PREDICTIVE METHODS AND TOOLS

A Quick Overview
for

Forging Industry Association

Purpose
Overview of Predictive Maintenance - PdM
(condition based maintenance)
What Why How

Introduce three useful technologies

Thermography Vibration measurement Ultrasound

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Outline
Bathtub curve Maintenance strategies Three technologies for Predictive Maintenance

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Bathtub curve components

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Bathtub curve

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Reactive

Run to failure

No cost until failure Unpredictable Expensive if misapplied

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Preventive

service before theres a chance to fail

More reliable than Reactive Higher cost & more errors then necessary

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Predictive

detect onset of failure, then service

More reliable than preventive Cut unexpected failures

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Proactive

control failure root causes

More reliable than predictive Increase uptime, lifetime

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Comparison
Reactive
Unpredictable Can be expensive

Preventive
Cut known failure modes Simple to implement Higher waste & error

Predictive
Cut unexpected failure Reduce cost and error

Proactive
Remove root causes Stabilize and extend life

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Predictive Maintenance - Why

Cut unexpected failures Eliminate unnecessary service Maximize runtime

Reduce introduced faults

Improve Overall Equipment Effectiveness

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Predictive Maintenance - How

How to start
Identify equipment that yields greatest benefit Select technology(ies)

Build plan
Equipment routes and schedules Aquire and learn to use tools Develop benchmarks for trending

Develop information flow

Data for trending Actionable reporting

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Potential Pitfalls
Lack of planning No training Poor data and diagnosis False alarms, missed early warnings Early warnings ignored

All lead to a Failed Program

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Technologies for Predictive Maint.

Common
Thermography Ultrasound Vibration Analysis (Tribology - not part of presentation)

Overview for each

Description Application

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Thermography

Infrared (IR)

Subset of electromagnetic spectrum

All objects radiate according to temperature (freq temp) IR invisible so IR camera is used
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Thermography

Infrared (IR)

area of interest

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Thermography
Early Warning
Increased friction Abnormal resistance or current

Non-contact Realtime display Useful for electrical and mechanical

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Thermography
Typical Items Inspected Power distribution Fuse boxes Motor Controllers Switchgear Capacitors Transformers Motor leads

Electrical
Common Problems Found Unbalanced loads Excessive draw Faulty connections Component failure Harmonics

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Thermography
Left phase at 92 F Center phase at 116 F Right phase at 119 F

Electrical

Fuse at main disconnect was open

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Thermography
Typical Items Inspected

Mechanical
Common Problems Found

Bearings Gearboxes Drive Belts Motors (check cooling)

Inadequate lubrication Misalignment Blocked cooling

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Thermography

Mechanical

Motor misaligned

Motor running hot Vent clogged

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Ultrasound
Above audible range (20~100kHz) Travels through all matter Excellent for lubrication Electrical and mechanical

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Ultrasound

Bearings

Earliest indicator of fatigue When to grease, how much With FFT can determine failure mode
good bearing bad bearing adding grease 3 minutes later

sound files copyright of UE Systems

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Ultrasound
Arcing and tracking Corona over 1000V Used BEFORE opening panels

Electrical

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Ultrasound

Compressed Air Leaks

Easy to detect and locate Estimate 20% (+) of compressed air is lost
100hp compressor costs $35k~$50k yearly $7k~$15k savings in energy cost

Help pay for PdM expenditures

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Vibration Monitoring
Monitor bearing wear (Predictive) Rotating machine condition (Proactive)
Alignment Balance Mounting problems (softfoot, etc.)

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Vibration Monitoring
Types
High frequency narrow band Broadband Hybrid (attributes of other two)

Configurations
Portable (walk-around) On-line (permanently mounted and networked)

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Vibration Monitoring
High frequency
Early indication of bearing wear (similar to ultrasound) With FFT analysis can indicate bearing fault area (i.e. outer race, inner race, cage)

Broad band
Machine condition (alignment, balance, etc.) No early warning of bearing wear

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Predictive Maintenance
What monitor assets
plan service after early detection of problem verify repair reduce costs and faults extend runtime

Why cut unexpected failure

How select assets to monitor

choose monitoring technology(ies); train establish and maintain schedule develop concise reporting

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