Summary A key aspect of any world-class asset management program is a proactive, efficient work management process, designed to ensure the effective performance of maintenance on critical assets. To achieve maximum return on investment and maintain the greatest degree of productivity, it is pivotal that organizations have a process that effectively translates asset information to knowledge, and ultimately gain value from that knowledge. Work execution is where identified, planned and scheduled work is performed. Once work is completed, feedback from the field plays a key role in measuring the overall effectiveness of the AEO process and making refinements for even greater efficiency in the future.
AoM04005_fan_WE Rob Bretz 24 pages October 2004
SKF Reliability Systems @ptitudeXchange 5271 Viewridge Court San Diego, CA 92123 United States tel. +1 858 496 3554 fax +1 858 496 3555 email: info@aptitudexchange.com Internet: www.aptitudexchange.com Use of this document is governed by the terms and conditions contained in @ptitudeXchange. Copying or distribution of this document is prohibited.
AoM04005_fan_WE - Fans - Work Execution Table of Contents Table of Contents.............................................................................................................................2 Introduction......................................................................................................................................4 Installation........................................................................................................................................5 Balancing .........................................................................................................................................6 Precision Alignment.........................................................................................................................7 Shaft Alignment........................................................................................................................7 Belt or Pulley Alignment ..........................................................................................................8 Bearings & Lubrication....................................................................................................................9 Bearing Arrangement................................................................................................................9 Bearing Selection....................................................................................................................10 Lubrication Guidelines ...........................................................................................................10 Example: Small and Medium Size Cement Industry Fans .....................................................11 Refurbishment & Repair ................................................................................................................12 When to Recondition? ............................................................................................................12 Benefits...................................................................................................................................12 Fan Repair...............................................................................................................................13 Rebuild ("Design Out") ..........................................................................................................15 Post Maintenance Testing..............................................................................................................17 Mechanical Testing.................................................................................................................17 Acceptance Testing.................................................................................................................17 Feedback / Living Program............................................................................................................18 Root Cause Analysis...............................................................................................................18 Importance of RCA.................................................................................................................19 Job Plan Validation and Update .............................................................................................20 Audit Trail ..............................................................................................................................20 Towards a Living Program.....................................................................................................20 2004 SKF Reliability Systems All Rights Reserved 2
AoM04005_fan_WE - Fans - Work Execution Conclusions....................................................................................................................................20 References......................................................................................................................................21 Resources .......................................................................................................................................21 Acknowledgements........................................................................................................................22 Appendix A....................................................................................................................................23 2004 SKF Reliability Systems All Rights Reserved 3
AoM04005_fan_WE - Fans - Work Execution Introduction A key aspect of any world-class asset management program is a proactive, efficient work management process, designed to ensure the effective performance of maintenance on critical assets. To achieve maximum return on investment and maintain the greatest degree of productivity, it is pivotal that organizations have a process that effectively translates asset information to knowledge, and ultimately gain value from that knowledge. In order to put into perspective what work execution means in the overall scope, one must first understand a little about asset efficiency. To help organizations achieve these goals, SKF offers Asset Efficiency Optimization (AEO), a management process designed to achieve maximum efficiency and effectiveness from work management activities focused on business goals for the facility. The AEO process encompasses four key elements [1]: Strategy Identification Control Execution. Maintenance Strategy involves the evaluation of work activities in relationship to a facilitys business objectives, a procedure that creates the documented basis for the maintenance program. Maintenance strategy related to Fans is presented in Maintenance Strategy for Fans[2]. Work Identification is where work is identified from the evaluation of a comprehensive flow of data in conjunction with an integrated decision-making process. Key to the success of Identification is a comprehensive computerized maintenance program. Work Identification related to Fans is worked-out in Work Identification for Fans[3]. Work Control involves establishing procedures for planning and scheduling the work identified by the CMMS. Tasks are organized based on several parameters, including time and condition; job plans or procedures; man-hours required; data feedback; special requirements; and many other factors. Work Control related to Fans is outlined in Work Control for Fans[4]. Work Execution is where identified, planned and scheduled work is performed. Once work is completed, feedback from the field plays a key role in measuring the overall effectiveness of the AEO process and making refinements for even greater efficiency in the future. The AEO process transforms conceptual asset management into a tangible competitive edge. Each of the elements listed above contributes to the success of the AEO process. No matter how well defined and documented the maintenance strategy may be, it cannot achieve optimum effectiveness if badly implemented. Similarly good control and implementation practices are wasted if they are expended in performing the wrong tasks. This article focuses on the "work execution" element of the process. Within this article we will make the transition from the inputs from the work control process (see Work Control for Fans) into work execution [4].
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AoM04005_fan_WE - Fans - Work Execution Check hold down bolts are hardened up with nuts and washers.
