Operations and Maintenance Management … · Energy Management Teleworkshops March 2001 Operations and Maintenance Management Page 8 LOGOFY2001 Thermographic Analysis nFoundation

Energy Management Teleworkshops March 2001

Operations and Maintenance Management Page 1

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Operations and Maintenance Operations and Maintenance Operations and Maintenance Operations and Maintenance Management WorkshopManagement WorkshopManagement WorkshopManagement Workshop

TRAININGTRAINING

ENGINEERINGENGINEERING

ADMINISTRATIONADMINISTRATION

OPERATIONSOPERATIONS

O & MO & MINTEGRATIONINTEGRATION

MAINTENANCEMAINTENANCE

Ray PughRay Pugh

Pacific Northwest National LaboratoryPacific Northwest National Laboratory

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Workshop ObjectivesWorkshop Objectives

n Appreciate O&M and its importancen Understand the key elements of an

effective O&M programn Describe tools and technologies that

can be used in a predictive maintenance approach

n Describe some immediate O&M implementation ideas to generate energy and cost savings



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Maintenance PracticesMaintenance Practices

n The aggregate of direct and supporting actions that detect, preclude or mitigate the degradation of a system or component functionality, or restore that function to an acceptable level of performance following failure.

n See if its breaking, try and stop it from breaking, and if you can’t, fix it after its broken.

Maintenance

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Maintenance PracticesMaintenance PracticesA Closer LookA Closer Look

n Reactive maintenance (corrective)

n Preventive maintenance (PM)

n Predictive maintenance (PDM)

n Reliability centered maintenance (RCM)



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Predictive Maintenance Predictive Maintenance -- PDMPDM

Measurements that detect the onset of a degradation mechanism thereby allowing casual stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability.

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Predictive MaintenancePredictive MaintenanceA Third LifeA Third Life--Cycle AlternativeCycle Alternative

n Measuring component stress levels before they can cause a problem.– Measure component stresses (Vibration,

Thermography, Oil Analysis)

– Measure the degradation mechanism (Allignment/Balance)

– Evaluate component performance (Power consumption)



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Predictive Maintenance Predictive Maintenance AdvantagesAdvantages

n Increased component operational life/availability

n Allows for preemptive corrective actionsn Decrease in equipment or process downtimen Decrease in costs for parts and laborn Improved worker and environmental safetyn Improved worker moralen Energy Savingsn EPRI study showed a 8-12% savings over

preventive maintenance programs

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Predictive MaintenancePredictive MaintenanceOther BenefitsOther Benefits

n Eliminate most tear-down events

n Provides information to perform a root cause analysis

n Eliminate brush fire maintenance



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Predictive MaintenancePredictive MaintenanceDisadvantagesDisadvantages

n Increased investment in diagnostic equipment

n Increased investment in training of staffn Savings potentials not readily seen by

management

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Predictive Maintenance Predictive Maintenance TechnologiesTechnologies



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Predictive Maintenance Predictive Maintenance SavingsSavings

n Reduction in maintenance costs

n Elimination of breakdowns

n Reduction in downtime

n Increase in production

n Decreased spare parts inventory

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Predictive Maintenance Predictive Maintenance Technologies (PDM)Technologies (PDM)

n Thermographic analysis

n Vibration analysis

n Oil analysis

n Ultrasonic analysis



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Thermography Thermography -- What is it?What is it?

nDetection of the Infrared Electromagnetic Radiation emitted by any object at a temperature greater than absolute O.

