Operations and Maintenance Management … · Energy Management Teleworkshops March 2001 Operations...
Transcript of Operations and Maintenance Management … · Energy Management Teleworkshops March 2001 Operations...
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 1
LOGOFY2001
Operations and Maintenance Operations and Maintenance Operations and Maintenance Operations and Maintenance Management WorkshopManagement WorkshopManagement WorkshopManagement Workshop
TRAININGTRAINING
ENGINEERINGENGINEERING
ADMINISTRATIONADMINISTRATION
OPERATIONSOPERATIONS
O & MO & MINTEGRATIONINTEGRATION
MAINTENANCEMAINTENANCE
Ray PughRay Pugh
Pacific Northwest National LaboratoryPacific Northwest National Laboratory
LOGOFY2001
Workshop ObjectivesWorkshop Objectives
n Appreciate O&M and its importancen Understand the key elements of an
effective O&M programn Describe tools and technologies that
can be used in a predictive maintenance approach
n Describe some immediate O&M implementation ideas to generate energy and cost savings
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 2
LOGOFY2001
Maintenance PracticesMaintenance Practices
n The aggregate of direct and supporting actions that detect, preclude or mitigate the degradation of a system or component functionality, or restore that function to an acceptable level of performance following failure.
n See if its breaking, try and stop it from breaking, and if you can’t, fix it after its broken.
Maintenance
LOGOFY2001
Maintenance PracticesMaintenance PracticesA Closer LookA Closer Look
n Reactive maintenance (corrective)
n Preventive maintenance (PM)
n Predictive maintenance (PDM)
n Reliability centered maintenance (RCM)
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 3
LOGOFY2001
Predictive Maintenance Predictive Maintenance -- PDMPDM
Measurements that detect the onset of a degradation mechanism thereby allowing casual stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability.
LOGOFY2001
Predictive MaintenancePredictive MaintenanceA Third LifeA Third Life--Cycle AlternativeCycle Alternative
n Measuring component stress levels before they can cause a problem.– Measure component stresses (Vibration,
Thermography, Oil Analysis)
– Measure the degradation mechanism (Allignment/Balance)
– Evaluate component performance (Power consumption)
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 4
LOGOFY2001
Predictive Maintenance Predictive Maintenance AdvantagesAdvantages
n Increased component operational life/availability
n Allows for preemptive corrective actionsn Decrease in equipment or process downtimen Decrease in costs for parts and laborn Improved worker and environmental safetyn Improved worker moralen Energy Savingsn EPRI study showed a 8-12% savings over
preventive maintenance programs
LOGOFY2001
Predictive MaintenancePredictive MaintenanceOther BenefitsOther Benefits
n Eliminate most tear-down events
n Provides information to perform a root cause analysis
n Eliminate brush fire maintenance
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 5
LOGOFY2001
Predictive MaintenancePredictive MaintenanceDisadvantagesDisadvantages
n Increased investment in diagnostic equipment
n Increased investment in training of staffn Savings potentials not readily seen by
management
LOGOFY2001
Predictive Maintenance Predictive Maintenance TechnologiesTechnologies
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 6
LOGOFY2001
Predictive Maintenance Predictive Maintenance SavingsSavings
n Reduction in maintenance costs
n Elimination of breakdowns
n Reduction in downtime
n Increase in production
n Decreased spare parts inventory
LOGOFY2001
Predictive Maintenance Predictive Maintenance Technologies (PDM)Technologies (PDM)
n Thermographic analysis
n Vibration analysis
n Oil analysis
n Ultrasonic analysis
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 7
LOGOFY2001
Thermography Thermography -- What is it?What is it?
nDetection of the Infrared Electromagnetic Radiation emitted by any object at a temperature greater than absolute O.
