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Lesson Objectives
What is Failure?
Likelihood of
failure is higher
Load in this region
Causes of Failures
25-35% of equipment reliability issues are due to engineering/design
Poor Equipment Selection
Motors, pumps, couplings, gear box
Improper sizing of equipment
Improper piping design practices
Pipe strain on equipment
Torque method on fasteners
Poor base/foundation designed
Poor alignment or balancing
Causes of Failures
10-20% of failures are contributed to equipment fabrication
Improper piping practices
Pipe strain on equipment
Torque method on fasteners
Improper welding procedures
Improper fabrication practices
Unlevel base structures
Improper/lack of anchoring points
Inadequate piping support
Improper handling of finished equipment
Pick points/shipping points/tie down points
Improper shipping method
Improper packaging
Tie downs of critical parts
Causes of Failures
15-25% of failures are due to poor installation practices
Improper handling practices
Pick points, moving practices
Improper anchoring techniques
Improper anchoring bolts and torque
Insufficient anchoring points
Improper alignment and balancing
Poor lubricant selection and control
Incorrect viscosity
Dirty lubrication
Wrong lubrication/grease
Causes of Failures
10-20% of failures are due to operation issues
Improper starting and operating procedures
Starting equipment under full load
Insufficient monitoring
Thermal condition
Physical vibration
Lubrication condition
Maintenance: Methodologies
Failure-Based or Breakdown
Maintenance
Failure-Based or Breakdown
Maintenance
Disadvantages of CM
First, failures can be most untimely. There is
little that can be done beforehand to anticipate
the tools, personnel, and replacement parts
that may be required to repair the equipment
and return it to service.
Secondly, machines allowed to run to failure
generally require more extensive repair than
would have been necessary if the problem had
been detected and corrected earlier.
Failure-Based or Breakdown
Maintenance
Scheduled or Preventive
Maintenance
Goals of PM
Scheduled or Preventive
Maintenance
Scheduled or Preventive
Maintenance
Replace Part at
Optimal Risk
Rapid wear-
Random Punctures and Abuse out from use
60,000 km
Usage - Distance
In the random failure period carry spares for the This tell-tale up-turn is what we want
unforeseeable (like a puncture). During this phase to find for our wearing parts. We can
you have total control of how many times you then replace the part as preventive
overload/overstress the part, or whether you let the maintenance before the chance of it
local environment degrade to the point it starts to failing starts to get high with further
fatigue the part. use.
Rate of Blunting
Robustness of the Design
Quality (Precision and Accuracy) in
Manufacture
Roughness and Care during Use
The Quality of Maintenance
Care 50 100 150
Times Used
With a failure rate curve of this shape for a part we can see it gradually
degrading with use. That means we can set a usage limit, after which it will need
to be replaced or renewed as preventive maintenance.
Predictive Maintenance
Predictive Maintenance
Predictive Maintenance
Do Maintenance
Repair or Replace Equipment Airline 7 - 11%
& Condition
Unusable Airline 3 - 4%
Performance
Monitor Naval 6 - 9%
Operating
Naval 2 - 3%
Smooth Change in
Running Performance is Airline 1 - 2% Airline 14 - 15%
Detectable Impending Naval 10 - 17% Naval 42 -56%
Failure
Failed
When parts fail randomly you cannot predict which part will fail, or when it will fail. Unlike parts with wear-
out failure, which can be observed and replaced, the random failure part can only be observed at defined
intervals and monitored for evidence of developing, or impending, failure.
MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester
28
Predictive Technologies
Oil Analysis
Wear Particle Analysis
Vibration Analysis
Thermography
Mechanical Ultrasound
Motor Circuit Evaluation (MCE)
Non Destructive Testing (NDT)
Predictive Technologies
Oil Analysis
Oil Analysis-Moisture
Oil Analysis-Oxidation
Thermography
The second most popular use is in the electrical area.
These cameras have the capability to detect hot electrical
connections. These connections are hot due to poor contact or
overloading of that point in the connection.
These hot connections dont go away and usually lead to
downtime or possible fires.
The cameras are non contact making them safe to use around
rotating equipment.
Thermography-Example
Vibration Analysis
Vibration Analysis
Visual
Liquid Dye Penetrant
Magnetic Particle
Ultrasonic
Eddy Current
Radiography
Modified Pulse Echo (Shear Wave Analysis) (Shafts)
Hydrostatic Testing
Moving Practices
Maintenance category
Maintenance
REQUIRED BY REQUIRED BY
Safety Failures
On-condition monitoring - confirmed
Servicing - unconfirmed
Proactive Maintenance
Proactive Maintenance
Philosophy of Maintenance
The three strategic maintenance philosophies to be
discussed include:
1. Condition-Based Maintenance (CBM)
2. Reliability-Centered Maintenance (RCM)
3. Total Productive Maintenance (TPM).
Condition-Based Maintenance
(CBM)
The philosophy of Condition-Based Maintenance is
a practical maintenance strategy which seeks to
optimize the mix of failure-based, preventive,
predictive, and proactive maintenance practices.
The strategy is typically implemented by first
identifying a Reliability Team that performs a
qualitative assessment of plant processes and
machinery to determine criticality of the assets.
Condition-Based Maintenance
(CBM)
Second, the team studies the equipment to identify
which types of maintenance practices will be
applied to each asset. Fractional horsepower
motors, for instance, might simply be allowed to
run to failure.
Conversely, a critical machining tool or large
turbine/generator set will have a full complement of
PM, PdM and PaM techniques applied.
Condition-Based Maintenance
(CBM)
Third, a review of PM tasks should be
conducted to see which activities must be
conducted, which may be deferred based on
machine condition, and which activities may be
eliminated altogether.
Fourth, an evaluation must be performed to
decide which predictive and proactive
techniques to implement in-house, which to
out-source, and identify those that are not
applicable.
Evaluations must be carried out to identify the
appropriate equipment (hardware and software) and
vendors, and those tools must be procured.
Condition-Based Maintenance
(CBM)
Finally, the Reliability Team implements the
program on a building block basis introducing
new technologies and new tools as the program
matures.
Importantly, the team must espouse Continuous
Improvement and re-evaluate the program on a
semiannual or annual basis.
Reliability-Centered Maintenance
(RCM)
Very similar to CBM, Reliability-Centered
Maintenance is a technical maintenance strategy
that strives to identify the appropriate methodology
based on the maintenance requirements for each
asset.
The major difference between RCM and CBM lies in
the fact that RCM employs a rigorous quantitative
evaluation of equipment criticality based on
identified failure modes and effects.