FDP: IoT and its application on

Instrumentation
DAY 5: Machine health Monitoring and
Maintenance
 Agenda
• Signal Acquisition
• Feature extraction and selection
• Reliability
• Predictive Maintenance
• IOCL Case study
• Q&A
Signal Acquisition
 Steps
Before you start
• What am I trying to measure?
• How am I going to measure?
• How accurately do I want to measure?
• How often do I need to measure?

During
• Calculations, Data reduction, Alarms

After
• How am I going to recover my data?
• What am I going to do with my data?
• Post processing
 Parameters to measure
• There are many different parameters for which
sensors or transducers are commonly available
– temperature
– pressure, force, mass, weight
– velocity, acceleration, vibration
– strain, stress, distortion, fatigue
– flow, volume, level
– length, width, depth, thickness, displacement
– state, pulse, counter
– composition, concentration
 Support for sensors
• Sensors often require support that must be provided by the data
acquisition system or data logger
• sensor excitation
• signal conditioning
• compensation for cable effects
• management of references, zeros, etc
• scaling of the electrical output to parameter units
• Ability of data acquisition system or data logger to support sensors can
determine the effectiveness of a project
 Reading information from sensors
• Many sensors produce an analog signal, such as voltage, current,
resistance, frequency, etc.
• Analog signals are measured by a process of Analog to Digital Conversion
or ADC
• Important characteristics of ADC are
– accuracy
– resolution
– linearity
– repeatability
– speed
– common mode range
– electrical noise rejection
 Sampling Speed
• Sampling speed is the number of readings per unit time of a single channel, or of a group of
channels
• Expressed as samples/second (Hz, KHz)
• Varies from less than 1 Hz to 100s KHz for different data acquisition systems
• May be variable within the same system
• Appropriate sampling speed is dependent on many factors
• what type of information is to be captured - short term events, long term trends, both?
• when is information to be captured?
• what is the level of importance of various information?
• Aim to set a sampling speed to
• maximize sensitivity of data.
• minimize redundancy of data.
• optimize generation of reports.
• simplify archiving of data.
 Data recovery and transfer
• Data can be recovered from data acquisition systems and data loggers in various ways.
• Serial comms interface via direct connect, modem, cell phone, radio, satellite
• PCMCIA - modem, cell phone, LAN, memory card, USB memory device
• Network port - Ethernet, field bus, proprietary, etc
• Universal Serial Bus (USB)
• Data can be transferred and published using
• Local Ethernet network
• Intranet - email, web pages
• Internet - email, world wide web pages
 Data processing and reporting
• Collected data is analyzed and reported using any of
• generic packages such as
• ASCII text editors
• Spreadsheets
• Databases
• general purpose data processing packages
• general purpose SCADA packages
• proprietary host software packages
Usecase of data
acquisition
systems
Reliability
 Reliability Definition
Generally defined as the ability of a product to perform, as expected, over certain time.

Formally defined as the probability that an item, a product, piece of equipment, or system
will perform its intended function for a stated period of time under specified operating
conditions.

In the simplest sense, reliability means how long an item (such as a machine) will perform
its intended function without a breakdown.

Reliability is performance over time, probability that something will work when you
want it to.
 The Reliability definition has four important elements:
Probability (A value between 0 and 1, number of times that an event occurs (success) divided
by total number trials)

Performance (Some criteria to define when and how product fails, which also describes what
is considered to be satisfactory system operation)

Time (system working until time (t), used to predict probability of an item surviving without
failure for a designated period of time)

Operating conditions
These describe the operating conditions (environmental factors, humidity, vibration, shock,
temperature cycle, operational profile, etc.)that correspond to the stated product life.
 Basic Reliability Terms
Failure-A failure is an event when an item is not available to perform its function at specified
conditions when scheduled or is not capable of performing functions to specification.
Failure Rate-The number of failures per unit of gross operating period in terms of time, events,
cycles.
MTBF -Mean Time Between Failures-The average time between failure occurrences. The
number of items and their operating time divided by the total number of failures. For
Repairable Items
MTTF -Mean Time To Failure-The average time to failure occurrence. The number of items and
their operating time divided by the total number of failures. For Repairable Items and Non-
repairable Items
Hazard-The potential to cause harm. Harm including ill health and injury, damage to property,
plant, products or the environment, production losses or increased liabilities.
Risk -The likelihood that a specified undesired event will occur due to the realisation of a hazard
by, or during work activities or
 Basic Reliability Terms
Maintainability- A characteristic of design, installation and operation, usually expressed as
the probability that an item can be retained in, or restored to, specified operable condition
within a specified interval of time when maintenance is performed in accordance with
prescribed procedures.

MTTR -Mean Time To Repair-The average time to restore the item to specified conditions.
Maintenance Load -The repair time per operating time for an item.

Availability -A measure of the time that a system is actually operating versus the time that
the system was planned to operate.
It is the probability that the system is operational at any random time t.

