Equipment Maintenance

EQUIPMENT BASIC CARE
Fig. 1. The traditional bathtub curve illustrates

machine life.
2
Fig. 2. With a condition monitoring program,

the shape of the bathtub curve changes.
3
Fig. 3. This model may actually be

considered a great condition-based
maintenance success.
4
Basis for Condition Based Maintenance

Point Where Failure is
Point Where Failure

Starts
Detectable
P
Condition
Point Where it
has Failed
F
Time
P-F Interval
Time from Detection to
Failure
Risk Matrix
*
Consequence
II
IV
A
Work is required
Normally Scheduled Work
is usually justified
III
Normally scheduled work

may be justified. Tasks
should be cost effective
Work is not required.

Consider if cost effective
Probability
WHAT IS EQUIPMENT BASIC CARE?
Activities performed by Process to maintain optimum stable

equipment operation and to increase equipment reliability at tag
level.

What can be achieved through the Program?
Ensure that Refinery meets Production Plans and competitive cost objectives via correct,
optimum and stable operation of equipment
Proactive care of the Equipment at tag level to prevent deterioration and unpredicted breakdowns
Establish Unit, System and Tag Equipment, condition and Operating Envelope to run the
Equipment in a reliable state
Prompt detection and correction of abnormalities and recognition of incipient failures
Prompt operational adjustment and/or minor servicing to maintain Equipment within acceptable
Operating Envelope
Execution of Process Task generated via Equipment Strategy process
Communication and Documentation to Area Teams, to improve effectiveness of Selecting,

Planning and executing Equipment repairs that are outside the capability of Process personnel
WHAT NEEDS TO BE DONE

1. Operating Envelope
Document Max & Min Operating Limits for variables affecting Equipment Reliability
Plant System configured to monitor limits and alarm on infringement
Absence of data at Plant Information System, needs monitoring by Process

Surveillance Rounds
Deviations vs Tag Reliability Operating Envelope shall be corrected through

operational adjustment or minor servicing - all such actions needs to be logged
Prolonged Operating Envelope deviations shall be flagged as Operating Envelope

Exceptions requiring follow up

2. EQUIPMENT CONDITION THRESHOLD MONITORING
Document Equipment condition Thresholds, Monitoring Task and associated intervals,

Action Trigger level and required appropriate action should be defined for each
Threshold
Establish system of visual clues which should include color coding and posting at the
Equipment to facilitate efficient and effective Monitoring and Task Execution (e.g.
Establish and mark Vibration Monitoring points)
Monitoring Task Document should indicate the When, Why, Who and How of each
Task to foster repeatability and efficiency
All Task, including that generated through Equipment Strategy shall be included in a
Task Management System when due , Task should be assigned, completed and
signed off, documenting As found & As left conditions
Threshold Exceptions that cannot be corrected by Process shall be reported for follow
up
10

3. PROCESS SURVEILLANCE
Document minimum expectation for Process Technician Surveillance rounds and

Console Operator Surveillance
Develop standard for Equipment cleaning and Housekeeping that enables ongoing
monitoring, exposure of defects and effective use of visual clues
Visual clues should be installed to assist Technicians Surveillance for efficiency

and consistency
Abnormality detected by Surveillance should be corrected by Process if possible or

reported for follow up
11

4. OTHERS
A System should be in place to quality assure Operating Envelope application,

Equipment Condition Monitoring Task execution and Surveillance Activities to
ensure requirements are met
The Process organization should own a Database of Deviation Respond and

ensure that data is available to appropriate analytical group for inclusion in
activities performed as part of Performance Evaluation & Improvement
Appropriate training shall be provided for Process to handle activities compatible

with Process goals of improved reliability and control of the process
Activities that cannot be performed by Process are assigned to Mechanical by

