MINGGU VIII

LABORATORIUM SISTEM MANUFAKTUR TEKNIK INDUSTRI ITS SURABAYA 2010

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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 items 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
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Condition Based Maintenance

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

Much the same way a Doctor will check (measure) your health by checking your pulse, temperature, blood pressure etc

4 If these measures are abnormal the doctor may suggest

that they continue to take measurements but maybe more often. 4 Or based on the first set of readings he may recommend some process changes such as, better diet, more rest etc. 4 He bases his decisions on known values or a standard, on scientific research, or experience from training. 4 Thankfully the medical profession has a good understanding of what is normal and what is not.
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Condition Monitoring : The non-invasive monitoring of systems to obtain knowledge of their condition; to distinguish wear, 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
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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. Results indicate current and future functional capability.
Schedule maintenance activities when mechanical or operational conditions warrant to repair or replace deteriorated equipment before obvious problems occur.
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Predictive Maintenance
4 Maintenance action based on actual condition

(objective evidence of need) obtained from in-site, non-invasive tests, operating, and condition measurements.
4 kegiatan perawatan yang berhubungan dengan

memonitor kondisi program perawatan preventif dimana metode memonitor secara langsung digunakan untuk menentukan kondisi peralatan secara teliti (Blanchard, 1980)
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Predictive Maintenance
PdM adalah pemeliharaan berdasarkan penilaian atau analisa kondisi

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

Predictive Maintenance
Timeline to Failure
Stressor Applied

Noticeable Performance Degradation

Failure

Preventive Maintenance Zone Predictive Maintenance Zone

48 Months Additional 8% - 12% savings over a good preventive maintenance program

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

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. Interval waktu antar pemeliharaan diperpanjang (sesuai prediksi kondisi peralatan) dan volume pekerjaan pada setiap pemeliharaan bisa terukur (efektif) sesuai kebutuhan

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

Barriers to adoption
Lack of management commitment Failure to change traditional maintenance practices

Concern about acceptance by OEMs, insurance

and class Technical complexity Lack of independent advise Overworked crew

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Key elements for successful implementation

1. Clear maintenance policy
Maintenance plans will be developed using best available techniques, appropriate to the equipment's HSE and performance criticality. A risk-based approach to extent and timing of maintenance activities will be used. For rotating equipment , condition monitoring techniques will be applied with a view to optimising equipment availability and eliminating cause of failures"

2. Criticality analysis
Focuses attention on equipment items (or systems), failure of which will significantly affect safety, health, the environment, or business performance Considers 4 Likelihood of failure 4 Consequence of failure
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3. Select appropriate maintenance task reactive,

planned, oncondition
Run-to-failure A decision, based on a systematic analysis, not to undertake preventive maintenance E.g.- 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.g. 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.- overhaul inert gas fan when vibration readings exceed limiting values Re-design A decision, based on a systematic analysis, to reduce the probability of failure by modification of the item E.g.- re-design of a radar mast to reduce vibration-induced failures of a19 radar antenna

4. For on-condition tasks, choose appropriate

techniques, measurement intervals and limits.

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. Measure performance of cm programme

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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, jika perlu dilakukan perbaikan Menentukan panjang waktu sebelum kegagalan terjadi

Repair
Inspection schedule

Perbaikan jadwal terjadi kerusakan Menggunakan leadtime dengan baik

P-F INTERVAL
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example
4 Cracks in (railway) rails
4 Frequency of initiated cracks depends on traffic load, rail

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4 4 4

material, rail geometry, particles on the rails, shocks from trains with non-circular wheels, 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., CC difficult to assess) 25

CONDITION MONITORING TECHNIQUE

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Human Sense
sight, touch, smell, hearing, (taste)

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Fluid Analysis
lubricants, greases, hydraulic oil

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4 Process parameter

analysis temperatures, pressures 4 Vibration and acoustics vibration analysis, shock pulse, acoustic emission
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thermography
Termal imaging

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Thickness measurement steel structure

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PERBEDAAN TIME BASE & CONDITION BASE MAINTENANCE

EXAMPLE
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Obyek Pengamatan PdM

1. Tribologi, kegiatan pemantauan kondisi minyak pelumas yang
melibatkan pengetahuan tentang gesekan (friction) dari permukaan yang berinteraksi

2. Kualitas siklus air, pemantauan dan analisa sifat-sifat kimia air

untuk mengetahui dampak kerusakan terhadap logam yang dilaluinya

3. Vibrasi, kegiatan Pemantauan dan Analisa sifat sifat getaran peralatan,

untuk mencari penyebab-penyebab getaran yang tidak normal.

4. Termografi, pemantauan distribusi termal pada suatu permukaan

dengan menggunakan radiasi infra merah, untuk mencari lokasi sumber panas yang tidak normal.

5. Life assessment, kegiatan pemeriksaan, pengujian dan analisa

penyebab kerusakan terhadap bagian-bagian komponen (logam) peralatan yang kritis

Teknologi yang digunakan

Nondestructive testing : 1. Inframerah analysis, untuk memonitor kegagalan
mekanik dan/atau kegagalan elektrik.

2. Vibration Analysis, paling produktif pada putaran

peralatan berkecepatan tinggi dan pada part yang paling mahal

3. Oil analysis, lebih bersifat prediksi 4. Acoustical Analysis, dilakukan pada suatu tingkatan
sonik hanya untuk peralatan mekanik. Sedangkan teknologi ultrasonik lebih fleksibel dan reliabel untuk mendeteksi permasalahan mekanik dan elektrik.

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, 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, 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. 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.
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Equipment yang biasanya di PdM

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Example of degradation

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Regression Analysis

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Regression Analysis

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Regression Analysis

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Regression Analysis

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Oil condition

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Wind turbine oil test

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Automotive : Coolant and new oil

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Gearbox : water in oil

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Continuous Condition Monitoring

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communication

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