PREDICTIVE TECHNOLOGIES

TEL:+234 (0) 1 3423761

EMAIL: [email protected] WEB:
dexnovaconsulting.com
 Predictive Technologies
Oil Analysis
Wear Particle Analysis
Vibration Analysis
Thermography
Mechanical Ultrasound
Motor Circuit Evaluation (MCE)
Non Destructive Testing (NDT)
 Predictive Maintenance
✓Reduces collateral damage
✓Time to plan the work (35% more efficient)
✓Time to do the correct maintenance
✓Time to have correct parts (no expediting)
✓Time to do precision maintenance
✓Less spare parts – 30% less
✓More efficient use of maintenance time
✓Less Emergency Downtime
✓Repair work can extend equipment life
✓Safer work conditions
 Predictive Technologies
“The Silver Bullet Theory”

Is there one Technology that will work for

all failures?

How do I know which one to use?

We must control costs and make sound

decisions!
 Predictive Technologies
Oil analysis can not detect coupling
misalignment.

Vibration analysis can not detect depleted

lubricant additives.

Thermography can not detect imbalance.

 Predictive Technologies

When selecting the correct predictive

technology you must understand what specific
failure mode you are trying to find.

The cost of the technology can not be

more than the cost of the potential true
downtime or failure.
 OIL
ANALYSIS
 Oil Analysis
What are we looking for?

• Moisture
• Oxidation
• Additive Depletion
• Particle Counts
• Viscosity
• Acid or base number
Moisture:

The number one destroyer of lubricating oil.

Must be monitored and controlled!

Every oil test should include moisture

Moisture:

Check for moisture in new oils

Should be less than 1/10th of 1%

Monitor increases in moisture on

operating equipment. Start reacting when
level increases or at 1%.
1-2 ounces of water in a 55 gallon drum
can reduce bearing life by 50%
Tests Limit of Detection Test Cost Advantages
Disadvantages
Crackle 1000 ppm (0.1%) low A good field indicator, easy to
perform qualitative only, not suitable for trending
FT-IR water 1000 ppm (0.1%) low quantitative, good for
trends, easy to perform other liquid contaminants (glycol)
present can confuse the spectrometer.
Centrifuge 1000 ppm (0.1%) low Still widely used for fuels
testing and the BS&W tests not as effective nowadays because
of demulsifier additives
Karl Fischer 10 ppm (0.001%) low The best test for low
moisture levels. Very accurate. Required for turbine systems &
transformers Unless lab has a nitrogen spurge, lubricant
additives may cause interference. Need some lab expertise to run
correctly.
Oxidation:

We can not stop oxidation, we can only

delay it with additives and control of
conditions.
Increased oxidation occurs from high
temperature, moisture, and contaminants.
Additive Depletion:

If we know what additives are in our

lubricating oils we can test for them.

When they are depleted the lubricating oil

will start to loose it’s lubricating capability.
Particle Counts:

Total particle counts tell you if the oil is

gaining in particles or the equipment is
making more particles.

Particle counts in different size ranges

helps you monitor what is going on in your
equipment.
Viscosity:

The most important property of the oil and

it must be monitored closely.

Viscosity changes with moisture, oxidation,

pH changes, and with contamination.
Acid/Base Number:

This test will determine the pH of the

lubricant. Establish this number when the oil
is new and when you see a change the
lubricant is changing for some reason.
These tests show up as TAN or TBN. They
represent Total Acid Number or Total Base
Number.
 Oil Analysis

Which tests do we run?

It depends on the equipment.

Total particle counts

Particle counts in different size ranges.
Glycol test only for specific equipment
 Oil Analysis

Which tests do we run?

It depends on the environment.

➢Wet areas need more moisture analysis

➢Dirty areas need more particle monitoring
➢Hot areas need oxidation monitoring
 Oil Analysis
Perform Oil Analysis more often on highly
critical equipment.
– Monthly on some equipment, every 3 months on
other equipment.
– Some equipment never
– Get results in 24 hours on critical equipment. 3
days on less critical items.
– Establish your alarm points!
 Oil Actions

What if oil or grease is found to be in an

alarm state and shutdown is not possible?
Oil can be drained and good oil added,
Pumps reservoirs can be changed on the run if
care is taken.
 React to what the analysis results are
telling you.

Plan your work strategy to keep the

lubricant in top condition. If you have moisture
eliminate it, if you have particles eliminate
them.
The technology will run $25-$50 per
sample.
WEAR PARTICLE

ANALYSIS
 Wear Particle Analysis
This predictive technology looks at the
particles in our lubricants and tells us what
they are.

Are they dirt from your process, dirt from

the process next door, or are they pieces of
bearings or gears from your equipment?
 Wear Particle Analysis

A technology called Analytical

Ferrography can actually look at the particles
and give you pictures. You can see wear
pieces, rust pieces, and other foreign material.
Slides of engine particles on new startup and normal operation
 Wear Particle Analysis
Expense:

Wear particle analysis is more expensive.

Perform these analysis based on results

from oil analysis.
 Wear Particle Analysis
Make sound decisions on what equipment
to use this technology.

Use asset criticality or let the RCM process

guide your decision.

How often to run them is again based on

previous tests or the asset itself.
MECHANICAL

ULTRASOUND
 Mechanical Ultrasonic Inspection
Ultrasonic inspection equipment has been
available and in use since the early 80’s. There is
an operation in Sidney, Ohio that has used this
technology since the early 80’s with excellent
results. This plant used the Ultrasonic unit on all
motor bearings and bearings on attached
equipment. They reduced their unplanned
downtime by 60% just using this technology. This
worked by setting a base line for failure action.
ULTRAPROBE
ULTRAPROBE
 Mechanical Ultrasonic Inspection
How does it work?
– Can pick up frequencies in the range of 20 to 100
Hz.
– Can be used on many applications in any plant
process.
– Can be used in noisy areas.
 Mechanical Ultrasonic Inspection
What are the uses of this mechanical probe device:

Use it to check individual bearings

Use it to listen to gearbox internals
Use for lubrication
Listen as you pump in grease, stops over greasing
Use it to know when to grease
Use to determine how bad is the component
Mechanical Ultrasound
 Airborne Ultrasound Imaging

• Now, what if we hear a sound that does not

conform to the “good” condition?
• Let’s listen to two samples.

