CONDITION MONITORING
PROVIDING PREDICTIVE
MAINTENANCE
Why Predictive Maintenance?
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Run to Failure > Preventive
Maintenance > Predictive Maintenance
A program to regularly inspect
machinery to detect subtle changes or
deterioration in its mechanical
condition and performance
z A philosophy: Perform corrective
maintenance only when needed
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Evolution of Maintenance
World Class
Administrator
Firefighter
Entirely reactive
Little structure
No formal planning and
scheduling
Very few performance
measures
No budgets
Limited PM
No formal Materials
Management Function
Few systems
Controller
More reactive than
proactive
Functional orientation
Daily planning and
scheduling
Performance measures
typically against budget
Cost reduction
programs
PM programs in place
Some storeroom control
Isolated systems and
cost reporting
More proactive than
reactive
Balance between
functional orientation &
customer
Weekly planning &
scheduling
Maintenance
effectiveness measures
Unit Cost Management
High compliance to PM
programs
Materials management
focus
Computerized work order
management system
Work is performed
according to plan
Multi-functional
integration and
self-managed teams
Longer term focus with
high schedule
compliance
Customer satisfaction
and total cost focus
Total productive
maintenance orientation
Ongoing assessment of
PM program
effectiveness
Total supply chain
Focus
On-line, integrated
system
Why a Predictive Maintenance Program?
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To support corporate objectives;
generate maximum revenues at minimum costs
Reduces fuel/energy costs
Reduces parts and labor
Extends time between overhauls
Increased machine availability
Increased throughput
Fewer catastrophic failures
Improved safety
Optimizes manpower deployment
What is Needed?
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Management commitment to program
Analysis equipment which matches the
analysts capabilities
Software which is easy to use
On-going training and support program
A decision on who should collect data external specialists, internal
engineers/mechanics, or plant operators
Critical Elements of Predictive Monitoring
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Consistent, frequent inspections
Detection of all significant mechanical and
performance deterioration
Integrated information
Normalized parameters
Trending for failure profile analysis
Prediction of repair - failure
Cost effectiveness
Economics
Expect program costs to increase in the
first year
z Once program becomes effective;
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Maintenance costs reduced
operating costs reduced
Increased efficiency
Increased availability
Better deployment of manpower
All of this equals increased profit($)
Example : MOST COMPLEX
Condition Monitoring on
Reciprocating Machines
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Typically these machines are on major
pipelines and are un spared
What choice of Condition Monitoring
System?..Permanent-online
Portable, battery operated real-time analyzers
Scope based, AC powered real-time analyzers
Parameters include TIME, VIBRATION,
PRESSURE, ULTRASONICS & INFRARED
measurement
Real-Time Analyzers for
Reciprocating Machines
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Portable Systems
High productivity
More condition based
information can be
collected
Takes advantage of
new technology
Trending
Historical comparisons
Population based
analysis
Scope Based
Manpower intensive
Requires AC power
High complexity
requiring extensive
expertise to operate
Reduced frequency of
analysis
Technology outdated
Compressors
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Condition Measures
Leaking valves and
rings
Rider band wear
Crosshead wear
Liner damage
Excessive frame
vibration
Lack of Rod reversal
Foundation or grout
damage
Performance Measures
Horsepower
Capacity
Efficiency
Valve dynamics
Gas pulsations
Pressure - Volume
Pressure - Time
P-T with Vibration
P-T with Ultrasonics
Health Reports
Clearance Data
Horsepower and Losses
Engines
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Condition Measures
Detonation
Misfires
Firing pressure
unbalance
Leaking valves and
rings
Worn or scored
liners
Turbo charger faults
Performance Measures
Combustion
Fuel consumption
Horsepower
Efficiency
Health Report
Pressure - Time
Pressure - Volume
Peak Pressure
Power Stroke Re-Expansion
Combustion Stroke
Exhaust
Combustion Report
Multi-Channel, Multi-Parameters
The Dynalco RT9240 and its
competitors can operate in one, two,
three or four channel mode
z Simultaneous,Any combination of
transducers
z Multi-channel stacked display
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The System advantages
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Provides easy access to system
functions
Zoom, Add Notes, Battery level
Review Data, Zero Transducer
Allows flexibility for future options
z Can be monitored using L.E.O. radio at
remote sites
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INFORMATION PROVIDED BY :
Dynalco Controls
1322 Space Park Drive
Nassau Bay, Texas 77058
713-946-9469
Dynalco Controls
3690 N.W 53 rd Street
Ft. Lauderdale, Florida 33309
800-368-6666
OTHER MONITORING STRATEGIES
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Most systems are simple and stand alone. Dynalco
uses the most sophisticated and integrates vibration,
ultrasonic, infra red and a host of pressure,
temperature and position measurements
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For normal plant use
Vibrationbasic - $1000 to advanced.$80,000
Infrared basic - $25,000 to advanced.$125,000
Ultra sound..basic - $6,000 to advanced..$15,000
Oil analysis..basic - $500 Unless at a very remote site
this is done by a specialist laboratory
OTHER MONITORING
STRATEGIES ( Cont )
Remote emissions detection $8,000/point
z Motor current analysis - $18,000
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The process will tell you about
the equipment condition !
Track and trend the parameters
Set base lines of pressures and
temperatures against ambient
conditions
z Select a couple of dozen points to be
routinely monitored on a monthly
basis
z This can be visual or measurement of
some parameter
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