Work Request. In making this determination, training Skills, Work load and Safety
are considered
12
REPORTING
1.Compliance to Task (%)----------------------------------------------------MONTHLY
2. Failure Caused by gaps in Basic Operator Care (#)---------------------MONTHLY
3. Operating Envelope Exception (# with reliability objective)------------MONTHLY
4. Equipment Failure Avoided/Saved due to Basic Operator Care (#)---MONTHLY
13
1. Standard Task 3a- Primary Walkabout Surveillance

a)
Verify Oiler Level is correct (non Oil Mist & Purge Mist)
b)
Verify Mist is showing from Telltale or collection Bottle (Pure Mist/Purge Mist)
c)
Listen & feel for strange noise and vibration along pump row
d)
If both spare & main operating, find out why
e)
For auto-start pumps check line up
f)
Check Seal flush line for flow and temperature-check seal pot level.
14
What Lubricant Must Do
Reduce friction by forming a film between rolling and sliding surfaces of Bearing
Prevent Wear and Corrosion
Guard against solid and liquid contamination
Remove heat
Minimum Viscosity change with temperature change (high VI)
Dont oxidize easily
Dont foam easily
Good load carrying ability
15
VISCOSITY:
Measurement of a fluids resistance to flow. The common metric
unit of absolute viscosity is the poise
For convenience, the centipoise (cp) one one-hundredth of a
poise is the unit customarily used.
16
LUBRICATION PROPERTIES
VISCOSITY INDEX (V.I.)
Empirical, unitless number indicating the effect of

temperature change on the kinematic viscosity of an oil.
Liquids change viscosity with temperature, becoming less
viscous when heated; the higher the V.I. of an oil, the lower
its tendency to change viscosity with temperature.
17
a) Verify Oil Level is correct
CONSTANT LEVEL OILER (TRICO)
18
Bearing Oil Level
19
PUMP BEARING LOCATION & OIL RINGS
20

a)
b)
c)
d)
e)
21
HOW OIL MIST SYSTEM WORKS

Oil is atomized at the Mist Generator by high velocity air
Baffles intercept large particles and return them back to Oil
Reservoir
Remaining smoke like suspension of minute oil particles is
distributed through Piping, Tubes and Hoses
The low pressure and velocity Mist flow is metered to each
Lubrication point by application fittings
3 main type of fittings: Mist, Spray and Condensing
Turbulence in and around Rolling Element Bearings cause oil to
wet out from the mist directly on to Bearing Elements
Spray & Condensing fittings Reclassify the dry mist into
larger droplets
Spray Fittings expel oil as fine wet spray while Condensing
Fittings reclassify oil to larger drops which drip or run down
adjacent surfaces
22
How Oil Mist is Generated
23
Oil Mist System & Application Fittings
24
ADVANTAGES OF OIL MIST SYSTEM
2. PURGE MIST SYSTEM
Employed together with conventional system
In conjunction with the advantage of positive oil circulation created by Oil Rings
Bearing Housing under positive pressure-contaminant ingress prevented
Constant Level Oiler has overflow feature to prevent flooding of Bearings
25
PURGE MIST SYSTEM
26
ADAVANTAGES OF OIL MIST SYSTEM
1.PURE MIST SYSTEM
Air oil mist fed under pressure directly into Bearing Housing
No reservoir of oil in the housing & has no oil rings
Provide uncontaminated environment with oil deposited on to Bearing elements
Heat build up is eliminated
Needs pre oil film forming when oil mist system is down.
27
PURE MIST SYSTEM
28
Oil Mist Lubrication
29
Motor With Oil Mist Lubrication
30
31
TYPES OF LUBRICATION
3 Types of Lubrication situations can exist between two surfaces

separated by lubricant:
1. Hydrodynamic or Full Fluid Film Lubrication-surfaces are
completely separated by lubricant
2. Boundary Lubrication-Lubricant too thin to provide total surface
separation
3. Elastrohydrodynamic Lubrication-viscosity of lubricant has higher
shear strength than metal surface resulting in metal surface
deforming elastically and decrease effectiveness of Lubricant
32
1. HYDRODYNAMIC LUBRICATION
Sliding and rolling materials are separated by thin film of