Sample 1 Sample 2
 Airborne Ultrasound Imaging
•A compressor valve opens and closes rapidly. In good
operating condition, what type of sound do you think it would
make ?
• Let’s listen

• Was that what you thought it

would be?
 Airborne Ultrasound Imaging
• What do you think a leaking
compressor valve would
sound like?

• Did that seem obvious?

• If not, lets view the spectra of
the good compressor valve
versus the leaking valve.
 Good Valve – Bad Valve

Time series view of a Good Time series view of a Leaking

Compressor Valve. Note the Compressor Valve. Note the
short “open” moment. prolonged “open” moment.
 Airborne Ultrasound Imaging
Electrical equipment can provide warning signs
acoustically as well as thermally. Incorporating the
“Audiolizing” concept with the inspection can help us
understand the severity of the condition.
>38.5°C

35.0

30.0

25.0

<22
 Airborne Ultrasound Imaging

Most often, when inspecting electrical

equipment with ultrasound, one would expect
to hear little to no sound.

When sound is heard, it is important to

know what might be considered “inherent” to
the equipment and what could require further
examination.
 Airborne Ultrasound Imaging
Corona, as we know, does not show up with
typical IR scans, but can be heard with
ultrasound.
What sound quality would you “Audiolize” for
corona?
 CORONA
• Glow or Electrical
Discharge Around
Conductors
– When Surrounding Air is
Stressed Beyond its
Ionization Point without
Developing Flashover.

MPEG

Corona Seeks a Path to the Ground.

This Is a Night scope Image Of Corona
Corona
 Airborne Ultrasound Imaging
• This is a spectral view of Corona. Note the constant
harmonics of 60 cycles throughout the spectra.
 Airborne Ultrasound Imaging
Here’s what Tracking looks like in the time series. You can see as
well as hear the popping in real time.
 Airborne Ultrasound Imaging
Arcing is an even more
severe condition than the
other two. Failure is
occurring.
What sound quality do you
“Audiolize”?
Arcing contains uneven,
almost violent starts and
stops.
Note the harmonics of 60
cycles are fewer than the
previous examples. Also note
the frequency content
between spikes.
 Airborne Ultrasound Imaging
What about enclosed transformers? They are difficult
to IR without IR Windows or removing covers. Most of
them hum (because they don’t know the words).
If you know your transformer sound, you can
“Audiolize” the sound and recognize an anomaly when you
hear it.
 Airborne Ultrasound Imaging

A technician can use the dB as a guide to

determine when to STOP applying lubrication and
prevent over lubrication.

Here is a spectra of a new motor bearing in need

of lubrication. Note how the sound level drops as
the lubricant is applied.
 TYPICAL APPLICATIONS
PRESSURE/VACUUM LEAKS (TURBULENCE) MECHANICAL INSPECTION
COMPRESSED AIR BEARINGS
OXYGEN LACK OF LUBRICATION/FAILURE
HYDROGEN ETC. PUMPS
HEAT EXCHANGERS MOTORS
BOILERS GEARS/GEAR BOXES
CONDENSERS FANS
TANKS COMPRESSORS
PIPES CONVEYERS
VALVES
STEAM TRAPS
ELECTRIC EQUIPMENT
(Arcing/tracking/corona)
SWITCHGEAR
TRANSFORMERS
INSULATORS
POTHEADS
JUNCTION BOXES
CIRCUIT BREAKERS
 Case Study
Monitoring of air diaphragm pumps on
sulfuric acid. Could be checked from 30 ft to
hear one of the pumps bypassing.
Over lay of multiple pumps to compare.
Noise from flat screen monitors causing
headaches.
Ultrasonic pest controllers affecting people
and animals.
Mechanical Ultrasonic Inspection

The unit can record the following:

1. A number value based on

ultrasonic reading.
2. A visual chart of sound wave.
3. An actual sound bite of the
component..
Mechanical Ultrasonic Inspection

The equipment can be purchased with a

sound library for comparing your sound bites.

Examples from sound library.

 Mechanical Ultrasonic Inspection
This technology can be used by anyone with
little training. Does have Level 1 and Level 2
certifications but can produce effective results
with one training session at the plant level.
Instrument can be purchased and if used
regularly has less than one year payback. With
level 1 training will payback 10 times the
investment.
 Mechanical Ultrasonic Inspection
Equipment can be purchased and used in
house or bring in an outside service to quickly take
readings. Results can be quickly checked against
baseline and repairs planned.

Can be used on all mechanical, electrical, and

pressurized systems.
Si1z0e0PoSIfand1C8cuenbtsi/cMCF,opCerautibngic8760hoDurso/ylelaarrs/ Dollars/ Dollars/
Leak ft/min ft/day day month year
1/64 .45 576 $.10 $3.00 $36.00
1/32 1.60 2304 $.40 $12.00 $144.00
3/64 3.66 5270 $.95 $28.50 $342.00
1/16 6.45 9288 $3.70 $49.50 $594.00
3/32 14.50 20,880 $4.65 $112.50 1500.00
1/8 25.80 37,152 $6.70 $201.00 2412.00

3/16 58.30 83.952 $15.10 $453.00 5436.00

1 /4 103.00 148,320 $26.70 $801.00 9612.00

5/16 162.00 233,280 $42.00 $1260 15,120

 Case Study
Herman Miller Furniture Company saved
$247,000 at 3 plants by eliminating air and
argon leaks.

They have 40 locations worldwide. Are

they more competitive?
 Mechanical Ultrasonic Inspection

New advances in equipment.

