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MODERN OUTLOOK TO CONDITION BASED MAINTENANCE ON BOARD MERCHANT SHIPS

SYNOPSIS Maintenance is commonly overlooked as profit centre in todays modern dynamic business environment. In fact, maintenance is purely seen as cost. It is not unusual for reactive and unplanned maintenance to absorb as much as 80% of the maintenance efforts. The spiraling consequences for the business are increasing costs, continually stretched maintenance resources and reduced operational capacity. Todays trend is towards condition monitoring, predictive maintenance, reliability improvement, maintenance planning, plant assessment and root cause analysis. Condition monitoring soft wares and broad range of condition monitoring technologies enable early fault detection and ability to address the factors that causes faults to develop in the first place. With the information to eliminate breakdowns, increase production capacities and extend the plant capabilities and the lifetime of productive machineries, CBM helps organizations to target their maintenance more effectively. Providing means to monitor how productive the plant is performing and the expertise to identify how, where and when the machinery will develop problems, reliability focused asset management utilizes analysis technologies to open a window into the health of the operating machinery without causing interruption or interference to plant operation..
Condition Based Maintenance (CBM) systems move the maintenance effort from a scheduled preventative format to a more flexible and accurate condition based predictive format. CBM will keep you up-to-date on how your installation is doing and help you detect any disorder or deviation from expected normal performance data in good time. CBM makes maintenance proactive, rather than reactive, by spotting fault sources and emerging operational trends well before any failure occurs. The main aims are to :1. balance the time between overhauls, 2. to minimize downtime and to 3. guarantee optimized engine performance under all conditions

CBM VERSUS PLANNED MAINTENANCE

Maritime industry is in many aspects using maintenance strategies from the past. By focusing on reliability the indirect effects from doing the wrong maintenance can be reduced considerably. Shipping industry has from a maintenance aspect been doing the wrong things correct for many years. The opportunity is now to do the right thing correct instead. It has already been proven by using different CBM systems that the profit that condition based maintenance has is incomparable to that of either the preventive or breakdown maintenance has. Modern management has to take steps towards treating maintenance as a means of realizing the profit potential inherent in each vessel. Correct maintenance strategy based on condition monitoring ; no doubt increases initial investment ,but results in increased profits , better return rates ,increased reliability , gives less spare parts consumption and a longer production life to the vessel ; to a much larger degree than shown by a traditional maintenance strategy based on preventive maintenance.

ADVANTAGES OF CBM
The advantage of the CBM is that work can be planned according to actual condition of the machinery and thus the reliability also increases. The labour costs, spare parts costs & the machinery downtime is considerably reduced if opening of good machines on the sole basis of running hours can be avoided. The TBO (time between overhauls) of almost all the moving machineries can be considerably increased if CBM system is made use of. Not only the reliability of the shipboard machineries can be improved, but performance & overall efficiency of an individual machinery and the system as a whole can be effectively increased using the modern practices .e.g. The performance and efficiency of the main engines can be continuously monitored and an action or an alarm is triggered if either the SFOC (specific fuel oil consumption) or SCOC(specific cylinder oil consumption) of SLOC(specific lube oil consumption) goes beyond the predefined limits . The condition monitoring system keeps a continuous check on the systems performance & takes the corrective action or warns the operator of the corrective action to be taken based on the current condition. Good overall efficiency will decrease the operational costs of the engine & operation within predefined limits ensures reduction in maintenance costs and the downtime by increasing TBO & preventing any breakdown

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CBM : INVESTMENTS VERSUS RETURNS

Every industry in the market looks for maximum returns for the investments it does. This has been so far & will be in future, the most debatable topic in the shipping industry as far as maintenance costs are concerned. The problem with maintenance is that its investments are very easily measured while its returns are not. The maintenance cost is of significant amount when compared to the overall budget of the vessel ,but its contributions to vessel revenues remain hidden .It has become a general tendency for the ship-owners and the ship-managers to cut down on the maintenance costs and the quality and the number of personnels operating a ship in order to minimize running costs. Low quality machines and spare parts, breakdown maintenance strategies, reduced manpower with increase in unskilled labour inevitably gives overall higher running costs for a vessel. The machine breakdowns are quite often leading more downtime & increased spare requirement. The unplanned maintenance by unskilled crew creates new problems when they open up any machines for inspections or overhauls. The returns of maintenance can only be realized if the total cost analysis of one vessel is done over its complete lifetime. Doing these analysis based on the data collected over a short period of time gives misleading indications & results .Using correct maintenance strategy and use of adequate number of professionally trained and skilled manpower onboard will result in greater returns over the complete lifetime of a vessel than compared to the traditional methods. Shipping industry should realize this fact at the earliest to maximize profit & to stay competitive in the market. All investments in the maintenance initiatives must provide a return on investments (ROI) the broad advantages that can be claimed are as follows:-

INCREASED MACHINERY UTILISATION/ LESSER DOWN TIME DUE TO BREAKDOWN. LOWER MANAGED MAINTENENACE COSTS- DUE TO REDUCED SPARE INVENTORY, LABOUR COSTS LOWER RUNNING COSTS REDUCED FUEL AND LUBE OIL CONSUMPTIONS AND SPARES CONSUMPTION. LOWER WASTE GENERATION DUE TO UNNECESSARY MAINTENANCE AND REDUCE EMISSIONS DUE TO BETTER COMBUSTION. INCREASED LIFECYCLE OF MACHINERY. INCREASED SAFETY.

