Simple Predictive and Preventive Maintenance: Your Roadmap to Machine Wellness by Dale Nicholson, PE, CMRP,CRL Reliability Engineer, Tate & Lyle “Digital Tools for Manufacturing” November 20, 2019
Plant Reliability Dale C. Nicholson, PE, CMRP, CRL November 20, 2019
Proactive vs. Reactive Proactive: That motor has a bearing defect, let’s stage a spare and dedicate a crew to swap it out during the next planned outage. Reactive: That motor stopped running and we’re not making product. Hurry and get it fixed NOW!
When Do You Change Your Tires? When they’re new? That would obviously be a waste of money. When they have no treads left? They are still functional, and may have many miles left in them. However, the loss of traction may leave you or your loved ones stranded, with a wrecked vehicle, or worse yet, injured. Do you run them right down to the wires, getting every last penny out of them? Do you assume that they will blow out at a convenient time and place? Or do you consider that risk unacceptable?
At the Doctor’s
What, exactly, is your point?
Oil Storage & Handling • Filtration • Clean, enclosed, dedicated containers • Label containers and reservoirs • Sight glasses • Desiccant breathers Esco 3D Bullseye, $30
Oil Analysis (OA) • In-house oil lab: $100,000 • Oil sample (external lab): $30
Engineering Flowchart
Ultrasound Energy (UE)
Air Leaks Cost of air leaks, 100 PSI system pressure, $.07 per KWH Leak Diameter Annual Cost 1/64" $ 49 1/32" $ 196 1/16" $ 785 1/8" $ 3,143 1/4" $ 12,572 3/8" $ 28,288 1/2" $ 50,169 5/8" $ 78,456 3/4" $ 112,909 7/8" $ 153,770 1" $ 200,795 11
Bearing Examples Bearing A Bearing B Grease added to motor bearing Tool for airborne & contact UE: $3,000 12
Infrared (IR)
Infrared (IR) • FLIR One $200 • FLIR C2 $450 • FLIR E6 $2,000
Strobe • Couplings • Belts • Should have 2% - 4% slip • Rolls • Shafts • Anything else that moves https://empoweringpumps.com/a-coupling-inspection/ $600 15
Vibration Analysis (VA)
Motion Amplification Video (MAV)
Motor Circuit/Electric Signal Analysis (MCA)/(ESA)
Predictive Tools
But Wait, There’s More! • Look at assets regularly • Check for: • Loose bolts • Oil leaks • Plugged cooling vents • Odd noises or smells • Jog equipment monthly 20
PF Curve
Bearing Failure Bearing surface spalling – a common failure mode • Fatigue cracking, caused by compression/tension cycles. • Microscopic cracks form below the metal surface. • Eventually they grow to the point where the surface flakes off. • Once spalling starts, it is likely that there are many other cracks around the • ball path surfaces. It will continue until the bearing is thrashed. • http://www.me.metu.edu.tr/courses/me5 60/Wear.htm 22
Bearing Failure Asphalt wikipedia.org Steel http://www.me.metu.edu.tr/courses/ me560/Wear.htm 23
PF Curve Lubrication & precision maintenance (laser alignment) extend the green line – the time before failure is initiated.
Nowlan & Heap
Nowlan & Heap
Preventive Maintenance (PM) • Wear and failure modes: What can go wrong? • Use PdM technologies and running inspections to watch for those defects/potential failures • Establish PM procedures to address remaining wear & failure modes • E.g. use gauges to check belts & sheaves • Check maintenance manual for additional PM items • Wear components • Clearance settings/adjustments 27
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