introduction to predictive maintenance for forging

7/31/2019 Introduction to Predictive Maintenance for Forging

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PREDICTIVEMETHODSANDTOOLS

A Quick Overview

for

Forging Industry

Association


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PRAIRIEPREDICTIVESERVICESSPP

Purpose

Overview of Predictive Maintenance - PdM(condition based maintenance)

What

Why

How

Introduce three useful technologies

Thermography

Vibration measurement Ultrasound


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Outline

Bathtub curve

Maintenance strategies

Three technologies for Predictive

Maintenance


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Bathtub curve components


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Bathtub curve


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No cost until failure

Unpredictable

Expensive if misapplied

Reactive Run to failure


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SPP

More reliable than Reactive

Higher cost & more errors then necessary

Preventive service before theres a chance to fail



SPP

More reliable than preventive

Cut unexpected failures

Predictive detect onset of failure, then service



SPP

More reliable than predictive

Increase uptime, lifetime

Proactive control failure root causes


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SPP

Predictive Maintenance - Why

Cut unexpected failures

Eliminate unnecessary service

Maximize runtime

Reduce introduced faults

Improve Overall Equipment Effectiveness


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Predictive Maintenance - How

How to start

Identify equipment that yields greatest benefit

Select technology(ies)

Build plan

Equipment routes and schedules

Aquire and learn to use tools

Develop benchmarks for trending

Develop information flow

Data for trending

Actionable reporting


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Potential Pitfalls

Lack of planning

No training

Poor data and diagnosis

False alarms, missed early warnings

Early warnings ignored

All lead to a Failed Program


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Technologies for Predictive Maint.

Common Thermography

Ultrasound

Vibration Analysis (Tribology - not part of presentation)

Overview for each

Description

Application


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Subset of electromagnetic spectrum

All objects radiate according to

temperature (freq

temp) IR invisible so IR camera is used

Thermography Infrared (IR)


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Thermography Infrared (IR)

area of interest


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Early Warning

Increased friction

Abnormal resistance or current

Non-contact

Realtime display

Useful for electrical and mechanical

Thermography


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Thermography Electrical

Typical Items Inspected

Power distribution

Fuse boxes

Motor Controllers

Switchgear

Capacitors

Transformers

Motor leads

Common Problems Found

Unbalanced loads

Excessive draw

Faulty connections

Component failure

Harmonics


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Thermography Electrical

Fuse at main disconnect was open

Left phase at 92 F

Center phase at 116 F

Right phase at 119 F


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Thermography Mechanical

Typical Items Inspected

Bearings

Gearboxes

Drive Belts Motors (check cooling)

Common Problems Found

Inadequate lubrication

Misalignment

Blocked cooling


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Thermography Mechanical

Motor

misaligned

Motor running hotVent clogged


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Ultrasound

Above audible range (20~100kHz)

Travels through all matter

Excellent for lubrication Electrical and mechanical


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Earliest indicator of fatigue

When to grease, how much

With FFT can determine failure mode

Ultrasound Bearings

good

bearing

bad

bearing

adding

grease

3 minutes

later

sound files copyright of UE Systems


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Arcing and tracking

Corona over 1000V

Used BEFORE opening panels

Ultrasound Electrical


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Easy to detect and locate

Estimate 20% (+) of compressed air is lost

100hp compressor costs $35k~$50k yearly

$7k~$15k savings in energy cost

Help pay for PdM expenditures

Ultrasound Compressed Air Leaks


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Monitor bearing wear (Predictive)

Rotating machine condition (Proactive)

Alignment

Balance

Mounting problems (softfoot, etc.)

Vibration Monitoring


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Vibration Monitoring

Types

High frequency narrow band

Broadband

Hybrid (attributes of other two)

Configurations

Portable (walk-around)

On-line (permanently mounted and networked)


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SPP PRAIRIEPREDICTIVESERVICES

Predictive Maintenance

What monitor assets plan service after early detection of problem

verify repair

Why cut unexpected failure

reduce costs and faults

extend runtime

How select assets to monitor choose monitoring technology(ies); train

establish and maintain schedule

develop concise reporting

introduction to predictive maintenance for forging

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