Supportability -The ability of a service supplier to maintain the Plant inbuilt reliability and to
perform scheduled and unscheduled maintenance according to the Plant inbuilt
maintainability with minimum costs.
Generic Failures
Failure rate over the life of a product
The failure rate is expected to vary over the life of a product –
‘Bathtub Curve’
 Bathtub Curve.
A-B Early Failure / Infant mortality / Debugging / Break-in
•‘Teething’ problems. Caused by design/material flaws
Eg: Joints, Welds, Contamination, Misuse, Misassembly

B-C Constant Failure / Useful life.

•Lower than initial failure rate and more or less constant until end of life

C-D End of life failure / Wear out phase.

•Failure rate rises again due to components reaching end of life
Eg: Corrosion, Cracking, Wear, Friction, Fatigue, Erosion, Lack of PM
Bathtub Curve Summary
Managing Reliability
Predictive Maintenance
Evolution of maintenance
Predictive Maintenance
Case Study (Indian Oil)
  High failure rate  High costof
 Low MTBF and high MTTR maintenance-
Lubricants- Non-
 No focus on Root Cause
standardized spares
Analysis

BACKGROUND

 Inadequate skill
of Maintenance
 Conventional reactive technicians and
maintenance- low Focus operators
on CBM
 THE PROBLEM

They don’t lubricate

Maintenance the machines

They don’t repair the

equipment properly

Maint. doesn’t
know its job Operation
 Major Paradigm shift are needed……
…… from reactive to proactive

Reactive domain Fix it after it breaks

Firefight with each new crisis; spend
(Respond to Events)
whatever is necessary

Planned domain Fix it before it breaks

(Pre=plan all work) Predict, Plan and Schedule all work

Proactive domain Don’t just fix it, improve it

Eliminate defects from all sources;
(Organizational discipline)
maximize equipment uptime

Strategic domain Differentiate

(Organizational learning) Maximize Integrated value
 EVOLUTION OF MAINTENANCE

WORLD CLASS
MANUFACTURING
STABLE DOMAINS

Continuous
IMPROVED Improvement
PRECISION
MANUFACTURING
PERFORMANCE

PLANNED Maintain it so it
MAINTENANCE doesn’t break
(TPM; RCM)
Fix it before it
REACTIVE breaks
MAINTENANCE

Fix it after it
breaks

RESPONSIVE PLANNED ORGANIZATIONAL ORGANIZATIONAL

WORK WORK DISICIPLINE LEARNING
NATURE OF BEHAVIOUR
 Toreduce
 Toachieve Zero maintenance cost
breakdown

AIM

 Focus on CBM To enhance skill

effectiveness of maintenance
technicians
 TARGET

Corporate Cult ur al Change

ZER O BREAKDOWNS
ZER O DEFECTS
ZER O ACCIDENTS
ZER O LOSSES
ZER O DEFAULT
SIX ZERO BREAKDOWN MEASURES

•Evaluate equipment & understand situatio

•Reverse deterioration & correct weakness

•Build an information management system

•Build a periodic maintenance system

•Build a predictive maintenance system

•Evaluate the planned maintenance system

Heart of Autonomous Maintenance

The way
a mother
owns
her child
 PHILOSOPHY OF TPM IMPLEMENTATION
BEFORE TPM

MAINTENANCE OPERATION

HIGH SKILL OF EQUIPMENT DISTANT ISLANDs WITH

VERY FEEBLE LINK &
EXCELLENT FEELING OF
MAINTENANCE UNDERSTANDING EQUIPMENT BEHAVIOUR

AFTER TPM

MAINTENANCE POSSESS MORE

OPERATION KNOWLEDGE ON
POSSESS MORE
EQUIPMENT
KNOWLEDGE ON PROCESSES INTRICACIES
C OMMON AREA OF UNDERSTANDING
EVOLVED– In harmony with nature
Barauni Refinery
 Responsibilities of Autonomous Maintenance v/s
Planned Maintenance
Sl Equipment Autonomous Maintenance Planned Maintenance
No Group Activities Activities
.
1. Compressor/ 1. Cleaning 1. Complete Overhauling
Turbine 2. Checking of oil level & top-up if 2. Replacement of coupling
required bolt/spider.
3. Checking Vibration & 3. Specialized Maintenance
Operational
parameters
4. Checking Sound
1. Cleaning
2. Checking of oil level & top-up if 1. Complete Overhauling
2. Centrifugal
required 2. Replacement of coupling
Pump
3. Greasing bolt/spider
4 .Checking Vibration & Operational 3. Replacement of impeller / shaft /
parameters gland packing / gaskets.
1. Inspection of Overall
condition
2. Checking for leakages
3. Static
Equipment 3. Checking damaged insulation
1. Complete Overhauling
2. Condition Monitoring
 SUPPORT TO JISHU
HOZEN
JISHU HOZEN STEPS PLANNED MAINTENANCE SUPPORT

1. Initial cleaning 1. Safety Instructions

2. Tools/ Resources Management

2. Countermeasures 1. Arresting major sources of leakages

2. Awareness for fixing/tightening

3. Standard preparation Helping the circles to prepare standards:

 What to inspect & what should
be the standard
 What & how to clean
 Lubrication

Jishu Hozen is a Japanese word that means autonomous maintenance

 PHASE-2

LENGHTHEN EQUIPMENT LIFE

•Evaluate equipment to select PM items

•Rank failure according to seriousness

•Prevent measure breakdown from recurring

•Correct equipment design weakness

•Eliminate unexpected failures by preventing operating and repair

errors.

