Libyan Academy of Graduate Study

maintenance systems and engineering : EM 782

predictive Maintenance

Sumitted by: Mousa Hassen( 4957 ) Ahmad Mohamed ( 6362 ) Bakkar Lanjhi( 6361 ) Instructed by : Dr. Omar M Elmabrouk spring . 2012/2013

CONTENTS A. Predictive maintenance basics, B. Machinery fault diagnosis using vibration analysis, C. Correcting faults that cause vibration, D. Oil and particle analysis , E. Other predictive maintenance techniques

introduction Equipment failures may arise during the most unexpected times. When this happens, it could lead to unplanned downtime in production and expensive replacement of inefficient parts. In addition, machine failure may also lead to environmental and safety concerns. However, these situations may be avoided by applying predictive maintenance techniques.

This process for monitoring equipment efficiency allows you to identify any deterioration in the machine. With regular monitoring of equipment, you can avoid unplanned maintenance and expensive operational costs.

Figure 1: predictive maintenance

Predictive maintenance techniques

(a) Vibration monitoring: This is to undoubtedly the most effective technique detect mechanical defects in rotating machinery. (b) Oil analysis: Here, lubrication oil is analyzed and the occurrence of certain microscopic particles in it can be connected to the condition of bearings and gears.

(c) Particle analysis: Worn machinery components, whether in reciprocating machinery, gearboxes or hydraulic systems, release debris. (d) Thermography: Thermography is used to analyze active electrical and mechanical equipment.

Machinery fault diagnosis using vibration analysis

Present day requirements for enhanced reliability of rotating equipment are more critical than ever before, and the demands continue to grow constantly. Advances are constantly made in this area, largely due to the consistent demand from the hydrocarbon, power generation, process and transportation industries.

Using vibration analysis, the condition of a machine can be constantly monitored. Detailed analyses can be made to determine the health of a machine and identify any faults that may be arising or that already exist.

Commonly witnessed machinery faults diagnosed by vibration analysis

Unbalance Bent shaft Rotor rubs Looseness Gear defects Bearing defects Electrical faults Oil whip/whirl Shaft cracks Belt drive problems

1. Unbalance: Vibration due to unbalance of a rotor is probably the most common machinery defect. It is luckily also very easy to detect and rectify. There are three types of unbalance that can be encountered on machines, and these are A. Static unbalance. B. Couple unbalance. C. Dynamic unbalance.

A. Static unbalance: For all types of unbalance, the FFT spectrum will show a predominant 1X. rpm frequency of vibration. Vibration amplitude at the 1X. rpm frequency will vary proportional to the square of the rotational speed. It is always present and normally dominates the vibration spectrum

Figure -2: FFT analysis unbalance defect

2. Eccentric rotor: Eccentricity occurs when the center of rotation is at an offset from the geometric centerline of a sheave, gear, bearing, motor or any other rotor. The maximum amplitude occurs at 1 x rpm of the eccentric component in a direction through the centers of the two rotors. Here the amplitude varies with the load even at constant speeds

Figure-4 : A belt-driven fan/blower vibration graph

Figure _5 : Eccentric rotor

3. Bent shaft: When a bent shaft is encountered, the vibrations in the radial as well as in the axial direction will be high. Axial vibrations may be higher than the radial vibrations. The phase will be 180 apart in the axial direction and in the radial direction.

This means that when the probe is moved from vertical plane to horizontal plane, there will be no change in the phase reading.

Figure -6 Note the 180 phase difference in the axial direction

Correcting faults that cause vibration No predictive maintenance program is complete until it has the three basic components: detection, analysis and correction. Balancing : It is very rare to come across a vibration spectrum of a machine that does not show a 1X component indicating some residual unbalance.

Unbalance causes high levels of vibration amplitudes at the 1x rpm of the machine. Unbalance is often defined as simply the unequal distribution of weight about a rotors centerline. The ISO defines it as a condition that exists in a rotor when the vibratory force or motion is imparted to its bearings as a result of centrifugal forces. Correction of this unequal distribution of weight about a rotor is called balancing.

Balancing compensates for less-thanperfect manufacturing. The main causes for unbalance during manufacture are Materials do not have uniform density. Holes are not bored exactly parallel to the center. Imperfections occur in machining round or symmetrical shapes. Assembly errors.

