CBM-2011 Condition Monitoring Forum Agenda

Monday, May 2
1:00 pm Welcome Address by Terrence O'Hanlon, CMRP, Publisher Uptime Magazine and Reliabilityweb.com
1:15 pm The Big 5: Understanding the Fundamentals of Condition Monitoring Technologies by Carey Repasz, Allied Reliability
2:45 pm Refreshment Break
3:00 pm Predictive Maintenance and Condition Based Maintenance Program Descriptions moderated by Terrence O'Hanlon, CMRP, Uptime Magazine and Reliabilityweb.com
5:00 pm - 7:00 pm Welcome Reception
Speed Networking
Dinner
Tuesday, May 3
8:00 am Establishing Ultrasound Testing as a CBM Pillar by Tom Murphy, SDT Ultrasound Solutions
12:00 pm Lunch
1:00 pm Drive Efficiency Improvements with Electrical Signature Analysis Testing by Richard Borge, President, Performance Evaluation Inc. and Richard Scott, General Manager, ALL-TEST Pro, LLC
2:00 pm Refreshment Break
2:15 pm Bearing Fault Detection by Jason Tranter, Director, Mobius Institute
4:15 pm Wind Down or
Optional RPI Theater (viewing past presentations)
Wednesday, May 4
8:00 am Infrared For Electrical and Mechanical Condition Monitoring by Wayne Ruddock, Author, Basic Infrared Thermography Principles
12:00 pm Lunch
1:00 pm Vibration Monitoring Program Design – what is the best methodology to get the best data? By Rod Acklin CMRP, Commtest
2:00 pm Refreshment Break
2:15 pm Oil Analysis Program Upgrade (Case Study) by Cary Forgeron, CLS, Director of Sales, Analysts, Inc. and Troy Lindsay, I&C Technician, Osceola Generation Station
3:15 pm Predictive Maintenance at Upper Occoquan Service Authority by Saul Cizek, Lead Maintenance Planner, Upper Occoquan Service Authority
5:00 pm Beach Dinner/Networking Event
Thursday, May 5
8:00 am Vibration Analysis & Laser Alignment "Technologies Working Together" by Ray Wonderly, Retired from General Motors Corporation, Owner of Advanced Maintenance Technologies and Trent Phillips, Condition Monitoring Manager, LUDECA Inc
9:00 am Refreshment Break
9:15 am Ultrasound Assisted Lubrication Best Practices by Adrian Messer, Manager, US Operations, UE Systems, Inc.
10:30 am Refreshment Break
11:00 am Precision Alignment Short Course: Soft Foot by Alan Luedeking – LUDECA Inc.
12:00 pm Lunch
1:00 pm Benefits of a Complete Motor Electrical Maintenance Programs by Joe Geiman, Baker Instruments/SKF
2:00 pm Refreshment Break
2:15 pm OSHA and NFPA 70E by Rob Miller, CMRP, Senior Technical Advisor, IRISS, Inc.
3:15 pm Panel Discussion
4:00 pm Wind Down or
Optional RPI Theater (viewing past presentations)
Friday, May 6
8:00 am Designing a CBM Program through a Failure Mode Based Maintenance Strategy by Carey Repasz, Allied Reliability
9:00 am Refreshment Break
9:15 am CBM Program Setup and Implementation by Carey Repasz, Allied Reliability
10:45 am Refreshment Break
11:00 am CBM Program KPIs and Management by Carey Repasz, Allied Reliability
12:00 pm Pizza Party and Wind Down

 

Presentation and Workshop Descriptions

The Big 5: Understanding the Fundamentals of Condition Monitoring Technologies by Carey Repasz, Allied Reliability

This short coursesession will walk the attendees through the fundamental principles of the five predictive maintenance technologies most prevalent in industry today: vibration analysis, infrared thermography, airborne & structure-borne ultrasonics, oil analysis and motor circuit analysis. Attendees will be walked through the capabilities of each technology along with the common traps that may be encountered during the application of these technologies.

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Predictive Maintenance and Condition Based Maintenance Program Descriptions moderated by Terrence O'Hanlon, CMRP

An interactive discussion to discover what can learned from the attendees current program regardless of the maturity level. Each attendee will have an opportunity to explain:

1) What technologies are currently in use
2) How they developed the skills required
3) How they prioritize or determine what will be monitored
4) What is the most effective part of the existing PdM/CBM program
5) What new things do you have planned for near term implementation
6) What would you like to learn or take away from CBM-2011

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Establishing Ultrasound Testing as a Condition Based Maintenance Pillar by Tom Murphy, SDT Ultrasound Solutions

In a world full of acronyms and buzzwords it is all too easy to forget the real meaning and purpose of our Condition Based Maintenance (CBM) journey. This half day short course is designed to help maintenance establish Ultrasound Testing as a pillar of your CBM program. The course will refocus the principle goals of your program by identifying what to do (and not do) first, why to do it, and most importantly, how to do it. Take away from this course an understanding for:

80% of all reliability programs fail to sustain any tangible benefits because they don't get past the implementation stage.  This short course strips away the mysteries of implementation by sharing their experiences in helping customers just like you.  If you have been tasked with implementing CBM at your plant this seminar is a must to attend.

