All Member Open Forum

Good morning all,

I am currently working on assigning maintenance strategies to my companies assets.  I have completed assigning asset criticality.  I am interested in hearing what are some of the other considerations you have used in your assessment of which assets should get what type of condition monitoring.  At one of my sites some of the most critical assets have smaller gearboxes and motors.  It is hard to justify setting the gearboxes up for filtering when many of them hold 5 gallons or less of oil.  The same can be said for motor circuit analysis.  I am eager to hear what you have to say.  Thank you in advance.

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Jason Resler, CMRP
Corporate Reliability Manager
Green Plains Inc

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Hello Jason,

It is refreshing to see at a minimum, a criticality analysis performed. I hope it was part of a greater FMECA effort. As a general rule of thumb, PdM is assigned to critical equipment as part of their regular maintenance routine, in addition to any other recommendation emanating from SME's. We have three classifications of criticality, hence the ABC record rating at the equipment level. We employ a comprehensive suite of PdM technology, most of it performed in-house. The are:

1. Partial Discharge Analysis - semi-annually and combined with rotor flux analysis on large generators (power industry), buss bars
2. Rotor Flux Analysis - semi-annually
3. Vibration Analysis - quarterly, apply this to pump, fan, blower assemblies, not individual components
4. Infrared Spectroscopy - annually, apply this to circuit breakers, and even rotating element bearings, air-cooled condensers (yes-really) 
5. Motor Current Analysis - semi-annually, either static or dynamic testing to fit plant outage schedule
6. Megger/Polarization Index - anytime a machine is taken out of service or worked on
7. Lube Oil Analysis - much too involved and detailed required to adequately expound on within this venue. We have test slates which are site/equipment specific. These are deployed using strategy-based PMs within SAP PM
8. Transformer Oil - DGA performed on all GSU's regardless of criticality - due to the logistics of procuring one if one failed given persistent supply chain issues. Since the inception of this program, we have installed Serveron on-line DGA monitors which have proven themselves valuable for transformers in remote areas.
9. High Energy Piping - annually

AND Ultrasonic Testing - typically used in conjunction with other PdM technologies, ei - IR when troubleshooting transformer bushing issues, or steam condenser vacuum problems....hugely under-rated PdM technology tool. 

You can use discretion when applying PdM such as for motor MCA - use on motors:

• which operate at higher voltages of 600V or greater
• do not have redundant functional capability
• are of an unusual frame type or other constraint which will require rewinding in the event of failure and thus lead to lengthy down time

I agree with the small quantity of oil components. Just replace the oil at a given interval, preferably based on usage and maybe spot-check it occasionally just to see what wear particles you have and whether or not the additives are holding out ok. Best to replace early rather than late. I am sure I missed a bunch. 

All the best with your maintenance strategies

Ed Espinosa, CMRP, CRL, PMP
Asset Management
Puget Sound Energy
 





------------------------------
Ed Espinosa, CMRP, CRL, PMP
Sr. Performance Analyst
Puget Sound Energy
Bellingham WA
------------------------------

Thank you for your feed back, it is much appriciated.

------------------------------
Jason Resler
Corporate Reliability Manager
Green Plains Inc
Fergus Falls MN
------------------------------

Original Message:
Sent: 07-28-2022 06:36 PM
From: Edward Espinosa
Subject: Asset maintenance strategy

Hello Jason,

It is refreshing to see at a minimum, a criticality analysis performed. I hope it was part of a greater FMECA effort. As a general rule of thumb, PdM is assigned to critical equipment as part of their regular maintenance routine, in addition to any other recommendation emanating from SME's. We have three classifications of criticality, hence the ABC record rating at the equipment level. We employ a comprehensive suite of PdM technology, most of it performed in-house. The are:

1. Partial Discharge Analysis - semi-annually and combined with rotor flux analysis on large generators (power industry), buss bars
2. Rotor Flux Analysis - semi-annually
3. Vibration Analysis - quarterly, apply this to pump, fan, blower assemblies, not individual components
4. Infrared Spectroscopy - annually, apply this to circuit breakers, and even rotating element bearings, air-cooled condensers (yes-really) 
5. Motor Current Analysis - semi-annually, either static or dynamic testing to fit plant outage schedule
6. Megger/Polarization Index - anytime a machine is taken out of service or worked on
7. Lube Oil Analysis - much too involved and detailed required to adequately expound on within this venue. We have test slates which are site/equipment specific. These are deployed using strategy-based PMs within SAP PM
8. Transformer Oil - DGA performed on all GSU's regardless of criticality - due to the logistics of procuring one if one failed given persistent supply chain issues. Since the inception of this program, we have installed Serveron on-line DGA monitors which have proven themselves valuable for transformers in remote areas.
9. High Energy Piping - annually

AND Ultrasonic Testing - typically used in conjunction with other PdM technologies, ei - IR when troubleshooting transformer bushing issues, or steam condenser vacuum problems....hugely under-rated PdM technology tool.

