中国寰球工程公司

CHINA HUANQIU CONTRACTING &ENGINEEGING CORP.

Maintenance Methods
Definition of Failure

Equipment Lost Function

Abnormality
Impact

Stress

Failure

Stress Damage abnormality Symptom

• Rotation • Crack • Surging • Vibration
• Weight • Strip • Water hammer • Abnormal noise
• Temperature • • Cavitation • Heating
• Pressure Deformation • Beat • Lighting
• Velocity • Damage • Whirl • Ultrasonic wave
• Acceleration • Abrasion • Looseness • Current
• Environment • Scorch • Plug • Voltage
 Cases needed to be maintenance

The purpose of maintenance ;

Operate the machine and plant for safety and economic

Cases Basis of Decision Decision Mechanism

Cost budget and The economic loss caused by the

Loss of operating
recognize of related
Efficiency
issues Reduction efficiency > Maintenance costs

should be eliminated by prior maintenance

Safety Risk measures, that need to predict maintenance
method
Loss of function
Optimal maintenance method should
Downtime cost
be selected to maximum benefit and
and Repair cost
minimize total cost.
 Selection criteria for key parts
Maintenance activities should focus on components that may cause the equipment or
system to lose its function

Key factors Typical Cases Selection Criteria

Re-confirm the design of the system, through the
Components that are subject to intermittent
Failure relevant operational experience analysis, identifi
overload, excessive load, wear, corrosion,
Probability cation. Parts that will be in failure easily shall be
and other environmental factor
managed individually
Nuts, bolts and other parts that are easily If there is no safety requirement, no specific mai
The time required replaceable, or parts that can be restored ntenance is required after replacing or repairing t
for replacing the immediately through the sparing system. he parts.
defective parts Status monitoring and maintenance plan shall be
Parts that need a long time to replace.
prepared in advance.
In the event of a failure, it can be cause of
the entire system failure and trigger Need to be carefully selection
continuous damage to the parts.
The Impact of
Component Failure In the event of a failure, parts that cause
In order to determine the safety level, there must
on the System other parts to overload and cause system
be fault effect analysis (FEA)
malfunction.
In the event of a failure, only the parts that
Economic Effects Analysis of Failure is needed.
cause low performance of system.
Maintenance Method

Maintenance
Characteristics
Method
1) Equipment which is not key or with spare unit.
Breakdown
2) Applicable for equipment not causing big problem even though in failure
Maintenance
3) Not a good method to improve productivity.

1) Time Based Maintenance (TBM)：According to the analysis of previous failure data a

nd Mean Time Between Failure(MTB), specify the maintenance interval. This is a perio
dic maintenance method.
2)Weakness is that there will be maintenance for normal equipment, that is excessive
maintenance, and can not cope with failure between two periodic maintenance and
Preventive
sudden failure.
Maintenance
3) Maintenance period shall be shorter than shortest life cycle of the parts as it is difficult t
o confirm life cycle of the parts in the beginning.
4) Experience of other companies is to preventively set the average failure cycle based on t
he data after the start up of equipments and maintain accordingly. By this method, the m
ore equipments ,the more complex will the maintenance be.

1) Condition Based Maintenance (CBM)：Judging the equipment condition with the

help of equipment diagnose and status monitoring technology. Find out the problem
Predictive
before failure occurs, predict its development and maintenance in an appropriate time.
Maintenance
2) Comprehensively evaluate the degree and speed of equipment degradation. Minimizing
the influence on production cost shall be the criteria to decide maintenance period.
 Maintenance Method (1)

Method Advantage Disadvantage

1) Continuous damage cost is high and there is

danger.
Breakdown Maintenance is easier, if there is no 2) product solidification or degradation and other
Maintenance danger or continuous damage, this maint reasons, resulting some equipments can not be
(After damage enance will be the most affordable soluti shutdown emergently.
maintenance) on. 3) failure occurred in emergency, it is very difficult
to assign maintenance personnel and to replace
parts.

1) reduce the risk of failure in operation.

1) can not predict the time of failure.
Preventive 2) beneficial to pre-planned operations
2) During inspection, the good parts also need to
Maintenance and availability of special tools and
be disassembled and checked. The reassembling
spare parts
(Periodic will influence is original performance.
3) is particularly suitable for parts of whi
Maintenance) 3) the inspection process takes considerable time,
ch the volume changes(such as filters,
causing significant production losses.
etc.)
 Maintenance Method (2)

Method Advantage Disadvantage

1) need to have the appropriate staff and spare parts,
Opportunistic Main
the cost will be increased.
tenance
2) only combined with Condition Based Maintenan
(Need to use the No loss of running time
ce and Preventive Maintenance, will there be a subs
workshop or equipme
tantial effect.
nt for maintenance)
3) Failure may occur during operation.
Equipments can keep running until it
Condition Based is close to failure. Equipments can be Can only find out the equipments which are very
Maintenance shutdown as per original plan to prone to fault. Instantaneous failure parts can not be
(Condition minimize maintenance cost. provided with necessary pre-inspection.
Based Monitoring) Continuous damage caused by failu Parts failure caused by any overload in operation
re avoided.

