Predictive Maintenance
Predictive Maintenance
Predictive Maintenance
PREDICTIVE MAINTENANCE
(CONDITION MONITORING)
CONDITION BASED MAINTENANCE
(CBM)
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PROACTIVE MAINTENANCE
Proactive
Maintenance
merupakan
aplikasi
PdM
sejak
design,
CONDITION MONITORING
Condition Monitoring (Deferred Maintenance): Merupakan monitoring
dan diagnosis kontinu atau periodik terhadap unjuk kerja dari suatu
komponen / equipment untuk memprediksi kerusakan (failure) yang
mungkin terjadi pada equipment tsb. Dalam industri istilah Condition
Monitoring dikenal sebagai Predictive Maintenance (PdM).
Objectif dari CONDITION MONITORING
1. Meningkatkan on-stream plant availability dan reliability
2. Meningkatkan plant dan personel safety
3. Mengoptimalkan maintenance costs
a. Maintenance man - hours costs
b. Spare parts costs
c. Maintenance consumable costs
d. Tools, test equipment and other utilities and infrastructure
facilities costs.
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NDT
Radiography
Ultrasonic
Magnetic Particle Testing
Dye-Penetrant
Hydrostatic Testing
Eddy Current testing
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PREDICTED TREND
DATA
FAIL
ACTION LIMIT
PREDICTED
TREND
Lead time
available
TIME
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Kurva P F
Titik dimana kerusakan (failure)
mulai terbentuk (belum terdeteksi)
Condition
Interval P - F
F
Time
Titik F dimana kerusakan (failure)
terjadi (Functional failure)
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CONDITION
P1
Change in vibration
(P-F: 1 9 bulan)
Audible noise
(P-F: 1 4 minggu)
P4
TIME
FUNCTIONAL FAILURE
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kerusakan
(failure)
equipment
tidak
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FUNCTIONAL PERFORMANCE
Smooth
running
Change in
performance is
detectable
Impending
failure
FAIL
TIME (FROM HOURS TO HOURS)
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FUNCTIONAL PERFORMANCE
CBM STRATEGY
Do maintenance
Condition monitor
Smooth
running
Repair atau
Replace
Equipment
Unusable
Change in
performance is
detectable
CONDITION
INSPECTION
FREQUENCY
Impending
failure
FAIL
Resistance to failure
IMPENDING FAILURE
Operational level
Onset of failure
Functional
failure
Age or Usage
Time of Onset of failure
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INFRARED THERMOGRAPHY
1. Mengukur suhu: Difrensial atau absolut
2. Cepat, aman (Non-contact), dan Akurat
3. Dapat digunakan pada Mekanis, Elektris, dan Konstruksi
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kategori CRITICAL, dan pada suatu saat mesin tsb dibuat pada posisi
STANDBY, maka mesin ini tetap kategori CRITICAL, yang tetap
mendapat perhatian dan selalu ada pada kondisi SERVICEABLE
STATE. Tetapi perlu diingat bahwa mesin STANDBY tidak memerlukan
condition monitoring bila mesin tersebut tidak sedang dioperasikan.
iii. HAZARDS INVOLVED IN THE CASE OF FAILURE. Perlu juga
pada
setiap
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THERMOGRAPHY
komponen yang saling bergesekan akan menimbulkan panas yang dapat menaikkan
suhu bila terjadi keausan pada komponen yang bergesekan. Thermographic
equipment yang digunakan dapat berupa alat ukur suhu sederhana sampai alat ukur
yang menggunakan sistem infrared. Kemampuan dan tingkat akurasi alat akan
menentukan harga alat ukur ini.
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OIL ANALYSIS. Oil analysis tool dapat digunakan untuk menganalisis dua hal yaitu
kualitas minyak pelumas dan partikel-pertikel yang terdapat dalam minyak pelumas
itu sendiri. Kualitas minyak pelumas dapat diketahui: apakah minyak pelumas ini
sudah terkontaminasi atau tidak, dan hal ini dapat diketahui dari corrosion
resistance, wear resistance, load rating atau minyak lumas rusak akibat panas
berlebihan (overheating). Adanya partikel dalam minyak pelumas menunjukkan
terjadinnya keausan pada komponen yang dilumasi. Jika laju keausan meningkat,
maka bagian yang mengalami keausan tersebut diteliti lebih mendalam dan dicari
penyebabnya dan selanjutnya dilakukan perbaikan.
