1. CONDITION BASED
MONITORING
A PROJECT ABOUT PLANT PREVENTIVE MAINTENANCE
IMPLEMENTED
AT
BARNES REINFORCING INDUSTRIES (PTY) LTD

3. 1.WHAT IS CONDITION BASED MONITORING(CBM)?
•DEFINITION :
Condition-based monitoring (CBM) is
maintenance that is regularly performed
on a machine to lessen the likelihood of
the machine to breakdown.

4. BACKGROUND/HISTORY :

5. 2.WHY IMPLEMENT CBM at BRI?
• ADVANTAGES :
REDUCES MAINTENANCE LABOR COSTS.
MINIMIZE THE COST OF SPARE PARTS.
ELIMINATES MANUFACTURING INTERRUPTIONS.
PRODUCES MAXIMUM QUALITY OF PRODUCTS.
INCREASES MACHINE LIFE SPAN.

6. 2.WHY NOT IMPLEMENT CBM AT BRI?
• DISADVANTAGES :
CONSUMES TOO MANY RESOURCES.
MAINTENANCE DEPARTMENT MAY FIND IT DIFFICULT TO
MANAGE CBM AND BREAKDOWNS AT SAME TIME.
THERE IS NOT ENOUGH TIME AND MANPOWER TO MANAGE
CBM AND OTHER IMPORTANT DAILY MAINTENANCE TASKS.
IT TAKES LONG TO SEE THE RESULTS.

7. • Project aim:
To monitor the condition of rotating and heating equipment
in machines by means of condition-based monitoring and
preventive maintenance.
 To identify equipment failure which causes the machines to
experience frequent breakdowns.
3.METHODOLOGY AND OBJECTIVE FOLLOWED :

8. • SPECIFIC TOOLS USED:
TOPTRONIC T306 INFRARED THERMOMETER.
3.METHODOLOGY AND OBJECTIVE FOLLOWED :

9. •SPECIFIC TOOLS USED:
Brit IR THERMOGRAPHIC CAMERA.
3.METHODOLOGY AND OBJECTIVE FOLLOWED :

10. • SPECIFIC TOOLS USED:
SKF MACHINE CONDITION ADVISOR.
3.METHODOLOGY AND OBJECTIVE FOLLOWED :

11. • Project Objective:
1. Engineering trainees will determine the components to be
monitored.
2. The project manager together with engineering trainees
will determine the monitoring schedules for the equipment
to be monitored.
3.METHODOLOGY AND OBJECTIVE FOLLOWED :

12. • Project Objective:
3. A monitoring procedure will be determined, which will
demonstrate the methodology of conducting the project.
4. Tools for monitoring such as infrared thermometer,
thermography camera, vibration analyser and other
technologies will be determined and used by engineering
trainees for monitoring equipment.
3.METHODOLOGY AND OBJECTIVE FOLLOWED :

13. 4.LIMITATIONS OF PROJECT:
CBM took much time and sometimes produced little
results.
an urgency of continuation of production by
management, whilst machines were scheduled for
maintenance.
routine tasks were done too often than required.

14. 5.BUDGET FORECAST:
ACTIVITY COST
REGISTRATION FOR P2 EXPERIENTIAL LEARNING R 1 750
STUDENT STIPENDS * X 12 MONTHS R 67 956
PROPOSAL PREPARATION AND SUBMISSION PRINTING COSTS R 200
LITERATURE STUDY AND INTERNET PROVISION R 1 000
OFFICE EQUIPMENT R 10 000
INSTRUMENTS/TOOLS FOR TESTING PURPOSES R 20 000
ELECTRONIC/MECHANICAL COMPONENTS NEEDED R 10 000
MACHINE INSTALLATION AND COMMISSION R 57 000
LANGUAGE EDITING, ADVISE AND BINDING R 0
OTHER R 10 000
TOTAL ± R169 656

15. 6.PROPOSED TIMETABLE:
TO DO LIST….
PROPOSED CONDITION
MONITORING
REQUIREMENTS SHOULD BE
COMMENCED BY BEGINNING
OF SEPTEMBER 2016
COMPONENTS TO BE
MONITORED MUST BE
DETERMINED BY THE
END OF SEPTEMBER
2016
THE REPORT SHOULD
BE SENT IN FOR
LANGUAGE EDITING
AROUND THE ENDING
OF NOVEMBER
MONITORING
SCHEDULES AND
PROCEDURES SHOULD
BE COMPILED AND
APPROVED IN MID
OCTOBER 2016
IDENTIFIED COMPONENTS
SHOULD BE TESTED USING
SPECIALIZED TOOLS BY END OF
OCTOBER 2016

