M2 - Preventive Maintenance Technology

....
Your platform to do MAINTENANCE EXCELLENCE in the work place®
M2 – PREVENTIVE
MAINTENANCE TECHNOLOGY
ONLINE TRAINING SESSION

Concept of PREVENTIVE MAINTENANCE
TECHNOLOGY
HSE Institution Training Academy

Learning Objectives
▪types of maintenance activities

▪Appreciation of the benefits of preventive
maintenance
▪Understanding of lean principle preventive
maintenance schedule
▪Awareness of specific challenges to implementing
preventive maintenance
3
Copyright © 2016 BMU. All rights reserved.
The PM Program a “Controlled Experiment”
4
5
6
7
Preventive Maintenance Impact
8
Proactive Maintenance
9
10
11
12
13
Classification of Maintenance Work
14
Types of Maintenance
Breakdown Maintenance:
 Waiting until equipment fails before repairing or servicing it
Preventive Maintenance (PM):
 cleaning, or replacing parts to prevent sudden failure
 (Predictive) On-line monitoring of equipment in order to use
important/expensive parts to the limit of their serviceable life
Corrective and Predictive Maintenance:
 Improving equipment and its components so that
preventive maintenance can be carried out reliably
15
Types of Maintenance
“…the cost of breakdown maintenance is usually much greater than
preventive maintenance.”
oPreventive maintenance…
oKeeps equipment in good condition to prevent large problems
oExtends the useful life of equipment
oFinds small problems before they become big ones
oIs an excellent training tool for technicians
oHelps eliminate rework/scrap and reduces process variability
oKeeps equipment safer
oParts stocking levels can be optimized
oGreatly reduces unplanned downtime
16
The Manufacturing Game
Similar to the Beer Game..
¾ Simulates a typical plant with three roles:
¾ Operations Manager
¾ Maintenance Manager
¾ Spare Parts Stores Manager
¾ Each round, participants make decisions such as:
¾ Which equipment to take down for PMs
¾ How to allocate maintenance resources
¾ How many spare parts to order
¾ Revenue, cost, output, uptime, inventory are recorded
17
The Manufacturing Game Results
Teams who follow a cost-minimization strategy (reactive
maintenance policies) are able to keep costs low for a
uptime falling and costs rising.
➢ Teams who follow a preventive maintenance strategy
initially find higher costs and reduced uptime as
equipment is taken offline for planned maintenance.
Soon, however, these teams begin to greatly outperform
teams following a cost-minimization strategy
18
When Does PM Make Sense?
19
Optimizing a PM Schedule
20
PM Durations: Simulation 1
21
22
23
24
PM Durations: Why they matter
25
The “Waddington Effect
26
The “Waddington Effect
27
Challenges to Implementing Preventive Maintenance
28
Concluding Comments
29
Concluding Comments
30
Concluding Comments
31
PREVENTIVE MAINTENANCE
TECHNOLOGY

Definitions
• Maintenance
• The combination of all technical and administrative actions, including supervision
actions, intended to retain an item in, or restore to, a state in which it can perform a
required function
• Preventive maintenance
• The maintenance carried out at predetermined intervals or according to prescribed
criteria and intended to reduce the probability of failure or the degradation of
the functioning of an item
• Corrective maintenance
• The maintenance carried out after fault recognition and intended to put an item into
a state in which it can perform a required function
• Maintenance optimization
• Balancing the cost and benefit of maintenance
33
Scope of maintenance optimization
• Deciding the amount of preventive maintenance (i.e.

choosing maintenance intervals)
• Deciding whether to do first line maintenance (on the cite),
or depot maintenance
• Choosing the right number of spare parts in stock
• Preparedness with respect to corrective maintenance
• Time of renewal
• Grouping of maintenance activities
34
“Maintenance theory”
• The bath tub curve is
Failure rate
a basis for choosing
maintenance activities
Time
• There are two such curves
• The hazard rate for ”local time”
• The failure intensity for ”global time”
• Combining the two:
35
 The hazard rate for local time
Performance loss
is appropriate for components
such as light bulbs in the signalling
Performance loss system. Methods are RCM and FMEA
Failure intensity/
1
Local time Local time Local time
4
3  Complete renewal will be