BETTER ASSET MANAGEMENT

Modern outlook of maintenance leads to overall improved asset management for the company. If savings or reduced costs of one department reflects in increased costs elsewhere leading to higher overall costs, obviously the profit is going to be reduced. If we go by traditional maintenance strategies then this is what actually happens. There has been a tendency of cutting on the manpower even on increased size of the vessels. Engine Rooms have gone from Watch-keeping mode to the UMS modes .Automation is increasing day by day & now-a-days ships are coming with ICS (integrated control system) where all the controls, functions, monitoring and alarms of all the shipboard machineries are integrated into one system. This leads to reduction in manpower requirement .But the quality of manpower should not be compromised. A CBM system needs highly skilled technical hands to interpret the information and to take right actions at the right time. The labour cost for this is certainly higher but the positive effect on the profit is even bigger. By maintaining the value of the assets the vessel can be used for a longer period even after the investment is written off. This is a very profitable period for the ship and the return on investment can be optimized They put additional professional maintenance staff onboard and save millions of dollars per ship by doing this.

TRADITIONAL STRATEGY FOR MAINTENANCE

In a traditional maintenance strategy the resources are to a large extent used to open up machines that are in good condition, it is difficult to make changes. There is simply no time; the resources are organized for, cleaning and lubrication. Everybody is working hard driven by unnecessary planned stops, breakdowns, and unplanned stops. The management is chasing ways to cut maintenance costs because the company is not profitable enough. No one knows how to calculate the contribution from maintenance. To introduce condition monitoring in a company with this culture always fails. If the program starts it will normally be short lived, the resources for doing condition monitoring is needed to do more important work - overhaul machines.

RELIABILITY CENTRED MAINTENANCE ( RCM ) ANALYSIS

It is a means of determining the most cost efficient and effective method of maintenance for specific equipments or machineries based on their function and operating context. For instance, although a preventive maintenance plan might stipulate the replacement of a component after a certain number of running hours, RCM analysis may show that the component actually outperforms these criteria and can therefore be left to run for longer time with acceptable risk in terms of probability and consequences of failure.

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Research has revealed that most equipment failures are random in nature and that the traditional concept of age-related failure, with its regime of calendar-based intrusive maintenance, is both wasteful in terms of equipment life and extravagant in terms of maintenance effort. RCM is a methodology used to determine the maintenance requirements of shipboard equipment to ensure that it fulfils its intended function within its operating context. It has been widely used in the commercial world, including the commercial aviation and nuclear power industries, and is recognized as being the key to ensure reliability and cost-effective maintenance. The RCM process takes account of how the asset is used and the function it performs to determine a failure management strategy that will ensure that it can continue to achieve its required performance. RCM then determines the most cost-effective method of maintaining optimum operational availability, taking account of all appropriate safety, environmental and operational consequences. The maintenance resources in the organization must now be focused on the activities that drive the reliability of the ship: 1) Design out the repetitive problems 2) Increase the lifetime of the machines 3) Condition monitoring during normal operation 4) Condition monitoring during planned stops 5) Time based overhauls 6) Redundancies are designed into the process 7) Corrective work The condition-monitoring program becomes necessary, as the pre-warning time of developing machine problems are vital for the strategy. The maintenance work is carried out during planned stops and all unplanned activities are considered as a problem that has to be prevented from occurring again. The unnecessary overhauls and breakdowns are eliminated so the labour hours can be freed to work on improving the quality of the machines. Condition monitoring is also used to identify the route-cause of the problem so the right corrections or design changes are made. This strategy becomes a positive spiral that feeds on it-self with, fewer breakdowns, less spare part consumption, better planning of needed man hours, increased safety, better environment and improved reliability. When a full cultural change has been made only 20% of the work is actually spent on the traditional maintenance work. The resources can be allocated to maintain the asset value of a ship and the reliability improved at a lower cost; the profits go up. Reliability-based maintenance involves the use of data on the performance of equipment across a fleet of ships to determine whether or not a specific component or piece of equipment is performing as required. Using this data, owners and operators can make informed decisions about how to schedule their maintenance and whether to repair or replace items, resulting in more costeffective maintenance.

LLYODS REGISTER AND RESURGENCES WAVE SOFTWARE:

Benchmarking, previously the preserve of the manufacturing, commercial aviation and nuclear power industries, has started to make headway in the shipping industry. One area of ship operations which could benefit substantially from the application of benchmarking is that of shipboard maintenance, especially at a time when ship-owners have to operate in an environment which makes it increasingly difficult to strike a balance between quality of operation and cost-efficiency. Currently, most ship operators employ a preventive planned maintenance approach that involves performing maintenance on components or equipment according to a prescribed schedule. However, the industry is now displaying a marked interest in what is known as reliabilitybased maintenance, an approach based on benchmarking principles which helps owners and operators to not only reduce their maintenance costs but to also enhance the safety of their operations. Ship-owners and operators stand to benefit from lower overall maintenance costs and better availability by applying reliabilitybased maintenance onboard their ships. There is now a marine-specific software system called Wave produced by US-based company Resurgence and jointly marketed with Lloyds Register which allows users to do this easily and efficiently. Wave is an effective tool which can help users to realize these benefits.

WAVE FUNCTIONALITY
Wave can be used to generate a number of reports based on 14 equipment performance indicators. These reports include: 1. Mean time between failures (MTBF) target assessment, which allows users to determine which pieces of equipment are not performing at the required level 2. Chronic failures, which enables users to identify pieces of equipment which consistently fail 3. Manufacturer benchmarking, a tool for comparing the reliability of different pieces of equipment to aid better procurement decisions. The software system also includes a charting module which allows users to identify trends over time and to gauge ongoing performance through the creation of a range of charts, as well as a failure review board module which can help to facilitate root-cause analysis of failures, enabling the elimination of repetitive failures.

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EASE OF USE
The minimal data entry requirement and the ability of the Wave system to Interface with a few existing planned maintenance systems, such as AMOS-D , SafeNet and Ulysses Task assistant make the system easy to use. The data entry requirements are minimal. It has been designed to integrate with the existing system. The software is licensed on a per ship, per year subscription basis and includes all upgrades and unlimited technical support.

