Condition based Maintenance

Condition based Maintenance

n Condition-based maintenance (CBM), shortly
Condition-
described, is maintenance when need
arises.i.e.
arises.i.e. to maintain the correct equipment at
the right time. This maintenance is performed
after one or more indicators show that
equipment is going to fail or that equipment
performance is deteriorating.
n CBM primarily uses non destructive testing
techniques,visual inspection & performance
data to assess machinery condition thus
replacing arbitarily timed maintenance tasks
with appropriate maintenance tasks at only
when warranted by equipment condition.
 Advantages of CBM over Preventive
maintenance & Corrective maintenance
n CBM identifies incipient faults before they become
critical, thus enabling more accurate planning of
preventive maintenance.
n CBM enables the user to take maximum
advantage of useful life of a component such as
bearing because the equipment can be left in
service if it meets the desired performance
standards.
n Decreased number of maintenance operations
causes a reduction of human error influences
n Decreased maintenance costs
Comparison of CBM,Preventive maintenance &
Corrective maintenance
 General Condition Monitoring categories
n Temperature measurements (e.g. temperature
recording with the help of laser gun , thermography)
helps detect potential failures related to a
temperature change in equipment. Measured
temperature can indicate problems such as excessive
mechanical friction (e.g. faulty bearings, inadequate
lubrication), degraded heat transfer (e.g. fouling in
heat exchanger) & poor electrical connections (e.g.
loose corroded or oxidized connections).
n Dynamic Monitoring (e.g. signature analysis of
vibration)
n Oil Analysis: e.g. Oil analysis (e.g. ferrography,
particle counter testing) -indicates problems such as
machine degradation, oil contamination ,improper oil
consistency & oil deterioration. Oil analysis falls into 4
main areas:
Ø a) fluid physical properties(viscisity,appearance).
Ø Fluid chemical properties (Viscosity, appearance)
 General Condition Monitoring categories
Ø Fluid contamination (ISO cleanliness, ferroraphy)
Ø Machine Health (wear metals associated with plant
components)
q Nondestructive Testing: NDT involves performing
tests (e.g. x-
x-ray, ultrasonic)
q Electrical Testing & Monitoring: e.g. power signature
analysis, high potential testing-
testing-involve measuring
changes in system properties such as resistance
,conductivity--helps detect electrical insulation
,conductivity
deterioration, broken motor rotor bars.
q Observation & Surveillance: Visual, audio & touch
inspections
q Performance Monitoring: Monitoring changes in
variables such as pressure,temperature,flow
rate,electrical power consumption
 Condition Based Maintenance task intervals
nCBM task intervals must be properly
understood & should be determined based on
expected P-
P-F interval i.e. Potential failure-
failure-
Functional failure interval.
 Condition Based Maintenance task intervals

n CBM task intervals must be determined based on

the expected P-
P-F interval. Following sources may
be referred to as an aid to determine P- P -F
interval:
Ø Expert opinion & judgments (i.e. manufacturer’s
recommendations)
Ø Published information about condition –
monitoring tasks.
Ø Historical data (e.g. current condition –
monitoring task intervals)
q Initial CM task intervals:-
intervals:-i) If existing CM task
interval has proved effective-
effective-use it. ii) If using
existing CM task interval failure has occurred
lower the interval.
Condition Monitoring Practices
for
Critical Equipments
BBGS
 Major Areas

n Lubricating oil
n Transformer oil
n Process Parameter Monitoring of
Boiler and
n Circuit breakers
n Rotating equipments like all load
bearing pumps and fans
n Switchyard
 Populati Freq. Data
Type of Major Eqp / Testing
on of of owners Reporting
test oil agency
m/c testing hip

TG lube oil 3
Monthly

BBGS
Moisture & BFP oil 7 Monthly In-house Home Page
Ops
TAN Draught fans
16 180
oil
FRF 3 Weekly

TG lube oil 3

FRF 3

WDA, HP LP bypass 3 Report of M/s

Six BBGS IIPM is kept
moisture, IIPM
BFP oil 6 monthly Ops in Dy Mgr
TAN, Ops room.
viscosity Draught fans
16
oil
Coal mills 17
 Populati Freq. Data
Major Testing
Type of test on of of ownershi Reporting
Eqp agency
m/c testing p
BDV, Neutralization
factor, Moisture GT 7
content, Specific
resistance,
Interfacial tension, 2 years Shanthala BBGS -EMD Home page
Flash point, Tan
delta, Sludge ST, UT 3 each
content, DGA

CHT 6

AHT, CTT 4 each

BDV,Moisture,
Acidity WST,DMT,
2 each 180 days In-house BBGS -EMD Home Page
IAPAT, IWT

HCSS 1
ESP 62
132 KV
Tan Delta Switchyard 96 5 years T/D BBGS -EMD Home Page
all CT,PT
132 KV
DGA Switchyard 96 5 years Shanthala BBGS -EMD Home Page
all CT,PT
 Major Populatio Freq. of Testing Data
Type of test Reporting
Eqp n of m/c testing agency ownership
Fly Ash
Combustible and
3 7 days Lab BBGS -Ops. Home Page.
Analysis Bottom
Ash

PF Grading Coal Mill 17 15 days Lab BBGS -Ops. Home Page.