2 required at some point of time.
Global (system) time JBV method=LCC.
 Rail grinding is a maintenance  Point replacement of sleepers is a

activity to extend the life mean to postpone the complete
length of the rails. JBV renewal of sleepers. JBV method=LCC.
method=LCC.
36
Preventive maintenance and RCM
• In this course we have main focus on preventive

maintenance (PM)
• Maintenance optimization is thus more or less the same as
establishing an optimal maintenance program
• Reliability Centred Maintenance (RCM) is often considered
to be the “best” approach in this context
• RCM is a systematic consideration of system
functions, the way functions can fail, and a priority–
based consideration of safety and economics that
identifies applicable and effective PM tasks
37
Renewal and Life Cycle Cost
• As the system deteriorates, traditional preventive maintenance activities
could not bring the system to a satisfactory state
• Renewal of the entire system, or part of the system is required
• The cost of renewal is often very large ➔ we need formalised methods
to determine when to perform renewal
• In this course we will present methods for optimum renewal strategies
based on LCC modelling
• The following dimensions are included in the LCC model:
• safety costs
• punctuality costs
• maintenance & operational costs
• cost due to increased residual life length
• project costs
38
Effective failure rate
•This effective failure rate is the failure rate

we would experience if we (preventive)
maintain a component at a given level
•Notation: E = E()
• E is the effective failure rate = expected number of
failure per unit time
•  is the maintenance interval
39
Effective failure rate and optimization
•There are two challenges

• First we want to establish the relation  = E()
depending on the (component) failure model we are
working with
• Next, we need to specify a cost model to optimise
• The cost model will generally involve system models as
fault tree analysis, Markov analysis etc. This enables us to
find the optimum maintenance intervals in a two step
procedure
40
Introductory example
• Component model
• Effective failure rate is given by  = E() =  /100
•  is the maintenance interval
• Total cost of a component failure
• CMCost = 10
• Corrective maintenance cost including loss of production during the repair
period
• Cost per preventive maintenance action carried
• PMCost = 1
• The total cost per unit time
• C() = PMCost /  + CMCost E() = 1 /  +  /10
41
Solutions
•Graphical
•MS Excel Solver
•Analytical
42
MECHANICAL MAINTENANCE APPROACH

PLAIN BEARINGS
▪ Lubricant Supply. Proper bearing design and material are necessary to
achieve long service life but are not by themselves sufficient.
▪ The lubricant is the key component of the system which determines
bearing life. Reduced to simplest terms, if a sleeve bearing is provided with
an adequate flow of the proper clean lubricant, long life should be realized.
▪ Lubricant flow to the bearings is a function of the equipment design.
▪ Oil pressure at specified speeds should be within the limits given by the
equipment builder.
▪ Lower values suggest worn bearings.
▪ In this case, replacement should be made as soon as is feasible.
▪ Excessive pressures indicate a blockage or restriction somewhere in the
system.
44
PLAIN BEARINGS
Lubricant Type.
Ensuring an adequate flow of clean lubricant makes long bearing life