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Drive Efficiency Improvements with Electrical Signature Analysis Testing by Richard Borge, President, Performance Evaluation Inc. and Richard Scott, General Manager, ALL-TEST Pro, LLC

Efficiency means different things depending on the context that it is used in, such as with Energy, where we discuss motor efficiency, energy consumption, power factor, etc. With respect to a Predictive Maintenance program the context may include how many machines can or should be included in the program, how many machines can be evaluated per day, and how many of the components in the machine should preferably be evaluated, etc…

Traditional on-line test methods, such as Motor Current Signature Analysis (MCSA) and Vibration Analysis (VA), provide valuable information regarding components within the electrical motor system. However, with respect to the entire motor system both provide a limited view.

Electric Signature Analysis (ESA) combines Power Analysis, Voltage Analysis, and Current Analysis into a single package. ESA allows the technician to evaluate virtually the entire motor system from incoming power to the machine, the motor electrically and mechanically and down through the driven load.  

Therefore, ESA provides the answers to the Efficiency of the Motor System with respect to Energy.

ESA also provides a means to increase process efficiency and effective availability because it improves the Detection Phase of a PdM testing program. I.e. evaluate the entire motor system and allows for bringing more machines into the program when compared to other traditional test methods.

This presentation is not about replacing existing test methods at your plant, but discusses and demonstrates key areas that ESA can add real value to an existing PdM program.

Besides providing information about ESA, examples will be discussed that demonstrate some key areas of neglect for many plants with respect to the analysis of:

 

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Bearing Fault Detection by Jason Tranter, Director, Mobius Institute

Rolling element bearings are critical components in the majority of rotating machinery.  If they fail there will be downtime, secondary damage, safety concerns, and probably overtime labor costs.  In this presentation, Jason Tranter will provide a three-pronged approach to avoiding catastrophic failures through vibration monitoring, and reducing the incidence of new failures.
1.       Care: The presentation will begin with an overview of why bearings typically fail and what you can do to avoid the failures.  Topics include: correct installation, lubrication, storage, transportation, and operation.  You will learn why shaft alignment and balancing and other corrective measures can extend the life of the bearing.

2.       Monitor: Next the presentation will provide an introduction to vibration analysis and the nature of the vibration patterns generated by bearings.  Two basic approaches to bearing health monitoring will be presented:

 

3.       Forensics: Just like the CSI TV program, we can open the failed bearings and learn why it failed.  Armed with this information we can complete the cycle and ensure that we prevent the problem from occurring again.

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Infrared For Electrical and Mechanical Condition Monitoring by Wayne Ruddock, Author, Basic Infrared Thermography Principles

Infrared imaging is a powerful technology with many applications in industrial plant electrical and mechanical systems. The price of infrared cameras has dropped significantly and the capabilities have improved making them a great addition to any condition monitoring and asset health program.

Attend this short course to gain a better understanding of many of the applications for Infrared in your organization, what type of skills and knowledge are required and how to create and manage a successful program.

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Vibration Monitoring Program Design – what is the best methodology to get the best data? By Rod Acklin CMRP, Commtest

Vibration monitoring and analysis is a powerful technology for diagnosing the onset of a potential failure in rotating equipment however mastering the available technology, making the right choice of continuous or portable system and applying software can be overwhelming. Join us for an overview of how to design and manage a successful Vibration Monitoring Program.

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Oil Analysis Program Upgrade (Case Study) by Cary Forgeron, CLS, Director of Sales, Analysts, Inc. and Troy Lindsay, I&C Technician, Osceola Generation Station

How do you know if your oil analysis program is providing you the information you need to make proper maintenance decisions? This case study focuses on how a power plant was utilizing an oil analysis program, but was not getting value out of the information provided. Working together with a commercial laboratory, they were able to restructure their lube oil sampling program resulting in a documented savings of over $100,000 in the first year.

Osceola Generation Station is a 600MW power plant. The plant had experienced a number of unit trips, plugged filters, and sticking servo valves in their control system. All of these resulting in additional Operation and Maintenance costs. However, the oil analysis reports continued to come back with "Normal" reports.

Partnering with a commercial laboratory, the plant was able to develop a test package to measure and monitor specific parameters unique to their applications. The results identified major issues previously not caught by oil sampling.