CT and Bi-
annual. In house -
Condenser 3
(Apr to Ops
BBGS -Ops.
performance test Sep.)

Boiler efficiency 3 months In house -

3 BBGS -Ops.
test interval Ops

Corrosion
(CT/CW) 3 Monthly Chembond BBGS -Ops.
measurement

Corrosion
(DMCW) 3 Quaterly Chembond BBGS -Ops.
measurement
 Populatio Frequen Measuring Report
Mode of
Major Equipment n of cy of Equipmen Agency Generatio
reading
machines reading ts used n

Cooling Tower Fan 52 Monthly

PA Fan 6 Monthly
Coal Mill 17 Monthly
SA Fan 8 Monthly
Report
CEP 6 Monthly Frequency submitted
Compressors 20 based by M/S
Monthly SKF Under AMC
vibration SKF.
FD Fan 6 Monthly Analyzer measurement of M/s SKF Available
Rotary Breaker 2 Monthly and analysis in Home
DMCW Pp. 12 Bimonthly Page.
BFP 7 Bimonthly
CW Pp. 7 Bimonthly
ACW Pp. 6 Bimonthly
ID Fan 8 Bimonthly
 ISO 10816 Present
Standards Vibration Health
Sl No Readings taken in Velocity (mm/sec) in RMS Velocity Condition
Mm/sec
Normal Alert Alarm

1 < 4.5 4.5 -11.2 >11.2

FEB - 2011 14.2 Alarm
MARCH -2011 (Decoupled
1.5 Normal
Reading)
MARCH -2011 20.4 Alarm

Action Plan: Suggested by SKF

Check the pump impeller for unbalance issue & for proper clearance in its casing.
Check the pump shaft for bend or eccentricity issue. Check the pump shaft bushes for proper
fitment & in proper condition.
Also check the internal clearance of the pump bearing & for defects with respect to the raceways &
if required replace them.
Also once verify the alignment between motor & pump.

MMD’s Observation : Bend shaft , impeller unbalance and damage to all the bushes.
 Freq. of Testing Testing Reportin
Location of test
testing agency M/c g

Thermal insulation Report is

In house – IR Gun / submitted
checking for Boiler
Pre-survey and Planning FLIR IR to MMD for
casing, steam piping post survey Dept Camera corrective
Turbine casing action.

Report is
In house – IR Gun / submitted
Pre-survey and
High energy drains post survey
Planning FLIR IR to MMD for
valves and steam traps Dept Camera corrective
action

Report is
Outdoor Electrical switch In house – submitted
Pre-survey and FLIR IR
yard joints and post survey
Planning
Camera
to EMD for
Dept corrective
connectors.
action
 Testi
Populati Data
Major Freq. of ng
Type of test on of ownershi Reporting
Eqp testing agen
m/c p
cy
Bearing health
monitoring of Vital
load bearing motors
motors
Partial Discharge Important
Monitoring in HT and LT
Electrical Boards boards
Equipment arrived recently (Ultraprobe
Partial Discharge 10000). Implementation planning in
Monitoring of
132KV/220KV
All progress.
CT, PT

Partial Discharge
Monitoring in
All
transformers
(Dry, Oil filled)
Present Status

Coal mills 17
Electro
ELC m/c
static Turbine
3 remains
Cleani MOT
always ON.
ng WT-1,SAC
WT- 2

Continuous running of ELC machines in coal mills have resulted in :

Reduced wear and tear

Reduced oil consumption (Earlier oil had to be replaced after every two
months, at present done only after running for 10000 hrs)
Less maintenance
Higher availability
Plan is to fit the same in all ID/FD/PA gearboxes. Already fitted in FD-3A and PA-3A.
Sample ELC test certificate
 Transformer Oil
§ The following tests are carried out on Transformer Oil of GT (1
& 2), UT (1 & 2) and ST (1 & 2) once a year by CPRI / Shanthala:
- BDV, Neutralisation factor, Moisture content, Specific
resistance, Interfacial tension, Flash point, Tan delta at 90°
90°C,
Sludge content, DGA
§ BDV, Moisture and acidity of the following transformers are
carried out in-
in-house bi-
bi-annually
- SATs, UATs, CHTs, ACTs, CWLTs, AHTs, and ESP
Transformers
 Audiometric study

§ Audio metric study at different zones of the boilers of both

the units is carried once every week.

§ This study is primarily carried out to preempt any boiler tube

leak.