possible but
does not guarantee it. The oil must be the proper one for the
application. From a bearing performance viewpoint, lubricant viscosity is
the most important parameter. Lower-viscosity (i.e., thinner) oils reduce
oil film thickness. This increases the wear rate and can possibly lead to
failure. It is critical that the equipment manufacturer’s lubricant
recommendations be followed.
45
BEARING MATERIALS
Surface Action.
Sometimes referred to as slipperiness or compatibility, surface action is the
ability of a material to resist seizure when contacted by the shaft. Contact
takes place every time the equipment is started or stopped and can also occur
during momentary overloads.
Embeddability.
The ability of a material to absorb foreign particles circulating in the oil stream
is referred to as embeddability. Some particles will go unfiltered, so the
material must be soft enough to ingest them.
Conformability.
The material also must be soft enough to creep or flow slightly to compensate
for the minor geometric irregularities which are present in every assembly.
These include misalignment, out-of-round, and taper.
46
BEARING MATERIALS
Fatigue Strength.
This is the ability of a bearing material to withstand the loads to which it is
subjected without cracking. Bearings should not fatigue prior to the normally
scheduled overhaul.
Temperature Strength.
As operating temperatures increase, bearing materials tend to lose strength.
This property indicates how well a material carries a load at elevated
temperatures, without breaking up or flowing out of shape.
Thermal Conductivity.
Shear of the oil film by the shaft generates significant heat, most of which
is carried away by the oil. Nevertheless, it is important for the bearing to
transfer heat rapidly from its surface through its back to avoid overheating and
resultant reduction in life.
47
BEARING MATERIALS
Corrosion Resistance.
Oils oxidize with use, and the products of this degradation can be corrosive.
Blow-by products and fuel or coolant contamination of the oil also promote a
corrosive environment. Bearing materials should be resistant to these effects
48
BEARING NOMENCLATURE.
49
BEARING NOMENCLATURE.
50
BEARING RETENTION
DURING INSTALLATION..
51
ANALYSIS OF USED BEARINGS
Normal Appearance and Wear.
Most wear occurs during break-in, when minor geometric deviations are being
accommodated. Thereafter, in a properly maintained engine, only those dirt
particles too small to be filtered will be present to abrade the bearing surface.
Two features usually mark normal wear. First, if the bearings are of trimetal
construction, some of the overlay will have been removed, exposing the thin
barrier layer between the overlay and the intermediate layer and possibly
some of the latter as well. If of a bimetal construction, the surface will be
noticeably burnished. There also may be minor surface scratches. These are
generally not serious unless the intermediate layer has been deeply penetrated.
52
Dirt.
Dirt is responsible for more bearing failures than any other mechanism.
When dirt particles are large or numerous, they embed in the bearing
lining, deforming the structure beneath and displacing the surrounding
metal upward. The resulting high spot may be large enough to contact
the journal. (A heavily embedded bearing will have numerous halos from
this action.) Rubbing then creates heat which can, in conjunction with
the stressed structure beneath, cause a rupture and removal of the
bearing lining
53
Excessive Wear.
Some of the same factors that produce fatigue also can cause
excessive wear.
Generally, what determines the phenomenon that prevails is
the load level and the severity of the irregularity which causes
the problem. Geometric defects not only concentrate loads but
also cause oil films to be thinner than normal. This results in
more frequent metal-to-metal contact and wears the lining
much faster than normal
54
Fatigue.
Generally speaking, bearing fatigue results when either the load or time in
service exceed the alloy’s capability. There are several possible causes: load
concentrations due to dirt, poor shaft or bore geometry, misassembly of the
bearing, material weakness caused by high-temperature operation or corrosion,
or simply exceeding the bearing’s normally expected life span. Fatigue cracks
initiate at the bearing surface and propagate perpendicular to it. Before reaching
the steel, the cracks turn, run parallel to the steel, and join. The material can
then flake out. The most common type of fatigue is that of the overlay on
trimetal bearings. But since the primary overlay functions are to absorb small
dirt particles and provide a slippery surface for starting and stopping conditions,
slight overlay fatigue is not regarded as a bearing failure. The load-carrying
strength of a bearing is in its intermediate layer. A true fatigue failure involves
the intermediate material rather than the sacrificial overlay.
55
Foreign Material on Bearing Back.
Dirt on the bearing back causes high spots on the I.D. It also
prevents good heat transfer in these areas, which leads to
localized overheating. The end result may
be either severe local wear. Clearly, this type of problem can be
prevented through proper cleaning and burr removal prior to
assembly.
56
Hot-Short Phenomenon.
A bearing suffering this type of failure is unmistakable in