THE WARTSILA CBM SYSTEM

Wartsila has developed a CBM system which uses various inputs such unique combination of visual and manual inspections , online monitoring of mechanical conditions using built-in sensors , system efficiency data and many other indicators. Entering all this information into the CBM system enables them to accurately determine the real overall status and condition of your system and ultimately the maintenance needs .

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HOW IT WORKS? 1. DATA COLLECTION AND CONNECTIONS

Data collected at site by computers and in built sensors is automatically sent to the Wartsila CBM Centre. Installations are normally connected to the CBM Centre by ISDN/ADSL lines. Marine applications mainly use satellite connections.

2. REPORTS
After evaluating the performance data the CBM Centre sends the report to the installation. This report includes statistics from the past as well as trends and maintenance recommendations. With many installations, sending or retrieving a batch of operating data once a day is sufficient to assess the present condition of the installation and to predict the future maintenance need.

3.CBM INSPECTIONS
Inspection agreements are mainly used in marine applications and are suitable for customers who want to outsource inspections. Here Wartsila service engineers visit the installation, e.g. the vessel in port, collect the data and send it to the CBM Centre where it is analyzed and reported back to the customer.

4.THE WARTSILA SERVICE CBM CENTRE

At the Wartsila CBM Centre all the CBM connected installations are monitored and the operation data evaluated. Wartsila utilizes software specially developed for calculating the ideal operation data for any installation under actual ambient conditions .The software enables comparisons with similar cases from the past thus optimizing in-house knowledge. The CBM centre analyzes and evaluates operation data on a daily basis or even more frequently if required. Each installation has its own unique operating environment which includes an operation profile, fuel type, load pattern, ambient conditions and many other factors, all of which influence the maintenance programme. The Wartsila CBM Centre calculates the ideal operation data for all engines including parameters such as engine load, ambient conditions and the engines specifications .If the measured operating data is outside the pre-set ideal, the CBM system will give an early warning and suggest possible reasons. At the same time, trend prognostics will identify any corrective action to take and when this is required. The early warning or alert indication is sent out to the customer well before the real alarm set value is reached, thus giving more time for planning appropriate maintenance .With Wartsila CBM control and monitoring system you monitor all operation data. The CBM reports can be optimized for different users such as top management, middle management and operators. The reports include traffic lights indicating the level of maintenance required: When the engine operation data is within the ideal window the measured values are shown in black and the engine symbol is green. When the operation data falls slightly outside the ideal window, the data will be yellow. When the operation data is outside the yellow range the data will turn red. The performance reports typically include: Fuel consumption Operation data evaluation Heat recovery Comments and suggestions. The environmental report typically includes: Emission calculations. The technical report typically includes: Upcoming maintenance Trends and alarm analysis

Comments and suggestions.

CBM BASED ON DCS (DISTRIBUTED CONTROL SYSTEMS)

The approach exploits the capability of Distributed Control Systems (DCS) in a networked environment to support a system-wide condition based maintenance (CBM) concept in a cost effective way. Condition Based Maintenance (CBM) functionality can be viewed as a tightly integrated suite of software applications operating throughout the ship distributed computing infrastructure. It integrates sensors, algorithms, and software, and supports automation of the distributed control system operation in three ways:

1) Condition Assessment: Assesses the condition of the equipment automatically to reduce human inspection tasks and unnecessary maintenance that occurs in a traditional periodic maintenance scheme. System assessment also provides valuable real-time decision support data for operational planning.

6 of 19 2) Prognostics: Predicts the onset of machinery failure to allow the command structure to match the use of the ships
machinery to the mission plan, or to enhance maintenance support. Prognostic capability expands support options and allows for cost effective planning and management.

3) Automated Logistics: Allows advanced scheduling and coordination of maintenance actions. Advanced triggering of
logistics support events improves system availability and resource utilization. Condition Assessment has two corollary functions: 1) To continuously monitor and estimate machine condition as the machine degrades with use and eventually degrades beyond designed engineering limits. 2) To identify unreliable or failed machine elements. The ultimate CBM objective is to determine the overall health of the system and to provide a comprehensive assessment of diagnostic condition (hard failures), and prognostic condition (pending failures). Moreover, the CBM functionality supports the management of the system configuration as well as providing a capability to exercise the test/maintenance features of the subsystems. In order to identify both pending and actual failures, the CBM applications process the prognostics captured by the distributed control Systems (DCS). The CBM applications compute performance indices such as performance degradation or damage accumulation based on known component analysis models/algorithms available for the plant equipment. It then compares the computed performance index to a mapping of health phases to determine if the component has transitioned to a different state of health or degradation. Depending upon the component and its health phase, an appropriate automated action alert (such as an indication to order a replacement part) may be triggered to facilitate resolution of this prognostic evaluation. The following figure depicts the distributed architecture applicable to ship machinery condition diagnostics and prognostics. A typical distributed control system operates at the component or equipment level where data from equipment sensors are collected, conditioned, and analyzed for machinery behavior. Depending on the maintenance philosophy and on the interaction among ship equipment, further diagnosis and prognostics may take place at higher level in the architecture, i.e. zonal, system, or ship-wide.

Ship Equipment Maintenance Hierarchical Architecture

7 of 19 CBM Data Flow

It is envisioned that the CBM applications continuously monitor the ship equipment by analyzing data from CBM-specific sensors and data from the equipment control systems. Following fig. illustrates the conceptual flow of data and the CBM analysis process. The process starts with sensor data collection at the process control level. The data is subsequently delivered to the CBM condition assessment algorithm for a particular machinery element. The condition assessment algorithm determines the condition of this element using a combination of engineering models that represent the process the element performs. This information is used as input for optimizing the ships operation by determining which machines to operate. The prognostic algorithms use the condition assessment information to update or otherwise estimate the operating time available before a failure occurs. The prognostic information is then made available to the operators for further action. The ships crew can then use the current and projected status to evaluate and update mission plans including maintenance activities.