Balancing methods Single plane balancing vector method

Single plane balancing is used for machines that operate below their critical speed and have an L/D ratio lower than 0.5 (L, length of rotor, excluding support length; D, diameter of the rotor). It is also recommended to avoid the use of this method for rotors operating at speeds greater than 1000 rpm. For cases where L/D ratio is greater than 0.5 but less than 2, this method should be applied for rotors that do not operate beyond 150 rpm. For L/D ratios greater than 2, the limit is 100 rpm.

Balancing machines There are four basic types of balancing machines: 1. Static balancing stands 2. Hard bearing machines 3. Soft bearing machines 4. High-speed machines.

Figure -7Hard bearing balancing machine (IRD balancing machines)

Figure -8 Soft bearing balancing machine (Shimadzu balancing machines)

Oil and particle analysis

Oil analysis is not merely a tool to analyze the condition of a lubricant. With modern diagnostic tools, it is used to monitor the condition of equipment as well. By utilising these advanced techniques, equipment reliability can increase, and unexpected failures and downtime are minimized. There are many wear mechanisms that lead to the deterioration of machine components.

techniques to evaluate the type and concentration of such particles Spectrometric analysis Particle counting Some types of oil analyses are Viscosity Solids content Water content Total acid number

Mineral oils The general principles of lubricant base oil manufacture involve a series of steps to improve certain desirable lubricant properties, such as: 1. Viscosity index. 2. Oxidation resistance. 3. Heat resistance. 4. Low-temperature fluidity.

Setting up an oil analysis program A systematic approach is required to set up an oil analysis program in a production plant.

It consists of basically four steps: A. Equipment audit : 1. Equipment criticality. 2.Equipment component and system identification. 3. Operating parameters. 4. Operating equipment evaluation 5. Operating environment 6. Maintenance history 7 .Oil sampling location 8. Oil tests. 9. Database development.

B. Lubricant audit : 1. Lubricant requirements. 2. Lubricant supplier 3. Oil storage. 4. Handling and dispensing 5. Waste oil 6. Baseline readings 7. Equipment evaluation. 8. Sampling 9. Testing. 10. Exception testing.

11. Data entry, 12. review and reporting. C. Monitoring : 1. Routine monitoring. 2. Frequency of monitoring. 3. Post overhaul testing 4. Data analysis 5.Reports D. Program evaluation:

Oil analysis sampling methods Sampling port location Diagnosis of component health using oil analysis is greatly enhanced by providing sampling ports at proper locations. Ports should be in locations so that oil from individual components can be collected. This provides an analytical edge for detecting incipient failures and arriving at the root cause of failures. Sample ports are generally divided into two categories, primary and secondary

Figure -9 Location of sampling ports

Sampling best tools

Figure -10 Hydra-Check inline oil sampling valve Figure -11Sampling bottle with vacuum pump

Other predictive maintenance techniques

There are dozens of predictive maintenance technologies, and some have become a standard in many industries. The standard technologies include vibration analysis, ultrasound, oil analysis, wear particle analysis and thermography.

Ultrasound

Most machines emit consistent sound patterns under normal operating conditions. These sound patterns (sonic signatures) can be defined and recognized, and therefore changes in these signatures can be seen as components begin to wear or deteriorate. The above properties of ultrasound are exploited to make it a useful technique in providing early information in cases of: Bearing inspection Steam trap inspection Valve blow-by

 Integrity of seals and gaskets in tanks, pipe systems and large walk-in boxes Pump cavitations Detection of corona in switch gear Compressor valve analysis.

Infrared thermography Thermography is a useful predictive maintenance technique in the following ways: It does not make contact with the surface. The technique does not involve any hazardous actions. It can be used in hazardous zones. It is not affected by electromagnetic waves.

Figure 12 Resistive heating at an electrical connection

Example 9.1 A sample of 15 machines that underwent maintenance was examined for maintenance related defects. Table presents maintenance-related defects associated with each machine. Construct the c-chart using the specified data. By summing the defects of Table, we get the following total: MD=45. where =the Poisson distribution mean MD= total number of maintenance related defects

Machine no.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

No. of MaintenanceRelated Defects 2

6 1 5 3 0 6 4 1 5 1 3 2 4 2

N= total number of equipment. Thus, the average number of maintenancerelated defects per machine is 3.

= standard deviation. UCL= + 3 UCL=3+3(1.7321)=8.1962 LCL= - 3 LCL=33(1.7321)=2.1962 Where : UCL=upper control limit, LCL=lower control limit.

As the calculated value of LCL= 2.1962 is impossible for plotting purposes, it is changed to zero, i.e., LCL =0.