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VIBRATION ANALYSIS LEVEL-I

Centre for Vibration Analysis And Machine Condition Monitoring

Directorate of Nuclear Power Engineering-Reactors

INTRODUCTION OF CVCM

 Universal application of fault detection techniques in NPPs, nuclear reactors,

industrial plants for prevention of critical equipment damage.

 Fault correction with precision balancing, laser alignment, vibration analysis.

 Collection of baseline signatures of major equipment for trend monitoring

equipment performance.

 Shock & Vibration Testing/Measurements on Structures.

 Develop reactor surveillance and condition monitoring systems.

 Organize certification, CM training, workshops and conferences.

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Course Facilitator
Course Timings: (09-00AM TO 03-30PM)
Maintenance Practices Mr. Ghulam Mustafa
Day 1 Condition Monitoring Mr. Hamid Raza
Lunch Break (13.00-14.00)
Principle of Vibration Mr. Hamid Rafique
Instrumentations and Data Acquisition Mr. Abid Khan
Tea Break (10.30-11.00)
Day 2
Signal Processing Ms. Ayesha Tahir
Lunch Break (13.00-14.00)
Vibration severity criteria Mr. Naeem Abbas

Vibration Analysis and Machine fault Diagnostics Mr. Naeem Abbas

Day 3
Tea Break (10.30-11.00)
Lunch Break (13.00-14.00)

Hands-on training, Fault diagnostics Mr. Altaf Hussain

Day 4 Tea Break (11.30-12.00)
Certificate Distribution (12.00-12.30)

Presentation Layout

Maintenance Practices
 What is breakdown maintenance and when should be it
employed?
 What is preventive (calendar based) maintenance, and
what are its major flaws?
 What is predictive (condition based) maintenance, and
what are its benefits?
 What is proactive (reliability centered) maintenance,
and what are its benefits?

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Maintenance

Activity involved in maintaining something in good

working order.
• Equipment maintenance refers to items and
mechanical systems that support a facility or help to
make the product efficient and functional.
• It can include maintenance equipment and any
equipment that fulfills product delivery.

Maintenance Terms

Terms associated with maintenance activities include:

 Clean
 Replace
 Repair
 Prevent
 Protect
 Preserve
 Fix
 Change over
 Set up

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Principle Objectives in Maintenance

 Maximize useful life of equipment.

 Keep equipment safe and prevent safety hazards.
 Maximize production capacity.
 Less production downtime.
 Less standby equipment needed, thus reducing capital
investment.

Rotary Equipments in Process Industry

 Electric Motors
 Pumps
 Compressors
 Gear Boxes
 Rollers
 Fans
 Blowers
 Turbines
 Engines and other rotating equipments 8

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Maintenance Progression

First Fix it when it broke 1940-1950

Generation
Second Schedule overhauls 1955-1975
Generation Systems for planning and controlling
work
Big slow computers
Third Condition monitoring 1975- 2000
Generation Small, fast computers
Failure modes effects analysis
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Maintenance Progression

• Risk Based Inspection

• Risk Based Maintenance
• Risk Based Life assessment
• Reliability Centered
Current Maintenance
2000+
Generation • Condition Based
Monitoring
• Computer aided
Maintenance Management
and Information System
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Maintenance Techniques

 Break Down or Run to Failure

 Preventive Maintenance
 Predictive Maintenance
 Proactive Maintenance

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Break Down or Run to Failure

 Corrective or Breakdown maintenance implies that

repairs are made after the equipment is failed and can
not perform its normal function anymore.
 Has the concept ‘fix it when it breaks’.

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Break Down or Run to Failure

This is probably the most common type of maintenance in

industry today but can be the most costly, especially on
critical machines.
 Machine is operated until it breaks down
 Old technique now adopted only for non critical
machines.
 Maintenance costs are usually higher due to the
catastrophic failure that occurs.

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Break Down or Run to Failure

 Results in unplanned shutdown

 Also damage associated parts.
 Considered to be cheap
 No policy to develop
 No routine maintenance to budget for

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Break Down or Run to Failure

Breakdown generally occurs leading to poor and hurried

maintenance.
 Excessive delay in production & reduces output
 Faster plant deterioration
 Increases chances of accidents and less safety for both
workers and machines
 Direct loss of profit.
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Break Down or Run to Failure

 Safety risk
 Unscheduled down time
 Damage to plant
 Teams always to be ready
 Loss of confidence.