Check other remaining hold down positions were shimmed to provide full support to the pedestal. Check foundation block is smooth (except in the area where the hold down bolts had been grouted). The key element when installing a machine is to provide a foundation, which will provide sufficient support and stiffness to maintain alignment between components under dynamic conditions. In the case of a pedestal being grouted to a foundation and held in place with anchor bolts, the foundation should be prepared in a manner that will ensure the support and alignment of the components over an extended period of time. Figure 1 Work Execution Process - Principal Inputs & Outputs Along with work control, work execution includes precision practices such as fan installation, alignment, balancing, vibration, lubrication, repair, and redesign. Post maintenance testing is followed up with work order procedures. The resultant output is what is referred to as a living program, which provides the feedback for a continual improvement process. SKF Service recommends that grout be floated in rather than troweled. Floating the grout in place provides a more uniform support to the pedestal and if done correctly ensures that air pockets beneath the supporting areas do not occur. Installation Like any piece of equipment, fans require a sturdy foundation from which they can operate without problem. According to Frank Bleier, cement is the preferred foundation material. The foundation should be level, rigid, and of sufficient massequal to three or four times the fan weight. [6].
The foundation needs to be cleaned and roughened to a depth of at least one inch in the area where the grout will be poured in contact with the foundation. This is done to ensure a contiguous structure beneath the pedestal supporting the fan components. Leveling screws should also be in place on the pedestal and the levelness checked and fan correctly positioned prior to connecting ductwork. The grout should then be poured and allowed to cure prior to carrying out the precision alignment.
Even with the successful installation of a fan, regular foundation inspection is suggested. General visual inspection of the foundation (e.g., suitable support to the pedestal to maintain the alignment of the fan components). Resilient mounting of fans is done either to isolate the machine vibrations from the structure or isolate structurally born vibrations from the machine. In the first case fans used in office buildings are typically mounted on resilient mounts to reduce the vibrations being transmitted into the building and contributing Check fan and pedestal in position and connected to the ductwork. Hold down bolts and shims in place. 2004 SKF Reliability Systems All Rights Reserved 5
AoM04005_fan_WE - Fans - Work Execution to an uncomfortable environment. In the second case stand-by equipment, or equipment which operates periodically, is mounted on resilient mounts when placed in areas where other machines may be operating and structurally borne vibration is present. Bearings in machines resting idle under these conditions will prematurely deteriorate. In either case the number one consideration is maintaining the machine component alignment under dynamic conditions by providing a rigid base support connected to the resilient mounts. For further reading on machine installation, the reader is referred to [7]. Balancing Fan rotors must be balanced; otherwise, vibrations that could damage the bearings or other parts will be produced. Balancing is accomplished by redistributing the mass so that the principal inertia axis more nearly coincides with the axis of rotation. Because perfect balance is never achieved, specifications usually list the permissible unbalance. This can be stated in terms such as ounce-inches, which reflect the size and radius of a balancing mass that would bring the rotor into balance. Also, eccentricity, the distance between the principal inertia axis and the axis of rotation, can be specified. Specific unbalance, or unbalance divided by rotor mass, can be specified, too. However, the most common specifications deal with the vibratory effects of unbalance. That is, a limit is placed on the displacement, velocity, or acceleration that can be measured on a vibrating part.[5] Balancing will reduce only those vibrations caused by unbalance. Vibrations caused by looseness between parts, coupling misalignment, mismatched belts, or other external sources must first be corrected before balancing is attempted. The effects of a bent shaft can sometimes be balanced out but only if the bend is slight.[5] Most fans are balanced before shipping. In the field, fans are usually balanced with the aid of a portable, electronic balancing machine. Such machines can indicate the vibration amplitudes in terms of displacement, velocity, or acceleration. They can also indicate frequency and, with the aid of a strobe light, phase angle, too. Most use a seismic-type velocity probe and can filter out all frequencies outside the narrow band of interest.[5] An example includes an equipment cooling fan, running at 1760 RPM.
Figure 2: Cooling Fan. The Arrow indicates the Fan Impellor where Measurement is taken. The overall vibration levels were about 0.6 ips (inches per second) before the balance was performed. The vibration spectrum shows a high peak of 0.52 ips at fan RPM (Figure 3). An out of balance condition will generate a frequency equal to that of the shaft RMP. Care should be taken as several other conditions will exhibit similar symptoms. Taking phase readings and examining the phase relationship of the one times RPM component will assist in determining if the major problem is indeed an out of balance condition. As the phase measuring equipment is necessary for the balancing, and readings can be taken before the equipment is dismantled, this relatively 2004 SKF Reliability Systems All Rights Reserved 6
AoM04005_fan_WE - Fans - Work Execution quick check could determine if balancing is actually required. In this case, the out of balance diagnosis was confirmed. The fan shroud was removed consequently, and the fan was cleaned and balanced appropriately. After balancing, the peak value dropped from 0.52 ips to 0.04 ips.