Lubricant held in place by pressure created between surfaces.
33

separation
34
2.BOUNDARY LUBRICATION
Lubricant too thin to provide good total surface separation, resulting in

contact and frictional heat generation at microscopic peaks. Protection is
provided through chemical additives.
35

separation
36
3.ELASTROHYDRODYNAMIC LUBRICATION (EHD OR EHL)
Load increased to high level where Lubricant shear strength is higher than
supporting metal surface resulting in metal surface deform and decreased
effect of Lubrication.
37

a)
b)
c)
d)
e)
38
Irregularity in Bearings can be identified by listening

Abnormal noise can be traced to an individual machine component by an experienced
Operator
A good operating Bearing produces a soft purring noise
Grinding, squeaking and other irregular noise points to poor operating condition
Squeaking noise inadequate lubrication
Metallic tone- insufficient bearing clearance
Indentation at outer ring raceway cause vibration & smooth clear tone
Intermittent noise may indicate damage to rolling element
Grinding noise dirt in bearing
Irregular & loud noise indicate severe bearing damage
39
BEARING PROBLEMS
Normal fatigue spalling

The limiting criterion for fatigue damage is largely application dependent. For the purpose of
establishing bearing dynamic ratings, it has been arbitrarily set as a spall size of 0.01 square
inches in area.
Abrasive wear
Foreign material can enter the bearing through a damaged or worn seal or during
cleaning, when water or other cleaning fluids contaminate the lubricant. This causes
premature wear of the bearing.
Pitting and bruising

Larger metal clips or particles of dirt entering the bearing can cause pitting and bruising.
Etching and corrosion
Moisture in the bearing results in etching or corrosion. Causes include condensation from a humid
environment or moisture passing through a damaged or worn seal.
Scoring
Inadequate lubrication of the rib face and roller end results in metal-to-metal contact and
scoring.
Cage breakage and peeling
Cage breakage doesn't happen often. It can occur as a result of vibration, orbital
rotation (in plant idler bearings), or rapid acceleration or deceleration of the bearing.
Other factors are
marginal lubrication systems or excessive end play in the bearings.
40
BEARING PROBLEMS
Bearing adjustment
Bearing adjustment is a critical component of successful bearing operation. With excessive end play
in the bearing, rollers are very loose out of the load zone, resulting in skidding and sliding and
cause scalloped wear on the cup race.
Misalignment
Bearing misalignment results in reduced bearing life, depending on the amount of
misalignments as well as the loads and speeds involved. If misalignment exceeds set
limits, the load on the bearing is concentrated in one area on the bearing races, resulting
in high edge stresses and subsequent fatigue spalling.
False brinnelling/impact damage
False brinelling is bearing surface wear. It occurs when the rollers slide axially back and
forth on the race while the bearing is essentially stationary but subject to vibration. A
groove is worn into the race by the roller's sliding action.
Electric current
When electric current passes through a bearing, arcing or burning occurs at the point of
contact between the races and rollers. This may cause a single burn or appear as a line
of small burns, called "fluting," along the line of contact of the rollers and the race.
41
42
IF YOU CANNOT HEAR OR SEE THIS YOU MUST BE DEAF &

BLIND
43
CAUSES OF NOISE & VIBRATION
1. NOISE
Unusual noise is a sign of :

- Bearing problem
- Pump Cavitation
- Loose connections/fittings
- Leak
- Overload/under load
- Rub
- Operating outside of design envelope
- Resonance
- Improper fitting (not meeting tolerances)
- Change in flow
- Generally indicating something is not right
44
PUMP SUCTION CAVITATIONS

Suction Cavitations occurs when the pump
suction is under a low pessure/high vacuum
condition where the liquid turns into a vapor at
the eye of the pump impeller. This vapor is
carried over to the discharge side of the pump
where it no longer sees vacuum and is
compressed back into a liquid by the discharge
pressure. This imploding action occurs
violently and attacks the face of the impeller. An
impeller that has been operating under a
suction cavitations condition has large chunks
of material removed from its face causing
premature failure of the pump.
45
PUMP DISCHARGE CAVITATIONS