§ All records are maintained and studied for and deviation.

§ Any increase in noise level by 5 dB is investigated.

 Illumination Study

§ Illumination at different pre defined spots covering the entire

station is checked once every month.

§ All data obtained from the checking are tabulated and reports

published.

§ Corrective action are taken based on the reports.

 Case studies on failure analysis
1) Vibration analysis of Fans & pumps:
üReduced excessive vibration with SKF CMXA 70
Analyzer in SA Fan 1A-Seal Air Fan.
Issue: High vibration observed of around 8.1 mm/sec
at Motor bearing. Spectrum analysis reveals
misalignment between drives and bearing inaccuracies
observed in fan bearing.
Solution: SA Fan for maintenance during a planned
shut down and precision alignment done between
drives and vibration come down to 2.2 mm/sec.
üReduced excessive vibration with SKF CMXA 70
Analyzer in DMCW Pump -3A
Issue :High vibration observed of around 8.3 mm/sec
at Pump NDE bearing. Spectrum analysis revels
looseness at Pump base
 Case studies on failure analysis
fixing location along with rotational looseness observed
at Pump DE & NDE bearing.
Solution: Tighten the Pump base fixing location and
tighten the Pump DE & NDE bearing sleeve and
vibration come down to 2.8 mm/sec.
2) Thermography study of high energy drains:
drains:-
upstream & down steam temperature of high energy
motorized drain valve are measured to ascertain
passing of valves. Valves if found passing the
upstream manual isolating valves are kept
closed.Thermography
closed. Thermography 12-
12-13
13\\MC_drain_2013_2.xls
3) Infra red thermography study of hot spots on grid:
Infrared Thermography is the science of acquisition
and analysis of thermal information by using non
contact thermal imaging devices. The Infrared
THERMOGRAPHY locates the Hot Spots in Grids thus
making possible elimination of root
 Case studies on failure analysis
cause of abnormalities. This process resulted in
reduction of hot spots & inadvertent network tripping.
It has become important because of following : 1. It
is non-
non-contact –uses remote sensing; 2. It is two
dimensional ;3. It is real time;
nIn BBGS we carry out IRT by

•numbering each and every joint in our 132 KV

switchyard , so that we can easily identify any
joint;Thermography1
joint; Thermography1\\SLD 132kv Feeder Bay.doc
• We carry out thermography of every point , after
ensuring that the point is carrying load.
•We keep a record of temperatures of all points so that
we have a history
•We save images for points which are having hot spots
 The THERMOGRAPHY program
Preventive Maintenance: Rectification of identified HOT SPOT

Temperature
Category Actions
measured

<700 C Normal Keep monitoring

Schedule
700 C<**<1000 C Alarm Preventive
Maintenance

>1000 C Critical Immediate action

 Thermographic assessment of
Busbar Condition
Tests are done to identify
looseness in joints which cause
huge heat loss and result
premature breakdown

After necessary maintenance the

same IR Thermography was taken
and the results are shown
 Case study -1 (Before Survey)
Drg No: 61 Bay: GT--2
GT SLD Point 20
No:

Y-Phase Isolator
pad to 3” IPS (
Location:
flexible )

Max Temp:
220 ° C
Action On: 06.01.10

Action taken:

ØCopper flexible connectors

were found to be prone to
temperature rise due to
sulfation at the contact area
between Al and Cu although bi
metallic strip was present,
resulting in high resistance,
heating and pit marks so
Copper Connectors were
replaced with AL flexible
connectors.
 Case study (After Survey)
Drg No: 62 Bay: GT--2
GT SLD Point 20
No:
29A B-
B-Phase
Isolator pad to 3”
Location:
IPS ( flexible )

Max
Temp: 43.6 ° C
Action 16.02.10
On:

Analysis:
It was observed that the
abnormal temperature
rise in this case was due
to mismatch in AL-
AL-Cu
joint.
 Maintenance Planning & Optimization
ü In BBGS we follow a Routine maintenance schedule
which are periodically reviewed & changed based
on feed back received from checklists of previous
R/Ms.
ü For carrying out Routine maintenance we have a
schedule & accordingly planning department
convenes planning meeting everyday in the
afternoon ,where personnel from OPS &
Maintenance departments meet & chalk out plan
for maintenance of equipments to be carried out in
the next day. maintenance planning meeting.doc
ü By following the above mentioned procedure we
are able to reduce unscheduled disruptions and
technical breakdowns thus ensuring equipment
availability above 96%.
 Capital overhaul
v Meticulous planning is done before every capital
overhaul, to minimize cost involvement & down
time of equipments.
v Planning for annual overhauling referred to as
Survey is done based on feedback received from
OPS department & from previous R/M checklists.
v Details of execution on hourly basis is planned
involving the contractors who will be actually
carrying out the job. unit1 2012_Survey plan.xls