You can use discretion when applying PdM such as for motor MCA - use on motors:

• which operate at higher voltages of 600V or greater
• do not have redundant functional capability
• are of an unusual frame type or other constraint which will require rewinding in the event of failure and thus lead to lengthy down time

I agree with the small quantity of oil components. Just replace the oil at a given interval, preferably based on usage and maybe spot-check it occasionally just to see what wear particles you have and whether or not the additives are holding out ok. Best to replace early rather than late. I am sure I missed a bunch.

All the best with your maintenance strategies

Ed Espinosa, CMRP, CRL, PMP
Asset Management
Puget Sound Energy






------------------------------
Ed Espinosa, CMRP, CRL, PMP
Sr. Performance Analyst
Puget Sound Energy
Bellingham WA
------------------------------

As far as the gearboxes go, if they are critical with minimal oil, extract a sample of the oil when changing it out, that way at least you can get a picture of what's what regarding asset health. Condition monitoring is not just for critical assets IMHO. Assets you want to avoid the repair and/or replacement cost / downtime of could benefit from condition monitoring. Ultimately what drives which technique and technology are the alignment of failure cause to just that.

------------------------------
Michael Trainor
The Hershey company
Cochranville PA
------------------------------

Thank you for your feedback.

------------------------------
Jason Resler, CMRP
Corporate Reliability Manager
Green Plains Inc.
Omaha, NE
jason.resler@gpreinc.com
218-770-3719
------------------------------

Original Message:
Sent: 07-29-2022 07:29 AM
From: Michael Trainor
Subject: Asset maintenance strategy

As far as the gearboxes go, if they are critical with minimal oil, extract a sample of the oil when changing it out, that way at least you can get a picture of what's what regarding asset health. Condition monitoring is not just for critical assets IMHO. Assets you want to avoid the repair and/or replacement cost / downtime of could benefit from condition monitoring. Ultimately what drives which technique and technology are the alignment of failure cause to just that.

------------------------------
Michael Trainor
The Hershey company
Cochranville PA
------------------------------

Some of the strongest in the industry and can help you determine when you have component degradation over time while protecting bearings and seals.
https://oneeyeindustries.com/products/






------------------------------
Daniel Stoye
Maintenance and Reliability Technical Advisor
Pioneer Natural Resources
Midland TX
------------------------------

Original Message:
Sent: 08-01-2022 09:54 AM
From: Jason Resler
Subject: Asset maintenance strategy

Thank you for your feedback.

------------------------------
Jason Resler, CMRP
Corporate Reliability Manager
Green Plains Inc.
Omaha, NE
jason.resler@gpreinc.com
218-770-3719
------------------------------


Original Message:
Sent: 07-29-2022 07:29 AM
From: Michael Trainor
Subject: Asset maintenance strategy

As far as the gearboxes go, if they are critical with minimal oil, extract a sample of the oil when changing it out, that way at least you can get a picture of what's what regarding asset health. Condition monitoring is not just for critical assets IMHO. Assets you want to avoid the repair and/or replacement cost / downtime of could benefit from condition monitoring. Ultimately what drives which technique and technology are the alignment of failure cause to just that.

------------------------------
Michael Trainor
The Hershey company
Cochranville PA

Oil analysis lets you monitor contamination, internal wear/damage, and chemistry/viscosity (additives, oxidation, water, acidity, etc.), and you could potentially have problems in all of those areas. Doing regular oil analysis will allow you to keep an eye on them. If the gearbox is small enough, you will have to top off occasionally to make up for all the oil samples, which will naturally remove contamination (as long as you're filtering your new oil) and will keep your additive package freshened up. Your reports will tell you if/when you actually need to do full-on oil changes. Your sampling frequency will of course depend on the asset criticality and the severity of the service.

Motor circuit analysis isn't a used as commonly as most of the other PdM tools because it takes longer and it requires the machine to be offline, but if the asset criticality warrants it, by all means go for it.

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Dale Nicholson, PE, CMRP, CRL
Reliability Engineer
Evonik Corp
Lafayette IN
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