Discharge Cavitations occurs when the pump
discharge is extremely high. It normally
occurs in a pump that is running at less than
10% of its best efficiency point. The high
discharge pressure causes the majority of the
fluid to circulate inside the pump instead of
being allowed to flow out the discharge. As
the liquid flows around the impeller it must
pass through the small clearance between the
impeller and the pump cutwater at extremely
high velocity. This velocity causes a vacuum
to develop at the cutwater similar to what
occurs in a venturi and turns the liquid into a
vapor. A pump that has been operating under
these conditions shows premature wear of the
impeller vane tips and the pump cutwater. In
addition due to the high pressure condition
premature failure of the pump mechanical seal
and bearings can be expected and under
extreme conditions will break the impeller
shaft.
46
EFFECT OF CAVITATION
Fig 1- Initial Bubble
Fig 3- Forming of liquid jet
Fig 2- Initiation of Collapse
Fig 4- Impact & Metal

Extrusion
47
1. Vibration
Unusual Vibration is a sign of :

- Bearing problem
- Rub
- Resonance
- Imbalance
- Misalignment
- Pump/valve cavitations
- Foundation problem
- Flow changes
48
VIBRATION TELERANCE CHART (ISO 23720
= Small (up to 15Kw)
II
= Medium (15 to 17Kw)
III = Large (Prime movers on heavy foundation)

IV
= Large (Prime movers on light foundation)
49

a)
b)
c)
d)
e)
50
PROCESS CONDITIONS REQUIRING PUMP PARALLEL OPERATION
Making up for design shortfall
Making up for individual Pump inefficiency
Correcting Process upset conditions
Operating condition change (system head increased)
Increased throughput
Startup
51
IDENTICAL PUMPS PARALLEL OPERATION
Single Pump (Pt. A): Head=85Ft, Flow= 470 gpm

Parallel Operation (Pt. B): Head=105Ft, Flow=660 gpm
52
PARALLEL OPERATION-DIFFERENT PUMPS
3 Pump (A) : Head=70 Ft , Flow= 300 gpm

4 Pump (B) : Head=87.5 Ft , Flow= 410 gpm
Both Running: Head=87.5 Ft , Flow= 460 gpm
53
PROBLEMS ENCOUNTED WITH PARALLEL OPERATION
Either or both pumps operating below recommended minimum continuous flow

Higher system head
Possible lower efficiency
No contingency spare
Higher life cycle cost
Increased load on condition monitoring activity
Suction/Discharge piping not similar-both pumps operating point not similar
54

a)
b)
c)
d)
a)
55
AUTO CUT IN LINE UP
Auto cut-in switches needs to be set for spare to cut in
Markings and tags must clearly indicate spare and running

equipment
56
2. Standard Task 3b Supplementary Walkabout Surveillance

a)
b)
Drain water from Bearing Housing or Bracket

Feel Bearing Housing for heat and vibration
57

a)
b)

58
Water Contamination in Lubrication Oil and its

effect
59

a)
b)

60
EFFECT OF HIGH TEPERATURE ON LUBRICATION OIL
61
EFFECT OF TEMPERATURE ON MINERAL OILS
At temperatures above 90C (195F), Mineral Oil can oxidize rapidly
62
VISCOSITY CHANGE WITH TEMPERATURE
63
COMMON CAUSES OF BEARING OVERHEATING
Inadequate lubrication (Wrong type of grease or oil)

Insufficient Lubrication (Low oil level loss of lubricant through seal)
Insufficient Bearing Clearance (Wrong fit selection)
Bearing pinched in the housing (Bore out of round)
Oil Gauge breather hole is clogged (indicate incorrect oil level)
Constant oil level cup (incorrect level)
Incorrect positioning of flingers (Rubbing against cover)
64
Oil lubrication:
Preference is given to oil lubrication, when the speed of rotation
or operating temperature makes it impossible to use grease,
when heat has to be removed from the bearing
assembly by the lubricant and of course when the bearings are
mounted in an oil-lubricated construction, for example a
gearbox.
Grease lubrication:
Grease lubrication is usually chosen for applications in which
the bearing operates under normal speed and temperature
conditions. Grease has a number of advantages
over oil. For example, it enables simpler (i.e. cheaper)
installation, offers better adhesion and provides protection
against damp and impurities. Most bearing assemblies are
greased
((Bearing diameter in inches x breadth in inches) x 1.29) / 7) = Daily cc's of lube
65
Required Grease Quantity For Regreasing
66
3. Standard Task 3c, 4a, 8a Manual Vibration Data Collection