Maintenance / repla In order to predict the life cycle of parts, the

Only for instantaneous failure parts
cement based on the condition monitoring of the parts must be carried
(safe method).
life cycle of parts out.
Comparison
Item Preventive Maintenance
1) statistics, probabilistic prediction
General Chara 2) More concerned on failure results
cteristics 3) no need for experience, more objective
4) Information control is strong
1) unified plan, centralized management is
Planning in easier
Management 2) ignore the reality, difficult to allocate
responsibility
1) No need for initial investment
2) Data collection takes time and money
3) can not limit the increase in costs, there is
the possibility of rapid increase
4) regular overall inspection, to determine and
Economics replace the abnormal components
5) There is a possibility that the normal
component is also replaced
Predictive Maintenance
1) More based on Measurement, the conclusio
n is predictive
2) attention to physical defects
3) experience is necessary, more subjective
4) Information control is weak
1) planning and management is a little difficult
2) realistic, easy to allocate responsibility
1) high initial investment in equipment
2) data collection time is short and cost is low
3) can limit the increase in costs, no possibility
of rapid increase
4) Replace and repair degraded component
5) Maintenance as needed
Compare with result of maintenance method
Height of the column represent maintenance effect
 Maintenance cost and CBM
 Relations between equipment operating time and maintenance costs
The operation of equipment during life cycle can be divided into the abnormal period during start up (caused
by many errors not found during installation), the normal period of stable operation, and the degradation
period when the equipment components start to degrade.
During degradation period, equipment parts starts to degrade and degradation may expand with time, the
corresponding maintenance costs will rise. We need to comprehensively consider the degree and speed of
degradation ,and minimizing the impact on production costs shall be criteria when deciding maintenance
period. Degree and speed of degradation can be evaluated by state monitoring.
 Method of CBM
The vibration is periodically measured during the normal stabilization period, and the measurement interval
is gradually shortened after entering the degradation period to monitor the trend. progressively monitored.

Vibration
Level
Malfunction
Ratio
Breakdown

renewal Trend watch

period renewal
Start
Breakdown

Operation Operation
Time Time
Initial Normal Stable Aging
Malfunction period Process Maintenance Maintenance
 Maintenance Cost

 Cost during equipment maintenance

1) Repairing cost: repair and replace degraded parts, including preventive and
breakdown maintenance(2 or 3 times follow-up maintenance)

2) Check cost: machine and labor cost for checking equipment.

3) Opportunity loss cost: production loss cost during equipment failure. Different
operation condition and output during failure will end up to much different loss
during equipment failure.
Maintenance method and cost

Method Maintenance Cost

No inspection before failure occurs. Maintenance is carried out after failure occurs.
Breakdown
Although there is no inspection cost, the production losses and maintenance costs are high
Maintenance
when the failure occurs.

No inspection is carried out and periodic maintenance is unconditional.

Although there is no inspection cost, the maintenance cycle and the equipment degradation cycl
Preventive
e are not exactly the same, resulting in both preventive maintenance costs and breakdown ma
Maintenance
intenance costs. So the cost is relatively higher than CBM, and there also production loss.

Regular inspection is carried out and maintenance is based on inspection results.

The state check is a method in which the inspector performs a quantitative and qualitative monit
Condition
oring on the degradation state according to the feeling (qualitative), the measuring device (quant
Based
itative), and the monitoring device. As the inspection with the monitoring device is highly reliab
Maintenance
le maintenance can be carried out at the most appropriate time. That is Minimum maintenance
cost and no production loss, but high inspection cost.
Maintenance basis and cost
 In general, the higher the maintenance basis, the higher cost of inspection and
the lower production loss and maintenance costs.
 On the contrary, the lower the maintenance basis, the lower the inspection cost
and the higher the production loss and maintenance costs.
 There is an optimal point, that is the lowest cost point between the combined cost
(inspection cost + maintenance cost + production loss) and maintenance basis.

