Reliability Engineering for MaintenancePosts about Root Cause Analysis
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Hi for everione [ more ]
I intend to evaluate the reliability of the Station-keeping of the FPSO, it can be for 3DOF or 6DOF, it doesn't matter. The objective is heading optimization, mooring stability and DP optimization. I am basing myself on the treatment given by Sorensen (2011) \dot (x) = Cp(x,w) which implies switches for the different modes of operation of the Vessel, Cr determine the state space equations of the process, x is state vector and w is the environmental disturbance vector. I see station-keeping... [ more ]
Hi R eliability Scholars , Hope you all doing well. I am new in the comunity. Did any of you worked on classical reliabity of an FPSO Station-keeping using Weibull distribution. The objective is to a sure the maitenance of the position and heading. If so, can you give tips on how you got a good review? I am defining Station-keeping as the set of turret, mooring and dynamic position (DP). I evaluate each of these subsystems, and then Rsk(T) = R(turret)xR(mooring)xR(DP). With regards Hlunguane J [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Root Cause Analysis
As others stated, mechanical looseness is present. The sidebands are most likely from the outer or inner race spinning. When the bearing spins in the housing/shaft, it is turning at a different speed which will create a frequency very close to running speed. Have seen worn gear couplings exhibit this same pattern. Down and dirty way of checking. Dial indicator on shaft of interest at top dead center, long bar and block/s of wood, gently pry up on shaft and record total indicator movement. [ more ]
any other idea for this reading from experts [ more ]
5x?...how many blades the impeller? 1x, there is the unbalance, is clare. how many blades per impeller there is an imbalance, it is clear but, regarding the last photo, many nx armonics indicated like bearing/housing looseness... we see high 14x armonic, probably 14 impeller blades? but the sideband from 6x to 18x is look like a rotor bar problem about motor...? many things, but just my opinion [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Root Cause Analysis
Sharath, Not sure of your pumping drive or piping configuration, IF this is a self priming application, then read on. You state pump is submerged 5 meters under the water? What is design point, pressure/flow rates, pump manufacturer, model number etc You do not address the fact that the suction lift for the pumps is not possible? 15 to 17 meters is 49 feet, ALL CENTRIFUGAL PUMPS follow the same laws of physics, the maximum amount of suction lift at sea level is 10.33 meters at sea level,... [ more ]
Hey Dave thanks for your reply and ur time on this. The sea level is approximately 15 to 17 mts from the right-angle gearbox and the pump is submerged in water ~5mts. And all the pumps are placed on different platforms with different suctions and we also have 2 jockey pumps with same height and length but there is no any oscillation in column as fire pumps. All the pumps are installed recently may be 20 months. Suction lift and discharge pressure are getting as required but the only issue is... [ more ]
Sharath, The suction lift you are trying to do is not fundamentally possible? Theoretically, all centrifugal pumps can lift water not more than 10.33 m at sea level. If the liquid is below the pump datum, the vertical distance between the pump impeller and the surface of the liquid on the suction side of the pump is referred to as the suction lift . Apr 13, 2017 Are these newly installed? Are there more than 4 fire pumps? Do the each have their own suction pipe? What is the altitude of the... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Thanks Venkatesh.V.. I already check the breather condition also [ more ]
You can check breather condition also [ more ]
Thanks Kishore, Temperature is increasing gradually. We have protection tripping logic has installed at Pump bearing temperature.. That's why we are monitoring closely. Do you think bearing housing imperfections may leads to high in temperature? [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
For real-time and reliable monitoring of vibrations, offline analysis tools for validation and optimization cannot be trusted uppm. A real-time Torsional Vibration Analysis system must be implemented. It can offer you coordinated tools for vibration monitoring and analysis combined with process data in real-time. This system can monitor the individually adjustable frequency band monitoring, a self-learning module for monitoring frequency spectra, and the angular shaft motions. Integrating a... [ more ]
Hi! We have similar system for monitoring vibration for 7 channels. [ more ]
Hi Phil, I already used metrix, system 1&evo & alta solution 1250FE and i would recommend AS 1250FE if your budget is tight, this same as adre p408 or if you dont mind the cost just go to BHGE product or metrix setpoint. regards, [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reciprocating pumps and reciprocating compressors may cause severe pulsation and vibration in your assets, which could result in damages of supports, foundations and instruments. This may result in unstable process operation or malfunction of your assets. The pulsation and vibration analysis of reciprocating compressor/pump systems are required at the design stage to prevent such undesirable conditions. A Torsional Vibration Analysis system can help monitor and reduce the vibration at the... [ more ]