appearance: Large areas of the lining have been cleanly
removed from the steel back. The damage
occurs when the bearing temperature exceeds the melting
point of its lowest-melting-point metal, usually lead or tin. This
heat, in conjunction with shear due to shaft-to-bearing contact,
leads to the “hot-short” (brittle when hot) condition. Causes of
the failure can be insufficient oil flow, excessive dirt in the oil, a
rough shaft, or severe misalignment
57
Crush Problems.
If crush is insufficient, relative movement occurs between a bearing

and its bore.
So-called fretted areas will be visible on the bearing back and
sometimes on the parting lines. These will appear to be highly polished
and/or pitted. Corresponding damage also may be present in the
housing bore. Fretted areas are points of stress concentration.
58
Crankcase and Crankshaft Distortion.
These structural defects primarily affect the main bearings. Distortion

causes increased loads and lower oil films, with conditions being worst
at the point of
maximum distortion. The damage varies from bearing to bearing, with
the center main usually showing the greatest amount. If the crankcase
is distorted, a wear or fatigue pattern will be present on either the
upper or lower bearings
59
SHAFTS
Shaft.
After cleaning the crankshaft, measure all the main and

crankpin journals at several points to determine the out-
of-round and taper. If any journal measures 0.001 in.
less than the manufacturer’s specified diameter, has
more than 0.001 in. taper, or is more than 0.001 in. out
of round, the crankshaft should be reground before
rebuilding the engine. Specifications on tolerances and
permissible values for geometric irregularities are given
in Table
60
SHAFT TOLERANCES
61
SHAFT TOLERANCES
62
ROLLING-ELEMENT
BEARINGS
63
RADIAL BALL BEARING TYPES.
64
ROLLER BEARING TYPES.
65
THRUST BEARING TYPES.
66
SINGLE-ROW DEEP-GROOVE BALL-BEARING.
67
SINGLE-ROW DEEP-GROOVE BALL-BEARING.
68
BEARING SERIES
Metric rolling-bearing boundary dimension plan.
69
BEARING SERIES
Spherical roller bearings of different diameter
70
BEARING SERIES
Metric tapered roller-bearing diameter
71
BEARING MOUNTING
72
BEARING MOUNTING
73
DIRECT (A) AND INDIRECT (B) ARRANGEMENTS.
74
ANGULAR-CONTACT BALL BEARINGS.
Double-nut and lock-washer adjusting device End-plate and shims adjusting device
75
ANGULAR-CONTACT BALL BEARINGS.
End-cap and shims adjusting method. Cup-carrier and shims adjusting method
76
MOUNTING AND DISMOUNTING
Mounting of a self-aligning ball

Direct shaft mounting of a spherical bearing with an adapter sleeve
roller bearing.
Mounting of a spherical roller

bearing with removable type of sleeve
77
MOUNTING AND DISMOUNTING
Drilling and grooving of the shaft to Use of a hydraulic nut to mount a

reduce bearing driving force. spherical roller bearing
78
DETERMINING INTERNAL BEARING CLEARANCE
79
LUBRICATIONS
80
BEARINGS LUBRICATION
The friction torque in a ball bearing lubricated with oil consists essentially of
two components. One of these is a function of the bearing design and the
load imposed on the bearing, and the other is a function of the viscosity and
quantity of the oil and the speed of the bearing. It has been found that the
friction torque in a bearing is lowest with a very small quantity of oil, just
sufficient to form a thin film over the contacting surfaces
The energy loss in a bearing is proportional to the product of torque and

speed, and this energy loss will be dissipated as heat and cause a rise in the
temperature of the bearing and its housing. This temperature rise will be
checked by radiation, convection, and conduction of the heat generated to an
extent depending upon
the construction of the housing and the influence of the surrounding
atmosphere
81
BEARINGS LUBRICATION
recommendations for selection of oil for all bearing