Data collected with Handheld monitor for ascertaining that vibration is tolerable.
Monitor will be calibrated to show Good, Tolerable, Bad and Shutdown levels
When at Bad level Maintenance reliability team will be alerted to do a Diagnostic

vibration data collection
At very high Shutdown levels arrangement must be made to have the machine
shutdown
Data should be taken whenever Walkabout surveillance show machine vibration is
higher than normal
67
1. Vibration
Unusual Vibration is a sign of :

- Bearing problem
- Rub
- Resonance
- Imbalance
- Misalignment
- Pump/valve cavitations
- Foundation problem
- Flow changes
68
Comparing Circular and Sinusoidal Motion
As a point rotates counterclockwise around a circular path in the

complex plane the real component (blue line) oscillates back and
forth along the real axis as a cosine function. Meanwhile, the height
of the imaginary component (red line) oscillates up and down as a
sine function. (By Dan Russell)
69
VIBRATION MEASUREMENTS
Peak-to-Peak is mostly used as a basis for displacement units (sometimes

referred to as Zero-to-Peak)
Peak is used as a basis for velocity units (sometimes referred to as Zero-toPeak)
Rms refers to terms of root-mean-square used to mathematically determine
its value
70
71
TYPES OF VIBRATION & RESONANCE

There are two general classes of vibrations - free and forced.
Free vibration takes place when a system oscillates under the action of
forces inherent in the system itself, and when external impressed forces
are absent. The system under free vibration will vibrate at one or more of
its natural frequencies, which are properties of the dynamic system
established by its mass and stiffness distribution.
Forced Vibration takes place under the excitation of external forces. When
the excitation is oscillatory, the system is forced to vibrate at the excitation
frequency. If the frequency of excitation coincides with one of the natural
frequencies of the system, a condition of resonance is encountered, and
dangerously large oscillations may result.
Resonance can possibly cause the failure of major structures such as
bridges, buildings, or airplane wings. Thus, the calculation of the natural
frequencies is of major importance in the study of vibrations.
72
VIBRATION MEASUREMENTS
Displacement is a distance, usually measured in mils ( 1 mil=0.001 inch) or in microns

(1 micron= 1 millionth of a meter). Displacement is usually the preferred unit for low
frequency vibrations of machines with running speeds < 1000 rpm.
Velocity is the rate of change of displacement, usually measured in in/sec or mm/sec.

Used for higher frequency measurements.
Acceleration is the rate of change of velocity with units of in/sec or mm/sec. Used for
analysis of high frequency (gearmesh vibrations)
73
Frequency
The repetition rate of a periodic vibration, per unit of time, determined by
taking the reciprocal of the period (T).
Frequency is expressed in three ways:
-Hz (how many cycles per second)
- cpm (how many cycles per minute)
-Orders (how many cycles per shaft turning speed [TS])
Frequency is also the x-axis of the vibration spectrum; it identifies the
source of the vibration.
74
BEARING FAULT FREQUENCIES
Bearing Frequencies
Faults in any of the four bearing components will generate specific frequencies
dependent upon the bearing geometry and rotating speed.
BPFO - Ball Pass Frequency, Outer Race (generated by balls or rollers passing over
defective outer races)
BPFI - Ball Pass Frequency, Inner Race (generated by balls or rollers passing over
defective inner races)
BSF - Ball Spin Frequency (generated by ball or roller defect)
FTF - Fundamental Train Frequency (generated by cage defect or improper

movements)
75
BEARING ELEMENTS
76
77
78
FAULT ANALYSIS BASED ON VIBRATION FREQUENCY
Unbalance is the most common

fault associated with rotating shaft.
Unbalance vibration is mainly radial.