Figure 3: Peak at Fan RPM, indicating Unbalance. For further reading on balancing principles, the reader is referred to [8,9]. Precision Alignment Shaft Alignment Shaft misalignment induces abnormal loads, which causes a fan to run improperly and eventually leads to a decreased life expectancy. Fundamentals on shaft alignment can be found in [10,11]. An example of precision shaft alignment of the rotating components of a fan are carried out with soft foot checks to all components and confirmation of the inducers central location to the impeller. Alignment targets are for example zero at all feet in all directions. The acceptable limits, unless specified by machine manufacturer or coupling manufacturer are less than 0.002 at all feet in all directions. Soft foot targets are also zero with the acceptable limits being less than 0.002 under all feet unless otherwise specified by the machine manufacturer. Inducers are located as centrally as the components will allow, based on the levels of precision used in their manufacture. 2004 SKF Reliability Systems All Rights Reserved 7
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Figure 4 Example Motor Fan Alignment (Horizontal) (*) Represents quantity of shims under each foot. (**) Represents soft foot measured under each foot with laser.
Figure 5 Example Motor Fan Alignment (Vertical). Belt or Pulley Alignment Belt alignment or pulley alignment is an important maintenance task. When carried out correctly, it can prevent breakdowns and save considerable costs. Belt alignment and pulley alignment are synonymous, as the process of belt alignment hinges on the correct alignment of the pulleys on which the belt runs. For the sake of clarity, we speak of belt alignment. Belt alignment concerns aligning the belts in a way that results in the least wear on the belts and lowest energy loss for the machine or driver unit. This means that the grooves of the pulleys are in line with each other in practice.
Figure 6. The grooves of the pulleys are in line. 2004 SKF Reliability Systems All Rights Reserved 8
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Figure 7: Belt-driven fan. For further reading on belt alignment, the reader is referred to [12,13]. Bearings & Lubrication Bearing Arrangement Figure 8 and Figure 9 show two principle different fan mounting configurations: overhung load, and straddle. The overhung load configuration is identified by the placement of the bearings, on the shaft as compared to the fan position on the shaft. As can be seen in the left configuration in Figure 8, the motor and coupling are on one side of the bearing set, and the fan is on the other side. The same configuration can be seen on the right, only a multi-grooved sheave replaces the motor and coupling.
Figure 8 Overhung Load Configuration Figure 9 illustrates the straddle configuration of a fan assembly. The configuration on the left demonstrates the motor coupling assembly, then the first bearing. In the straddle configuration, the fan is then located between the two bearings. Similarly, the configuration on the right is the same, only with the motor coupling assembly replaced with a multi-grooved sheave.
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Figure 9 Straddle Configuration Bearing Selection In the design or rebuild of the fan bearing arrangement, the following configurations are generally considered by SKF: Application - heavy duty (process fans), light duty (e.g. ventilation fans) Fan Type - centrifugal, axial Mount Type straddle, overhung Drive Method belt/pulley, direct drive Shaft Orientation vertical, horizontal Inlet Type (for centrifugal fans) single, double Blade Pitch (for axial fans) fixed, variable Radial Loads high, medium, and low Axial Loads high, medium, and low Speed High, medium, and low Bearing Temperature High, medium and low Bearings normally used are SRB, SABB , CARB but also DGBB and ACBB. Most bearings in fans are sleeve mounted. Today there are new concentric offers available for the whole shaft. Labyrinth seals are normally used due to high speed. Lubrication Guidelines The lubrication of a fan generally means lubricating the bearings of the fan shaft. If rolling element bearings are to operate reliably they must be adequately lubricated to prevent direct metal-to-metal contact between the rolling elements, raceways and cages. The lubricant also inhibits wear and protects the bearing surfaces against corrosion. The choice of a suitable lubricant and method of lubrication for each individual bearing application is therefore important, as is correct maintenance. A wide selection of greases and oils is available for the lubrication of rolling bearings and there are also solid lubricants, e.g., for extreme temperature conditions such as hot gas fans. The actual choice of a lubricant depends primarily on the operating conditions, i.e., the temperature range and speeds as well as the influence of the surroundings. The majority of fan bearings are grease lubricated with regreasing possibility. The following SKF guidelines apply: 2004 SKF Reliability Systems All Rights Reserved 10
AoM04005_fan_WE - Fans - Work Execution - Initial fill for grease lubrication at start up: Generally, when greasing split pillow blocks containing SRBs and SABBs fill the bearing 100% full (CARB fill bearing full), housing 1/3 full, and labyrinth seals grooves 100%. Note that the temperature at start up generally goes up well above steady state temperature after running a while. Oil in grease is typically an ISO VG 100 to 220 C (depending on operating temp.)