A reciprocating pump is a pump that uses backward and forward movement to move fluid. In a reciprocating pump , a piston, plunger, or diaphragm moves backward and forward. A reciprocating pump is one in which the liquid follows the movement of a piston during suction and delivery strokes. Talking about vibration limit ISO-10816-6 may be applicable where vibration evaluation for hydraulic power generating and pumping equipment. Have you tried Polycab self-priming monoblock pump if not have a... [ more ]
Hi, Vibration analysis is a tedious job. The below mentioned link help me to understand it better. Refer: https://rms-reliability.com/pr...on-analysis-service/ [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Lube oil analysis is crucial for the overall maintenance of machinery. However, the primary step of lube oil quality management is oil sampling . It is important to consider this aspect as 54% of machines usually fail due to poor lubrication. To ensure the smooth operation of your assets, it is imperative to first collect lube oil samples before forwarding them to your plant and have an oil filtration system in place. The main objectives of lube oil sampling are: Oil Flowing through... [ more ]
Dear Ali, All information are valued especially while coming from experienced hands. I am also planning for mandatory inspection . cleaning of lube oil tank every 5 or six year ,But major hurdle is the access and confined space issues [ more ]
Pre-filtering is a best practice. You'll need a setup for that which might be the main hurdle for most people to do the pre-filtration. This would be a necessity if the new oil is far away from the cleanliness level you target. Oil reservoirs are inspected where I work every time the oil is replaced. I'm talking about medium to large machines. Many times, the inspection reveales key findings like corrosion and pin holes. Maybe these are more common with steam turbines (most of my... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
When managing your asset’s overall health, the condition of the machine’s bearings plays a crucial role. An issue with even a single bearing can cause the machine to break down, resulting in production loss and costly downtime. Carefully lubricated bearings can almost have an infinite life. Also, if the torsional vibration is not controlled or correctly measured, it can cause unplanned machine breakdowns. This is where Torsional Vibration Analysis for bearings comes in. This technology can... [ more ]
Greetings Mr . M NADEEM ANJUM . You can monitor regular trend and analyze fault respective machine component frequencies . Typical acceleration data related to all types of bearings in general rotating equipment. (Exceptions = Diesel Engines & Rock Crushers.) EXCELLENT LEVELS = Usually .10 G or Less. No action required. GOOD LEVELS = Usually .35 G or Less. No action required unless noisy. FAIR LEVELS = Usually .50 G or Less. No action required unless noisy. (If you have no records... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
A long answer for a short question. If you are new to balancing, perhaps it is good to search about the vector method. I should mention, however, there are simplifications (or oversimplifications) in many of the articles, videos, etc compared to what you may face at the field/shop. Regards- Ali M. Al-Shurafa [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Is the pump running at BEP or away from it. [ more ]
what was the cause of the 5X ? [ more ]
GREETINGS WELL NOTED. THANKS FOR YOUR FEEDBACK. PLEASE FOLLOW THIS METHOD AND TRY HOW YOUR VIBRATIONS ARE INDICATING. 1. CLOSE DISCHARGE VALVE AND START THE PUMP AFTER FEW SECONDS AT FULL SPEED AT MAXIMUM PRESSURE MEASURE THE VIBRATION SLOWLY OPEN DISCHARGE VALVE AND MEASURE THE VIBRATION. IF FLOW INCREASING TIME VIBRATION RISING IT IS RELATED TO FLOW SURGES CAUSING THE VIBRATION. IF STEADY AT EVERY DISCHARGE VALVE POSITION THEN THE VIBRATION IS NOT FLOW RELATED. ALSO TAKE RUN UP AND COAST... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Predictive maintenance solutions can be implemented in a plant to predict issues and asset machine breakdowns. This technology uses machine-learning and AI-powered solutions to gather historical data and predict which parts of an asset could fail and at what time. Advanced sensors are installed and technicians can have information about accurate data points, remotely. The collected data can then be analyzed by advanced analytical tools and predictive algorithms. With this information, the... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
For the members in the forum to give meaningful comments, I guess you need to provide more details, otherwise you may receive general comments and guesses. My general comment and wild guess, this could be normal behavior. Regards- Ali M. Al-Shurafa [ more ]
Thanks Mr. Shurafa for the response. Steady State forward precession is observed steadily, but coast-down forward and reverse precession 1X orbit 💫 observed intermittently. Even though Vibration amplitudes are well within the limit, I want to know why this behavior happens and what are all the possible reasons for this issue.. [ more ]