•Update adjustment and setting skills.

SAMPLE WHY-WHYANALYSIS FOR P-108AOF AVU3

High Vibration in Motor

Why

Due to Softfoot in Motor base

Why

Uneven levelling & poor rigidity

Why

No provision for proper vibration dampening

Why

Design deficiency
 TPM - One Point Lesson Barauni Refinery

TPM Secretariat
THEME AC MOTOR TEMPERATURE DIAGNOSTIC NO
PATTERN DATE 21/3/06
CLASSIFY BASIC KNOWLEDGE IMPROVEMENT CASE TROUBLE CASE PILLAR GROUP LEADER PREPARED
BY
PM S. GHOSH SK DAS
Temperature high in the middle-
a winding problem or overload

Temperature is
high at the back -
Temperature
airflow or bearing
high near front
problems
- bearing
problem
 PHASE--3

PERIODICALLY RESTORE DETERIORATION

•Build a periodic maintenance System.

•Perform periodic servicing
• Perform periodic Inspection.
•Establish work standard.
•Control spares

•Recognise process abnormality signs and detect abnormalities

early.

•Deal with abnormalities correctly.

 PHASE-4

PREDICT EQUIPMENT LIFE

•Build a Predictive management system

• Trian equipment diagnostician

•Introduce diagnostic techniques.
•Perform condition monitoring

•Consolidate improvement activities.

• Perform sophisticated failure analysis

•Extend equipment life by developing new materials and
technology
 Predictive Maintenance
Activities
S.No Condition Monitoring Equipment Photograph
Technique

Vibration Analysis : Vibration Analyzer- 03 nos.

1
-Enpak1200A
 Spectrum Analysis
-SKF CMVA70
Spike Energy
Level Detection -SKF CMVA70

Vibration Pen- 04 nos.

2
-SKF CMVP50

Temperature Monitoring Thermograph-01 nos.

3
 Infrared Thermography
Spot
Temperature Laser Thermometer- 02 nos.
measurement -SKF/Raytek

Sound Level Monitoring Decibel m eter- 01 nos.

4
-Lutron SL4010

Thickness Measurement Ultrasonic thickness gauge

5

Wear Particle Analysis Ferrogram (Outsourced)

6
Predictive Maintenance Activities
LASER THERMOMETER

VIBRATION SPECTRUM
SPOT TEMPERATURE
VIBRATION MONITORING MEASUREMENT

DECIBEL
INFRARED
THERMOGRAPHS METER

SOUND LEVEL
MEASUREMENT OF
INFRA-RED THERMOGRAPHY AIR FIN COOLERS
 METHODOLOGY OFANALYSIS

DATA COLLECTION FOR WEAR & TEAR

ROOT CAUS E ANALYS IS

ES TABLIS HING THE CORRELATION BETWEEN DATA

LIFE ENHANCEMENT ACTIONS

RES IDUAL LIFE ES TIMATION

 RESIDUAL LIFE ESTIMATION
CONCEPT
INCREASING DETERIORATION PARAMETER (e.g. VIBRATION)
 RESIDUAL LIFE ESTIMATION - SAMPLE
Trend of Fractionator Bottom Pump P06B of Coker-A

8 Failure Thresholdvalue: 7.1 mm/s

7

V i b r a tio n V e lo c ity
6
5
4 Acceptable threshold value : 3.5 mm/s
Corrective Intervention:
3 PDM-based
(m m / s )

2
1
RESIDUAL LIFE
0 ESTIMATED:
2-3 MONTHS
1 2 3 4 5 6 7 8 9 1011 12131415161718 1920 212223 24
Time (Months)
RESULTS AND BENEFITS
 Interruptions
87.5%
9 reduction
8
8

No. of Interruption
7
6
5 5
5
4
3
2 2
2
1
1
0
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10
 The Journey to CBM
EQUIPMENT BREAKDOWNS (NOS.)
LESS FOCUS
ON CBM
•MORE FOCUS ON CBM

343 Better
BM
350
300
242

(ROTARY EQUIPMENT)
NO. OF BREAKDOWNS
250 •MINIMUM TBM
•EMPHASIS ON CBM
200
136
150
100 71
44 29
50 Increased
0 PDM
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 effectiveness
 THANKS
kaushal@uniconvergetech.in
UniConverge Technologies Pvt. Ltd.
(www.uniconvergetech.in)
&
The IoT Academy
(www.theiotacademy.co)
C56/11, Sector-62, Noida