– Noise signatures from failures
– Grease gun Ultrasonic.
– Specialized attachments for use in all areas.
– Pipe attachments for leak detection.
 Mechanical Ultrasound
Excellent Technology

This predictive tool can guide the use of

some of the other predictive technologies.
Set alarm points and react to what they
are telling you to do.
 Thermo-graphic Analysis

What can a guy running around the plant with a

thermo imaging camera possibly tell me?
 Thermo-graphic Analysis
The number one use for these cameras in the
past was energy conservation. In plants where
equipment is insulated to retain the heat of the
process these camera can detect bad insulation
and hot spots.

Energy is very expensive and these cameras

can detect heat release and have a good payback.
Building heat loss can also cost a lot of money to
plants and can be detected.
 Thermo-graphic Analysis

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 don’t go away and
usually lead to downtime or possible fires.
The cameras are non contact making them
safe to use around rotating equipment.
 Thermography
Thermography cameras pick up infrared in
the range of 9-12um. This is an invisible range
to the naked eye.
What you Can See
 Emissivity
Is a material property based on color and material
composition.
It is a correction factor that needs to be
understood to get accurate results from the
camera.
Example:
Blackbody = 1.0
Perfect reflector = 0
Other bodies = 0 to 1.0
 Emissivity
Examples:
➢Paint = .90
➢Stainless steel = .85 (weathered)
➢Stainless steel = .75 (polished)
➢Copper = .70 (oxidized)
➢Copper = .25 (polished)
➢Steel = .79 (oxidized)
➢Aluminum = .03 to .35 (clean or dirty)
 Camera’s
The Hotshot is made by Electro physics.
It is very versatile and has many good characteristics
for ease of use and function.

Hotshot LT Hotshot XL

Electrophysics.com
Thermo-graphic Analysis
Hot Connection
Thermo-graphic Analysis
Electrical Thermo
Transformer

Transformer under a load

Thermo-graphic Analysis
PC Board Fault
 Thermo-graphic Analysis
Other uses of the Thermo-graphic
technology is finding mechanical issues that
sometimes go undetected. In a few hours at a
fairly large facility the following mechanical
potential failures were found.
Would these failures have been found with
normal operator/maintenance inspections
before failure occurred?
Thermo-graphic Analysis
Thermo-graphic Analysis
Thermo-graphic Analysis
Thermo-graphic Analysis
Thermo-graphic Analysis
Thermo-graphic Analysis
Motor winding issue
Bearing Failure
Thermo Graphic Analysis
127.0°F

120

100
SP01: 128.3°F

80
78.4°F
 Thermo-graphic Analysis
Anything that is generating heat is using
plant energy. Like we will discussed later,
coupling misalignment can be 3-7% energy
costs. Belts alignment can be 2-3% energy costs.
Electrical shorts and hot spots are energy loss
plus safety.
With this technology you find them fast and
can get them corrected before the technician
returns in 2-3 months.
 Thermo-graphic Analysis
The equipment is very expensive and there are
a lot of variables in the correct operation. Again
these technicians are highly trained and certified.

Stainless steel, color, wind, and sun all have an

effect on the readings.
Great tool to watch for trends over time.
Some camera’s will shut down in very hot
environments
 Thermo-graphic Analysis
What equipment do we use this technology?

Can be used on any and all processes!

Can be done every two or three months and
compared to earlier results.

Only keep documentation of problem areas.

 Thermo-graphic Analysis
Thermo Camera’s have many applications
and uses in industry for energy savings, process
detection, and documented information.

The cost is high for the camera systems but

can be rented from companies to gather your
information and keep records.
 Thermographic Analyst
Technician:

Make sure the technician has been trained

and certified.
Make sure he has good equipment, time,
date, temperature bar, reporting system.
Understand wind, color, and material
issues.
 Thermo Reporting
What are we looking for?

Changes in temperature from last report.

Alarm set points on specific equipment
types.
Don’t waste time with equipment that is
below alarm.
 Thermographic Analyst
Should you own a camera or get the
service from an outside vender?

Cameras are getting cheaper

Call in the experts after seeing problems.

Get some training on be efficient in the

technology.
VIBRATION

ANALYSIS
 Vibration Analysis
All items in a process have a natural
frequency.
In vibration it is key to baseline machinery
frequencies and amplitudes to determine
machinery health and to recognize if something is
changing.
Baselines should always be gathered on new
equipment after a short run-in period.
 Vibration Analysis
Vibration Analysis is a predictive technology
that if performed correctly gives more detailed
information than any of the other technologies.
Vibration analysis is an art, and to take full
advantage of this technology you must used highly
trained technicians. We don’t just want to know its
vibrating, we want to know from where and how
much.
Lets look closer at this Technology
 Vibration Analysis

As we look at this predictive technology,

remember, we are only discussing the basic’s. I
recommend you do more reading and
training. Or hire companies that are highly
experienced in this field.
 Vibration Analysis
Common Vibration terms:
– Amplitude: Amplitude is how much movement
occurs, also called displacement. 1 mil = .001 of an
inch.
– Frequency: How often the movement is occurring.
In relationship to RPM or CPM.
– Phase: What direction is the movement occurring.
Vertical, Horizontal, Axial.
 Vibration Analysis
What can Vibration Analysis tell us?

Imbalance - 1 x RPM is usually imbalance

Misalignment - 2 x RPM is usually misalignment
Looseness - 3 x RPM is some form of looseness
Loose bolts, loose base, cracked base, bad
clearances, or possible resonance.
 Vibration Analysis

Other frequencies may relate to

component part design, bearing frequencies,
or electrical phase.
Vibration Analysis
 Vibration Analysis
Example:

If you have a centrifugal pump and it has 5

vanes on the impellor, you will likely see a spike
at 5 times RPM.