On overhung rotors, axial
components may be present as
well.
High 1X is commonly considered as

the unbalance symptom, however it
can be misalignment, bent
rotor or cracked shaft, and
further investigation of what may
cause the defect is often necessary.
79
80
VIBRATION TELERANCE CHART
81
ISO2372 ( BS 4675 , VDI 2056 )
82

4. Standard Task 3e- Spare Pump Swap
Pump swapping activity is more for Confidence building
Too frequent swapping has been known to cause increased failures
Equipment Strategy recommended swapping intervals to be followed
All normal pump starting check list to be followed-detailed written startup procedure for
each pump
Swapping activity is preferably done during day hours where Maint. Personnel are
available
A Spare Pump Operating procedure will be in place process run plan in place to
maximize reliability of spare pump when main pump is under repair ( for critical pumps)
83

5. Standard Task 3g- Visual Oil Quality Check
Check Oiler Bulb for oil colour- cloudy oil is a sign of contamination
Unusually dark oil also indicate deterioration
Change the oil if it shows sign of contamination or deterioration
Oil misted equipment check vent and drain line for plugging
Drain a small amount oil and check for contaminant-also feel the oil a rough viscosity
check
84
6. Standard Task 3i- Bearing re-greasing
Re-grease Bearings (greased Bearings) as per Equipment Strategy Schedule
Only the Grease in the Bearing should be replaced
Re-greased amount depends on Bearing size and a chart needs to be established
Use only recommended Grease
Make sure all Greasing equipment are kept clean
Make sure Grease gets to the Bearing (check tubing for plugging and rupture)
85
EXAMPLE OF GREASE NOT GETTING TO BEARING
Figure 1. Pillow block bearing

from fan assembly.
Figure 2. Bearing partially

removed from housing.
Figure 3. Bearing offset

relative to fitting.
Figure 4. Inside of the pillow block.
86
EFFECT OF OVERGREASING
Figure 1.
This was a control rod drive (CRD) fan motor at
Watts Bar Nuclear Plant. The bearing experienced a
ball cage failure due to the bearing shield (Figure 2)
being pushed down on the ball cage due to over
pressurization of the grease cavity.
Figure 2.
End bell with bearing shield that has become
dislodged from the bearing.
87
USING A GREASE GUN
Always make sure the dispensing

nozzle of the grease gun is clean before
using.
88
89
90
91
7. Standard Task 3j Change Lube Oil

Oil change as per recommended interval as per Equipment Strategy
When changing oil on running equipment, need to stay clear of moving
parts
It is best that some oil is being poured in while draining so that all sludge
is removed.
Care should be taken to not to overfill or underfill ascertain constant
level oiler is set properly and is controlling oil level in bearing housing
Make sure oil used is the correct type and proper container is used
Good practice to collect and check quality of drained oil
Maintain good housekeeping and dispose used oil properly
92
CHOOSING THE CORRECT LUBRICATION

1.
The right lube oil is determined by following factors:

The type of lubrication in the application
Manufacturers recommendations-most important as they know their machine best
The viscosity and correct additive in the oil for the srvice
The ambient and operating temperature of the application
The loading or abnormal pressure and speed of the application if changed from
original design
Best to do some research to confirm lubrication currently used is correct type
93
CHOOSING THE CORRECT LUBRICATION
2. Viscosity and Additives

Viscosity is the resistance to flow or how thick the oil is at given temperature
High pressure additives added to enhance performance
Oxidation inhibition additives to improve oil life
Rust-inhibitor additive to prevent rusting through moisture condensation
94
USING PROPER LUBRICATION OIL

CONTAINERS
Sometimes the most creative ideas are the wrong ideas.

