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nstec presentation title maintenance programs where are you vision ­ service ­ partnership page 1

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nstec presentation title where are you maintenance programs · · panic maintenance maintenance performed only after a machine fails or experiences problems pm preventative maintenance actions performed on a time or machine-run-based schedule that detect preclude or mitigate degradation of a component or system with the aim of sustaining or extending its useful life and reduce the need for major repairs pdm predictive maintenance attempts to evaluate the condition of equipment by performing periodic or continuous online equipment condition monitoring basically predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition of the machine rather than on some preset schedule proactive maintenance concentrates on the monitoring and correction of root causes to equipment failures rcm part of which is root-cause-analysis laser alignment precision balancing are all part of proactive maintenance initiatives initiatives vision ­ service ­ partnership page 2 · ·

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nstec presentation title panic maintenance pimit · · · · · · · crisis mitcii maintenance reactive maintenance rtf r ti m i t unplanned downtime g p p high parts and labor costs due to unplanned downtime and equipment damage inefficient use of staff resources maintenance and repair is controlled/set by machine failure vague equipment status and reliability cannot predict equipment reliability vision ­ service ­ partnership page 3

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nstec presentation title preventative maintenance p v t tiv m i t · histories of each machine type are analyzed and periodic overhauls are scheduled before statically expected problems occur potential for incidental damage to components in conducting unneeded maintenance catastrophic failures still likely to occur typically creates unwanted corrective maintenance in some companies over 50 of total cm s includes performance of unneeded maintenance expensive inefficient use of resources for most equipment not taken seriously by most craft · · · · · vision ­ service ­ partnership page 4

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nstec presentation title preventive maintenance risk p v tiv m i t preventive maintenance does involve risk the risk here refers to the potential for creating defects of various types while performing the pm t ti l f ti dftfit hil f i th task in other words human errors committed during the pm task and infant mortality of newly installed components eventually lead to additional failures of the equipment on which the pm was performed frequently these failures occur very soon after the pm is performed f tl th f il ft th i f d typical examples of human errors are shown on the following page especially disturbing about these types of errors is the fact that they go unnoticed until they cause an unplanned shutdown there is some published data that illustrates this point it comes from the fossil-fuel power industry a review of the data from fossil-fueled power plants that examined the frequency and duration of forced outages after a planned or forced g p maintenance outage reinforces this concept that data showed that of 3146 maintenance outages 1772 of them occurred in less than one week after a maintenance outage clearly this is pretty strong evidence that suggests that in 56 of the cases unplanned maintenance outages were caused by errors committed during a recent maintenance outage vision ­ service ­ partnership page 5

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nstec presentation title self induced failures 70-80 70 80 of equipment f il f i t failures are self induced self-induced · putting hydraulic fluid into a reservoir without filtering it gqpg gp p y · welding on equipment without grounding properly · running equipment to failure when it is not part of your maintenance strategy · aligning couplings without using a laser · improperly lubricating electric motors vision ­ service ­ partnership page 6

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nstec presentation title predictive maintenance p di tiv m i t · · · · · · · · · · based on machine condition while it is running b d hi diti hil i i dependent on components providing early warning g y y non-destructive testing pdm tools vibration analysis oil analysis ir ultrasound motor analyzer tester etc allows management to control machinery and maintenance allows for preemptive corrective actions increases plant readiness greater mainline reliability reduces expenditure on spare parts and labor r d di dl b reduces the likelihood of catastrophic failure improvement in worker safety p y vision ­ service ­ partnership page 7

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nstec presentation title key t h ologi s for k technologies fo pdm p og programs s predictive mitp di ti maintenance tools t l · infra-red thermography · ultrasound · vibration analysis · motor/transformer tester analyzer · oil lubricant and wear particle analysis oil proactive maintenance tools · rcm · root cause analysis · laser alignment · precision balancing vision ­ service ­ partnership page 8

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nstec presentation title infra-red thermography ifrd th og ph thermography is the measurement of surface temperature through remote means to indicate equipment health and assigning a color based on the temperature uses include · equipment startup acceptance and commissioning · temperature survey of low voltage 600 volts and less nominal electrical · temperature survey of medium voltage 600 to 47kv electrical distribution di t ib ti · temperature survey of high voltage greater than 47kv electrical transmission and distribution · electro-mechanical equipment condition monitoring hvac hvac pumps motors bearings gearboxes belt-drives etc · building envelope inspection · heat loss and gain evaluation g · cooling loss and gain evaluation · roofing inspection for wet insulation · inspection of insulation characteristics vision ­ service ­ partnership page 9

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nstec presentation title infra-red thermography ifrd th og ph vision ­ service ­ partnership page 10

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nstec presentation title ultrasound ult so d · · · · · · · · · · · · · · equipment startup acceptance and commissioning eittttdiii pressure and vacuum leaks detection bearing inspection and monitoring high speed gearbox defect detection steam trap leakage inspection check valve functional verification pump cavitation electrical arcing y g electrical system corona discharge heat exchanger and condenser tube and tube sheet leakage boiler monitoring boiler tube leakage tank and pressure vessel leakage enclosure leakage inspection vision ­ service ­ partnership page 11

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nstec presentation title ultrasound ult so d vision ­ service ­ partnership page 12

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nstec presentation title vibration analysis vib tio a l sis · e i equipment startup acceptance and commissioning ttttdiii · rotating equipment analysis on hvac pumps motors bearings gearboxes belt-drives etc · high speed >600 rpm component vibration analysis speed rpm ibration anal sis · low speed <600 rpm component vibration analysis · shock pulse analysis bearing lubrication issues · structural analysis · looseness of transformer coils · misalignment · belt tension and alignment · unbalance condition · lubrication issues · bad bearings · mechanical looseness · worn gears · electrical problems rotor stator issues vision ­ service ­ partnership page 13

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nstec presentation title vibration analyzer vib tio a l vision ­ service ­ partnership page 14

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nstec presentation title off-line moto /t off li motor/transformer tester a sfo t st analyzer l detects any type of motor electrical fault · turn-to-turn coil-to-coil and phase-to-phase faults · shorted windings · open phases · burned or contamination windings · insulation breakdown · poor connections · ground faults · phase unbalances · cable faults cab e au ts · all types of rotor faults example broken/cracked rotor bars and rotor casting voids rotor eccentricity · good for testing spare motors to confirm their status and insures against installing a faulty motor itit lli f lt t note it tests virtually any size or type of motor generator or transformer transformer even from a remote locations locations vision ­ service ­ partnership page 15

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