24 .

particles on the rails.. and so on Inspection by a special rail-car with ultrasonic inspection equipment (implies high cost) Detection probability depends on the depth of the crack PF interval is the time interval from the crack is observable until a critical failure occurs A critical failure may involve derailment and fatalities (i.e.example 4 Cracks in (railway) rails 4 Frequency of initiated cracks depends on traffic load. shocks from trains with non-circular wheels. rail 4 4 4 4 material. CC difficult to assess) 25 . rail geometry.

CONDITION MONITORING TECHNIQUE 26 .

smell.Human Sense sight. hearing. touch. (taste) 27 .

greases.Fluid Analysis lubricants. hydraulic oil 28 .

pressures 4 Vibration and acoustics – vibration analysis. shock pulse. acoustic emission 29 .4 Process parameter analysis – temperatures.

thermography Termal imaging 30 .

Thickness measurement – steel structure 31 .

PERBEDAAN TIME BASE & CONDITION BASE MAINTENANCE .

EXAMPLE 33 .

Termografi. Kualitas siklus air. Vibrasi. kegiatan Pemantauan dan Analisa sifat sifat getaran peralatan. Life assessment. 4. pemantauan distribusi termal pada suatu permukaan dengan menggunakan radiasi infra merah. untuk mencari lokasi sumber panas yang tidak normal. kegiatan pemantauan kondisi minyak pelumas yang melibatkan pengetahuan tentang gesekan (friction) dari permukaan yang berinteraksi 2.Obyek Pengamatan PdM 1. 5. Tribologi. untuk mencari penyebab-penyebab getaran yang tidak normal. pengujian dan analisa penyebab kerusakan terhadap bagian-bagian komponen (logam) peralatan yang kritis . kegiatan pemeriksaan. pemantauan dan analisa sifat-sifat kimia air untuk mengetahui dampak kerusakan terhadap logam yang dilaluinya 3.

dilakukan pada suatu tingkatan sonik hanya untuk peralatan mekanik. untuk memonitor kegagalan mekanik dan/atau kegagalan elektrik. . lebih bersifat prediksi 4. Acoustical Analysis. Sedangkan teknologi ultrasonik lebih fleksibel dan reliabel untuk mendeteksi permasalahan mekanik dan elektrik.Teknologi yang digunakan Nondestructive testing : 1. paling produktif pada putaran peralatan berkecepatan tinggi dan pada part yang paling mahal 3. 2. Inframerah analysis. Oil analysis. Vibration Analysis.

Which technology you use will depend on the equipment you have. However vibration measurement is the most versatile and gives the most information which is why it is the most used measurement parameter.If you were measuring the current draw and the outlet flow of a pump and could see that the draw was increasing yet the outlet flow was decreasing. 36 . assuming of course that all the other variables had stayed the same such as the material the pump was pumping was the same etc. Flow and current cannot be measured on all the machines so you have to choose a measurement parameter that is more suitable for the majority of your equipment. as compared to the measurements you had taken over the previous months. you would be right in assuming that the condition was deteriorating and that some maintenance was due for the pump.

37 .

38 .

39 .

Equipment yang biasanya di PdM 40 .

Example of degradation 41 .

42 .

43 .

Regression Analysis 44 .

45 .

46 .

47 .

Regression Analysis 48 .

Regression Analysis 49 .

Regression Analysis 50 .

51 .

52 .

Oil condition 53 .

Wind turbine oil test 54 .

Automotive : Coolant and new oil 55 .

Gearbox : water in oil 56 .

57 .

Continuous Condition Monitoring 58 .

communication 59 .

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