LOGOFY2001
Insert Applicable sectionInsert Applicable sectionof CSI of CSI ThermographyThermography
VideoVideo
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 8
LOGOFY2001
ThermographicThermographic AnalysisAnalysisn Foundation of electrical component predictive
maintenance– Can be used on mechanical and structural
componentsn Based on the principle that frictional and
resistive changes result in changes in temperature
n Detection of infrared emissionsn Can be used to analyze patterns of heat loss or
gainn Non-intrusiven Non-contact
LOGOFY2001
ThermographyThermography Uses Uses --Electrical ComponentsElectrical Components
n Electrical switches
n High voltage lines
n Motor control centers
n Electrical substations
n Transformers
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 9
LOGOFY2001
LOGOFY2001
ThermographyThermography Uses Uses --Mechanical ComponentsMechanical Components
n Bearings
n Drive belts
n Steam lines and traps
n Piping insulation
n Valves
n Refractories
n Heat Exchangers
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 10
LOGOFY2001
ThermographyThermography Uses Uses --Structural ComponentsStructural Components
n Roofs
n Building Insulation
n Storage Tanks
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 11
LOGOFY2001
LOGOFY2001
n Infrared Camera or Gun
n Software program– route description and tracking– data collector
– field analysis
n Report generator and data storage
What’s NeededWhat’s Needed
Thermographic Analysis
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 12
LOGOFY2001
n Fairly expensive (50K and up)
n Limited mechanical troubleshooting
n Cannot read through glass or metal covers
n Data affected by reflective nature of surface
LimitationsLimitationsThermographic Analysis
LOGOFY2001
Advantages and Pay BacksAdvantages and Pay Backs
n Particularly good for large, distant, or hazardous applications
n Camera operations relatively easy
n Only a moderate amount of training needed
n Service companies readily available
n 12 month or less cost recovery
Thermographic Analysis
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 13
LOGOFY2001
IR Web Page ResourcesIR Web Page Resources
LOGOFY2001
Academy of Infrared Academy of Infrared ThermographyThermography((www.www.infraredtraininginfraredtraining.net.net))
nLevel I, II, and III certification information and training schedule.nOnline store (books, software, videos)nOnline resources (links, image gallery,
message board)nCommunication (classifieds, news,
industry related informationnCompany profile and contact information
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 14
LOGOFY2001
Snell Infrared Snell Infrared ((www.www.SnellinfraredSnellinfrared.com.com))
nTraining and course information
n Industry Links
n IR Library
nNews Letter
nClassifieds
n IR Application Information
LOGOFY2001
FLIR Systems FLIR Systems ((www.www.flirflir.com.com))
nProduct Information
n Image Gallery
nApplication Overview with Images
nUsed Camera Source
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 15
LOGOFY2001
Vibration AnalysisVibration Analysisn Foundation of rotating machinery
predictive maintenance n Involves measuring the forces created
from vibrationsn Non-intrusiven Most widely known PDM technology
LOGOFY2001
Insert Applicable sectionInsert Applicable sectionof CSI Videoof CSI Video
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 16
LOGOFY2001
UsesUsesn Pumps
n Motors
n Compressors
n Gear Boxes
n Diesel Engines
n Gasoline Engines
Vibration Analysis
LOGOFY2001
Failures DetectedFailures Detectedn Defective bearings
n Mechanical looseness
n Worn/Broken gears
n Shaft misalignments
n Out of balance conditions
Vibration Analysis
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 17
LOGOFY2001
What’s NeededWhat’s NeededVibration Analysis SystemVibration Analysis System
n Vibration Sensor– Accelerometer– Velocity Probe– Displacement Probe (permanent installations)
n Signal Acquisition Unit– Signal recording device– Signal analyzer– Analysis software– Computer
Vibration Analysis
LOGOFY2001
LimitationsLimitationsn Fairly expensive (20K - 50K)
n Fairly complex: Training is required
n Limited application (Rotating Machinery)
n Requires additional staff resources
Vibration Analysis
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 18
LOGOFY2001
Advantages and Pay BacksAdvantages and Pay Backs
n Measurements easy to take
n Considerable cost reductions due to ...– Reduction in machine overhauls– Extended operations
– Increased availability
n 18-24 month cost recovery
Vibration Analysis
LOGOFY2001
Vibration AnalysisVibration AnalysisWeb Page ReferencesWeb Page References
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 19
LOGOFY2001
www.www.reliabilitywebreliabilityweb.com.comfree stufffree stuff
free onfree on--line vibration trainingline vibration training
LOGOFY2001
www.plantwww.plant--maintenance.commaintenance.com
nTraining Material
n Industry Links
nFree Software– FFT/CMMS/Inventory Control
nTechnical Articles
nMaintenance Related Articles
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 20
LOGOFY2001
www.bk.dk.comwww.bk.dk.com
nProducts
n Industry Articles
nLinks
LOGOFY2001
www.www.skfusaskfusa.com.com
nReferences and Links
nArticles
nProducts
nTraining– Classes/schedule/prices
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 21
LOGOFY2001
Ultrasonic AnalysisUltrasonic Analysisn Ultrasounds are detected utilizing
an ultrasound scanning device.
n Changes to a component’s ultrasonic signature are easily recognized as the component begin to wear and deteriorate.