Electrical and bearing problems vibrate at

different frequencies than exact multipliers.
 Vibration Analysis

Vibration Analysis can detect:

– Coupling wear
– Bearing wear
– Structural looseness
– Gear wear
 Vibration Analysis Detects
Belt wear and looseness Bent Shafts
Cracked gears Chain looseness
Cavitation Bearing bore problems
Sheave run out Resonance
Oil Whirl Which gear is bad
Which bearing is bad Motor rotor pass
 Vibration Analysis

As we look at the next slide we need to

understand the internal components.

What size bearings

How many teeth on the gears
How fast they are turning
Vibration Analysis Detects
 Vibration Analysis
How to determine technicians knowledge:
– Ask about his certification level
– Ask about his companies technical support
– Does he ask you specific questions about your
equipment?
– Does he ask you about equipment load?
– When he is complete does he give you
recommendations?
 Vibration Analysis
Certification Levels
Novice – Able to take some readings and detect
problems.
Level 1 – Trained and certified on how to take
readings and able to interpret some data
Level 2 – 3-5 years experience as Level 1 and
certified to interpret data form readings.
Level 3 – 3-5 years experience at Level 2 in reading
data and certified in technical interpretation.
Level 4- new certification level in last two years,
mostly level 3’s grandfathered, everyone else to be
tested and certified.
 Vibration Analysis

Will the vibration Technician always be right in

his prediction of vibration cause?
Impact of Vibration Reduction on Bearing
Life
Percent Increase in Bearing Life
Ball Bearing Other Rolling Element
Percent Reduction in Bearings
Vibration

5 17 19

10 37 42

15 63 72

20 95 110

25 137 161

30 192 228

40 363 449

50 700 908
 Vibration Analysis
– What equipment do we perform vibration analysis?

– Determine your critical assets. What equipment will

have major costs or consequences if it unexpectedly
down?

– Do I need to know in advance of a failure?

MOTOR CIRCUIT

EVALUATION
 Motor Circuit Evaluation
This technology has other names such as
Motor Circuit Analysis and Motor Circuit
Testing.

All of them serve the purpose of giving you

information on the insulation and winding
conditions of the motor.
 Motor Circuit Evaluation

The technology in the last 2 years has

made dramatic improvements in the
information that can be acquired from the test
results.
Motor Theory
The Polyphase Induction Motor

Stator Stator Rotor

Windings Laminations Bearing

Fan
 Interaction of Rotor Field and
Stator Field
Interaction of Two Magnetic Fields

Electrical Energy
to
N Mechanical Torque

Rotor Field Stator Field

S
 MCE Motor Testing
Motor Circuit Evaluation

How can I use his technology?

Two methods of testing

Off-line
On-line
•
ALL TEST
Stores over 500 motors with
IV PRO™ Features
test results
• Automatically compares
stored references with results
• Automatically measures:
Resistance; Impedance; Phase
Angle; Inductance; I/F; and
Insulation
• Detects turn to turn faults at
early stages
• Includes Software for
download to PC and trending
• Light weight and hand held:
4.8” x 9.92” x 2”, 1.7lbs
• Non-Destructive, Repeatable
Testing
• Safe Use
• All test results in Engineering
Units
Testing Equipment
The Six Electric Fault Zones are:

1. Power quality

2. Power circuit

3. Insulation

4. Stator

5. Rotor

6. Air gap
 MCE Motor Testing
Off Line Testing

This can be used to test your spare motors

and verify motor rebuild specifications.

You can also specify these tests be

performed and certified on your rebuilt motor
coming from a motor rebuild shop.
 MCE Motor Testing
Test and Parameters:
Resistance to ground
Capacitance to ground
Phase resistance and imbalance
Phase inductance and imbalance
Air gap
Insulation quality
 MCE Motor Testing
Conductor Path Resistance

Less than 2%- Expected and acceptable

Greater than 5%- Plan troubleshooting to find the
problem
Greater than 10%- Schedule effort to locate
problem to extend motor life
 MCE Motor Testing
Inductive Imbalance
Less than 10% acceptable from OEM or Rebuild
shop.
10-15% acceptable in operation
Greater than 15% Isolate cause, increase checks
Greater than 25% begin planning repair/replace
Greater than 40% Failure within weeks
 MCE Motor Testing
Capacitance Imbalance

Tells us we have moisture or dirt in motor

circuit components.
– Happens with storage methods, dirty operations,
over greasing, and wet area start/stop operations.
 MCE

Uneven voltage and uneven current flow

can destroy electric motors and VFD’s

Always check incoming and outgoing

voltage and current from VFD’s.
 Phase Angle (FI)

Phase angle on all 3 phases should be off

no more than 1 degree.
Stator and Rotor Reliability

Causes of Motor Failure

Rotor
Failures
10%
Bearings
Stator 41%
Failures
37%
Balance
and
Alignment
12%
 MCE Motor Testing
On-line testing

Testing of the motor and wiring while the

equipment is in operation. A lot of the same
testing and more can be performed. These tests
results can help us determine when a motor
failure may occur months before it happens.
Safety Precautions!!!
 Rotor Testing
• Flux linkage across
airgap
• Inductive balance
depends on rotor bar
and winding location
• Detects: Broken rotor
bars; poor airgap;
voids in rotor casting
 Rotor bar failures
Rotor bar failure on the left may not be as serious due to closed design of rotor

Rotor bar failure on the right may be very serious since rotor bar can shift and rub
on stator
 Air Gap

The first type is called static eccentricity.

Figure 1 and Figure 2 show an example of
what static eccentricity looks like,
physically and inductively. This type of
eccentricity is caused by problems like a Figure 1
misaligned endbell or the shaft sitting low
in the bearing. The physical result is that
the shaft is always in the same place out of
the electric center.

Figure 2
 Air Gap

The second type of eccentricity is called

dynamic eccentricity. This results when the
rotor does not stay in one place but is
allowed to move within the space of the
stator as seen in Figure 1.
Figure 1

The inductive result is the movement of all

three inductance values up or down,
depending on which phase is closest to the
rotor at a given degree rotation. This is
seen in Figure 2.