Total Cost
Cost

Check Cost Relation with

Maintenance
cost and basis

Product Lost
Maintenance cost

Maintenance Level
Calculation of Maintenance Cost
MTBF : Average Failure Time
MTBR : Average Repair Time ,
CF : Breakdown Maintenance cost, CR : Preventive Maintenance cost,
C0 : Production loss,
Ti : Inspection cycle, Ci : Inspection cost, Ch : Machine cost for inspection

Maintenance Failure Repair Preventive

Inspection cost Production loss
cost cost Maintenance cost

Breakdown
CF / MTBFb C0 / MTBFb
Maintenance cost

Preventive
CF / MTBFt CR / MTBRt C0 / MTBFt
Maintenance cost

CBM CF / MTBFc CR / MTBRc Ci / Ti + Ch C0 / MTBFc

 Calculation of MTBF and MTBR
 Replace cycle in Breakdown Maintenance :
MTBFb = Td + Te Defect

 Replace cycle when TBM failure occurs :

MTBFt = { Tn + (1- A) Re/Rd B - (1- C) Rd/Re B}
Fault
/{1 - (Re A- Rd C)/B }

Aging Level
 Replace cycle in Preventive Maintenance :
MTBRt = { Tn + (1-A) Re/Rd B - (1- C) Rd/Re B}
/{Re A - Rd C)/B} Stable
 Replace cycle when CBM failure occurs :
MTBFc = { Td + (1- P0)Te}/ (1- P0) Time
 Replace cycle in Preventive Maintenance :
MTBRc = { Td + (1- P0) Te}/ P0
Degradation Trend Graph
Among which,
Tn : time from the beginning to use of equipment to a stable period
(shortest time taken from previous failures that occurred)
Td :time from stable period to the time of defect (equipment starts to be abnormal)
Te : time from the defect to failure(maintenance starts to be necessary)
Rn, Rd, Re : the probability of failure corresponding to each time
P0 (= Pt/Pi) : Inspection accuracy of the defect (the accuracy of the technical inspection/
inspection cycle probability)
B = Re – Rd, A = exp{- Rd (T – Tn)}, C = exp{- Re (T – Tn)}
 Favorable factors for CBM

Factors Mechanism

Because the cause of the failure may Typical cases include petrochemical plants, nuclear
cause safety risks power plants, personnel transport machinery.

Workshop or equipment is the latest State monitoring can detect defects in the early stages of
design, there maybe problems on the damage, provide useful evidence for design improveme
development nts, and dominate in consultation with the manufacturer.

Relatively ignoring the daily damage, State monitoring can help to shutdown the equipment be
while these damage will cause significant fore a major accident, so that there is sufficient time to
damage to high-priced equipment. check for defects.

For equipment for which manufacturers Can reduce the user costs, manufacturers can feedback
can provide status monitoring services. relevant information of product design and development
Business and Capability of Diagnose Personnel

Business Necessary capability

Collect relevant information from operator
Have a deep reasoning ability and theoretical
and maintenance personnel and reflect the
knowledge.
problem.
Through the diagnostic equipment or status
With insight to determine the state of the
monitoring system for data analysis, state
equipment through the data
identification.
The theoretical knowledge and experience to
Confirm the type, cause, position and degree identify the problem from equipment
of the problem. structure by means of data and test charts
representing the state of the equipment.

Ability to predict the time from equipment

Predicted lead time before failure occurs
defect to equipment failure.

Ability to find the best solution to the

Propose solutions to fix problems
problem.
 Maintenance Result to Equipment Design
Opportunity
1)Maintenance activities can record and analyze
problems during the life of the equipment
2)In particular, to record and save the failure mod
e under certain conditions.
1) The reanalysis of the maintenance problem
can determine the maintenance time of parts
2) The characteristics and causes of the problem
can determine the definition of design
principle
Maintenance activities can reduce downtime due
to equipment defects and provide opportunities to
adjust the design.
Remark
This is the only source of information that is
valuable to the design process and product
development.
Is beneficial to the establishment of maintenance
plans, especially for simple, low-cost
maintenance.
The subsystem equipment is designed to be
replaced directly and easily when a defect occurs.
Practical problems can be corrected offline with
the experimental equipment, subsystem
equipment needed to be returned.
 Basis of
Equipment Diagnosis
 Life Cycle and Diagnosis

Diagnosis type Characteristics

1) Carry out in the commissioning phase after installation is finished

2) Initially investigate whether there is a problem
Initial Diagnosis
3) referenced as baseline data for future diagnosis
4) usually precision diagnosis

1) Purpose is to identify the problems as early as possible

Periodic Diagnosis 2) taking specific equipments as diagnosis object
3) Perform a simple diagnosis firstly, and precision diagnosis after problem is confirmed