There are literally hundreds of oil analysis tests available in the market. While the typical "Packages" offered by commercial labs can meet most needs, it is imperative for end-users to understand the limits of these tests and know that there are additional tests that can enhance the information they are receiving.

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Predictive Maintenance at Upper Occoquan Service Authority by Saul Cizek, Lead Maintenance Planner, Upper Occoquan Service Authority

This presentation will discuss the challenges we faced in deploying a predictive maintenance and condition monitoring program using airborne ultrasound, vibration analysis, oil analysis and motor current signature analysis. This presentation will also explain cost justifying the program to ensure good use of public monies and how we gained critical "buy-in" from trade techs.
Bio: Employed by Upper Occoquan Service Authority – Centreville, Va. (uosa.org) as Lead Maintenance Planner. Responsible for developing and implementing planned maintenance activities for a 54 MGD wastewater reclamation facility.
He has electrical, mechanical, electronic, pneumatic, hydraulic, optical and engineering abilities. He has experience in handling material and supervising personnel as well as writing instructions. He operates light and heavy equipment and has general computer skills. He designs, documents and fabricates equipment in metal, wood and synthetics.

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Vibration Analysis & Laser Alignment "Technologies Working Together" by Ray Wonderly, Retired from General Motors Corporation, Owner of Advanced Maintenance Technologies and Trent Phillips, Condition Monitoring Manager, LUDECA Inc

This discussion will focus on the use of Vibration Analysis to verify machinery problems or faults, primarily misalignment. Case studies will be presented to highlight the benefits of using Vibration Analysis for the early detection and verification of misalignment problems and the use of Laser Alignment systems to correct problems found.

After corrective actions are performed and problems eliminated, new vibration measurements should "always" be taken to confirm satisfactory results. The intent is to illustrate how Vibration Analysis can save valuable time when used in conjunction with Laser Alignment to verify the root cause of problems found and to confirm satisfactory results.

We'll also discuss common characteristics of misalignment, different types & causes of misalignment and things to consider when performing precision alignment of equipment.

Classic "textbook" case histories will be presented (as time permits) of misalignment problems along with some factory floor case history examples to illustrate unique situations when special vibration measurements such as high resolution or high frequency instrument setups were needed and proved very beneficial in determining the true source or "root cause" of machinery problems.

A case history involving acceptance testing of a recently rebuilt 800 hp 2-pole motor & Centac Compressor will be presented where the true source of excessive vibration levels were questionable in terms of whether they were more related to mechanical (misalignment) or electrical vibratory forces.

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OSHA and NFPA 70E by Rob Miller, CMRP, Senior Technical Advisor, IRISS, Inc.

The Occupational Health and Safety Administration (OSHA) enforces electrical safety regulations in the United States. Although OSHA has not adopted and does not mandate NFPA 70E compliance, you can be cited for non-compliance. If you wonder how this could be possible, remember that OSHA's authority to do so stems from the occupational Safety and Health Act in particular Section 5(a)(1) and 29 CFR 1910.2(g).

Section 5(a)(1) "The general Duty Clause" of the Occupational Health and Safety act, states that employers "shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees". This is the clause most cited by OSHA where unsafe work conditions are found to exist.

Section 29 CFR 1910.2(g) states a "National consensus standard" means any standard or modification thereof which has been adopted and promulgated by a nationally recognized standards-producing organization under procedures whereby it can be determined that persons interested and affected by the scope or provisions of the standard have reached substantial agreement on its adoption". NFPA 70E is considered a national consensus standard and as such, non compliance leaves employers open for citation under this clause if they are found not to be in compliance.

This paper discusses in detail the interrelation of OSHA safety standards and NFPA in greater detail as well as discussing some of the major changes in the upcoming 2012 edition of NFPA70E.

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Precision Alignment Short Course: Soft Foot by Alan Luedeking – LUDECA Inc.

Bio: Alan Luedeking - Training instructor and field service engineer for alignment of rotating machinery. Alan's formal education includes a Bachelor's degree from the University of Colorado, and 28 years field experience with all types of machinery in a wide range of industries including breweries, mines, power plants, paper mills, chemical plants, oil refineries, food processing plants, shipyards, and others.

Abstract:

This presentation is an in-depth treatment of the subject of soft foot, or machine frame distortion, in directly coupled rotating machines. The presenter will cover how to measure soft foot with different methods and discuss the pros and cons of each. He will also discuss how to diagnose and correct soft foot conditions, and will then take your questions concerning these topics.