CBM Data Flow

Distributed Control System (DCS) Characteristics

In addition to having the usual control logic, modern DCSs have the following features: High-speed data collection and signal conditioning: Many signal input/output modules within the DCS have on-board processors that independently handle the numerical calculations. Vibration analysis algorithms: Vibration signal analysis that makes use of different computational strategies such as Fast Fourier Transform (FFT), Neural Nets (NN), and Wavelet. Dynamics identification algorithms: These are methods to estimate the online dynamic operational parameters of the equipment. These features are available in many commercial DCS and also in some smart sensors and actuators.

U.S. NAVYS DISTRIBUTED MULTI-ALGORITHM PROGNOSTIC/DIAGNOSTICS SYSTEM (MPROS)

This system consists of MEMS (Micro Electro-Mechanical Systems) and conventional sensors on the machinery, local intelligent devices called Data Concentrators (DCs) and a centrally located subsystem called Prognostics, Diagnostics ,Monitoring Engine(PDME). MPROS includes and augments periodic vibration analysis by collecting data continuously from vibration and other sensors, including temperature, pressure , current , voltage , and others .These data streams are integrated as necessary in the data concentrators (DCs).

MPROS System

DATA CONCENTRATORS (DCS)& DATA FUSION(DF)

Devices called DCs are placed near ships machinery. Each of these is a computer in its own right & has the major responsibility for diagnostics and prognostics. The prognostics and diagnostics algorithm run on the DC. Conclusions reached by these algorithms are then sent over the ships network to a centrally located machine containing the other part of the system called PDME.

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PROGNOSTIC/DIAGNOSTIC/MONITORING ENGINE (PDME)& KNOWLEDGE FUSION (KF)

KF is the coordination of individual data reports from a variety of sensors. It is higher level than pure DF which generally seeks to correlate common platform data. Two levels of KF have been implemented :1. For Diagnos tics Implementin g KF for Diagnostics uses DempsterShafer belief maintenance for correlating incoming reports .DempsterShafer theory is a calculus for qualifying beliefs using numerical expressions. The system was augmented by heuristically collecting similar failures into logical groups . Failures that are related to each other form one logical group.

2. Extension for Prognostics (remaining life) Prognostic level KF combines time to failure estimates. Prognostic vectors represent time to failure in the system as a list of one or more time points (e.g. days , weeks , months , or R/Hrs.) with respect to the probability of failure.

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PDME block diagram OBJECT ORIENTED SHIPS MODEL (OOSM)

Entities in the OOSM are modeled as objects with properties & relationships to other entities .Some of the OOSM objects represent physical entities like sensors, motors, compressors, decks, and ships while other OOSM objects represent more abstract items such as failure prediction report or a knowledge source. Diagnostic & Prognostic conclusions are stored in the OOSM both those of individual algorithms and those reached by KF. Also PDME is the OOSM.

CONDITION MONITORING TECHNIQUES:

The CBM plant monitoring system designer has the expertise to select or combine any of the condition monitoring tools to provide the most effective monitoring solutions:Vibration analysis:- detects bearing defects, lubrication deficiencies, imbalance, worn out gears, worn coupling linkages, and misalignment in active machinery. Commonly used to monitor key equipments like blowers, compressors, purifiers, pumps, motors. Tribology:- monitors oil condition to detect the lubrication effectiveness, water/dirt contamination, oil additive performance, and to identify internal components which being worn out from the ferrous debris analysis (ferrography). Thermography:- Efficient, precise and non-contact analysis of machinery condition using the heat generated images to highlight faulty components such as bearings, motors , fuses relays and the steam pipes, drive gears, belts. Insulation testing current measurements:- Analyze and detect winding failures in motors, generators and transformers. Air leak surveys:- Using ultrasonics to detect air/gas/Freon/ steam leaks in the pipe works to minimize losses of working gas, prevent explosions from combustible gas leaks and improve compressor performance.

Condition Monitoring Techniques VIBRATION RESPONSE MONITORING:

Many mechanical problems are initially recognized by a change in machinery vibration amplitudes. In addition, the frequency of vibration, plus the location and direction of the vibratory motion are indicators of problem type and severity. Vibration characteristics can be distinctively divided into two types: forced vibration and free vibration. Typical forced vibration relates to problems such as mass unbalance, misalignment, and excitation of electrical or mechanical nature. Free vibration is a self-excited phenomenon that is dependent on the geometry, mass, and damping of the system, and typically caused by structural, acoustic resonance, and by aerodynamic or hydrodynamic excitation. Vibration signals carry information about exciting forces and the structural path through which they propagate to vibration transducers. A machine generates vibrations of specific color when in a healthy state and the degradation of a component within it my result in a change in the character of the

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vibration signals. A large variety of machinery possesses intrinsic dynamic characteristics that can provide a signature indicating their state of health. The state of health for the most part can be measured and analyzed in terms of the vibration signals. Advanced distributed control systems include digital processing techniques to analyze the equipment vibration signals in both time-domain and frequency-domain. Time domain information is useful to detect short duration features and frequency domain data is necessary for tracking multiple frequency components that shift in time. The implementation of the signal processing algorithms can be done using different computation techniques. These techniques include but are not limited to Fast Fourier Transform (FFT), Neural Network, and Wavelet analyses which have been applied to vibration monitor and detection in gas turbine control systems. Fig. illustrates the process of analyzing a time-based vibration signal data using Fourier technique. The result is a frequency spectrum which indicates the magnitude of the vibration at discrete frequency ranges. The control system can then utilize this information to determine if there has been a change in machinery characteristics and whether the change is acceptable for continued operation.