I assume you implicitly ask if this reverse precession orbit is acceptable or not. Regards- Ali M. Al-Shurafa [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Repair in case of emergency would be my philosophy If you apply anything to impeller, it is now out of balance. Unless the material your are applying is harder than base impeller material, it too will fail. What costs more, identify and fix the cavitation issue thru piping or liquid level changes or putting a bandage on a problem. In some cases, a change of materials of construction is needed, like from bronze to stainless. As you stated originally, you have a cavitation problem, seen by... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Hi JC L., I started study RCM and read some documents about IRCMS, but I try to find the software but the links to the software isn´t working more. Is there one link to get the IRCMS software? I notice that all information about the software is out of date but I was interesting in know this software. Regards, Giuliano Luz [ more ]
Another package is RCM++ from ReliaSoft this package incorporates Criticality Analyisis, Task Packaging, costs parameters and optimisation features and links to their other reliability tools. You can download a demo and a training guide from http://www.reliasoft.com BUT it is a big programme because of the high degree of customisation and features. They have work wide offices. Dave http://www.Ramsoftuk.com ReliaSoft partner [ more ]
Can we easily do uploading into cmms? No standard tutorial? [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Hello. We have similar column pipe bolt sheared. Shaft bent.Bottom neck ring to impeller stuck causing cold welding. But unable to find the cause. No overload motor trip. Few possibilities are 1) Column pipe bolt loose causing offset of bowl assembly. 2) Pump operating at closed shutoff. Recycle line PRV failure . 3) Low clearances of neck ring to impeller. Foreign particle stuck. Please provide your inputs. [ more ]
Hi CBM, Dave Reynolds has attached some very good info on breakages and in Dave's literature there are images of misalignment breakages with ratchet marks, this breakage appears very similar with fine ratchet marks around the circumference of the shaft breakage, if you are still trying to solve this let us know and I’ll ask our metallurgist for an opinion and if it is of use we can post his comments here to assist, regards Rob S [ more ]
The double paste can be edited by the OP, can it? [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
API 617 would be helpful [ more ]
Mohiuddin, There are many references that can be suggested to use but perhaps they are not useful for you; they may not be applicable. Your case can be for a factory test, site test, shop test, after an overhaul, collected by a routine handled analyzer, collected by an online system connected to a shutdown system, for a compressor whose bearings are anti friction type or journal bearing etc. Search for ISO and API standards on compressors and you may find some figures to start with. If you... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Capital Projects
Independent companies are exclusive organizations, associations, or sole ownerships that have less workers and additionally less yearly income than a normal estimated business or partnership. From; South African Trademark Search [ more ]
Hi everyone, I am new to this forum but have some suggestions on business centered maintenance. My view is why not treat maintenance like a business? The goal of any business is to maximuize the outcome while minimizing the input. That is to improve the return on investment. In maintenance you do this by improving usable capacity, reducing costs and reducing the working capital investment. From this everything else follows. I could go on about how targeting PM programs is analogous to... [ more ]
Did you have an industrial/pharmaceutical companies association back there in Malta? [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
david, thank zou very logical analysis, i will go through these points thx Pizo [ more ]
Pizo, Your original post said that this has happened three times this year, I take that to mean that it does not happen every shutdown. This could be an error in the operator shutdown procedure or it could be an error in the operator running procedure. They may not be siphoning all of the condensate out during normal operations. You'll have to look for inconsistencies in how they run as well as how they shut down. Keep in mind that this only happens in one dryer section, what is different... [ more ]
Hi, David, thank you... we opened all the cylinders check hole, the water was in several cylinder but little. it seems that this little water in many cylinders form an extra load on the motor. this happen only in a specific drying group, the other groups are working fine. they checked the siphons, they are ok. what a human error could be ? thx Pizo [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
The design of the motor at 4000hp running at 6000rpm will be critical, the mechanical stresses on the windings especially winding overhangs of the rotor will require special material and construction, something to consider for long term management of the asset and its reliability. [ more ]
