Vibration Measurement, Analysis, Control and Condition Based Maintenance 14 Predictive maintenance Dr. Michiel Heyns Pr.Eng. T: +27 12 664-7604 C: +27 82 445-0510 mheyns@investmech.com

Section 14. Predictive Maintenance Objective To give an introduction to predictive maintenance in a maintenance management programme – with specific focus on vibration-based predictive maintenance After completion you will be able to: Describe predictive maintenance List PM management types – Is done in other PMM subjects List the important factors in a PM programme – Is done in other PMM subjects Start a predictive maintenance programme – Is done in other PMM subjects PMM Students: Because these topics are presented in other parts of you course, only an overview will be given in class 9/20/2018

Maintenance management types Run-to-Failure Preventive Time-driven Mean-time-to-failure (Bathtub curve) Predictive Monitor condition = actual operating condition Condition-driven preventive maintenance program Proactive Root cause-based To eliminate failures in plant components. Reliability-based Maintenance Balance of preventive, predictive and proactive maintenance. 9/20/2018

Benefits of PM Lower maintenance costs (50-80%) The statistics documented in this part was found from a 1988 survey of 500 plants that have successfully implemented predictive maintenance methods. Industries in the United States, Canada, Great Britain, France and Australia were included in the sample group. Lower maintenance costs (50-80%) Fewer machine failures (50-60%) Less repair downtime (50-80%) Overtime premiums (20-50%) Reduced parts inventory (20-30%) Longer machine life (20-40%) Increased productivity (20-30%) Improved operator safety Verification of new equipment Verification of repairs Overall profitability (25-60%) Programs fail because of a lack of planning and management support. Further reading: http://www.nrel.gov/wind/pdfs/day1_sessioni_04_garradhassan_leblanc.pdf 9/20/2018

Predictive Maintenance Techniques Vibration monitoring Thermography/Temperature monitoring Tribology/Lubricant monitoring Process parameters Visual inspection Ultrasonic monitoring - NDT Acoustic emissions, eddy currents, magnetic particles, residual stress 9/20/2018

Selecting a PM system – Is done in other PMM subjects The complete system User-friendly software and hardware Automated data acquisition, management and trending Flexibility Reliability Accuracy Training and technical support System and operating costs 9/20/2018

Selecting a PM system – Is done in other PMM subjects The microprocessor Expertise required to operate Accuracy of data Alert and alarm limits Data storage and transfer The host computer The software program User-friendly Automatic trending Automatic report generation Simplified diagnostics Transducers 9/20/2018

Establishing a PM programme – Is done in other PMM subjects You need Clearly defined objectives and goals with measurable benefits Financial analysis Management support Dedicated personnel Efficient data-collection and analysis procedures Record-keeping & information organisation procedures Communications capability Evaluation procedures 9/20/2018

Objectives, goals & benefits from Predictive Maintenance Eliminate unnecessary and unscheduled maintenance Reduce rework costs Reduce lost production Reduce repair parts inventory Increase process efficiency Improve product quality Extend operating life Increase production Reduce maintenance costs Increase overall profits 9/20/2018

Management support Invest in capital equipment and personnel, training, consulting support Management must understand the long term benefits Start with most critical machine 9/20/2018

Personnel Full attention in achieving goals Part-time personnel not recommended Accountability of PM group and measures of program effectiveness 9/20/2018

Data-collection Concentrate in areas that will provide maximum results On-line systems will provide efficient data analysis, but is expensive Include methods, schedule, parameters for data acquisition, analysis and report generation in the programme 9/20/2018

Condition data base On-line systems with software and built-in data management If too expensive, use consultants Cloud computing offers attractive solutions 9/20/2018

On which equipment must I start? Do plant survey to class equipment according to their impact on production capacity etc. Essential : On-line or plant down Critical : Reduce production capacity by 30% Serious : Not dramatic impact on production Others : Replacement < Monitoring costs Selection of method: Characteristics of failure mode and class of equipment 9/20/2018