applications, but two general considerations are
dominant:
1. The desire to reduce friction to a minimum, which
requires a small quantity of oil of low viscosity.
2. The desire to maintain lubrication safely without much
regard for friction losses, which results in using larger
quantities of oil and usually of somewhat greater viscosity
in order to reduce losses from evaporation or leakage.
82
GREASE LUBRICATION
Where grease lubrication is used, we need to consider a few of the basic

physical and chemical characteristics of the lubricant. Greases are a mixture
of lubricating oil and usually a soap base. The base merely acts to keep the
oil in suspension. When moving parts of a bearing come in contact with the
grease, a small quantity of oil will adhere to the bearing surfaces. Oil is
therefore removed from the grease near the rotating parts. Bleeding of the
oil from the grease obviously cannot go on indefinitely, so new grease must
come in contact with the moving part or a lubrication failure will result.
Many maintenance departments want to use one grease to lubricate all
bearings in the plant. Some lubricant suppliers even advocate this technique.
However, it is a risky procedure at best, since there is no true universal ball
and roller bearing grease. A ball bearing is best lubricated with a fairly stiff
grease which will channel.
83
DROP POINT
Another characteristic of a grease that must be considered is its drop point.
This is the temperature at which the grease passes from a semisolid to a
liquid. Typical dropping points are as follows
84
GREASE FORMULA
following formula to determine the correct amount.
85
GREASE selection
Selection of Lubricant. Research in elastohydrodynamics (EHD) has

contributed greatly to the knowledge of lubricants, rolling bearings,
and how they work. Results of this work have been published in
various forms that may be used as a guide in the selection of the
correct lubricant. Table next, is an example of these data in graph
form which plots required viscosity of the lubricant in centistokes at
operating temperature as a function of bearing size and speed. The
abscissa of the curve is the bearing size, expressed as mean diameter
in millimeters; the diagonal lines are the speed in rpm; and the
ordinate is the required viscosity at the operating temperature of the
bearing. It is obvious from an examination of this chart that the larger
the bearing and the slower the speed, the higher is the required
viscosity.
86
GREASE Selection
87
ALIGNMENT READINGS.
88
Pump-to-motor alignment guide..
89
90
91
92
93
Multi Pump-to-motor alignment guide..
94
Across-the-flex alignment
95
96
97
98

M2 - Preventive Maintenance Technology

Uploaded by

Copyright:

Available Formats

M2 - Preventive Maintenance Technology

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

M2 - Preventive Maintenance Technology

Uploaded by

Copyright:

Available Formats

....

Your platform to do MAINTENANCE EXCELLENCE in the work place®

ONLINE TRAINING SESSION

HSE Institution Training Academy

▪types of maintenance activities

HSE Institution Training Academy

• Deciding the amount of preventive maintenance (i.e.

• The bath tub curve is

3  Complete renewal will be

 Rail grinding is a maintenance  Point replacement of sleepers is a

• In this course we have main focus on preventive

•This effective failure rate is the failure rate

•There are two challenges

HSE Institution Training Academy

Ensuring an adequate flow of clean lubricant makes long bearing life

Normal Appearance and Wear.

A bearing suffering this type of failure is unmistakable in

If crush is insufficient, relative movement occurs between a bearing

Crankcase and Crankshaft Distortion.

These structural defects primarily affect the main bearings. Distortion

After cleaning the crankshaft, measure all the main and

Metric rolling-bearing boundary dimension plan.

Spherical roller bearings of different diameter

Metric tapered roller-bearing diameter

Mounting of a self-aligning ball

Mounting of a spherical roller

Drilling and grooving of the shaft to Use of a hydraulic nut to mount a

The energy loss in a bearing is proportional to the product of torque and

recommendations for selection of oil for all bearing

Where grease lubrication is used, we need to consider a few of the basic

following formula to determine the correct amount.

Selection of Lubricant. Research in elastohydrodynamics (EHD) has

You might also like

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.