Fourier Analysis of vibration data DYNAMIC PERFORMANCE MONITORING:

The dynamic response of the equipment is a good measure of its operational performance. Dynamic behavior of a system can usually be measured in two ways: step response and frequency response. To measure the step response, for example, the control system generates an excitation signal (step) to a selected piece of equipment. The appropriate equipment parameters are then measured and stored for a predetermined time frame. The analysis step involves constructing the time response of the parameters and comparing them against a known response of the system. The known response may be derived from mathematical models of the equipment in combination with engineering experience. Figure below illustrates a step response analysis where the equipment is perturbed by a step input signal generated by the control system. The output of the system is measured and compared with that of a predefined model for the same input signal. Variations between the actual and the model (expected) output are analyzed to determine the possible performance degradation. For frequency response analysis, a similar process to the step response is performed, but now the input excitation signal is a sinusoidal signal having different frequency components. The system performance is then analyzed in terms of the frequency spectrum.

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Condition assessment based on step response

THE SHOCK PULSE METHOD (SPM)

The Shock Pulse Method (SPM) is the easiest and most reliable method for front line monitoring of rolling element bearings. It was developed by SPM Instrument AB in Sweden in the 1960s and has been used ever since. Shock pulses are transient pressure waves in the material, caused by mechanical impacts. When a metal ball hits a metal bar, the first result of the impact is the shock pulse. Its magnitude is a function of impact velocity and independent of the mass and shape of the colliding objects. The next result is a vibration of the bar. The transducers are constructed to measure only the shock. The shock wave excites the shock pulse transducer at its own resonance frequency of 32 kHz, thus amplifying the signal. The SPM measuring circuit is electrically and mechanically tuned to filter out all other vibration. Consecutive shock waves are registered as a rapid sequence of pulses with different magnitudes. All rotating bearings generate shocks. Shock pulses & vibration Their magnitude depends on the state of the bearing surfaces and on the lubricant film between rolling element and raceway. Low level shock carpet indicates an undamaged, well lubricated bearing. When the oil film is too thin, there is metallic contact between the bearing surfaces and the level of the shock carpet rises. The typical development of the shock signal during a bearings life time is shown by this curve. If the bearing is properly installed and lubricated, its shock signal remains low and stable during most of its life. Installation faults are indicated by an abnormally high shock level right from the start. Stress in the surfaces increases the shock level. This is followed by a rapid, large increase when visible damage sets in. Surface damage and metallic particles in the lubricant produce individual shocks which are much stronger than the shock carpet. Bearing Condition

determines the shock value

The advantage of the SPM Method are few and easily obtained input data (rpm and shaft diameter), allowing a direct evaluation of the measuring result (green - yellow - red condition display by the instrument). Bearing condition can be monitored throughout the bearings life time (detection of installation faults, poor lubrication, and misalignment).

VIBRATION SEVERITY
Vibration severity measurement is the ISO recommended method for general machine condition monitoring. To assess general machine condition and detect out of balance and misalignment, one can measure vibration severity according to ISO 10816. Vibration severity is defined as the RMS level of vibration velocity, measured over a frequency range of 10to 1000 Hz. This requires a different transducer type and a different way of signal processing. Instead of measuring the amplitude of a transient at a single high frequency, the vibration severity reading represents an average of all vibration components within a wide and comparatively low frequency range .Vibration severity is directly related to the energy level of machine vibration, and thus a good indicator of the destructive forces acting on the machine

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Oil Analysis
The science of oil analysis falls into 4 main areas, which are listed below: Fluid Physical Properties (Viscosity, appearance) Fluid Chemical Properties (TBN, TAN, additives, contamination, % water) Fluid Contamination (ISO Cleanliness, Ferrography, Spectroscopy, dissolved gases[Transformer ]) Machine Health (wear metals associated with plant components) Why Use Oil Analysis?
Powerful Machine Health indicator Gearboxes dont always respond to vibration monitoring A good lube analysis costs from as little as 20 Reduces wear & tear on critical assets Reduce cost of oil replacement & disposal One of the few transformer monitoring methods

Laboratory based oil analysis can provide the Fluid components, however the return of well informed machine health data from an oil analysis service provider will require the following: A real understanding of the machine and the associated contamination risks. The ability to analyse oil data and relate that to the specific machine using the lubricant. Wear mode analysis through machine knowledge, particle shape, texture and composition

Some pitfalls
Beware the following types of oil analysis service provider: Free analysis with the supply of oil - The oil lab should be independent as far as possible from the lubrication supply, free service means there is a hidden charge and any margin calls will fall on the side of replace the oil. Lights out analysis facilities These are production line facilities that provide a production line output, they tend to automate the diagnosis and the Machine Health aspects are virtually useless. Oil analysis labs that sub contract both the Fluid and the Machine Health components of the analysis. This results in the provision of a Lights out quality of analysis with an added mark up on price.

On site screening
If your reliance on optimal lubrication and hydraulic oil cleanliness is very high OR the volume of oil for analysis is prohibitively expensive OR the option of lab based oil analysis is not there (shipping, nuclear, highly contaminated). The use of on-site testing methods warrants consideration.

Visual appearance and smell

In the most extreme cases metal particles can be seen to glitter and water will come out of solution to provide a water layer. In these cases the full laboratory analysis route is rather late. Here are a few simple guides to the visual inspection of oil for water content and odour relating to contaminants.

Water Contamination
As little as 1 % water can reduce the life of a Journal bearing by 90 % [2] The plot inset below shows how little water is required to make the oil appear cloudy. When one considers the dramatic effect of oil on mechanical components such as rolling element and journal bearings, the level of vigilance is clear. A hot plate crackle test will also indicate the presence of water as a contaminant.

Smell

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A lot of caution should be exercised when smelling oil samples. Do not place the bottle directly under your nose. Remember that there may be toxic chemicals in the sample. Rather, wave your hand above the opening to waft the scent toward your face. Sometimes it helps to heat the oil, which increases the likelihood of detecting certain contaminants and degradation by-products.