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Application of Break Down Maintenance

 Quite justified in small factories where:

• Down times are non-critical and repair costs are less
than other type of maintenance
• Financial justification for scheduling are not felt
 More popular and used in our country.

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Preventive Maintenance (Calendar Based)

Also known as ‘Shutdown Maintenance’. This is based

upon ‘Timed Intervals’ between maintenance.
 A better technique mostly used by process industries
 Life of every part or machine is calculated and replace
it before time in planned shut downs
 Very useful for seals, oil and grease programs etc

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Computerized Maintenance System

Data Files Output Reports

Equipment file
with parts list Inventory and
purchasing reports

Maintenance Equipment
parts list
and work order
schedule

Equipment
Repair history reports
history file

Cost analysis
Data entry (Actual vs. standard)
– Work requests
– Purchase
Inventory of requests
– Time reporting
spare parts – Contract work
Work orders
– Preventive
maintenance
– Scheduled
Personnel data downtime
with skills, – Emergency
wages, etc. maintenance

Drawbacks of Preventive Maintenance

 Most of the parts do not attain their maximum service

life.
 Inventory of all the items has to be maintained.

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Predictive Maintenance (Condition Based)

Also known as ‘Condition Based Maintenance’. This

approach uses non-intrusive technologies to determine the
actual condition of a machine and its rate of failure.
Different techniques are adopted which include vibration
checking, oil analysis, noise analysis, thermography,
ultrasonics, temperature etc

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Predictive Maintenance (Condition Based)

 Modern technique of maintenance mainly introduced

in last decade of last century.
 The life of the equipment is monitored continuously
and remaining life is predicted.

 This can be very effective in extending machine life

with big financial savings if implemented properly.

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Benefits of Predictive Maintenance

 No need of maintaining the inventory of all the items.

 Shut downs are planned accordingly.
 To confirm good-condition machines.

 To detect developing problems.

 To determine the nature and severity of the problem.

 To schedule repairs that can best fit with production

and maintenance needs.
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Proactive Maintenance
(Reliability Centered)

 Often referred to as ‘Root Cause Analysis’. This

philosophy works hand in hand with Predictive
Maintenance, eliminating the source of the fault to try
to prevent it from re-occurring.
 A step ahead of predictive maintenance in the sense
that it not only predicts the life but also find the root
cause of problem
 A problem that is occurring again and again is rectified
e.g. whether it is unbalance or misalignment or bearing
or motor which is causing a failure
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Benefits of Proactive Maintenance

 Do not require the stoppage of machine

 Results in maximum outputs with minimum inventory
and unplanned shut downs

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Today’s Industrial Demand

 It should be unacceptable to deliver

• less performance for more money
• same performance for more money
 It could be acceptable to deliver
• same performance for less money
• more performance for the same money
• more performance for more money

 The desire is More Performance for Less

Money!!!!

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Predictive Maintenance Mechanism

 Establish a database of all the machines that need to be

monitored

 Establish a data collection route that best optimize the

data collection time

 Download route into the data collector

 Collect data

 Upload collected data into the database

Predictive Maintenance Mechanism

 Run exception reports to detect the problematic

machines

 Analyze only the machines in the exception reports

 Generate repair work to be performed

 Again collect data on the machine on which work is

being done.

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Predictive Maintenance

Rules
Start +
Experi

NO

YES
Create Regular Compare Fault Fault
Ref. Meas. limits Diagnostics correction

Input
m/c
specs
Create
New Ref. & Limits

Overview of
Condition Monitoring

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What is CBM & Why ?

 To try and maximise the plants production and

increase the mean time between outages many
industries are moved towards a ‘Condition Based
Maintenance’ approach.

 Condition Based Maintenance or CBM is an activity

that attempts to predict and trend component failure
non-intrusively given the end user valuable advanced
warning of the problem at hand.

What is CBM & Why ?

 Maximising asset reliability is very important in

today’s global economy.

 As competition and the pressure to produce products

cheaper increases the higher consequence of
machine/production failure becomes.

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Maintenance Techniques Summary

Maintenance
Techniques

Break Down Preventive Predictive Proactive

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