Grease stiffness recommended is NLG1 grade2 For grease lubrication the following general guidelines are recommended: o Mineral oil based grease can be used up to 80 C or 212 F o Synthetic oil based grease can be used up to 100 C or 176 F Above 100 C or earlier (above 80 C) go for oil bath lubrication. At oil bath lubrication the normal running temperature is substantially lowered in same application. Oil bath lubrication can be used up to 100 C. For oil bath applications above 100 C go for circulating oil. The oil flow can be set so the bearing temperature is 50 to 80 C. Most common oil viscosity grades are 100 to 220 cSt. The (base) oil viscosity ratio at operating temperature Kappa needs to be in an appropriate range [16]. Lubrication guidelines using the Kappa value are:
o For oil lubrication Kappa shall be over 1 and between 2 and 5 is good. o For grease lubrication Kappa can be up to 7
The lubricant in a bearing arrangement gradually loses its lubricating properties as a result of mechanical work, ageing and the build-up of contamination. It is therefore necessary for grease to be replenished or renewed and for oil to be filtered and changed at regular intervals [16]. For this purpose, automatic grease supply systems could be applied, single or multiple-point [16]. Example: Small and Medium Size Cement Industry Fans A spherical roller bearing (SRB) on the locating side and CARB on the non-locating side with tapered bore are recommended for smaller and medium size cement industry fans. (For very small fans, SABB may be used as the locating bearing). The bearings are typically mounted on adapter sleeves, but the SNL housings are also available for mounting directly on cylindrical seating. Figure 10 shows bearings mounted on withdrawal sleeves in SNL grease lubricated housings with labyrinth seals. Note that the locating and non-locating bearing positions are optimized due to the pulley belt load. The opposite arrangement of locating + non- locating bearing is also common. Concerning the locating and non-locating position, we generally recommend the locating position shall be on the drive side. Using the CARB and SRB arrangement, please note that both bearings/housings shall have locating rings mounted. For very dusty / wet conditions, it is advised to shield the housings and the shaft, e.g., by a "roof". The bearings are grease lubricated. Note; the CARB bearing must be lubricated from either side, through the bearing. 2004 SKF Reliability Systems All Rights Reserved 11
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Figure 10 Overhung centrifugal fan, pulley driven, plummer block housings. Refurbishment & Repair When to Recondition? Reconditioning can save money by significantly extending the operational life of bearings and bearing assemblies. For bearings, the process can range from simple re- polishing, to regrinding raceways and replacing components. In the case of units or assemblies, measurements are also taken to increase the service life of the unit as a whole. Bearing reconditioning is generally viable for: Expensive, large size and/or obsolete bearings (bearings with outside diameter larger than 200 mm) Bearings with short service lives Bearings with light damage (for instance, when potential problems have been detected at an early stage by condition monitoring) Bearing reconditioning tends not to be economically viable for: Small, low-price bearings (generally, it is not worth reworking bearings with an outside diameter less than 200 mm) Bearings that cannot be readily disassembled (e.g. those with special metal cages) Heavily damaged bearings showing excessive wear, broken rings, heavy material fatigue, etc. Typical applications where reconditioning has shown to offer significant savings include large size bearings for various industries, including paper and steel making, cement production, etc. As a result of regular vibration inspections, wear of large size bearings is often detected in time before the bearings are too heavily damaged. Benefits Due to the variety of reconditioning processes, an indication of prices vary between 10 - 15% of the new bearing net price, and up to 50 - 65%. Considering the bearing price and the service life extensions, a decision for reconditioning can be made. 2004 SKF Reliability Systems All Rights Reserved 12
AoM04005_fan_WE - Fans - Work Execution 2004 SKF Reliability Systems All Rights Reserved 13 Apart from the direct benefits, insight into bearing damage and its root causes can help the bearing user take proactive measures. Further, in certain situations, reconditioning may prevent production loss in case of delivery time of new bearings [17].
Figure 11 Example of Bearing Reconditioning Fan Repair Fan and component repair does not need to be difficult or present additional costs as opposed to complete replacement. As an illustration, we will look at a cooling tower fan coupling problem. This example case deals with the problem of a defective coupling on a cooling tower fan drive shaft. In the application, a large increase in the overall vibration level signaled that a problem had developed. Spectral analysis indicated that the problem was not occurring at the accessible measurement point, but was associated with the drive components. A loose coupling was discovered, repaired and the vibration returned to previous levels. Figure 12 provides a basic rendering of the cooling tower fan and components.
Figure 12 Cooling Tower Fan Coupling illustration General observations demonstrated that the cooling tower fan had been operating smoothly for several months and there were no clues in the vibration history to suggest that any trouble was imminent. The fan was monitored on a monthly basis, however measurements were confined to the motor because the remainder of the drive was inaccessible. The overall vibration levels that had remained at approximately 0.1 IPS for several months suddenly jumped to 0.74 IPS. The upper alarm had been set at 0.2 IPS. The vibration peak at one times motor RPM dominated the spectrum collected in the vertical plan, with a peak that had grown from less than 0.1 IPS to almost 0.7 IPS in a month (see Figure). In addition, 5x and 10x RPM peaks could be found in the spectrum.