Figure 2
 Did you Know your Motor Needs a Health
Checkup?
And that “Checkup” can tell you a lot about what is going on
with your rotating equipment. Motor Circuit Evaluation or
MCE Testing can detect mechanical and electrical problems
before catastrophic failures occur.
Electrical faults are responsible for nearly 50% of all motor
failures and taking proactive measures to identify and
correct these problems is an absolute necessity. MCE Testing
technology is:
✓ Comprehensive
✓ Portable
✓ Non-intrusive
✓ Applicable to any size motor
✓ Appropriate for AC or DC motors
 Items That Can be Measured
✓ Resistance-to-Ground (RTG) ✓ Capacitance-to-Ground (CTG)
✓ Phase-to-Phase Resistance ✓ Phase-to-Phase Inductance
✓ Rotor Influence Check (RIC) ✓ Insulation Tests:
✓ Average Inductance – Rotor/Stator Relationship - Dielectric Absorption (DA)
✓ Inductive Unbalance – Rotor/Stator Relationship - Polarization Index (PI)
✓ Capacitive Current ✓ Absorption Current
✓ Surface Leakage Current ✓ Conduction Current
Additional Testing Specific to DC Motors:
✓ DC Standard Testing ✓ Circuit Resistance
✓ Circuit Inductance ✓ DC Commutator Bar-to-Bar Testing
Testing Performed On-Line:
✓ Current Analysis
- Rotor -In-Rush - Air Gap
✓ Power Analysis
- In-Rush/Start-up
- High/Low Resolution Current Signature Analysis
- Power Quality
- Power Circuit
- Stator – Impedance Imbalance
- Demodulation – In Current signature Analysis
for Pole Pass Analysis
- Swirl Effect – Pole Pass Analysis
- Eccentricity – Increases Risk of Mechanical Damage
to Windings, Coils, and Insulation
 MCE Motor Testing

Some of the results from on-line testing

will just tell you that you need to disconnect
the motor for further testing.

It could be the motor or a wiring issue.

Some of the fault mechanisms that cause high
resistance connections are:
Corroded terminals
Loose cables
Loose bus bars
Corroded fuse clips
Corroded contacts
Open leads
Different size conductors
Dissimilar metals
 MCE/MCA

Can save energy dollars by finding and helping

you eliminate impedance, voltage imbalance,
and inductive imbalance.

Using this technology will pay for itself in the

early stages in energy savings.
 Using Old Motors

Old or some rebuilt motors can be used in

less critical applications, if you understand the
criticality of your equipment.
Non Destructive Testing
 N.D.T. Testing
Non Destructive Testing is a Predictive
technology that is used to find problems with
equipment from wear, corrosion, and erosion.
NDT looks for defects that would cause the
part to fail while in service. It makes sure the part
is within its specification tolerance. These checks
let you know well ahead of time of a potential
failure.
 N.D.T. Testing

This equipment is used mainly on

stationary equipment such as tanks, pipes,
boiler tubes, etc. It can be used on many
different materials, Steel, Copper, Plastics, and
other composite materials.
Other examples may be testing or
inspection of structures that support the
equipment.
Pipe Support Inspection
 N.D.T. Testing
Non Destructive Testing Methods:

➢ Visual
➢ Liquid Dye Penetrant
➢ Magnetic Particle
➢ Ultrasonic
➢ Eddy Current
➢ Radiography
➢ Modified Pulse Echo (Shear Wave Analysis) (Shafts)
➢ Hydrostatic Testing
 N.D.T. Testing
What can N.D.T. methods tells us?

➢ Cracks in vessels
➢ Erosion or corrosion of tanks/piping
➢ Weld Integrity
➢ Stress cracks
➢ Reductions in material thickness
➢ Boiler tube wall thickness
➢ Shaft material defects
We want to find these weak points before it creates a major incident
 N.D.T. Testing

Radiography
– This is an actual x-ray of the test area. It is the most
powerful of the testing methods and is the most
expensive. It is also the most dangerous for the
technician and others in the area.
– Use only on very critical equipment and when
others methods are not effective.
 N.D.T. Testing

High costs are due to safety issues and

expensive tracking of nuclear sources.

Very expensive clothing, shielding, and area

monitoring are required.

As material thickness increases radiography

becomes the only option.
Radiography
Radiography
 N.D.T. Testing

Ultrasonic testing (Imaging)

– Detection of deep surface defects. Use for checking
weld penetration and weld thickness at many
petroleum refineries.
– Does not produce harmful radiation.
– Can be used in tight areas and good for many
materials including plastics.
 N.D.T. Testing

Ultrasonic tools include an ultrasonic head that

can be used in direct alignment with the
surface and read surface thickness by measure
the return signal or strength of the signal.
This can be a direct reading on the instrument
or a data readout as visual charted data.
 N.D.T. Testing

The Ultrasonic probe can also be operated at

an angle and look at weld penetration on the
inside surface of pipe or plates.

Ultrasonic testing is strictly one dimensional.

Rust and buildup on the inside of pipes and
tanks can cause erratic readings.
 N.D.T. Testing

Ultrasonic testing of tanks and piping can

many times be completed while the systems
are in service.
Ultrasonic Testing
 Sound Energy

Sound energy will travel to the far side of a part, but reflect earlier
if a laminar crack or similar discontinuity is presented.
 N.D.T. Testing
Magnetic particle
– Used for detecting shallow defects in welds or metal
surfaces.
– Use two electrodes that produce a current between
them. Metal dust is sprinkle between the electrodes.
The dust will show cracks or breaks in the weld or
metal surface.
– Very fast testing procedure for welds and seams in
metal.
Magnetic Particle Testing
 N.D.T. Testing
Dye Penetrant
– Allows for a simple test to find surface imperfections.
– Surfaced can be cleaned, spray the dye on, wait for a
few minutes, Wipe off the excess. Some imperfections
where the dye has penetrated can be seen
immediately. A developer can then be sprayed on to
help visibility of the dye.
Dye-Penetrate Testing
 N.D.T. Testing
Eddy Current
– Used mainly on surfaces to detect thicknesses of
material or imperfections in metal components.
– Can detect surface and sub surface imperfections.
– Uses coils that induce varying currents that can be pick
up with another device to show cracks and
imperfections.
– Can also be used to show coating thicknesses.
 N.D.T. Testing
Modified Pulse Echo

Shear Wave Analysis

Used on new and existing shaft material

to detect cracks in highly critical equipment not
normally found with existing technologies.
 Collateral Damage
Which Technology could have detected this failure?
Predictable Failures
Predictable Failures
 Predictive Recap
Don’t start something you don’t want to finish!