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Sengaja dikosongkan
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VIBE
PROGRAM
Shaft Cracks
Not
Applicable
Strength
Wear Gear
Strength
Strength
Alignment
Not
Applicable
Strength
Lubrication
Condition
Monitoring
Strength
Not
Applicable
Resonance
Not
Applicable
Strength
Vibration program can detect a resonance condition. Lube analysis will eventually see the
effect
Root Cause
Analysis
Strength
Strength
CONDITION
CORRELATION
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LUBE
PROGRAM
VIBE
PROGRAM
CORRELATION
Oil Lubrication
Antifriction
Bearings
Strength
Strength
Oil Lubricated
Journal / Thrust
Bearing
Strength
Mixed
Machine
Unbalance
Not
Applicable
Strength
Water in Oil
Strength
Greased Bearings
Mixed
Greased Motor
Operated Valves
Mixed
Not Applicable random monthly vibe scan would detect the anomaly
Strength
Weakness
DEGRADATION MECHANISMS
1.
2.
3.
4.
5.
6.
7.
8.
Corrosion
Overload/Overheating
Fatigue
Erosion / Fretting Corrosion
Microbiological Corrosion
Mechanical Wear
Oxidation
Chemical Attack
Sources of Vibration
1. Imbalance
2. Misalignment
3. Impeller / Vanes
4. Gears / Bearings
5. Electrical (Rotor and Stator)
6. Mechanical Looseness
7. Belts and Sheaves
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Exfoliation
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Vibration Limits
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Interpretation and
Characterization
of Results
Governing Equations
(Equations of Motion)
Newton's Second Law
Euler Equations
Kane's Method,
(Principle of Virtual Work
and D'Alembert's Principle)
Lagrange's Equations
Hybrid Equations
Solution Method
Characteristic Equation
Reduction of Order
Linearization
(Equilibrium Points and Stability)
Change of Variables
Method of Undetermined
Coefficients (Guessing)
Superposition Principle
Fourier Series Expansion
Convolution Integral
Modal Analysis
Separation of Variables
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M.I.T study
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NO
===============
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NO
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NO
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NO
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NO
Benchmarking Process
1. Conduct an internal audit of a process or processes.
2. Highlight potential areas for improvement
3. Do research to find 3 or 4 companies with superior processes in the
areas identified for improvement
4. Contact those companies and obtain their cooperation for benchmarking
5. Develop a "pre-visit" questionnaire highlighting the identified areas for
improvement
6. Perform the site visits to the (3 or 4) partners
7. Perform a "gap analysis" on the data gathered compared to your
company's current performance
8. Develop a plan for implementing the improvements
9. Facilitate the improvement plan
10. Start the benchmarking process over again
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NO
Common Benchmarks
1. Percent of maintenance labor costs spent on reactive activities
versus planned and scheduled activities.
2. Service level of the storeroom: percent of time the parts are in the
storeroom when needed.
3. Percentage of maintenance work completed as planned.
4. Maintenance cost as a percentage of the estimated replacement
value of the plant or facility equipment.
5. Maintenance costs as a percentage of sales costs.
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DOWNTIME
DOWNTIME
Find the
Revalidate
Machine
Diagnose Find the
Repair
person who
or test the
stops
the fault spare parts the fault
can repair it
machine
Put the
machine
back into
service
REPAIR
TIME
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4. OIL ANALYSIS
Water content analysis
Particle counting
Viscosity measurement
Total Acid Number (TAN)
Elemental analysis (ICP)
Light Microscopy analysis
Scanning Electron Microscopy (SEM) analysis
Investigation of microorganisms by DNA examination
and growth tests
Gas Chromatography
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