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Insert Applicable sectionInsert Applicable sectionof CSI of CSI ThermographyThermography

VideoVideo



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ThermographicThermographic AnalysisAnalysisn Foundation of electrical component predictive

maintenance– Can be used on mechanical and structural

componentsn Based on the principle that frictional and

resistive changes result in changes in temperature

n Detection of infrared emissionsn Can be used to analyze patterns of heat loss or

gainn Non-intrusiven Non-contact

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ThermographyThermography Uses Uses --Electrical ComponentsElectrical Components

n Electrical switches

n High voltage lines

n Motor control centers

n Electrical substations

n Transformers



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ThermographyThermography Uses Uses --Mechanical ComponentsMechanical Components

n Bearings

n Drive belts

n Steam lines and traps

n Piping insulation

n Valves

n Refractories

n Heat Exchangers



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ThermographyThermography Uses Uses --Structural ComponentsStructural Components

n Roofs

n Building Insulation

n Storage Tanks



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n Infrared Camera or Gun

n Software program– route description and tracking– data collector

– field analysis

n Report generator and data storage

What’s NeededWhat’s Needed

Thermographic Analysis



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n Fairly expensive (50K and up)

n Limited mechanical troubleshooting

n Cannot read through glass or metal covers

n Data affected by reflective nature of surface

LimitationsLimitationsThermographic Analysis

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Advantages and Pay BacksAdvantages and Pay Backs

n Particularly good for large, distant, or hazardous applications

n Camera operations relatively easy

n Only a moderate amount of training needed

n Service companies readily available

n 12 month or less cost recovery

Thermographic Analysis



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IR Web Page ResourcesIR Web Page Resources

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Academy of Infrared Academy of Infrared ThermographyThermography((www.www.infraredtraininginfraredtraining.net.net))

nLevel I, II, and III certification information and training schedule.nOnline store (books, software, videos)nOnline resources (links, image gallery,

message board)nCommunication (classifieds, news,

industry related informationnCompany profile and contact information



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Snell Infrared Snell Infrared ((www.www.SnellinfraredSnellinfrared.com.com))

nTraining and course information

n Industry Links

n IR Library

nNews Letter

nClassifieds

n IR Application Information

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FLIR Systems FLIR Systems ((www.www.flirflir.com.com))

nProduct Information

n Image Gallery

nApplication Overview with Images

nUsed Camera Source



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Vibration AnalysisVibration Analysisn Foundation of rotating machinery

predictive maintenance n Involves measuring the forces created

from vibrationsn Non-intrusiven Most widely known PDM technology

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Insert Applicable sectionInsert Applicable sectionof CSI Videoof CSI Video



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UsesUsesn Pumps

n Motors

n Compressors

n Gear Boxes

n Diesel Engines

n Gasoline Engines

Vibration Analysis

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Failures DetectedFailures Detectedn Defective bearings

n Mechanical looseness

n Worn/Broken gears

n Shaft misalignments

n Out of balance conditions

Vibration Analysis



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What’s NeededWhat’s NeededVibration Analysis SystemVibration Analysis System

n Vibration Sensor– Accelerometer– Velocity Probe– Displacement Probe (permanent installations)

n Signal Acquisition Unit– Signal recording device– Signal analyzer– Analysis software– Computer

Vibration Analysis

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LimitationsLimitationsn Fairly expensive (20K - 50K)

n Fairly complex: Training is required

n Limited application (Rotating Machinery)

n Requires additional staff resources

Vibration Analysis



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n Measurements easy to take

n Considerable cost reductions due to ...– Reduction in machine overhauls– Extended operations

– Increased availability

n 18-24 month cost recovery

Vibration Analysis

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Vibration AnalysisVibration AnalysisWeb Page ReferencesWeb Page References



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www.www.reliabilitywebreliabilityweb.com.comfree stufffree stuff

free onfree on--line vibration trainingline vibration training

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www.plantwww.plant--maintenance.commaintenance.com

nTraining Material

n Industry Links

nFree Software– FFT/CMMS/Inventory Control

nTechnical Articles

nMaintenance Related Articles



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www.bk.dk.comwww.bk.dk.com

nProducts

n Industry Articles

nLinks

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www.www.skfusaskfusa.com.com

nReferences and Links

nArticles

nProducts

nTraining– Classes/schedule/prices



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Ultrasonic AnalysisUltrasonic Analysisn Ultrasounds are detected utilizing

an ultrasound scanning device.

n Changes to a component’s ultrasonic signature are easily recognized as the component begin to wear and deteriorate.

