Get Predictive with CMMS: What software can do when it comes to PdM
Written by Kris Bagadia and Brett E. Smith Wednesday, 25 August 2010
Many organizations are only using their computerized maintenance management system (CMMS) as a record-keeping tool, but by not fully utilizing the system, maintenance is missing out on opportunities to save time and money. A properly implemented CMMS will increase productivity by improving work process flow, helping to migrate from reactive to proactive.
At the most basic level, it is important to first establish a reliable system of entering and maintaining data (such as part quantities, reorder points, equipment associations, etc.). Part of this is also training staff to use the CMMS as the primary channel for this information and to not revert back to older methods. After that, it’s a matter of planning your predictive (PdM) and preventive (PM) maintenance, deciding which pieces of equipment warrant predictive maintenance and which will be effectively maintained with preventive maintenance. The final step is the integration of the technology or the CMMS itself.
PdM Basics
PdM must be looked at from the understanding that the action of the maintenance staff is geared to the actual condition of an asset. A condition-based maintenance management system will utilize the physical properties (or operating data gathered over time) from oil analysis, vibration, infrared or ultrasound information (points 1 to 4) to dictate the appropriate maintenance action. This differs from failure-based/reactive maintenance, which is initiated when an asset breaks down, or PM (point 5), where user-based maintenance is initiated by the calendar or individual meter readings. Non-invasive PdM monitoring tools be used during normal operation and make it possible to detect problems before suffering unplanned downtime.
1. Vibration.
All rotating equipment vibrates, and one must determine how much vibration can be accepted. A typical starting point is to trend a machine’s overall vibration level, beginning prior to installation or as soon after as possible. Monitoring options include low-cost vibration pens (best for detecting a vibration “spike”) or more sophisticated portable data collectors or online surveillance systems, which collect data at a predetermined interval. By tracking and trending conditions, one can plan and schedule maintenance/repairs before a catastrophic failure occurs.
How CMMS Can Help:
CMMS can be interfaced or integrated with vibration analysis and can assist in organizing a route to monitor critical equipment. The three components of an effective PdM vibration program are detection, analysis (track and trend) and corrective action.
2. Oil Analysis.
Studies have shown that 70 percent of mechanical failures and 20 percent of energy costs can be attributed to poor lubrication programs. The main advantage of an effective oil analysis program (see Page 20 to learn how to start one) is the early detection of oil contamination, oil degradation and machine wear. It is also necessary to differentiate machine types by test programs and individual requirements; also, to establish sampling time intervals short enough to detect failures, particularly in critical equipment.
How CMMS Can Help:
By employing a CMMS, a sampling route can be scheduled in order to minimize the impact on manpower and insure sample consistency. A CMMS can provide additional details as to equipment configuration changes and critical failures as well as track inspections and repairs.
3. Infrared Thermography.
The use of thermography can provide immediate feedback on the radiated heat from an asset without having to come into direct contact or having to shut the equipment down. Infrared testing has broad applications in power distribution, rotating equipment, piping and insulation.
How CMMS Can Help:
A CMMS needs to identify critical equipment and establish routine inspection routes of infrared survey data for maximum effectiveness and safety. Benchmarking ideally takes place at the beginning of the equipment’s service life as a basis for a trend analysis program.
4. Ultrasound.
Portable ultrasound equipment converts the high frequency sounds generated by installed equipment into audible frequencies that can be easily evaluated by trained technicians. The comparison of historical readings (lower signatures, new sounds, absent sounds) supports the troubleshooting process. Ultra-sound devices can pick up small frequency changes identifying internal bearing friction, fluid leaks and numerous electrical problems. As well, a leak audit can identify energy losses from compressed air and steam leaks.
How CMMS Can Help:
Readings from ultrasound equipment can be coded and integrated with a CMMS. Inspection routes can be established and monitored to assure that, over time, all plant equipment and service areas have been inspected thoroughly.
5. Preventive Maintenance.
The first step is to set up a basic PM schedule for the critical pieces of equipment. This involves specifying the PM tasks and procedures, PM frequency, the craft (electrician, mechanic, etc.), labour, material and tool estimates. It is then important to perform audits on a regular basis.
As well, optimize your PM program: if you are doing too little PM, obviously you will experience breakdowns and lose money in repairs; and if you are doing too much, you are still wasting money. You have to come up with an optimum frequency. Another part of the optimization audit is reviewing your PM tasks and procedures to insure that they are meaningful. Tasks and procedures only add value to a PM if they aid in the prevention of a failure and improve asset reliability. If they do not contribute to this goal in some way, they should be removed from your task list.
How CMMS Can Help:
The CMMS can set up a basic PM program, monitor it and then optimize PM frequencies based on criteria specified by the user. Below are a few examples:
Kris Bagadia is a consultant and educator and Brett E. Smith is a senior consultant, both with PEAK Industrial Solutions. For more information, visit www.peakis.com.
At the most basic level, it is important to first establish a reliable system of entering and maintaining data (such as part quantities, reorder points, equipment associations, etc.). Part of this is also training staff to use the CMMS as the primary channel for this information and to not revert back to older methods. After that, it’s a matter of planning your predictive (PdM) and preventive (PM) maintenance, deciding which pieces of equipment warrant predictive maintenance and which will be effectively maintained with preventive maintenance. The final step is the integration of the technology or the CMMS itself.
