This document introduces condition-based maintenance (CBM), which uses condition monitoring technologies to predict asset failures and schedule maintenance based on equipment condition rather than time. CBM aims to improve operating performance, ensure safety and environmental protection, reduce maintenance costs, and provide a comprehensive maintenance database. The CBM methodology takes a two-level approach using technologies to identify short-term failures and reduce medium to long-term maintenance tasks. CBM technologies discussed include oil and grease analysis, portable vibration analysis, portable ultrasonic analysis, and portable thermography analysis to monitor various mechanical and electrical equipment conditions.
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An Introduction to Condition Based Maintenance (CBM)
1. An Introduction to
Condition Based Maintenance (CBM)
An approach to CBM Application and Management by: GAA Optima
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2. The CBM Philosophy
It is about utilising the Condition Monitoring technologies to
predict the failure pattern(s) of an asset.
This will allow maintenance to be scheduled based on
equipment condition and not time.
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3. The Vision is to attain:
Meaningful set of maintenance schedules (Technical
Basis of Maintenance - TBoM)
Improved operating performance
Ensure safety & environmental protection
Reduced maintenance costs
Comprehensive maintenance database (Centralised)
Clearer view of resource requirements
CBM attains lasting benefits & can be applied across all or
just selected equipment
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4. The Methodology
The strategy uses a two level approach by overlaying Techniques &
technologies on monitored components
Level one (Short term): Identify and reduce equipment failures across site
Use technologies to troubleshoot and examine poor performing assets
Energy usage examinations
Level Two (Medium to long term): reduce maintenance exam tasks, extend
maintenance exam and Overhaul periodicities (TBoM integration)
Use technologies to reduce maintenance costs
Effective utilisation of work force
Increased knowledge of asset performance and condition
Feedback into TBoM
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5. CBM Financial Impact
Easy to Labour Low on
services
measure Overheads profit
Reliability
Safety Legislation Design Scrap
out
Availability
Catastrophic Poor
failures maintenance
Breakdowns
& Repairs
Use of
skills Warranty
Low
Flexibility
Hard to
High on
measure
profit
6. Some of the CBM Technologies employed
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7. Oil and Grease Analysis
Three dimensions:
Wear
Ferrous
Nonferrous
Contamination
Dust
Water
Fuel
Chemistry
Oil
Additive
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8. Portable Vibration Analysis
What does it monitor?
Imbalance Problems
Mis-alignment Problems
Bearing Problems
Electrical Defects
Where?
Cranes
Air Compressor motors
Brake resistor / Traction cooling fans
HVAC equipment
Alternators
Turbo charger
Gearboxes (wheel lathe)
Electrical motors
Cooling system pumps
Lubrication oil system pumps
Fuel Pumps
Diesel Engine
Axle boxes
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9. Portable Ultrasonic Analysis
What does it monitor?
Air Leak Problems
Electrical Problems
Mechanical Problems
Location?
Leak Detection
Valves
Air supply lines
Flexible hoses
Pneumatic systems
Pressurised systems Electrical
Vacuum system problems Arcing Detection
Compressor
Mechanical
Steam Traps
Bearing defects
Lack of Lubrication
Over Lubrication
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10. Portable Thermography Analysis
What does it monitor?
Electrical Problems
Mechanical Problems
Pipework Problems
Problems detected?
Electrical Problems
High resistance connection
Corroded / hot connections
Earth returns – Higher loading
Relay problems
Internal fuse damage
Internal circuit breaker fault
Cracking insulation
Overload or unbalanced load
Busbar faults
Couplings
Cooling jackets
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