16. PRIORITY MACHINES MONITORED
1) EURA 16
2) EVG (LML)
3) HEAVY MESH LINE(HML)
4) STRAIGHT AND CUT MACHINES
5) WIREDRAW

17. Procedure:
Monitoring an electric motor for temperature and vibration
analysis
Bearing temperature
(fan side)
Coil temperature
Bearing temperature (drive side)Gearbox (overall vibration)

18. Procedure:
Monitoring an electric motor for temperature and vibration
analysis
• Step 1: Mark the points of monitoring as shown in picture
above
• Step 2: Using a condition advisor tool place the tool on the
green mark-ups to take reading of velocity(mm/s)
• Step 3: Using an infrared thermometer aim the red light
from the tool to the orange mark-up for readings of
temperature in degrees (ºc)

19. Procedure:
Monitoring an electric motor for temperature and vibration
analysis
• Step 4: Capture the readings in table form in accordance to
the colour sequence
• Step5 : Repeat step 1 to 5 until you have 3 tables for each
machine monitoring.
• Step 6:Draw a temperature VS velocity graph to analyse the
results.

21. 7.PROJECT OUTCOME:
VIBRATION ANALYSIS OF RESULTS
As the results were analysed this was the outcome:
Envelope acceleration classification 1= bearing bore diameter of
200mm-500mm = Shaft speed of 500 RPM = ALERT
Envelope acceleration classification 2= bearing bore diameter of
300mm-400mm = Shaft speed of 1800 RMP = DANGER

22. 7.PROJECT OUTCOME:
VIBRATION ANALYSIS OF RESULTS
As the results were analysed this was the outcome:
ALERT MEANS :
1) IT ‘S A WARNING THAT MONITORED COMPONENT NEEDS TO BE
CHECK IMMEDIATELY FOR FAULTS
2) WARNS THAT IT MIGHT CAUSE BREAKDOWN LATER IF NOT
ATTENDED SOONER

23. 7.PROJECT OUTCOME:
VIBRATION ANALYSIS OF RESULTS
As the results were analysed this was the outcome:
DANGER MEANS :
1) THE COMPONENT MONITORED IS BEYOND REPAIR AND NEEDS TO
BE REPLACED
2) IT IS A DANGER TO THE MACHINE , BREAKDOWN IS ABOUT TO
OCCUR

24. 7.PROJECT OUTCOME:
THE GRAPH OF ELECTRIC MOTOR PERFORMANCE

25. 7.PROJECT OUTCOME:
EVG(LML)
THE GRAPH OF ELECTRIC MOTOR PERFORMANCE

26. 7.PROJECT OUTCOME:
WIRE DRAW LINE
THE GRAPH OF ELECTRIC CONTACTOR PERFORMANCE

27. 8.SUMMARY OF OUTCOME
As a result of completing the CBM procedure we found that most
neglected mechanical faults were the main causes of major
breakdowns compared to electrical faults.
Bearings of motor posed as fault to the overall of machine due to
overheating, fatigue failure, lubricant failure, misalignment and
corrosion.

28. 8.SUMMARY (Let’s Recap!)
BRI, a manufacturing organization is faced with the problem of
experiencing maximized breakdowns.
These breakdowns are caused by lack of proper maintenance
and mechanical faults causing major breakdowns compared to
electrical faults.
 The aim was to monitor the condition of the identified heating
and rotating equipment using condition-based monitoring.
The practice of CBM is necessary to achieve reducing spare parts
cost, maintenance labour costs, maximum machine life span, etc.

29. 8.SUMMARY (Let’s Recap!)
Specialised tools such as infrared thermometer, thermography
camera and vibration analyser were used to test for temperature
and vibration.
Condition-based monitoring is focused on correction of failure
modes found in equipment of machines.
It preserves, protects and extends the life of machine
equipment.
Condition-based monitoring reduces overall maintenance
cost.

30. REFERENCE
1) Andrew K.S. Jardine , Daming Lin, Dragan Banjevic,
“A review on machinery diagnostics and prognostics
implementing condition-based maintenance” Mechanical
Systems and Signal Processing 20 (2006) 1483–1510.
2)Y. Han and Y. H. Song, “Condition Monitoring
Techniques for Electrical Equipment—A Literature Survey”,
IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 18,
NO. 1, JAN 2003

31. 10. ANY QUESTIONS ? ? ?