Key Bullets:


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Benefits of a Complete Motor Electrical Maintenance Programs by Joe Geiman, Baker Instruments/SKF

Electrical predictive maintenance programs are an industry standard and are practiced worldwide; however, a complete electrical motor maintenance program can be more cost effective. Locating, diagnosing and correcting problems before equipment failure is the universal goal of these programs; however, predicting motor problems requires knowledge, experience, the appropriate tools, and commitment. Electric motors have numerous components including copper winding wire, insulation systems, bearings, and other mechanical and electrical features. These components combine with other items such as drives, intake pumps, compressors, conveyors among a long list of other items to create machines of industry. A complete electrical motor maintenance program includes testing and evaluating motors during repair and refurbishment, incoming and outgoing inspection, as well as predictive maintenance. This complete program also includes close evaluation and communication of the motor repair facility including the specification of parts, procedures and quality control tests.

In order to have a complete motor maintenance program, it is important to perform static tests that evaluate the motor circuit as well as all the insulation in the motor. Standardized tests include winding resistance, insulation resistance, polarization index (PI), DC step voltage and the surge test.

On the other side of electrical motor testing is dynamic motor monitoring. A motor is part of a machine system that is comprised of three components: the incoming power quality, the motor itself, and the load being driven by the motor. This dynamic tool can define subtle issues within the mechanical or electrical systems that often go undiagnosed. Issues such as harmonics, low or high voltage variations, voltage unbalances, rotor bar problems, bearing issues and misalignment are just some of the problems that can be identified. All of these issues will affect the motor system negatively, raising the cost of operations and lowering the efficiency of the overall operation.

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Ultrasound Assisted Lubrication Best Practices by Adrian Messer, Manager, US Operations, UE Systems, Inc.

Airborne and Structure-borne ultrasound has evolved into a technology that many would consider to be the cornerstone of an effective condition based maintenance program. From leak detection, electrical inspection, and various mechanical inspections, ultrasound is truly a versatile tool for anyone's PdM "toolbox." One application in particular is to utilize the technology for condition based lubrication and to prevent over lubrication in rotating equipment. This presentation will show how using structure-borne ultrasound, one can detect mechanical faults in rotating equipment and prevent failures due to over lubrication.

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Designing a CBM Program through a Failure Mode Based Maintenance Strategy by Carey Repasz, Allied Reliability

Building the foundation for a successful Predictive Maintenance Program is as important as the technologies you use and the skills of the people implementing the program. Taking the time to create foundational elements will increase the chance of success and sustain the health of your assets.
Any successful reliability initiative must start with a few key elements: accurate asset list, asset criticality ranking, failure modes, determining the right levels of targeted coverage, leaning out your PM tasks, developing standards for both technologies and personnel, optimizing work flows, report quality and the appropriate KPIs. Whether some or all of these elements have been addressed in your respective plant, a program's success will rest heavily on how well you combine these elements into a fully integrated Asset Health work management system.
During this presentation:

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CBM Program Setup and Implementation by Carey Repasz, Allied Reliability

Industrial equipment does not suddenly break down and stop working. The truth is that equipment breaks down gradually – over a period of weeks or months. During that gradual process, it gives off numerous warning signals. These early warning signs – such as, slight changes in temperature, vibration or sound – can be detected by PdM technologies. As a result, PdM gives you time to plan, schedule and make repairs before the equipment fails.
Despite what you may have heard, the foundation of a successful PdM program is a simple list: A detailed, accurate equipment list. Why? Because your equipment list is the foundation for all of the steps that follow. A good equipment list is essential for:

During the presentation Carey will discuss why it is so important to have PdM analysts who can make the right recommendations. At a minimum, your analysts must be equipped with:

Your PdM program will be most effective when the scope of the program is clear and well-defined. A design and scope document provides your team with the information necessary to clarify and fully understand the program. Basically, a design and scope document is a blueprint that helps plan, schedule and control the implementation of the project. In addition, it should also include the business case – an objective financial analysis of current and expected benefits of the Predictive Maintenance process. Having all of this information compiled and published in one final document is a powerful way to lay out your plans.

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CBM Program KPIs and Management by Carey Repasz, Allied Reliability

This presentation will demonstrate both how to analyze current organizational Key Performance Indicators (KPIs) for effectiveness as well as the development of new KPIs to drive different organizational behavior.
During the presentation Carey will discuss:
How to develop Leading and Lagging Metrics and KPIs specific for any organization to drive the right behavior and ensure alignment of the maintenance and reliability organization;
Specific tips for exposing others and providing "buy in" to new metrics and Key Performance Indicators in order to drive the right behavior;
How to develop KPIs for floor level personnel which will engage the maintenance staff;
The development process for great presentations using MS PowerPoint;
KPIs for best maintenance and reliability practices;
How to develop and define roles and responsibilities for metrics using a RACI chart

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