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Capabilities of
PREDICT/DLI
DLI
Who is PREDICT/DLI ?
PREDICT Technology
Cleveland, OH
Oil Analysis
DLI Engineering
Seattle, WA
Vibration Analysis
PREDICT/DLI
Integration
Product Development
Sales
DLI
PREDICT Technologies:
Early 1970s- Ferrography developed -
research for Department of Navy
1981- BP Oil Co. licensed technology
in the private sector
1985- PREDICT Technologies set up -
market technology outside BP Oil
1991- PREDICT sold to Man-Gill Chemical
DLI
PREDICT Technologies:
Leads industry in WPA -
original patents over 17 years ago
Sets the standard for the industry -
developed techniques & lab
equipment
New laboratories around the world -
instruments and training
Service programs worldwide
DLI
DLI Engineering:
1966- Diehl and Lundgaard Inc. - marine &
mechanical engineering consulting firm
1975- U.S. Navy contract - machinery
condition analysis on all aircraft carriers
1986- Portable data collector
automated diagnostic software
1991- Military Sealift Command contract -
Data collector / Field analyzer
1995- USPS Bulk Mailing Centers
DLI
DLI Engineering:
Introduced several key advances:
world's first triaxial accelerometer
first quick mount-attachment system
first Automated diagnostic system for
Machinery Condition Analysis
= fast, repeatable, reliable, accurate
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Worldwide
Customers
U.S. Navy
Military Sealift Command
Union Pacific
Boeing
NASA
Merck Pharmaceutical
Texaco
B.P. Oil
Baticim Bati Anadolu Cimento
Dow Chemical
Rhone Poulenc AG
Robe River Mining
Weyerhaeuser Paper
Glenhow Sugar Mill
Hershey Chocolate
PSE & G
3M Company
Fibras Quimicas
Amoco
Bechtel Corp.
Lockheed
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Predictive Maintenance in the
1990s
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Maintenance Program Goals
Reduction of Breakdowns
Anticipate and Plan Repairs
Increase Profits
Maintain Plant Production Capacity
Provide Reasonable work Hours for
Maintenance People
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History of Maintenance
Run-to-Failure
Periodic Preventive
Predictive
Proactive
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Where are we Today?
One-Half of Maintenance is Run-to-Failure
Ten Percent of Maintenance is Preventive
About Forty Percent of Maintenance is
Predictive
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Components of a
Maintenance System
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Hysterical Maintenance
Fix it When it Blows Up
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Periodic Preventive Maintenance
Time
Normal Operation
Wear Out Break In
Periodic Overhaul of Machines
Causes Problems in 20% to 25% of Machines
Inefficient Use of Resources
The Bathtub curve
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Predictive Maintenance
Based on Measuring the Machine's Condition
while Operating
Much Better Investment of Maintenance
Effort
Requires Collecting and Trending Several
Types of Data
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Techniques of Predictive
Maintenance
Periodic Vibration Measurement
Continuous Vibration Measurement
Oil Analysis and Wear Particle Analysis
Thermography
Motor Current Analysis
Electrical Surge Testing
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Benefits of Predictive Maintenance
Increased Product Quality
Decreased Parts and Labor Expense
Reduced Maintenance Costs
Increased Production
Longer Machine Operating Life
New Equipment Certification
Significant Energy Savings
Increased Worker Safety
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Proactive Maintenance
Root Cause Failure Analysis
Precision Alignment and Balance
Certification and Verification
Performance Specifications for Purchase and Rebuild
Training
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Benefits of Proactive
Maintenance
Machine Problems Designed Out
Extended Machine Life
Easily Added to a Predictive Program
DLI
Computerized Maintenance
Management Systems
(CMMS)
Shift from Reactive to Preventive Mode
Provide Historical Information
Automatic Work Order Generation
Inventory Tracking
Workforce Management
Purchasing
DLI
Knowledge Based Maintenance
Share information between all users
Root cause analysis (proactive) -
design problems out of machines,
fix the problem not the symptom
The Future
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Designing and Installing a
Vibration Monitoring system
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Preliminary Guidelines:
Concentrate on the Most Important
Problems
Imbalance
Misalignment
Bearings
Select Machines with Care
Effect on Plant Production
Cost of Repair
Designing and Installing a Vibration
Monitoring system
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What Machines to Monitor?
Electric Motors
Mechanical and Electrical Problems
Pumps and Fans
Constant Speed Easiest
Prone to Imbalance and Misalignment
Variable Speed Machines
Speed and Loading are Critical
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Preventive or Predictive?
Time
Normal Operation
Wear Out Break In
The Bathtub curve
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Predictive Maintenance
Based on Measuring the Machine's Condition
while Operating
Much Better Investment of Maintenance
Effort
Requires Collecting and Trending Several
Types of Data
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Designing Measurement
Points
Documentation of Machine Parameters
Components
Forcing Frequencies
Speeds and Loading
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Data Consistancy
Data Repeatability is Crucial
Sensor Mounting Consistancy
Operating Parameters
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Spectrum Comparison
The Reference Spectrum
The spectrum mask
Averaged spectra
Forcing Frequencies
Order Normalization
Trending Vibration Data over Time