Typical Odours From: Oxidation - sour or pungent odour, acrid (rotten egg) smell or something similar to stale cheese Thermal Failure - smell of burnt food Bacteria - stench, road-kill smell Running High Temperatures - no odour Contaminants - solvents, refrigerants, degreasers, hydrogen sulphide, gasoline, diesel, kerosene and process chemicals Amino Acids - fish odour Nitro Compounds - almond-like scent Esters (Synthetic Lubricants) and Ketones - perfume odour

Other On site screening Alternatives

Viscosity Tests Basic systems test at ambient temperature, the better systems offer temperature setting and measurement combined. Chemical Tests TAN, TBN etc. (can be bought as a lab kit from most oil analysis hardware providers) ISO screening A variety of methods are available, most are reliable and repeatable for oil screening Combined analysers These vary from a multi-function device that is virtually automatic to those with an excess of operations to collate the complete set of analysis results. Always look for the average sample processing time when considering a Combination Oil analyser (you may be unpleasantly surprised). The better analysers will take Contamination level, ferrous index and viscosity from a single sample.

Transformer Oil Sampling

The sampling and analysis of transformer oil is one of the must dos of the Predictive Maintenance world. If nothing else the following 4 tests must be included in any analysis:

Dielectric Strength (kV)

Dielectric strength is the ability of transformer oil to withstand electrical stress without failure. Moisture, sediment and conducting particles tend to reduce the dielectric strength of the oil.

Moisture Content (PPM)

Water in power equipment is attracted to areas of greater electrical stress and this is where it is most dangerous. Moisture accelerates the deterioration process of paper and oil, as well as badly maintained breathers and oil leaks. The moisture detected in the oil, by doing a moisture test, is directly related to the operating temperature of the transformer windings where the continuous migration of moisture is taking place as the temperature varies.

PCB Content
Polychlorinated Biphenyl is classified as a toxic material. No legislation has been finalized to date, however, a risk analysis should be carried out to identify and manage the product to prevent any contamination. COSHH 1994 and EPA 1990 provide guidelines for the reduction and handling of PCBs.

Whats New Oil Analysis

Most labs provide more for less cost. Oil Disposal costs are increasing pressure to monitor NOT Change. On Line systems & sensors technology will reduce cost

SUMMARY Oil Analysis

Looking and smelling can provide useful 1st Screen Choose an analysis service provider that will provide Machine Health feedback [Typical analysis 20] On site screening & analysis can be expensive and should be weighed against benefit Viscosity Testers [700+], ISO Testers [2000+] Combination Testers [9k +] Transformer sampling and analysis should always be considered

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On-line monitoring of CBM data

The complete coverage of this area is entirely beyond the scope of this technical paper. On-line systems are available to measure all CBM related data where a sensor exists. The scope includes the following areas of CBM: Vibration in all of its guises Temperature Oil Debris and optical particle count Pressure Volume analysis on Diesel and Gas Engines And will normally accept inputs from SCADA, DCS, 4-20mA sensors etc. Why Use On Line Systems
Plant is extremely Critical Staff not available for walk around testing Access is difficult for staff Mean Time Between Failure is short

Whats New On Line Systems

Pressure sensors available for gas engine temperatures System costs are much lower [4k entry] Web based systems available for NO Capex

Impact Technologies is developing an inexpensive, intelligent, and compact fluid management system that features embedded on-line/in-line sensing and on-board processing. The system employs a low-powered, broadband, AC impedance measurement and is coupled with a model-based analysis package capable of predicting fluid quality and degradation in hydraulic and lubricating oil systems. The system is anticipated to take a number of packaging forms including a SmartDipStick and SmartPlug design and custom, turnkey solutions are also available. The potential for wireless transmission of oil health state or degradation/contamination is also anticipated. Features:

Benefits:

Compact, lightweight design of about 150 grams Smart design with processor on-board Low-powered, broadband measurement Model-based analysis package Simple, inexpensive components and software reconfigurability

Applicable to mobility and stationary applications Reduces cabling, interface, and integration

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Captures information rich, broadband response of system with minimal power requirements Provides accurate assessment as model-based parameters are directly related to physical system Multiple form factors and turnkey solutions

ANALYSIS TECHNIQUES
LABORATORY INSTRUMENTATION 1. AE and FTIR Spectroscopy
The Atomic Emission (AE) Spectrometer determines the level of wear metals and contaminants in used lubricating oils and hydraulic fluids. The Fourier Transform Infrared (FTIR) Spectrometer is used to identify organic materials by measuring the absorption of various infrared light wavelengths by the material of interest.

2. Viscometry
The kinematic viscosity of a fluid is determined by measuring the time for a volume of liquid to flow under gravity through a calibrated Zeitfuchs cross arm glass capillary tube suspended in a water or oil bath, maintained at a constant temperature of 100C or 40C.

3. Moisture Titration
The volumetric water content of used lubricating oil is determined by Karl Fischer titration.

4. Acid and Base Titration

The Automatic Potentiometric Titrator (Karl Fischer) is used for the determination of the concentration of a liquid or solid by titration method. This allows for the measurement of acidic and basic constituents of the fluid. From this it can be determined whether the additive system is still capable of neutralizing acid residues.

5. Reserve Alkalinity Titration

The Automatic Potentiometric Titrator is also used for the determination of the effectiveness and remaining life of a coolant, based on additive degradation and contamination.

6. ISO Cleanliness
A fluid contamination comparator is used to estimate the amount and type of solid contamination in a hydraulic oil or lubricating oil. ISO Cleanliness Codes are given using the revised ISO 4406 (FDIS) procedure for reporting fluid cleanliness measurements resulting from APC's calibrated with the new NIST traceable method. 7. LMOA Pentane Insolubles A filtration procedure, in accordance with the LMOA Fuels, Lubricants and Environmental Committee Standard Insolubles Test Method Revision 3, is used for the determination of coagulated pentane insolubles in used lubricating oils.

