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An Introduction to Condition Based Maintenance (CBM)
An Introduction to Condition Based Maintenance (CBM)An approach to CBM Application and Management by: GAA Optima 4 July 2012 1
The CBM PhilosophyIt is about utilising the Condition Monitoring technologies topredict the failure pattern(s) of an asset.This will allow maintenance to be scheduled based onequipment condition and not time. 4 July 2012 4 July 2012 2
The Vision is to attain:Meaningful set of maintenance schedules (TechnicalBasis of Maintenance - TBoM)Improved operating performanceEnsure safety & environmental protectionReduced maintenance costsComprehensive maintenance database (Centralised)Clearer view of resource requirementsCBM attains lasting benefits & can be applied across all orjust selected equipment 4 July 2012 4 July 2012 3
The MethodologyThe strategy uses a two level approach by overlaying Techniques &technologies on monitored componentsLevel one (Short term): Identify and reduce equipment failures across site Use technologies to troubleshoot and examine poor performing assets Energy usage examinationsLevel Two (Medium to long term): reduce maintenance exam tasks, extendmaintenance exam and Overhaul periodicities (TBoM integration) Use technologies to reduce maintenance costs Effective utilisation of work force Increased knowledge of asset performance and condition Feedback into TBoM 4 July 2012 4 July 2012 4
CBM Financial Impact Easy to Labour Low on services measure Overheads profit Reliability Safety Legislation Design Scrap out Availability Catastrophic Poor failures maintenance Breakdowns & Repairs Use of skills Warranty Low Flexibility Hard to High on measure profit
Some of the CBM Technologies employed 4 July 2012 4 July 2012 6
Oil and Grease AnalysisThree dimensions: Wear Ferrous Nonferrous Contamination Dust Water Fuel Chemistry Oil Additive 4 July 2012 4 July 2012 7
Portable Vibration AnalysisWhat does it monitor?Imbalance ProblemsMis-alignment ProblemsBearing ProblemsElectrical DefectsWhere?CranesAir Compressor motorsBrake resistor / Traction cooling fansHVAC equipmentAlternatorsTurbo chargerGearboxes (wheel lathe)Electrical motorsCooling system pumpsLubrication oil system pumpsFuel PumpsDiesel EngineAxle boxes 4 July 2012 4 July 2012 8
Portable Ultrasonic AnalysisWhat does it monitor?Air Leak ProblemsElectrical ProblemsMechanical ProblemsLocation?Leak DetectionValvesAir supply linesFlexible hosesPneumatic systemsPressurised systems ElectricalVacuum system problems Arcing DetectionCompressor MechanicalSteam Traps Bearing defects Lack of Lubrication Over Lubrication 4 July 2012 4 July 2012 9
Portable Thermography AnalysisWhat does it monitor?Electrical ProblemsMechanical ProblemsPipework ProblemsProblems detected?Electrical ProblemsHigh resistance connectionCorroded / hot connectionsEarth returns – Higher loadingRelay problemsInternal fuse damageInternal circuit breaker faultCracking insulationOverload or unbalanced loadBusbar faultsCouplingsCooling jackets 4 July 2012 4 July 2012 10
Questionsabas@gaaoptima.comWill be happy to answer 4 July 2012 11