AoM04005_fan_WE - Fans - Work Execution Theoretically, the coupling problems can generate a one times RPM signal, multiples of frequency related to the number of bolts, teeth or grids. Cooling tower fans pose a unique problem to vibration analysts because gear components are not accessible during tower operation. Diagnosis must be based on information collected from the drive motor of the fan only, unless a transducer is mounted strategically, on the fan drive gearbox inside the cooling tower.
Figure 13 Single Spectrum Plot (Loose Coupling) Preliminary findings indicated that the high frequency signal was being generated by a loose coupling half. Vibration readings taken since the repair indicate that levels have returned to normal and the one times RPM peak in the vertical spectrum has dropped from 0.68 IPS to 0.022 IPS. Corrective action consisted of a physical inspection. The inspection of the fan drive was conducted, and the motor coupling half was very loose on the shaft. The coupling was repaired and the unit was returned to service. The example shows that coupling problems can generate a once per rev signal as well as a frequencies related to the meshing components of the connector. 2004 SKF Reliability Systems All Rights Reserved 14
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Figure 14 Overall Value vs. Time Trend (post repair) Rebuild ("Design Out") When the fan system is doing its job but not doing it as efficiently as possible, the plant can rebuild the system using components that match the originals. Before rebuilding a fan system, the plant should take precautions that can contribute to a successful project. These preventive strategies include carefully storing and handling replacement components - bearings, seals, etc. - to minimize contamination, oxidation and physical damage; double-checking new components to ensure they are direct replacements for the originals; and measuring all shafts and bores for size, roundness and profile. At one chemical plant, the maintenance crew had to temporarily fix a key induced-draft fan on a critical emissions system. The quick fix was required because a fire had occurred in the fan impeller casing. Plant management had two goals: to curtail the use of the backup fan, which costs an additional $3,000 per day, and to see the operation through to a scheduled shutdown three months down the road. Although the fan had performed acceptably over the years, improvements were needed. The system required a complete overhaul during the upcoming scheduled shutdown. Prior to the shutdown, the plant reliability team called on experts to perform a failure analysis on the bearing removed during the emergency fix. The company also authorized a team to perform a reliability analysis on the entire fan system to recommend changes to enhance the system's performance and reduce the total life-cycle costs for the system. The service team discovered thermal changes created by varying hot gas temperatures had the greatest effect on fan performance. These changes caused the shaft to expand and contract, impacting bearing life - in this case, spherical roller bearings commonly used on industrial fans. The service team recommended a change to a CARB toroidal roller bearing that cannot carry axial loads. However, it accommodates axial displacement and angular misalignment as it "floats" inside itself, allowing frictionless thermal expansion. The same team installed an automatic lubrication system on the fan and analyzed a possible resonance problem in the 2004 SKF Reliability Systems All Rights Reserved 15
AoM04005_fan_WE - Fans - Work Execution system. Several techniques were used, including operation deflection shape (ODS) analysis [18], a technique that produces an animated pictorial rendering of the relative movement between surfaces. The analyses confirmed that a switch to flexible inlet/outlet expansion joints installed during the earlier quick fix had alleviated vibration problems in the system. The analyses also pinpointed other changes to the system's support structure that would increase system life. These changes were made during the shutdown. In general, any change made to a fan system without reviewing all of its ramifications could adversely affect system life. A fan system with a recurring problem is something no operation should have to live with, but, in many cases, plant personnel do just that. A chronic fan-system problem requires an MRA, performed with an eye toward finding the root cause of the problem. Experienced technicians with the right set of diagnostic tools can get to the root of problems and recommend a fix to make the system more reliable. This kind of asset management can pay big dividends in terms of increased productivity and better risk management. At another chemical plant, failures of the solvent-recovery fan had occurred erratically over the 30-plus years the fan had been in use. A reliability analysis and implementation of its recommendations eliminated the causes of the system's failures. The company estimates these reliability improvements save approximately $80,000 annually. The root cause of the problems had little to do with the bearings, shafts, seals or any other component of the fan itself. Although evidence showed that some bearings were installed incorrectly, the lubrication might have been inadequate for the application, and both the motor and fan sheaves were incorrectly specified, an ODS analysis found the principal problems to be structural. The fan base was not correctly designed for the application, allowing excessive movement. Also, the fan pedestal under the bearing housings had a right-to-left crown and a front- to-back sag. Experts replaced the sheaves with the correct ones, trained plant personnel in bearing installation procedures and upgraded the bearings and lubrication. However, their "fix" for the solvent-recovery fan consisted primarily of creating a new base for the fan, stress-relieving the fan, properly grouting it in place and flattening the pedestal base. The reliability analysis report notes that technicians discovered vibration to be a significant contributor to bearing problems, but goes on to say: "While it would seem that balancing the fan would alleviate the problem, this is not true. Structure issues are not allowing enough system stiffness - for the system - to function properly." 2004 SKF Reliability Systems All Rights Reserved 16
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Figure 15 Shown here are excerpts from an ODS animation performed on a solvent-recovery fan to evaluate the relative movement of the structural components. The ODS revealed excessive movement of the fan base. Figure 15 shows excerpts from an ODS animation performed on a solvent-recovery fan to evaluate the relative movement of the structural components. The ODS revealed excessive movement of the fan base.