Dear Johan, totally agree with you.. the challenge is huge.. I heard with modern VFD not is necessary to get Gear Box, because the VFD can reach 7200 rpm in the motor, that is enough for the compressor. but I dont know the power limits for this application. thanks. [ more ]
Evening Ramon, some comments, depending on the voltage a VFD could be better option however voltage would dictate, high speed motors comes with its own challenges, keep an eye out for that, select gearbox carefully, high quality especially for that speed will be critical, wouldn't like to recommend publicly (can discuss with you if you are interested). Yes numerous ways to inspect and make foundation and base is suitable, would imagine if you go from steam turbine to electric motor there... [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
I think you are dealing with critical mechanical looseness, probably coming from the fan DE bearing (bearing housing / coupling / attachment as alternatives). Your spectra should have better resolution for detail analysis with some peak markers. Besides, imbalance could also be well increased, although it is hard to say in such bearing condition. I wouldn't operate much longer [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
thank you @Registered Member For you replay [ more ]
Hi Ahmad, Firstly, redundancy is not a maintenance strategy, it is an engineering/design strategy. I disagree with the explicit statement that "no need for condition monitoring for redundant system". Industry best practice would dictate that the decision on whether or not to conduct condition monitoring should be based from criticality of the equipment, regardless if it is spared or not. Your company should establish your risk matrix first similar to what you showed in slide 5, determine... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
I suggest checking the axial location of the bearings seats. Mind! There always MUST be one bearing on the shaft which is axially free (allows for shaft axial expansion). Bearings do NOT have enough internal clearance to compensate for such expansion!! If this is problem you will always see strange spikes during load change (usually start-ups) [ more ]
Greetings Mr. Vibration Expert, With the given data nothing can be concluded. give some vibration reports when normal load operation, How you noticed 10% amps dropped and minor maintenance carried out and what was the maintenance. When DE bearing increased to 60*C more what is the ambient temperature and what is actual temperature showing? What are the vibration readings when the temp rise was 60*C also what were the temperatures on Motor side. Motor DE/NDE and Blower side How many bearings,... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
On first view of the TWFs and FFT, it just smells like looseness and possible rubbing. But that is just a "fast I'm not sure" guess. You can put pieces of this puzzle together by providing more detail on the history of this fan....need lots of answers to what, wheres and whys - Were both fan bearings replaced? why did you replace them? and what condition did you find them in? are these pedestal type bearings? make/model? What was the condition of the shaft mating surface? Are you confident... [ more ]
At first look I would say mechanical looseness [ more ]
Motor power, rpm, measurement history, envelope.....? [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Greetings Pawan, Good case study. 1. One thing is sure after overhaul and fitted the piston ring failed with in 2 days. 2. Especially when lowering the piston into liner, the guide ring, if having any scratches or dents or when forcing the piston into the cylinder liner normally the bottom ring can stuck or break and continue to run the broken piece can damage the piston and liner. This failure occurs in Tandem compounding pistons. In Marine Industry we have faced this type of failures for... [ more ]
dear sir have you n checked the suction and discharge valves ? if you sure about maintenance of all components and installation procedures ,you should looking for cause around operation after overhauling .for example be sure about condensate gas or liquid drainage during operation. best regards [ more ]
Was the cylinder starved of processed gas? How about the end devices that was to shut down the unit for excessive vibration are they properly installed and working? from your explanation though not too clear- Rod reversal due to lubrication issues might be the root cause. [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Y7, Where I work, figures MTBF for pumps are reported on a monthly basis. A major challenge is to be consistent in your criteria. One of the very vital practices is to define the boundaries of a pump and make sure all involved employees follow the same definition. For example, which of these are/are not parts of a pump at your facility? 1. Shaft coupling 2. Instrumentations like shaft vibration probe, bearing temperature element, discharge pressure transmitter 3. Base, foundation, base plate... [ more ]
Y7, I think your approach is right. You are just looking and calculating MTBF of pump only. If you want to take whole system which may include, pump, strainers, etc.. then you have to consider all the failures in that system. [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