Use Predictive technologies to help you plan and

be more maintenance effective.

Don’t use them to tell you when you should

start waiting for the human senses to kick in.
Cinergy/Celanese
 Predictive Recap
This predictive training was just the tip of the
iceberg. 4-8 hour training on each of these
technologies can be set up to further improve
your knowledge on each of the technologies.
Resources in your manual will guide you to the
experts in the these areas.
 Predictive Comments
➢Understand the failure mode you are trying to
detect
➢Training to understand how to understand the
data collected
➢React to the data
➢Always take readings when equipment is
under operating load
➢Make sure the technology has a payback for
the cost of failure
 Preventive Maintenance
What is Preventive Maintenance?

Where does it fit in the curve?

 Preventive Maintenance
As you improve your knowledge and skills in
Predictive technologies, you will do less
traditional repair work tasks.
You will test the right equipment at the right
frequency.
You will replace and rebuild components before
collateral damage occurs.
 Predictive Conclusion
Conclusion
Using the correct predictive tool for the failure mode that you are
trying to eliminate is the best way to use predictive tools. Predictive
maintenance requires an integration of technologies and techniques for
accurate diagnosis. Knowledge of how equipment operates will enable an
inspector to anticipate the sounds of a normal “good” condition and
therefore determine a potential problem when there are acoustic
anomalies such as changes in sound quality or in amplitude.
Equipment such as UE Ultrasound tool and Ludeca’s vibration and
balance tool can give you early indication to make sound judgments to
guide you to your next step. Your next step may be scheduling a rebuild or
bringing in another technology with a highly trained professional to get
more information to make a logical decision.
My recommendation is to always use RCM Blitz™ to analyze all
components and determine the proper predictive or preventive
maintenance.
 Proactive Predictive Reactive
70-100 30-50 10-15

PP Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Equipment Performance

Supplier Specifications
Metrics
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS System

Time FF
RCA
Troubleshooting Analysis

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 OBJECTIVES

❑ State the reason for trouble-shooting an

equipment

❑ Describe logical trouble-shooting procedures

❑ Carryout systematic trouble-shooting

 Introduction

DEFINITION
Troubleshooting is a logical system of
investigation designed to yield the correct cause
of a breakdown within a shortest possible time
and with the least likelihood of error.
 Troubleshooting Procedure

➢ Symptom recognition
➢ Symptom elaboration
➢ Listing of probable faulty function
➢ Localizing the faulty function
➢ Localizing the faulty to a circuit or
component
➢ Faulty/failure analysis.
 Troubleshooting Steps
step step step step step step
1 2 3 4 5 6
Listing Localizing Localizing
Symptom of the trouble Failure
recognition Symptom probable analysis
faulty to the
elaboration faulty
functions
function circuit

Eyes Eyes Eyes Eyes Eyes Eyes

Ears Ears Ears Ears Ears Ears
Knowledge Knowledge Knowledge Knowledge Knowledge Knowledge
Think
Operational- Think Think Think Notes
control Notes Notes Notes Equipment-
Notes Equipment- Equipment- Equipment- diagrams
diagrams diagrams diagrams Testing-
Testing- Testing devices
devices devices Review
 Common Fault Associated with
Machinery
• Vibration
• Overheating
• Intermittent Operation
• Arcing
• Light Failure
• Leakages
• Electric Shock
 Vibration

Any equipment that has moving parts, either

rotating or reciprocating, will vibrate.
In some machinery the effect is so light that it is
negligible, in others e.g. very large compressors.
This vibration is unavoidable with machine
mounted.
 Methods of Detecting vibration

I. Feel

➢ Place the palm of the hand on the

stationery parts of the machine.
➢ Identify where the vibration
is greatest.
➢ Take care with high speed machines, as
vibration may be accompanied by
excessive heat.
 Methods of detecting vibration
II. Sound
Place a stethoscope on different stationery
parts of the machine to locate the point where
the sound is loudest.

III. Visual Indication

Place a small tin of light oil at various
points on the machine and locate the
position where the ripple pattern is
greatest.
 Method of detecting vibration
Once the location of maximum vibration has been
identified, this part of the equipment should be closely
examined for the cause.
It may be necessary to partially dismantle component parts
of a machine when locating the source of vibration.
To cure the vibration completely more than one source may
have to be located.
Vibration may be caused by:
A. Wear in machine components, such as:
i) Bearings
ii) Gears
iii) chains
Method of Detecting Vibration

B Out of balance of:

I. Mounted work-piece
II. Cutters and arbor
C. Misalignment of:
I. Shafts and couplings
II. Work centres
D. Lack of rigidity due to:
I. Insecure mounting or foundations
II. Loose machine components
III. Missing securing bolts or packing.
 Method of detecting Overheating

When a machine is running normally some heat

is generated. This will occur because of
mechanical friction (e.g at bearings)or heat loss
from electrical windings (e.g motors relays).
When a machine is overheating it must be
stopped at once and the cause investigated as it
could lead to complete seizure.
They can be detected through Feeling, Smell and
Sound.
 Causes and Rectification of Overheating