1) Taking equipment with problem (vibration, noise) as object

Abnormality Diagnosis
2) Analyze the cause of the defect with detailed diagnosis

1) to determine whether the equipment needs to be repaired

Repairing Diagnosis 2) to determine the specific repair sites and content according to the repairing diagnosis
3) After repair to confirm repair (this part requires precise diagnosis)

In addition to the above, there are improvement maintenance diagnoses for equipment
improvement, and the residual life diagnosis for determining whether the equipment is discarded.
 Diagnosis Definition and Procedure

1. Definition of equipment diagnostic technology

Equipment diagnosis technology refers to a technology that can grasp the current state of the
equipment, quantitatively measure state of equipment, determine the location or cause of the
equipment abnormality or fault, and predict the future status of the equipment.

2. Steps to diagnose the equipment

1) Figure out the state : to investigate the state variables of the equipment, and achieve digitization,
visualization and modeling of the state variables through measurement and analysis.
2) Determine degree of failure : accurately determine and measure various parameters reflecting the
actual situation equipment, compare with the basic parameters to determine whether there is
abnormal phenomenon, low performance or functional failure.
3) Distinction the problem: based on failure manual or theory , identify the type, cause and position
of the problem
4) Predict the problem: Predict the identified fault, how it will develop in the future, and when it
will enter the dangerous range.
5) Propose countermeasures plan: propose countermeasures according to 2), 3), 4) steps.
6) Implementation of measures: carry out measures according to plan and confirm result.
Need Technology of Diagnosis

Usually there are six technologies as follow;

 failure manual Set up technology based on theory or test data
 State variable measurement technology
 Signal processing technology
 identification technology
 Predicting technology
 Countermeasure (revised measures) technology
 Normal prediction of the state variables, track of abnormal problems, predict the
trend of deterioration, and determine the degree of deterioration and weariness.
There are two kinds of monitoring, one is periodic regular monitoring and the other
is trend monitoring to monitor trend of abnormal variables.
Method of equipment diagnosis (1)

 Active inspection method and Passive inspection method

State of equipment could change with and without corresponding symptoms.

Example) If corrosion part of pump impeller fall off, it will lead to vibration (with the
corresponding symptoms)
Pipe corrosion, even if there is abrasion, no fluid will leak (no corresponding symptoms)

1) Active inspection method: identify the signal representing changes of equipment state
(mainly for the symptom signal) to inspect
Example) vibration method, infrared method, current method, voltage method and so on

2) Passive inspection method: There is no signal representing changes of equipment state.

external signal has to be added externally and inspect with the help of feedback of signal
added
Example) ultrasonic method, radiation method, Current and Voltage method and so on
Method of equipment diagnosis (2)
Simple diagnosis method: is a method to identify the problem point initially, usually most
equipments can be taken as object. Generally, simple portable measuring device or electronic data
collector is used to determine whether there is a problem.

Precision diagnosis method: precision measurement and analysis of various data. Predict type of
problem, occurrence location, cause and the time of failure, and put forward countermeasures. A
high degree of professional knowledge is needed.

Simple diagnosis
Diagnosis Precision diagnosis
(Problem identifica
Method (Problem judgment)
tion)

Visual check Overall appearance color shape texture

Vibration Vibration modal analysis systematic analysis of

signal waveform signal (average,
method Parameter frequency distribution, stress)

Oil component Distribution of Shape of

Number and color
abrasive grain si Chemical Organization
Method of abrasive grain abrasive grain
zes
Problem and Effect of diagnosis technology(1)

NO Item Problem Diagnosis effect

Stress source on the new equipment is

Plan
not clear Quantitative analysis of the abnormali
1) Abnormality and degradation on the new ty and degradation can be feedback to
Design equipment is not clear, bringing difficulty the equipment design.
on the equipment design

In process or after manufacturing, investi

Manufactu Carry out quantitative diagnosis on eq
gation of abnormality and weakness is
ring uipment manufacturing.
not enough.

Installatio Can not measure installation method, pre Installation company can carry out qu
2)
n cision, and setting error quantitatively. antitative investigation

Commissioning relies on operators experi

Commissi
ence and intuition, which is not so reliabl Carry out quantitative commissioning
oning
e.

Many product and installation mistake and poor quality Problems can be fixed in essence.
Problem and Effect of diagnosis technology(2)

NO. Item Problem Diagnosis effect

Due to safety reasons, many equipments cannot be checked.