It is a good reference of best practices in changeover for spared equipment. It is important to consider factors like the type of service and risk associated with any disturbance during swapping. Some services like slurry or viscous fluid require extra care. For the pumps, I saw some site follow 75%, 25% scheme so pump A runs 3 months followed by one month by pump B as one cycle, this is to avoid simultaneous life related failure. This scheme was debated by Heinz Bloch in one papare giving... [ more ]
Hello, Thank you gentlemen, please see the expanded edition attached here; with ten pages that now includes A,B,C and A,B,C,D configurations. Abdulrahman Alkhowaiter [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Hi, Johan. Thanks for your help. I just want to correct my mistake: The transformer has a power of 400MVA and not 400kVA as I wrote earlier. [ more ]
Morning Vyacheslav, I would suggesting finding out what is causing the gas generation, yes and I know its easier said than than done, because of the complexities of trying to "look inside" a transformer, I don't think you will be able to stop the gas generation unless the root cause is established, it however sounds like you need to "buy some time" until you get the opportunity to take it offline and inspect properly, if so, I can put you in contact with an industry expert with regards to... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Having 2000 tons in a area now for conflict is a problem some tried to get authorities to reconsider the protein all risk but nothing happened someone figure out what 2000 ton of a potential explosive could do with a little help risk recognition and protential harm are not recognized [ more ]
I feel extremely heartbroken and tragic for what has occurred at the port. I wish the recuperation endeavors make it sooner than what individuals might suspect. Your inquiry is somewhat broad, along these lines, you may get general remarks. WE can use drones for the public safety it is a best machine learning programs Here are some websites who provides cloud programs for drones. https://www.measure.com/ https://droneshowsoftware.com/ https://flytnow.com/ and many more [ more ]
Dear Ali, Thank you for your reply, we all hope a fast recovery so people can return back to their "normal" life. Concerning your reply, you're 100% correct and that step should be done prior to the rest of the tests. Some of the problems that I came across were misaligned and unbalanced rooftop cooling tower and ventilation fans, the explosion had deformed the thin fan cover and in one case the impeller had impacted the cover and blades were worn/cracked/broken. Thanks again for your... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Thanks for Replay Mr. Kishor ji. [ more ]
Dear Pathu , could you post your spectrum with peak frequency labeling , so that we could identify the root cause .Also mention motor running r.p.m . As per my point of you : 1.Check Belt pulley sheaves alignment & Tension . 2.Check Belt pulley sheaves V-grove profile ,which might leads belts to uneven wear and repeated failure along with increase in vibration trend . [ more ]
Fan is overhung type [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Capital Projects
In case someone stumbles across this older post, feel free to check out www.roadtoreliability.com [ more ]
Kindly include my website, I just uploaded this recently heres the link : www.rsareliability.com My Warm Regards, Rolly Angeles Teacher www.rsareliability.com [ more ]
I'll agree there may be some energy dissipated in the damping of the pumped fluid if the motor is attached to a pump. We need to consider that along with the energy dissipated in the bearings. The energy dissipated in structures from vibration is still negligible. I still think it is not reasonable to estimate the energy put into the system or removed from the system based on the effort a human would perceive (break into a sweat). This was illustrated by my block example above. In short, you... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
I've some experience on these calculations and can say that different people use different "assumptions". When I pass my calculation to someone from another organization, questions and challenges are raised. So, my practice (that you are free to take or leave) is to state the assumptions when the MTBF figures are reported. For instance, what are the boundaries of the pump? Is the driver part of the pump? Is the coupling part of it? If the pump is noisy but producing the required pressure and... [ more ]
Thanks jim and pathu. there are instances where mtbf is calculated as a group (indicative).but yes mtbf per equipment is way better. In the example above that i share is when you dictate or know precisely the operating hours but if you want to calculate them per month so i guess maybe this would be right (31days x 5equipment)- days of breakdown / no of breakdown right? It may give you big mtbf number [ more ]
Calculation-wise, Pathu's answer if the correct one. See https://www.fiixsoftware.com/m...own%20eight%20times. You could "group" them per your example but I think you might lose perspective on the usefulness of the MTBF metric to assist in extending the MTBF of the machines. If they were all designed properly for the application, they all had the same lubrication schedule, they were all installed and maintained per manufacturer's specifications, they all were balanced and aligned to the same... [ more ]
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