16 of 19 3.0 Integration of CBM, Plant Inspection and CMMS

Operations and Maintenance are becoming impossible to separate, they are the main arteries that feed the optimal plant operation and without synergy and information exchange between the two. The only real path is through Integration and visibility. Thankfully integration is no longer a pipe dream, system do exist are affordable and can be implemented within a reasonable time frame [3]. The following areas of plant operations and maintenance need to integrate to complete the O & M picture, these are: CBM (Oil, Thermal, Vibration, On-line, Pressure Volume ) Test and Inspection (TPM, Rounds, Lubrication, Plant & Process Gauge Data) CMMS (Automation of triggered tasks, do work when required, consider process implications) Knowledge (Turn experience into a building block and re-use the expertise) Reporting & Metrics (Tools to help make sense of the benefits and information)

The best way to explain the benefits of integration is to show an example of integration at work within a plant environment. Appendix 2 shows an Integrated Work flow example that shows the following sequence: Operations Inspections and measurement of running hours trigger the issue of an oil sampling WO The data from the oil sample is assessed When the oil assessment shows a problem, a vibration reading WO is triggered In the case where the oil is BAD and the vibration levels are BAD, an overhaul WO is raised In the case where the Oil is BAD but the vibrations are OK, an oil change WO is raised

The above sequence and Appendix 2 show how previously scheduled calendar tasks can be removed from the program as a result of a Condition triggered task. Also the ability to decide on condition via a knowledge system creates an environment where tasks can be optimised based upon plant related dependencies. The completion of such integration using 3 or more software packages is virtually impossible. The solution is NOT interface, it must be integration.

Infrared Thermography
It is a technology that looks at the heat signature of objects to monitor the object's state or condition. All objects emit heat (energy) waves. If an object is cold, its molecules vibrate more slowly and energy of longer wavelengths is emitted. When the temperature of the object rises, its molecules vibrate faster and the wavelength becomes shorter. Every particular energy wavelength has a temperature associated with it. The lowest temperature that the human eye can visually detect is approx. 500 deg. Celsius. At temperatures cooler than that, the heat waves emitted are invisible and are called infrared waves. Infrared light comprises the lower frequency energy emissions which are undetectable by the human eye. Our eyes are not sensitive to such lowenergy radiation, but IR can reveal useful information about our environment. An infrared camera can see the "invisible" light and convert it to a video signal, which can be seen on a television or on the eyepiece of the camera, and can display the temperature associated with of any part of that image. The image can be stored on a flash card for viewing on a computer screen, or on videotape. Performing an infrared thermographic survey is a technique for monitoring the condition of equipment. This includes electrical systems, mechanical systems, heat exchangers and the insulated chambers for energy loss. Examining the images from the IR camera one can determine the condition of components, and discover any exceptional temperatures which might indicate that the component is approaching some stage of failure. IR images are examined using analysis software, and priorities are set as to how soon repairs are needed. This could be a failing motor bearing, a loose electrical connection, or a bad door seal. Each of these produces a heat signature, and when they are out of parameter a problem is indicated Accurate data is gathered at the inspection site by a qualified thermographer. It is then analyzed and a report is generated. The report is delivered to the person responsible for maintaining the equipment or facility so that timely repairs can be implemented

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.A laptop computer with PLC programming, communication, and operating programs are a necessary tool in today's modern plant. Engineers, production supervisors, maintenance supervisors, maintenance technicians, electricians, instrument technicians, and maintenance mechanics all need to have PLC and computer knowledge, training and skills in troubleshooting. On the job training on PLC's is usually not very effective until the person being trained has reached a certain level of expertise in several areas. Knowledge and skills in electricity, troubleshooting, and computer operation are necessary prerequisites to effectively assimilate basic PLC training. The manufacturer's courses are five, eight hour days. Class work is extremely fast and condensed in order to cover the amount of material involved. The instructors are very knowledgeable and covered the course material as we tried to input the programs into desktop training equipment in order to see how it worked. Basic troubleshooting techniques apply to every situation and occupation. Positive identification of the problem(s) is absolutely essential to solving the problems. Many times, the inexperienced troubleshooter will mistake one or more of the symptoms for the problems. Solving the symptom(s) will normally just postpone the problems to a later date. By which time, the problems may have grown to mountainous proportions. An example is when a person experiences a headache and takes a mild pain reliever, such as aspirin. The actual problem might be any number of things: eyes need to be checked, medication or lack of medication, muscle strain, stress, tumor, blood vessel blockage, or old war injury. The same thing occurs in industry, a fuse in a circuit blows and the maintenance person gets the replacement fuse and inserts it into the fuse holder. There are many things that could have caused the fuse to blow, depending on the complexity of the circuit. Excess current caused the fuse to open (blow). Excess current could have been caused by: overload on the load; short circuit between the wires, grounded wires, short circuit in the load, ground in the load, voltage spike, voltage droop, etc. If the maintenance person does not troubleshoot the circuit prior to replacing the fuse and restoring power, negative consequences could arise. It is not uncommon for a process to develop a number of small problems and continue to function at a degraded level of operational capability. Then, one more small problem occurs and the whole process breaks down. Finding and correcting the last problem will not necessarily restore the operational capability of the process. The process continued operations with the small problems, but the small problems may not allow the process to restart from a dead stop. All the other small problems must be identified and corrected before the process is restored to full operational capability. This situation arises in industry as well as a person. The person can continue to function with a number of small problems, such as fatigue, blood pressure problems, hardening of the arteries, artery blockage, but one more small blood clot in the wrong place could easily cause the death of the person. Clearing the blood clot does no good to the person. They will not be restored to full operational capability.