Post Maintenance Testing Mechanical Testing Various mechanical tests can be performed on a fan or its parts, either to provide a basis for design calculations or to verify them. Although destructive tests are occasionally useful, most fan testing is nondestructive.[5] Spin tests may be performed to determine the buckling speed of a blade, the yielding speed of a shroud, or the bursting speed of an impeller. Nondestructive spin testing may be used simply to prove that an impeller will be able to operate at a certain speed. That speed can be the expected operating speed or some higher speed. Over speed testing demonstrates that there is a margin of safety at the normal speed. Over speeding may also beneficially redistribute static stresses.[5] Acceptance Testing Most industrial assets from complex manufacturing plants to remote and mobile capital equipment experience a peak system availability of 85% to 95%. The downtime associated with these assets represents a significant, and often hidden, cost to corporations. Prior to reaching peak system availability there are abundant cases of infant mortality of equipment upon commissioning, which will prevent manufacturing plants from even reaching this kind of availability without significant setbacks. Although equipment warranty is desired as a means to protect the user from incurred costs associated with infant mortality of the 2004 SKF Reliability Systems All Rights Reserved 17
AoM04005_fan_WE - Fans - Work Execution 2004 SKF Reliability Systems All Rights Reserved 18 equipment. The larger pervasive costs that will drag down the ROA are unplanned equipment and manufacturing process downtime. For many operations executives, 95% uptime is accepted as the norm. Unfortunately, the acceptance of this ceiling masks the true costs associated with unplanned downtime, which can amount to 1%-3% of asset value per year for large capital equipment. For example, as a solution, SKF Reliability Systems in conjunction with a power cooling company, has developed a number of risk management solutions. There are two very strong recommendations to foster availability of assets. 1. Acceptance Testing 2. Proactive Reliability Maintenance - Fan Management Program Many manufacturers will provide some level of minimum specifications as acceptance criteria to commission equipment. However, the specification is just that: a minimum. A part of the core competencies within SKF utilizes a variety of technologies to verify that the machines are within this criterion to avoid a high incidence of infant mortality and move the facility much quicker to meeting peak system availability. These technologies include: Inspection of Foundation Lubrication Review (type, quantity, re- lubrication frequency, and analysis) Precision Alignment of machine train components Precision Dynamic Balancing of system. Baseline Vibration Analysis Survey of machine train Motor Current Spectral Analysis Baseline Machine Reliability Assessment of bad actors. Secondly, each fan program uses monitoring, data analysis and component upgrades to reduce life cycle costs. Fan reliability and maintenance issues are frequently complex, and solutions require special tools and expertise that are normally not available on- site. SKF offers service packages designed to help keep this critical element of production running more efficiently. The elements of each fan management program depend on the results of monitoring and manual inspections. Some of the components of an SKF fan management program include: Lubrication Analysis Advanced Vibration Analysis Vibration Monitoring Precision dynamic balancing Bearing System design upgrades Lubrication recommendations Precision Alignment Bearing installation Seal application review Trouble-Free Supply Feedback / Living Program Root Cause Analysis A problem is often the result of multiple causes at different levels. The root cause is the evil at the bottom" that sets in motion the cause-and-effect chain and creates the problem. In fact, RCA is a collective term used to describe a wide range of approaches, tools, and techniques used to uncover and model
AoM04005_fan_WE - Fans - Work Execution causes to problems. RCA is a method that helps professionals determine what happened, how it happened, and why it happened. It allows learning from past problems, failures, and accidents. RCA can be applied to any organizational, production, and administrative (etc.) problem [19]. Importance of RCA Why perform a RCA? If achievements from eliminating the problem and its consequences are larger than the efforts put into a RCA, this seems obvious. Although eliminating risk of recurrence of similar situations looks admirable, it could be perceived as the "program of the month." Resolving emergencies when they occur, while RCA aims to eliminate root causes and reduce the maintenance persons responsibilities, may recognize a maintenance person. Therefore, it is extremely important to align everyone in the same direction, both at the management level and production and maintenance personnel. Creating the right, open environment for learning from failures is essential [20]. Lets look at an example: Symptom: A cement plant has eight overhung fans running 24 hours a day, 7 days a week. The fan shafts are supported by spherical roller bearings in split pillow block housings. The fans have been in service for over