Presentation is loading. Please wait.

Presentation is loading. Please wait.

Vibration Measurement, Analysis, Control and Condition Based Maintenance 14 Predictive maintenance Dr. Michiel Heyns Pr.Eng. T: +27 12 664-7604 C: +27.

Similar presentations


Presentation on theme: "Vibration Measurement, Analysis, Control and Condition Based Maintenance 14 Predictive maintenance Dr. Michiel Heyns Pr.Eng. T: +27 12 664-7604 C: +27."— Presentation transcript:

1 Vibration Measurement, Analysis, Control and Condition Based Maintenance 14 Predictive maintenance
Dr. Michiel Heyns Pr.Eng. T: C:

2 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

3 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

4 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: 9/20/2018

5 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

6 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

7 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

8 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

9 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

10 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

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

12 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

13 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

14 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


Download ppt "Vibration Measurement, Analysis, Control and Condition Based Maintenance 14 Predictive maintenance Dr. Michiel Heyns Pr.Eng. T: +27 12 664-7604 C: +27."

Similar presentations


Ads by Google