PdM Basics
PdM must be looked at from the understanding that the action of the maintenance staff is geared to the actual condition of an asset. A condition-based maintenance management system will utilize the physical properties (or operating data gathered over time) from oil analysis, vibration, infrared or ultrasound information (points 1 to 4) to dictate the appropriate maintenance action. This differs from failure-based/reactive maintenance, which is initiated when an asset breaks down, or PM (point 5), where user-based maintenance is initiated by the calendar or individual meter readings. Non-invasive PdM monitoring tools be used during normal operation and make it possible to detect problems before suffering unplanned downtime.
1. Vibration.
All rotating equipment vibrates, and one must determine how much vibration can be accepted. A typical starting point is to trend a machine’s overall vibration level, beginning prior to installation or as soon after as possible. Monitoring options include low-cost vibration pens (best for detecting a vibration “spike”) or more sophisticated portable data collectors or online surveillance systems, which collect data at a predetermined interval. By tracking and trending conditions, one can plan and schedule maintenance/repairs before a catastrophic failure occurs.
How CMMS Can Help:
CMMS can be interfaced or integrated with vibration analysis and can assist in organizing a route to monitor critical equipment. The three components of an effective PdM vibration program are detection, analysis (track and trend) and corrective action.
2. Oil Analysis.
Studies have shown that 70 percent of mechanical failures and 20 percent of energy costs can be attributed to poor lubrication programs. The main advantage of an effective oil analysis program (see Page 20 to learn how to start one) is the early detection of oil contamination, oil degradation and machine wear. It is also necessary to differentiate machine types by test programs and individual requirements; also, to establish sampling time intervals short enough to detect failures, particularly in critical equipment.
How CMMS Can Help:
By employing a CMMS, a sampling route can be scheduled in order to minimize the impact on manpower and insure sample consistency. A CMMS can provide additional details as to equipment configuration changes and critical failures as well as track inspections and repairs.
3. Infrared Thermography.The use of thermography can provide immediate feedback on the radiated heat from an asset without having to come into direct contact or having to shut the equipment down. Infrared testing has broad applications in power distribution, rotating equipment, piping and insulation.
How CMMS Can Help:
A CMMS needs to identify critical equipment and establish routine inspection routes of infrared survey data for maximum effectiveness and safety. Benchmarking ideally takes place at the beginning of the equipment’s service life as a basis for a trend analysis program.
4. Ultrasound.
Portable ultrasound equipment converts the high frequency sounds generated by installed equipment into audible frequencies that can be easily evaluated by trained technicians. The comparison of historical readings (lower signatures, new sounds, absent sounds) supports the troubleshooting process. Ultra-sound devices can pick up small frequency changes identifying internal bearing friction, fluid leaks and numerous electrical problems. As well, a leak audit can identify energy losses from compressed air and steam leaks.
How CMMS Can Help:
Readings from ultrasound equipment can be coded and integrated with a CMMS. Inspection routes can be established and monitored to assure that, over time, all plant equipment and service areas have been inspected thoroughly.
5. Preventive Maintenance.
The first step is to set up a basic PM schedule for the critical pieces of equipment. This involves specifying the PM tasks and procedures, PM frequency, the craft (electrician, mechanic, etc.), labour, material and tool estimates. It is then important to perform audits on a regular basis.
As well, optimize your PM program: if you are doing too little PM, obviously you will experience breakdowns and lose money in repairs; and if you are doing too much, you are still wasting money. You have to come up with an optimum frequency. Another part of the optimization audit is reviewing your PM tasks and procedures to insure that they are meaningful. Tasks and procedures only add value to a PM if they aid in the prevention of a failure and improve asset reliability. If they do not contribute to this goal in some way, they should be removed from your task list.
How CMMS Can Help:
The CMMS can set up a basic PM program, monitor it and then optimize PM frequencies based on criteria specified by the user. Below are a few examples:
- Inform decisions: A CMMS produces reliable information to enable informed decisions at all levels of the enterprise, including requestors, engineers, maintenance technicians, service managers and corporate management.
- Identify non-value-added activities: Maintenance spends a great deal of time waiting for parts, management approval, instructions and equipment to be made available. CMMS can help identify where exactly maintenance is losing most of the available “wrench time.”
- Analyze data: CMMS is great for analyzing the data and making meaningful decisions. For example, reviewing work order schedule compliance, ratios of PM and repair work orders compared to total work orders and taking necessary corrective action.
- Keep a virtual paper trail: Maintenance operations frequently gather readings on a variety of equipment, such as boilers, chillers, compressors, etc. Some companies use CMMS to record and save these readings to identify abnormal readings and correct problems. After defining certain ranges and criteria, CMMS will flag a warning immediately. Maintenance planning can automatically incorporate usage and condition-based, preventive, predictive failure, and corrective maintenance resulting from abnormal readings.
Kris Bagadia is a consultant and educator and Brett E. Smith is a senior consultant, both with PEAK Industrial Solutions. For more information, visit www.peakis.com.
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Located on the edge of Lake Ontario just east of downtown Toronto, PEM’s 2011 Maintenance Award winner is Pickering Nuclear — one of the world's largest nuclear generating facilities. The massive plant has six operating CANDU reactors, and all together, the station has a total output of 3,100 megawatts. Learn how the maintenance team does it all.- Better Physical Asset Management - Initiatives that Work (May 28.05)
- PTDA Canadian Conference (June 07.06)