Thermal Techniques
Thermal measurement systems fall into the following categories Point/Zone Measurement 1. Dedicated temperature sensor 2. Hand held

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Thermal Picture:- Thermography Camera (Still or Video) Why Use Thermal Measurement?
Pinpoints specific hot spots Non intrusive method Implications of electrical failure are SEVERE Simple to interpret Hand held laser sighted Pyrometer 500 Abundance of Thermal service providers

Point/Zone Measurement These methods measure the temperature of a specific sensor touching the structure or the emitted temperature from a radiating area. They come in hand held and fixed variants and are very convenient and robust. Thermography Infrared detection systems provide a thermal picture of the target object, both accurate and visually clear. The following table outlines the more common types of measurement with comments on applications and a brief technical description of the method. Thermal Measurement Summary Table Description Applications Usually a thermocouple or Can be used on all accessible RTD. Often imbedded, can surfaces. Walk around versions be provided as an encapsulated take time to settle and are less sensor for permanent fit. robust than the pyrometer. Area Pyrometer Measures the emitted IR Very good for walk around radiation from a surface. Often temperature checks on machines with a Laser sight or area and panels. indicator. Temperature Paint / Stickers Chemical indicators calibrated Great for inspection rounds. to change colour at a specific temperature. Thermography Hand held still or video camera The ultimate, high-resolution sensitive to emitted IR. thermal picture. Camera costs 10k up, service 500 per day. Camera use and interpretation does require good training. Method Point temperature

Whats New Thermal Measurement

Cameras are lighter, cheaper. Hand held laser pyrometers have memory, route Output Still cameras offer a saving over video. Competitive service provision driving down costs

EXAMPLES OF CBM:
1. Turbocharger Condition Monitoring:
The turbo charger is a good example where it is very profit-able to go from time based to condition based maintenance. The change of a bearing package for an ABB turbo charger type 714 costs some 25.000 USD, a breakdown where the shaft has to be changed costs up to 120.000 USD. Considering that the bearings always are changed at the wrong time when going by running hours this is a very expensive maintenance strategy. CBM will increase the safety against catastrophic failures and lower the

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maintenance costs as the bearings normally can operate a longer time, there are turbo chargers that run well over 30.000 hours before having to change the bearings. The technical solution can consist of using a hand held instrument and measure shock pulse and rms vibration every month as long as the bearing is OK. The measuring intervals are then shortened as damages develop. Using an online protection system, can increase the safety; see fig 10.Specially designed transducers and bulkhead unions are installed to get access to the bearing housing.

2. Gas Turbine Condition Monitoring:

There has been significant development in the area of gas turbine condition monitoring products. Some notable effort is by General Electric and Lockheed Martin Corporations ho use control system information to perform gas-turbine condition monitoring. Intelligent Applications Ltd. developed Tiger, a gas turbine condition monitoring system, that has proven to reduce maintenance cost and improve operational performance. This system utilizes turbine control system information to perform conditioning monitoring and analysis. During on-line operation, Tiger performs a variety of checks, including design limits, dynamic response and, consistency with model-based prediction.

3. Condition-Based Maintenance of Electrical Machines:

Various efforts in industry have focused on the on-line monitoring of electrical equipment such as electrical motors and transformers. In many of these instances, local control systems collect data using advanced sensor technology and analyze them for equipment malfunction. This is primarily a part of the predictive maintenance development to detect electrical deterioration of equipment insulation system. For some components such as an electrical transformer, the condition of winding insulation has a major effect on longduration outage. The objective is to improve personnel safety and the application of on-line monitoring for incipient failures. Many manufacturers provide motor controllers integrated with motors for variable speed motor operation. The integrated motor provides a compact package for distributed control enabling the machine to continuously monitor its own health. The built-in algorithmic techniques establish whether the motors operating parameters such as vibration, current and temperature are within prescribed limits.

CONCLUSION
Distributed control system suppliers are continually working to provide more predictive maintenance (condition monitoring) features and to help the system users put a host of other information from the automation environment to good use. The advent of smart sensors and actuators capable of communicating through system networks make use of a tremendous amount of available reliability data for CBM utilization. As computing power becomes less expensive and can be economically distributed to the equipment level control systems, more analysis can be executed in parallel with the process control routines. The overall goal is to analyze the change in the equipment condition, predict potential failures, and proactively implement (through a CBM infrastructure) maintenance. The cost of CBM implementation can potentially be reduced by distributing the CBM functions to lower level equipment DCS. As the process control systems take on additional responsibilities in the areas of condition assessment, it will be necessary to develop better and more robust computational techniques to improve the efficiency and accuracy of data processing. Development in areas such as sensor data fusion, feature extraction, classification, and prediction algorithms are essential to determine the remaining useful life of a piece of machinery. Accurate prognostics for machine life prediction will only follow from a wealth of this type of multi-variant performance monitoring histories. There are many prognostic algorithms based on theoretical principals which must be tested and refined using consistent and accurate data acquired from machines as they are subjected to real operating conditions. The MPROS system provides a platform on which to implement and refine the complex prognostic algorithms required to achieve accurate prediction of remaining machine life. Condition Based Maintenance (CBM) systems move the maintenance effort from a scheduled preventative format to a more flexible and accurate condition based predictive format. CBM will keep you up-to-date on how your installation is doing and help you detect any disorder or deviation from expected normal performance data in good time. CBM makes maintenance proactive, rather than reactive, by spotting fault sources and emerging operational trends well before any failure occurs. CBM system suppliers are continually working to provide more predictive maintenance (condition monitoring) features and to help the system users put a host of other information from the automation environment to good use. Advent of smart sensors and actuators capable of communicating through system networks and as computing power becomes less expensive more analysis can be executed in parallel with process control routines .The overall goal is to analyze the change in the equipment condition, predict potential failures, and proactively implement (through a CBM infrastructure) maintenance .Development in areas such as sensor data fusion, feature extraction, classification, and prediction algorithms are essential to determine the remaining useful life of a piece of machinery