fifteen years, and share a common support platform. Within the last year, the bearing failure rate has been accelerating rapidly, and replacements are now occurring monthly. Operators have noted a marked increase in vibration in the area over the same timeframe. Investigation: The failed bearings show two sets of symptoms: failed bearings from two of the fans show excessive polish wear on their outside diameters, and evidence of a 360 degree load zone on the outer ring raceway. The other fans show bearing failure with grayish, washboard wear in a 120 degree load zone at the bottom of the outer ring. What's happening? Answer: If you guessed the bearing rings were spinning in the housing due to imbalance, you're halfway there: But what's driving this behavior? There are several possible root causes, such as wear of fan wheels, shrouds, missing components (half- keys, for example) or simply improper initial balancing. Excessive imbalance can induce outer ring creep, which is why the high polish in the OD surfaces was observed. The 360 load zone is also from the imbalance. Find and correct the imbalance: did anything happen a year ago (process change, maintenance or operations personnel change, etc.) that might be contributory? After startup, measure vibration signatures to comply with local or ISO standards to verify the imbalance has been corrected. What about the other bearings? These are showing signs of secondary damage. High vibration from the two bad machines is transmitted to the other fans sharing the support. Mix this ambient vibration with a bit of cement dust and you have a perfect recipe for "washboard" abrasive wear. Moral: Examining failed bearings inside and out is a key best practice for uncovering root causes of failure. But we must also learn to couple the postmortem with a sound knowledge of machine history, operating conditions, and current diagnostic and performance data to get a complete picture of the failure cause. Otherwise, we risk an incomplete conclusion, which could lead to the application of improper (and often ineffective) corrective actions. Another key practice is to verify the effectiveness of the corrective action. Did our change work? Using a minimum of two condition monitoring measurements (vibration, temperature, oil analysis, etc.) to verify results is a good idea. 2004 SKF Reliability Systems All Rights Reserved 19
AoM04005_fan_WE - Fans - Work Execution Job Plan Validation and Update Standard job plans should be subject to a regular review and update procedure. The job plan should make provision for feedback on completion of the work to validate the efficacy of the plan, and to prompt any revision that may be necessary. In [4], an example includes basic fan data for reference, such as a description for record keeping. The standard job plan then outlines the specifics of the fan asset such as: Part number(s) Special tools and test equipment required Personnel qualifications required to do the work Preparation(s) required (drawings, permits, lockouts, documentation, etc.) Implementation (step by step work instructions, etc.) Follow-up (post maintenance testing, clean tools, etc) A disciplined and effective approach to task close-out is important for a number of reasons. Appendix A, Work Control Task Close-Out Template, provides guidelines regarding the data that should be collected at closure of each job to support this process. Audit Trail An effective close-out procedure provides a good level of integrity for the audit trail and is a requirement of many regulatory bodies. The purpose of an audit trail is to identify errors in information, to explain inconsistencies in the information, and to properly manage the information. The key in ensuring ability to audit is providing information that was used to update each record. Towards a Living Program The Maintenance Strategy review (MSR) dictates what maintenance should be done, based (usually) on detailed study of the cost of undertaking that work versus the risk of not doing so. The MSR must be a reiterative process in order to ensure that the maintenance activities remain aligned to the business needs.[1] Where real-world experience dictates the need to change standard maintenance plans, this can be valuable input to the MSR review process, since it may have some effect on the "cost" side of this equation. It is therefore essential that the maintenance management system make provisions for collection and storage of this valuable information, and for efficient retrieval and analysis to support the update process. For further information on world-class maintenance management work process, have a look at an article by Mel Barratt called, Optimising Your Maintenance Strategy[21]. Conclusions The fan-system problems described illustrate two major points: A fan system is just that a system. Not only does it include the components one usually associates with a fan bearings, shafts, seals and lubrication systems it also includes physical and operational support structures. These often- ignored system parts should be included in assessments of a system's performance. Improving fan-system reliability requires diagnostic techniques adequate for determining the root causes of problems. If bearings or seals are failing and the root cause is structural, environmental or operational, no amount of assessment on the bearings and seals to the exclusion of the rest of the system will pinpoint the root cause of persistent problems. Ultimately, fan-system management 2004 SKF Reliability Systems All Rights Reserved 20
