13 - colin brookman

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London

29 September 2010

Colin BrookmanTraining Manager, Europe Division

ABS

Class & RegulationCM Techniques & Class Requirements

IMarEST Condition-based Maintenance

Conference 2010


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z ABS PM and RCM Programs

z Survey Policies

z CM and Vessel Life Cycle

z Supplemental Information

z Common CM Techniques

Outline


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z ABS has cooperated with ownerssince 1978 implementing preventativemaintenance (PM) programs

z First PM Guide issued in 1984:

Updated periodically

Now in Part 7, Appendix 14 of Rules

z Utilizes condition monitoring and planned maintenance

z Owners seeking:

Elimination of unnecessary inspections

Enhanced reliability and availability

Increased life of critical components

Overview of ABS PM Program

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z Applicable to all facets of machinerymaintenance

z

Reliability-centered maintenance (RCM)is a structured asset maintenancephilosophy designed to comprehensivelyaddress users need for:

Eliminating unnecessary maintenance tasks

Enhancing reliability and availability

Increasing the life of critical components Improving safety, environmental impact and economic return

z Improved understanding of relationship between

component failures and overall system performance

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Overview of ABS RCM Program


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z PM or RCM program requirements:

Vessel must be on special continuous machinerysurvey (CMS) cycle

Machinery must be operational

Maintenance plan must be maintained in a

computerized machinery maintenance system(CMMS)

z Initial and annual confirmation surveys

z Satisfactory survey results in credit towards CMSavoid opening equipment unnecessarily for specialsurvey

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Vessel Survey Policies (PM & RCM)


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Planned Maintenance

Condit ion Monitor ing

Failure Finding

Run-to-failure

Reliability-CenteredMaintenance

RCM Module Software

Result:Preventative

Maintenance Plan

ABS Nautical Systems NS5Maintenance & Purchasing

Modules

Result:Reliability AvailabilityMaintainabil ity (RAM)

Data

Update RCMAnalysis

Start

CM in RCM Program & Vessel Life Cycle


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z RCM and related software to develop preventativemaintenance plan

z ABS Condition Monitoring Guidance Notessummarize various techniques

z ABS Nautical Systems NS5 maintenance and

purchasing modules

z Maintenance activities are aligned with surveys andequipment condition

z ABS notations to show that advanced maintenanceprograms have been implemented

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Approach Towards Machinery Life Cycle


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Approach Towards Machinery Life Cycle

z Future trends:

Owners should apply risk to better understand their

operations Owners may require manuals describing system

interactions

ABS a repository of equipment and system reliabilitydata

Continuous improvement in system design

construction and operations

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Summary

z ABS has PM and RCM programs incorporatingCM techniques

z Surveys are coordinated to avoid unnecessaryopening of equipment

z CM has a role in vessel life cycle initiative

z Owners can use these techniques to understandrisk and improve vessel operations

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Supplemental Information

The following information is

provided as additional details

relating to condition monitoring


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What is Condition Monitoring?

z Condition monitoring is comprised of non-invasive andscheduled diagnostic technologies used to monitormachine condition and to detect a potential failure

z It measures present conditions enabling future trending

z Results of monitoring must be:

Consistent and sufficiently accurate

Relatively stable

Reproducible

Repeatablez Also referred to as:

On-condition task, or

Predictive maintenance task


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Time

Condition

Point where

failure begins

Inspection

interval

Point at which

we can detectonset of failure

Functional

failure

P-F Interval

P

F

P-F Diagram


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z Are these symptoms of your currentmaintenance program?

z High levels of reactive maintenance:

Too little proactive maintenance

Not the right kind maintenance

Spare parts supply or logistic problems

z Intrusive equipment maintenance leadingto more damage than good

z Unplanned downtime and reactivemaintenancedisruptingoperationalschedule

Why Use Condition Monitoring?


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Benefits of Condition Monitoring

z Complements and enhances a planned maintenance program:

Improves understanding of the relationship between componentfailures and overall system performance

Addresses both safety and environmental concerns

z Increased maintenance cost-effectiveness:

More condition monitoring and less intrusive planned maintenance

Extends equipment life by performing appropriate maintenancewhen its needed

z Increased revenue due to improved asset availability:

Less unplanned and planned downtime

Machines dont die.theyre murdered!R. Bennetts Article in Uptime Magazine


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z Observation and surveillance

z Dynamic monitoring (vibration)

z Oil analysis

z Infrared thermography

z

Nondestructive testingz Electrical testing

z Engine performance monitoring/

diagnostics

Condition Monitoring Techniques


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Observation & Surveillance

z Observation and surveillance are human sensory-based condition monitoring techniques

z

Visual, audio and touch inspections of machines orequipment are oldest and most common conditionmonitoring techniques used by engineers duringtheir watch rounds

z Activities can help identify a broad range ofmachinery equipment problems. Typically, thesetechniques may be followed by more in-depth

instrument measurements: infrared thermography,vibration analyses, etc.