❖ MECHANICAL CAUSES
➢ Operating clearances between moving
parts too small. (Adjust the clearances)
➢ Shaft or spindle out of line to bearing.
(Adjust the alignment)
➢ Exhausted, contaminated or incorrect
grade of lubricant. (Drain and clean out the
system. Replace with the correct grade of
lubricant).
➢ Mechanical overload. (Reduce load or
correct mechanical faults).
 Causes and Rectification of Overheating

❖ ELECTRICAL CAUSES
➢ Short circuited windings caused by
insulation failure between conductors or
to earth. (Isolate circuit and refer to
instructor to determine further action).
➢ Arcing caused by faulty connections.
(Isolate electrical circuit and repair faulty
connections).
Intermittent Operation of Equipment

When equipment is switched on it will normally

operates and continuously.
Intermittent operation may be caused by a
mechanical fault in the power transmission or
an interruption of the electrical power supply.
 Causes and Rectification of Intermittent
Operation

Mechanical causes may be:

➢ Slipping belt drive.(Adjust pulley centres or
fit new belt)
➢ Slipping clutch.(Adjust clutch pressure.)
➢ Broken drive pin or key.(Remove broken
pin or key and replace)
➢ Damaged gear train or linkage.(Replace
broken component.)
 Causes and Rectification of Intermittent
Operation

Electrical Causes may be due to:

✓ Loose connections.(Re-connect faulty
connections).
✓ Broken joints.(Re-solder faulty joints)
✓ Loose fuses:(Re-bend fuse clips to hold
fuse securely.)
✓ Dirty contacts.(clean contact points)
✓ Damaged contacts.(Replace contacts)
 Leakages
❑ Liquid leaks can be detected by:
Globules of liquid at joints
Continuous drips resulting in puddles and
damp patches.
❑ Gas leaks can be detected by:
A pressure loss
Smell of escaping gas
Noise of escaping gas
 Causes and Rectification of Leakages

Leaks may be caused by:

i. Mechanical damage
ii. Corrosion
iii. Extremes of Temperature
iv. Extremes of Pressure
(Shut off supply of gas or liquid
immediately. Identify and correct cause of
fault before repairing or replacing leak
component).
 Electric Shock

A particular hazard of electrical equipment

is that metal parts may become ‘live’ due to
faulty insulation or defective earth connections.
Personal contact with ‘live’ metal parts
may allow an electric current to flow through
the body to earth, causing shock.
The severity of the shock received will vary
according to the size of the current flowing.
 Insulation/Earthed

In order that electrical equipment may be used

safely and efficiently, adequate insulation must
exist between conductors and other metal parts
which must be earthed.
Causes and Rectification of Electric Fault

Faulty insulation due to:

i) accidental damaged caused by
chafing, impact, overheating or corrosion.
ii) Fractured earth conductors.

b. Defective earth caused by:

i) Fault earth connections
ii) Fractured earth conductors
Causes and Rectification of Electric Fault

Faulty insulation due to:

i) accidental damaged caused by
chafing, impact, overheating or corrosion.
ii) Fractured earth conductors.

b. Defective earth caused by:

i) Fault earth connections
ii) Fractured earth conductors
 Proactive Predictive Reactive
70-100 30-50 10-15

PP Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Equipment Performance

Supplier Specifications
Metrics
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS System

Time FF
RCA
Maintenance Work
Management
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dexnovaconsulting.com
 Objectives

❖Maintenance Work Flow.

❖Symptom of Poor Maintenance Work Flow.
❖Role of Work Order in Maintenance Work Flow.
❖Maintenance Work Order and It types.
❖Challenges of Effective Work Order.
❖5 Rights of Good Work Order.
❖Maintenance Planning and its benefit.
 Maintenance Work Flow

“Every maintenance activity (Work Flow) has a

starting point called – OPEN and a closure called
– CLOSED. The birth of every maintenance
workflow process start from Planning/Initiate,
Work Request, Work Order, Work Order approval,
Execution/Monitoring, Assessment and closure.”

OPEN MAINTENANCE CLOSED

 Maintenance Work Flow

2 3 5 6 7

8 9 10 11 12 13

. (1) Identify Work (2) Request Prioritized/Approval (3) Work Order (4) Back –
Log (5) Plan Work (6) Schedule Work (7)Schedule posted – Parts ready &
tools available (8) Emergency Work (9) Materials Available and Tools (10)
Execute work (11) Complete Work (12)Record Job Details (13) Continue
Improvement
 Maintenance Work Flow

Work
Fracas Identification
If a step in the
process is skipped
or performed at a
substandard level,
Work Order it creates defects
Maintenance
known as failure,
Close Out the output of a Planning
healthy reliability
process is optimal
reliability at
optimal cost.
Work Maintenance
Execution Scheduling
Maintenance Work Flow Terminologies
✓ Bill of material,
✓ CMMS – Computerized Maintenance Management System,
✓ Planned Work,
✓ Coordinator,
✓ Planner,
✓ PM Scheduled – which is the number of PM work order completed to the
number of PM work order schedule
✓ Schedule compliance – Number of scheduled jobs actually completed during
the period covered by an approved daily/weekly schedule. It is expressed in
percentage
✓ Schedule work
✓ Scheduler
✓ Scheduling
✓ Turnaround
✓ Work Order and Work Order plan.
 Maintenance Work Flow

Preventive Maintenance (CBM/PdM)

CM – New works resulting from PM/CBM activities

CM – Breakdown/Emergency work – (Reactive)

Maintenance Work Flow
 Key Player in Maintenance Work Flow

The key players in maintenance work flow process

are:
1) Coordinator – Asset/Resources
2) Planner
3) Scheduler
4) Configuration specialist/System Engineer
5) Craft Supervisor
6) Work performer while maintenance/System
engineers and MRO – materials personnel plays
supportive role.
 Maintenance Work Classification

