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  • Condition Based Maintenance: Building A Framework

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    Vinoth Kumar Subramani
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    This document discusses condition based maintenance and online predictive maintenance. It begins with an introduction of the presenter and their experience. It then discusses why condition based maintenance is important, noting that most failures provide evidence and occur randomly. It outlines inspecting assets on three dimensions: reliability-centered maintenance, technology-enabled inspection, and predictive maintenance. The rest of the document details a project to implement online predictive maintenance using vibration monitoring, oil analysis, and thermography. It provides screenshots of the monitoring software and discusses key results like increased safety and productivity and reduced costs.

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    This document discusses condition based maintenance and online predictive maintenance. It begins with an introduction of the presenter and their experience. It then discusses why condition based maintenance is important, noting that most failures provide evidence and occur randomly. It outlines inspecting assets on three dimensions: reliability-centered maintenance, technology-enabled inspection, and predictive maintenance. The rest of the document details a project to implement online predictive maintenance using vibration monitoring, oil analysis, and thermography. It provides screenshots of the monitoring software and discusses key results like increased safety and productivity and reduced costs.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    23 views19 pages

    Condition Based Maintenance: Building A Framework

    Uploaded by

    Vinoth Kumar Subramani
    This document discusses condition based maintenance and online predictive maintenance. It begins with an introduction of the presenter and their experience. It then discusses why condition based maintenance is important, noting that most failures provide evidence and occur randomly. It outlines inspecting assets on three dimensions: reliability-centered maintenance, technology-enabled inspection, and predictive maintenance. The rest of the document details a project to implement online predictive maintenance using vibration monitoring, oil analysis, and thermography. It provides screenshots of the monitoring software and discusses key results like increased safety and productivity and reduced costs.

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    © All Rights Reserved
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    of 19

    Condition Based Maintenance

    Building a Framework

    Fabio André Brand

    Webinar – August 2021


    Fabio Andre Brand

    Mechanical Engineer (Master’s degree in RCM)

    17 Years working in Maintenance & Reliability


    Steel Mills – Brazil, USA & CAN

    Coordinator: Maintenance, Reliability and Storeroom

    Project Manager: USD 1.5M Capex for Online Predictive

    CMMS (SAP-PM) Trainer

    Webinar – August 2021


    Objectives of Condition Based Maintenance

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Why Condition Based Maintenance (CBM)?

    Approximately 89% of Failure


    Modes occur RANDOMLY

    Most Failure Modes provide EVIDENCE

    Why Failures Happen?

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Why Failures Happen?
    Load Resistance

    2 Factors
    2 Reasons

    Load Resistance Load Resistance

    Load >
    Resistance
    Resistance
    < Load

    Inspection

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Inspection: 3 Dimensions

    Basics
    RBM – Rice & Beans Maintenance
    + Technology
    Industry 4.0

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Inspection: 3 Dimensions

    Failure Predictability
    Ultrasound Motor Testing
    Thermography
    High Predictive Vibration Fluid Analysis

    Human Senses Temperature


    Median Inspection
    Noise
    Simple Instrumentation

    Low Shift Maintenance


    Rounds High Frequency
    Operation (TPM)

    P-F

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Rounds / Daily Inspections

    ü Detect potential failures close to final failure

    ü Validates other 2 types: Ultimate Goalkeeper

    Maintenance Shift Inspections

    TPM Inspections

    Pre-Shift Inspections

    Equipment Safety Checks

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Inspection 360º

    ü Dedicated Inspectors using simple Predictive tools

    ü Can detect the majority of Failure Modes

    UV and white light Flashlight

    Handheld Laser Infrared Thermometer

    Vibration Pen

    Industrial Borescope

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Predictive Maintenance

    ü Very Specialized: High predictability

    ü Can be Offline or Online Monitoring

    Vibration

    Thermography

    Fluid Contamination

    Ultrasonic Detection
    …

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Project: Maintenance 4.0
    Online Predictive Maintenance

    Project Steps (Started in 2017)

    Project Team Definition

    Risk ranking – ABC Assets Classification

    RCM studies (Failure Modes) - Assets “A”

    Technology Selection =

    Sensors Installation and Configuration

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Online Predictive Maintenance – Vibration Monitoring

    Software

    Screen 3

    Screen 2

    Cloud - Online Vibration


    Condition / Automatic
    Alerts by E-mail/SMS

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Online Predictive Maintenance – Vibration Monitoring
    Screen 4

    Tendency / Spectrum

    Screen 5

    Online Vibration Condition:


    Velocity, Acceleration, Envelope

    429 Online Points


    Whole Plant
    185 Assets Monitored

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Online Contamination Control

    Online Contamination Control as ISO 4406

    IoT system to control filtering needs

    Proper Offline Filtering System

    Integration with Predictive Software

    ü Extended oil life by 50%

    ü Extended equipment life by 100%


    Online ISO 4406

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar - 2021


    ONLINE Thermography

    ü Monitoring of Critical
    Transformers

    ü Fixed Infrared Cameras


    (Flir AX8)

    ü Automatic Alarms (E-mail)

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar - 2021


    Case Study – Bearing on Dedusting Fan (Inner Diameter 6”)

    On April 16th, online system reported one Alert of higher


    vibration (Envelope 4,845 gE), with defect on inner ring of
    Bearing 22230 C3.

    Planned Corrective Order on April 22nd

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Key Points Results

    Rounds Inspection Predictive


    Higher Safety of the Crews
    Planned Corrective Orders
    Higher Productivity

    Planning & Scheduling Maintenance Delays (<2%)


    Execution

    Maintenance Cost (-15%)


    RCA and Reinspection

    Fabio Andre Brand Maintenance & Reliability 4.0 Webinar – 2021


    Condition Based Maintenance:
    Basics + Technology = Change the Future

    Fabio Andre Brand

    +55 (51) 99358 6086


    Contact:
    fabio.brand@gerdau.com.br (Company)
    fabiobrand@hotmail.com (Personal)

    fabio_andre_brand

    Maintenance & Reliability 4.0


    Questions Questions

    Heather and Ryan (Upkeep Team)


    Thank Gerdau
    Ozório Resende – Pred Engenharia

    Contact: fabio_andre_brand

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