AoM04005_fan_WE - Fans - Work Execution requires plant personnel to monitor, control and maintain elements that can reside well beyond the fan itself. References [1] McKenna, T., and Oliverson, R. Glossary of Reliability and Maintenance Terms. Gulf Publishing Company, 1997, ISBN 0-88415- 360-6 [2] Barratt, Mel. Maintenance Strategy for Fans. AoM04002_fan_MS. http://www.aptitudexchange.com [3] Bretz, Rob. Work Identification for Fans. AoM04003_fan_WI. http://www.aptitudexchange.com [4] Barratt, Mel. Work Control for Fans. AoM04004_fan_WC. http://www.aptitudexchange.com [5] Jorgensen, Robert. An Engineers Handbook on Fans and Their Applications. Howden Buffalo, Inc. 1999. [6] Bleier, Frank P. Fan Handbook: Selection, Application, and Design. New York, New York. McGraw Hill. 1998. [7] de Vlaam, Geoffrey. Machinery Mounting. GS02011, http://www.aptitudexchange.com [8] Barratt. Mel. Balancing. MB02004, http://www.aptitudexchange.com [9] Swansen, Doug. Machinery Balancing Fundamentals. DS03001, http://www.aptitudexchange.com [10] Fixturlaser. Shaft Alignment: Introduction. Fixturlaser_01, http://www.aptitudexchange.com [11] Barratt, Mel. Introduction To Shaft Alignment. MB03018, http://www.aptitudexchange.com [12] SKF Maintenance Products, Belt Alignment. GS04007, http://www.aptitudexchange.com [13] Bretz, Rob. V-Belts. RB02006, http://www.aptitudexchange.com [14] SKF, Bearings for Fans. SKF_3213_E, http://www.aptitudexchange.com [15] SKF, Self-Aligning Bearing Systems, SKF_4417E, http://www.aptitudexchange.com [16] SKF, Bearing Lubrication. JM02006, http://www.aptitudexchange.com [17] Braunegger, Hubert. Reconditioning Bearings and Units. GS02012, http://www.aptitudexchange.com [18] David Kadushin and Jason M Mais, Operating Deflection Shape Analysis. JM02024, http://www.aptitudexchange.com [19] Schram, G. Root Cause Analysis. GS02003, http://www.aptitudexchange.com [20] Latino, R.J., "Creating the environment for RCA to succeed", Maintenance Technology Magazine, April: 2001. [21] Barratt, Mel. Optimising Your Maintenance Strategy. MB04009. http://www.aptitudexchange.com Resources Air Movement and Control Association (AMCA) http://www.amca.org American Society for Mechanical Engineering (ASME) http://www.asme.org Fans for Hazardous Applications. Suffolk, England. Mechanical Engineering Publications Limited. 1994 2004 SKF Reliability Systems All Rights Reserved 21
AoM04005_fan_WE - Fans - Work Execution Higgins, Lindley R., Mobley, R. Keith, and Smith, Ricky. Maintenance Engineering Handbook; Sixth Edition. New York, New York. McGraw-Hill. 2002 Institute of Mechanical Engineers (IME) http://imeche.org.uk/ New Standards for Fans. London, UK. IMechE Seminar Publications, Professional Engineering Publishing. 2000. PTC 11-1984, Fans; Performance Test Codes. New York, New York. The American Society of Mechanical Engineers. Reaffirmed 1995. Acknowledgements Special thanks to Steve Kelly, SKF, for his contribution on rebuilding fans; to Hans Lindh for his contribution on fan configurations; and to Eytan Dor for the cooling tower fan coupling example. 2004 SKF Reliability Systems All Rights Reserved 22
AoM04005_fan_WE - Fans - Work Execution Appendix A Work Control Task Close-out Template 20. Task Procedure No. Task Duration. 22. Planned. 23. Actual. 21. Task Descriptor 24. When Actual Is > +/- 25% Of Planned. The Reason/s Are: 25. Scheduled Start Date. 26. Actual Start Date. 27 Remedial Work Required. 27a. Is Remedial/Follow-On Work Required? Yes Or No
27b. When Yes Must This Work Be Done By A Certain Date? Yes Or No
27c. When Yes State The Date <..> 27d. What Is The Work That Needs To Be Done? <.> 28. Actual Equipment Performance At Conclusion Of Work.
29. Was A Test Run/Performance Validation Conducted? Yes Or No
30. Is The Test Sheet/Calibration Record Attached To This Closing Work? Yes Or No
31. Structured Work Closeout/Feedback (Learning).
Is The Equipment Returned To Service In Its Original Fit, Form & Function? Yes Or No
When No How Is The Equipment Different & Why & What Does This Mean To The Owner/Operator? <..> Has A Permanent Modification Been Done? Yes Or No When Yes Attach The Authority To Change/Modify Per Management Of Change <> Has A Temporary Modification Been Done? Yes Or No
When Yes When Does The Temporary Modification Need To Be Actioned By <Date> Were You Able To Work Safely? Were The Mandatory/Optional Material Sufficient? Yes Or No
When No What Was Absent/Insufficient? Did You Have All The Necessary Known Spare Parts? Yes Or No
When No What Was Absent/Insufficient? Did You Have All The Special Equipment/Test Equipment That You Needed? Yes Or No 2004 SKF Reliability Systems All Rights Reserved 23
AoM04005_fan_WE - Fans - Work Execution
When No What Was Absent/Insufficient? Did You Have All Necessary Data, Documentation, Drawings, Vendor Manuals, QA/QC Forms? Yes Or No When No What Was Absent/Insufficient? Do You Think The Frequency Of This Task Needs Changing? Yes Or No
When Yes To What Frequency & Why? Do You Think That The Content (What You Did) Needs Changing? Yes Or No
When Yes What Needs Adding, Deleting, Amending & Why? Figure 16. Template For Structured Task Close-Out
2004 SKF Reliability Systems All Rights Reserved 24