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Vibration Monitoring

z The technique analyzes physical displacement of a component,its frequency, its velocity and/or its acceleration to identify theexistence of problems, such as bad bearings, poor alignmentand improper balance

z Measurements and analyses may vary from simple to complex.Readings can be collected continuously or periodically.

z Collection devices can be permanently or semi-permanently

mounted or portable


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z Broadband Analysis:

This analysis identifies changes in vibrationsignatures through the comparison of currentrecorded readings with previously recorded orbaseline vibration levels

Changes in vibration characteristics can be attributed

to fatigue, wear, imbalance, misalignment in shafts,bearings, pumps, gearboxes, turbines, pumps,motors, etc.

The analysis is an excellent screening tool foridentifying problems

Vibration Monitoring Analyses


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z Spectrum Analysis:

This technique transforms vibration spectra from timedomain to the frequency domain using Fast Fourier

Transform algorithm

Problems are identified by comparison of currentspectra to its previous spectra to defect changes in

amplitudes at selected frequencies



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z Shock Pulse Analysis:

This analysis is used monitor roller bearings orcomponents for which metal-to-metal contact is asource of wear

Measurements are taken of the shock pulsesproduced by component contact. Changes in pulses

indicate deterioration. It aids in identifying lubricant, oil seals and packing

problems and bearing installation or misalignmentproblems.

It should be used in conjunction with other vibrationmonitoring techniques, i.e., spectrum and waveformanalyses.

Vib ti M it i A l


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z Time Waveform Analysis:

This analysis identifies wide range of mechanicalinstabilities including chipped or cracked gear teeth, pump

cavitations, misalignment, loosen or eccentricity

Output from the vibrationanalyzer fed to an

oscilloscope whichcan generate a waveform representationvibration signature

Oil A l i


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Oil Analysis

z Oil analyses can be performed on lubrication, hydraulic,electrical insulating and fuel oils

z Ferrography, spectroscopy and moisture measurement and

viscosity analysis are common techniques currentlyemployed by a number of ship operators

z These techniques identify machine degradation (wear) oilcontamination, improper oil consistency and oil deterioration

Oil A l i


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Oil Analysis

Ferrography

z A technique that measures thedensity and size ratio ofsuspended particles in oil orgrease caused by wear

z The sample is diluted in a solvent

passed over an inclined glass slidewhich is subjected to a magneticfield. The magnetic field separatesferrous and non-ferrous particles

over the length of the slide.z Density of the particles and ratio of

large to small particles indicatesthe type and extent of wear

Oil A l i


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Oil Analysis

Spectroscopy

z This test identifies problems with contaminates, additives andlimited extent corrosion and wear metal in lubricating and

hydraulic oilsz A small sample is burned and the characteristic light

frequencies and intensities emitted determine the type andamount of compounds present

Oil A l i


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Oil Analysis

z Crackle Test

This test provides a simple method of detecting moisture inhydraulic or lubricating oil samples. Droplets of an oil sample are

place on a hot plate (150-205C). If crackling or vapor bubblesare not produced, emulsified water is not present.

z Karl Fischer Titration Test (ISO Standard 6296)

This test measures moisture by measuring electrical current flowbetween two electrodes immersed in an oil sample. A re-agent ismetered into the sample and results are given in ppm of water.

z Kinematic Viscosity Test

This test indicates deterioration over time or presence ofcontamination of lubricating oil by fuel, other oils or fluids bymeasuring the oil resistance to flow under a known pressure andtemperature

Infrared Thermography


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Infrared Thermal Image Visible Light Image

Note: photographs used with permission of Peterson Predictive Maintenance


z This non-contact technique measures the temperature ofheat-radiating surfaces within the line of sight of a camera.The camera measures infrared radiation emitted from anobject and it displays or records the temperature data andprofiles in a variety of video or audio formats for analysis.Cameras are available in a variety of sensitivities andresolutions.



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Advantages Disadvantages

z Cameras can be portableand easy to operate

z Dramatic images ofequipments temperaturecan be displayed

z Non-contact testing allowsfor testing of inaccessibleor energized equipment(i.e., energized switchgear)

z Results can be exported,logged or printed to otherdigital equipment

z Cameras features,resolution and sensitivity

are linked to price. Highquality means higher pricetag. Prices range from$4,000 to $25,000.

z Interpretation of the resultsrequires training andexperience

In the Future


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In the Future

z Wireless-sensor technology may help reduce installationcost especially on retrofitted systems

z Satellite communication may enable remote andreal-time monitoring of vital shipboard systems

z Smart boxes (equipment mounted diagnostic andprognostic algorithms) may become more common


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13 - colin brookman

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