Maintenance Work task can be classified into two major

categories: Preventive and Corrective.
❑ Preventive Maintenance PM includes:
i. Time (calendar)-based maintenance (TBM) which is
equipment age related
ii. Run-based maintenance (RBM) which is equipment usage
related
iii. Condition-based maintenance (CBM – aka Predictive)
which is equipment health related
iv. Operator-based (OBM – aka Autonomous maintenance, a
pillar of TPM which is equipment operator related
 Maintenance Work Classification

❑ Corrective Maintenance (CM) includes:

i. CM - routing work resulting from PMs:
planned & Scheduled
ii. CM – Major repairs/Projects: planned &
Scheduled
iii. CM – Reactive: Unplanned/Unscheduled
– (Breakdown/Emergency)
 Maintenance Job Priority
Job priority allow ranking job work order to get work accomplish in
order of importance. Job priority guidelines includes providing a
universal method of coding all work orders in terms of:
- Plant-wide asset priorities allowing for better plant-wide
utilization of resources.
- Operations requirements
- Improvement projects.
Accurate prioritization of two distinct decision-making processes:
❑ Asset Criticality
❑ Impact of task on work to be done on overall operations
 Maintenance Job Priority
❖ Asset criticality
5 – Critical safety-related items & productive devices
4 – Critical to continued production of primary product
3 - Ancillary (support) system to main production process
2 – Stand-by unit in a critical system
1 – Other ancillary assets
❖ Work Impact, if not corrected
5 – immediate threat to safety of people and/or plant
4 – Limiting operations ability to meet primary goals
3 – Creating hazardous situations for people or machinery
but not an immediate threat
2 – Will affect operations after some time, not immediately.
1- Improve the efficiency of the operation process.
 Maintenance Job Priority

Work Priority = Asset criticality × Work Impact

An asset criticality of 5 with a work impact of 4
gives an over all job priority of 20.
While an asset criticality of 4 with a work impact
of 4 will give an over all job priority of 16.
 Maintenance Job Priority Drawbacks

o Wasted maintenance man-hour on task of low relative

importance

o Critical tasks being lost in the maintenance backlog

o Dissatisfied operation customers

o Lack of faith in the effectiveness of the maintenance

delivery function.
Function of Work Order in Maintenance
Work flow
- It is a means to register the acceptance of completed
work
- It provide a means to record equipment history
- It input data for management information system.
- Means to analyze a failure and effectiveness of
preventive/predictive efforts.
- It is used for reporting status of jobs, cost by
departments type of work versus budgeted, actual
versus estimated cost comparison, open work order
e.t.c
 Type of Maintenance Work Order
I. Planned and Schedules – These work orders are requested and
screened by a planner, resources are planned, work is scheduled and
work information is entered in computer and the work order is filled.
II. Standing or Blanket – Standing or blanket work order are used
for:
- Repetitive small jobs where the cost of processing the paper work
exceeds the cost of doing the job.
- Fixed or routine assignments where it is necessary to unite a work
order.
iii. Emergency – This is usually written after the job has been
performed.

iv. Shutdown or Outage – Shutdown or outage work order are for

work that is going to be performed as a project or when the equipment
is down for an extended period.
 Maintenance Work Order Detail
LOCATION SPARE PART LIST EQUIPMENT
DESCRIPTION

EQUIPMENT NO.
DESCRIPTION
OF WORK AUTHOURIZATION

WORK ORDER TYPE OF

SYSTEM WORK

CLASSIFICATION HISTORY
TITHLE CHARGE CODE

REQUEST FOR
WORK ORDER
NUMBER
Maintenance Work Order

MONITORING & CONTROLLING

❑Monitor all open work order

❑Monitor Due date

❑Re-assign as needed

❑Re-Prioritized
Challenges of Effective Maintenance Work
Order
➢Inadequate preventive & predictive maintenance
programme – If an organization is in a reactive mode (
“Fire fighting mode”) It has little or no time to operate
a Work Order system
➢A lack of controls for the maintenance labour
resources ( Insufficient personnel of one or all crafts,
insufficient supervision of personnel, inadequate
training, lack of accountability for work performed.
➢Inadequate stress controls.
➢Lack of performance controls.
➢Inadequate or inaccurate equipment history.
5 Rights of a Good Maintenance Work Order
1. Right People Selection - This focuses on the correct skills required
for the scope of work as well as how many and how long it will take
to complete the task.
2. Right Place – You should have an accurate identification of the
process, equipment and location to reduce travel, investigations and
set-up times.
3. Right time – It includes opportunity to gain access, along with
operations expectations of starting or completing the work.
4. Right Parts, Tools and Equipment – All repair parts should be
identified, ordered and on-hand before scheduling. Arrangements are
made for additional specialty tools and equipment.
5. Right Specifications, permits, Hazards, Work instructions and or
appropriate documentation.
 Maintenance Work Flow Management

Maintenance work management helps to:

▪ Identify and clarify the right work
▪ Prioritizing work
▪ Developing work sequence and steps to complete task
▪ Identify necessary tools, materials and skills sets
▪ Assuming un-schedule availability of materials and skill set
▪ Assuming un-schedule availability of materials and assets
▪ Schedule work to be done with agreement from
production on schedule time
▪ Ensuring details of completed work are documented in
CMMS.
 Benefit of Maintenance Work Flow Management

❑ It gives room to appropriate number of open work

orders.
❑ Work order age is appropriate
❑ Backlog may be estimated
❑ If work is completed work order is closed
❑ No duplicate of work order or maintenance work
❑ It is easy to identify backlog and assigned to a group or
a person.
❑ Work order data is complete for reporting.
❑ Maintenance know when parts are available
❑ Less breakdown thereby reducing overtime cost.
“To move from reactive to proactive maintenance,
at least 80% of work should be planned and
compliance to the work schedule should be at
least 90%”- Ramesh and Gulati
Thank You

TEL:+234 (0) 1 3423761

EMAIL: [email protected] WEB:
dexnovaconsulting.com
 TEL:+234 (0) 1 3423761
EMAIL: [email protected] WEB:
dexnovaconsulting.com