LOGOFY2001
UsesUses
n Steam systems
n Compressed air/pneumatic systems
n Hydraulic systems
n Vacuum systems
n Bearings
Ultrasonic Analysis
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 22
LOGOFY2001
What’s NeededWhat’s Needed
n Ultrasound scanning device.– Handheld device usually with two modes:
• Scanning• Contact
– Ultrasounds are processed into the audible range for monitoring by the technician.
– Most effective when scanned close to the equipment being inspected.
– Increasing the sensitivity can allow scanning from a longer distance.
Ultrasonic Analysis
LOGOFY2001
Advantages and Pay BacksAdvantages and Pay Backs
n Moderate cost.(1K to 10K)n Simple to usen Savings potential is great
– Air leak identification– Steam trap leaks ($2000 per year can be
lost from a single trap)
n Pay back in one year or less
Ultrasonic Analysis
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 23
LOGOFY2001
Ultrasonic Ultrasonic Web Page ResourcesWeb Page Resources
LOGOFY2001
CSI atCSI atwww.www.compsyscompsys.com.com
nSound library
nApplication papers– Fundamentals of Ultrasonics
nProducts
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 24
LOGOFY2001
www.www.uesystemsuesystems.com.com
n Technology Overviewn Trainingn Links ****n Sound Demos
– Bearings– Traps– Air Leaks– Arcing– Corona
LOGOFY2001
Oil AnalysisOil Analysis
n Oldest predictive maintenance technology
n 50% of bearing failures are lubricant related
n Can detect machine faults up to two months before vibration analysis
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 25
LOGOFY2001
Oil AnalysisOil Analysis
n Monitors three conditions
– Lubricant condition
– Lubricant/Oil system condition
– Machine condition
LOGOFY2001
Oil AnalysisOil AnalysisAdvantages and Pay Backs Advantages and Pay Backs
n Simple
n Fairly Inexpensive
n Ease of trending
n Extremely effective
n 12 month or less cost recovery
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 26
LOGOFY2001
Oil Analysis Oil Analysis Web Page ResourcesWeb Page Resources
LOGOFY2001
Insite Insite Services atServices atwww.www.testoiltestoil.com.com
nFree sample kit
nFree oil analysis
nTest type overview
nOn-line sample results
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 27
LOGOFY2001
www.www.compsyscompsys.com.com
nOil analysis products
nTraining
nLibrary
LOGOFY2001
Other Benefits of Using Other Benefits of Using PDM TechnologiesPDM Technologies
n Identification of improper maintenance practices
n Identification of improper operating practices
n Identification of poor equipment designn Identification of excessive operating
conditions
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 28
LOGOFY2001
DSOMDSOM
Another Tool
LOGOFY2001
Play DSOM CD Play DSOM CD
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 29
LOGOFY2001
PDMPDMWeb Page ReferencesWeb Page References
LOGOFY2001
Maintenance TechnologyMaintenance Technologywww.www.mtmt--online.comonline.com
nMaintenance related articles for past three years
nProduct supplier information:– CMMS
– Predictive Maintenance Technologies
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 30
LOGOFY2001
www.plantwww.plant--maintenance.commaintenance.com
nTraining Material
n Industry Links
nReference Material
nFree Software
nTechnical Articles
nLinks
LOGOFY2001
www.www.reliabilitywebreliabilityweb.com.com
nArticlesnLinksnReferencesnOn-line chat and bulletin boardnFree Stuff!
– Audits / Training/ Software/ Oil Analysis– Maintenance surveys, etc.
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 31
LOGOFY2001
SummarySummarynPredictive maintenancenPredictive maintenance technologies
– Thermography– Vibration Analysis– Oil Analysis– Ultrasonic Analysis– DSOM
LOGOFY2001
Workshop Outline (PostWorkshop Outline (Post--Work)Work)
nO&M Ideas– Steam systems– Chillers– Cooling Towers– HVAC systems– Air Compressors– Pumps– Drives
Energy Management Teleworkshops March 2001
Operations and Maintenance Management Page 32
LOGOFY2001
Contact InformationContact InformationRay PughPacific Northwest National LaboratoryP.O. Box 999MS K5-20Richland, WA 99352(509) 372-4103fax (509) 372-6459email [email protected]
Greg SullivanPacific Northwest National LaboratoryP.O. Box 999MS K8-17Richland, WA 99352(509) 372-6212fax (509) 372- [email protected]