There are many checking items while not enough inspectors Fix in essence accordi
ng to equipment super
O Because of the inspector fault, checking precision is not enough. vision and function pr
P 1) depends on inspector ability otection
E
A 2) difficult to figure out internal state of the equipment
Check
T
cannot carry out quantitative check
I Fix in essence accordi
O 1) cannot make quantitative judgment
3) ng to condition of stres
N 2) cannot manage quantitatively s , failure degradation
and performance
S Impossible decision of Malfunction cause，rate，forecast, etc.
T
A To improve efficiency
G It takes time and energy to find out failure position. greatly by equipment s
Fault upervision technology
E finding
Make correct decision
Failure may repeat because based on correct diagn
osis
Problem and Effect of diagnosis technology(3)

N
Item Problem Diagnosis effect
O.
Because the scope and root cause of maintenance Correct maintenance can be done
and repairing are not clear, the correction method
or scope is not effective. with the correct equipment diagnosis

Can not inspect after the maintenance, there are m

maintenance any problems after installation. Correct maintenance can be done
4)
and repair with the correct equipment diagnosis
Maintenance takes time and effort while efficienc
y is low.

Rate of new failure is high because of the human Failure caused by human error can
be detected and corrected in advance
error. .
The unclearness of equipment diagnosis degradati
on will end result in following problems
Equip According to the equipment diagnosi
1) Inspection cycle
ment a Maint s, it can be resolved one time.
5) nd man enanc 2) maintenance cycle and range
ageme e Plan 3) selection of inspection object This is the main purpose of equipm
nt ent diagnosis.
Because the above problems will lead to lower bu
dget accuracy of maintenance cost.
Problem and Effect of diagnosis technology(4)
N
Item Problem Diagnosis effect
O.

As it can not grasp the deterioration or bad equi

pment, can not be appropriate management. You can through the equipment diagnosi
Spare part s to spare parts management to provide a
Managem Resulting in failure when there is no necessary technical basis for a substantial improve
ent parts, on the contrary do not need spare parts lo ment
Eq
ng-term inventory.
uip
me Because the equipment history data is not quant
nt Measures can be taken based on quantita
5) itative, it is difficult to take the correct measure
ma tive data.
s.
nag Equipment
em history ma Because the data can not be quantified, it is diff
ent nagement Can be technology accumulation and the
icult to carry out the accumulation of technolog
correct tendency to manage.。
y and tend to management.

Can not quantitatively measure performance, st

rength, and deterioration. Can quantitatively determine the perfor
Abandoned mance, strength, deterioration, the corre
6) And ct grasp of the best update range and per
And it is difficult to grasp the best update range
Update iod.
and period.
Effect of equipment diagnosis technology(1)
 Increased Productivity
1. Through the equipment diagnosis, equipments can be shutdown in plan and there are
following advantages:
1) adjust the production,
2) minimize the impact on the equipment vendors
3) improve the company production system (parts supply system, etc.),
4) minimize the time to shutdown equipment
2. improve the availability and reliability of equipment and reduce loss caused by shutdown of
equipments.
3. Definition of equipment reliability:
1) the rate of equipment achieving its original stability in a given time.
2) under the specified conditions of use, the probability of equipments successfully achieving
working goal when implementing specified performance or function.
3) shutdown loss caused by failure is very important, to be expressed as availability or MTBF
Availability: A = U / (U + D) = MTBF / (MTBF + D)
U: available time, D: unavailable time, MTBF: average interval between failures
4 ways to increase availability
1) through the equipment diagnosis, to find out precisely the problem and only repair the
necessary parts.
2) Prepare for parts needed to be replaced in advance to prepare for the job.
3) to prevent damage on parts caused by sudden accident, extend the maintenance time for
normal equipment, shorten the D
Effect of equipment diagnosis technology(2)

 Cost reduction effect

1) improve availability, productivity and quality to reduce associated costs.
2) Savings in repair costs
(1) determine necessity of repair, avoid regular repair and extend the
repair interval.
(2) designate repair site to shorten the repair time and reduce the
interference maintenance.
3) Savings in start-up costs
when starting up large equipments (turbines, compressors, etc.), find out
abnormalities by accelerating in to reduce unnecessary operating costs.
4) Savings in equipment costs
To prevent stress on the equipments due to sudden failure
Main purpose of equipment diagnosis

Item Description

1. Reduce maintenance costs

(1) to avoid unnecessary maintenance
Maintenance (2) optimization of maintenance plan
2. to prevent sudden failure (to prevent damage to equipment)
3. reduce equipment investment costs

1. to ensure and improve the quality and stability of production

2. Reduction of product costs
Production
3. to prevent production losses
4. to prevent the production of defective products

Safety 1. to ensure safety