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UsesUses

n Steam systems

n Compressed air/pneumatic systems

n Hydraulic systems

n Vacuum systems

n Bearings

Ultrasonic Analysis



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What’s NeededWhat’s Needed

n Ultrasound scanning device.– Handheld device usually with two modes:

• Scanning• Contact

– Ultrasounds are processed into the audible range for monitoring by the technician.

– Most effective when scanned close to the equipment being inspected.

– Increasing the sensitivity can allow scanning from a longer distance.

Ultrasonic Analysis

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n Moderate cost.(1K to 10K)n Simple to usen Savings potential is great

– Air leak identification– Steam trap leaks ($2000 per year can be

lost from a single trap)

n Pay back in one year or less

Ultrasonic Analysis



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Ultrasonic Ultrasonic Web Page ResourcesWeb Page Resources

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CSI atCSI atwww.www.compsyscompsys.com.com

nSound library

nApplication papers– Fundamentals of Ultrasonics

nProducts



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www.www.uesystemsuesystems.com.com

n Technology Overviewn Trainingn Links ****n Sound Demos

– Bearings– Traps– Air Leaks– Arcing– Corona

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Oil AnalysisOil Analysis

n Oldest predictive maintenance technology

n 50% of bearing failures are lubricant related

n Can detect machine faults up to two months before vibration analysis



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Oil AnalysisOil Analysis

n Monitors three conditions

– Lubricant condition

– Lubricant/Oil system condition

– Machine condition

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Oil AnalysisOil AnalysisAdvantages and Pay Backs Advantages and Pay Backs

n Simple

n Fairly Inexpensive

n Ease of trending

n Extremely effective

n 12 month or less cost recovery



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Oil Analysis Oil Analysis Web Page ResourcesWeb Page Resources

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Insite Insite Services atServices atwww.www.testoiltestoil.com.com

nFree sample kit

nFree oil analysis

nTest type overview

nOn-line sample results



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www.www.compsyscompsys.com.com

nOil analysis products

nTraining

nLibrary

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Other Benefits of Using Other Benefits of Using PDM TechnologiesPDM Technologies

n Identification of improper maintenance practices

n Identification of improper operating practices

n Identification of poor equipment designn Identification of excessive operating

conditions



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DSOMDSOM

Another Tool

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Play DSOM CD Play DSOM CD



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PDMPDMWeb Page ReferencesWeb Page References

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Maintenance TechnologyMaintenance Technologywww.www.mtmt--online.comonline.com

nMaintenance related articles for past three years

nProduct supplier information:– CMMS

– Predictive Maintenance Technologies



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www.plantwww.plant--maintenance.commaintenance.com

nTraining Material

n Industry Links

nReference Material

nFree Software

nTechnical Articles

nLinks

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www.www.reliabilitywebreliabilityweb.com.com

nArticlesnLinksnReferencesnOn-line chat and bulletin boardnFree Stuff!

– Audits / Training/ Software/ Oil Analysis– Maintenance surveys, etc.



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SummarySummarynPredictive maintenancenPredictive maintenance technologies

– Thermography– Vibration Analysis– Oil Analysis– Ultrasonic Analysis– DSOM

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Workshop Outline (PostWorkshop Outline (Post--Work)Work)

nO&M Ideas– Steam systems– Chillers– Cooling Towers– HVAC systems– Air Compressors– Pumps– Drives



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Contact InformationContact InformationRay PughPacific Northwest National LaboratoryP.O. Box 999MS K5-20Richland, WA 99352(509) 372-4103fax (509) 372-6459email [email protected]

Greg SullivanPacific Northwest National LaboratoryP.O. Box 999MS K8-17Richland, WA 99352(509) 372-6212fax (509) 372- [email protected]

Documents

Operations and Maintenance Management … · Energy Management Teleworkshops March 2001 Operations and Maintenance Management Page 8 LOGOFY2001 Thermographic Analysis nFoundation