Open top-up containers like this are magnets for
contaminants and can wreak havoc when used on small
sumps.
95
LUBE OIL STORAGE & CONSUPTION
96
8. Standard Task 3u- Develop rigid Operating Envelope including alarms
Establish Normal flow, Max flow, Minimum flow for pumps
Normal startup/shutdown procedure
Emergency startup/shutdown procedure
Normal vibration and temperature limits
Process run plan for critical equipment when spare is operating
97
9. Standard Task 3x- Develop special procedure for Seal leak/Emission control/fire risk
For severe HSE concern, have written procedure to mitigate risk
Signage at critical location with instruction is prefered
Drills exercise will help
98
10. Standard Task 4e-Check Fan Blade Pitch
Fan pitch or tilt angle is given by manufacturer for the required duty
For adjustable pitch, the pitch can be adjusted for higher or lower duty
Pitch angles are directly proportional to power consumption and this can be used as a
guide
Pitch can be checked using special Protector (supplied by Fan manufacturer)
Adjusting the pitch is an economical way of operating the cooler
For Fans with Pitch control device indicators will be provided to indicate pitch
99
11. Standard Task 4i Check Belt wear on Belt driven equipment
Belts should be properly ventilated as higher temperatures lower belt life
Belts should be properly tensioned a tension gauge should be used to check tension
Rule of thumb- a V-belt drive should give its thickness for every 4 feet span
Too much tension can cause wear on bearings
Belts should be replaced as a set
100
12. Standard Task 4j Check critical instrumentation
All instruments on Double Seal Pots should be checked as per Equipment Strategy.
101
THANK YOU
102

Equipment Maintenance

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What are some of the different types of equipment maintenance strategies discussed in the document?

What are some of the different types of equipment maintenance strategies discussed in the document?

What are some of the goals that can be achieved through an equipment basic care program?

What are some of the goals that can be achieved through an equipment basic care program?

EQUIPMENT BASIC CARE

Fig. 1. The traditional bathtub curve illustrates

Fig. 2. With a condition monitoring program,

Fig. 3. This model may actually be

Basis for Condition Based Maintenance

Point Where Failure

Normally scheduled work

Work is not required.

EQUIPMENT BASIC CARE

WHAT IS EQUIPMENT BASIC CARE?

Activities performed by Process to maintain optimum stable

EQUIPMENT BASIC CARE

Prompt detection and correction of abnormalities and recognition of incipient failures

Execution of Process Task generated via Equipment Strategy process

Communication and Documentation to Area Teams, to improve effectiveness of Selecting,

EQUIPMENT BASIC CARE

WHAT NEEDS TO BE DONE

Plant System configured to monitor limits and alarm on infringement

Absence of data at Plant Information System, needs monitoring by Process

Deviations vs Tag Reliability Operating Envelope shall be corrected through

Prolonged Operating Envelope deviations shall be flagged as Operating Envelope

EQUIPMENT BASIC CARE

WHAT NEEDS TO BE DONE

Document Equipment condition Thresholds, Monitoring Task and associated intervals,

EQUIPMENT BASIC CARE

WHAT NEEDS TO BE DONE

Document minimum expectation for Process Technician Surveillance rounds and

Visual clues should be installed to assist Technicians Surveillance for efficiency

Abnormality detected by Surveillance should be corrected by Process if possible or

EQUIPMENT BASIC CARE

WHAT NEEDS TO BE DONE

A System should be in place to quality assure Operating Envelope application,

The Process organization should own a Database of Deviation Respond and

Appropriate training shall be provided for Process to handle activities compatible

Activities that cannot be performed by Process are assigned to Mechanical by

EQUIPMENT BASIC CARE

EQUIPMENT BASIC CARE

1. Standard Task 3a- Primary Walkabout Surveillance

If both spare & main operating, find out why

For auto-start pumps check line up

What Lubricant Must Do

Prevent Wear and Corrosion

Guard against solid and liquid contamination

Minimum Viscosity change with temperature change (high VI)

Dont oxidize easily

Dont foam easily

Good load carrying ability

VISCOSITY INDEX (V.I.)

Empirical, unitless number indicating the effect of

EQUIPMENT BASIC CARE

a) Verify Oil Level is correct

CONSTANT LEVEL OILER (TRICO)

EQUIPMENT BASIC CARE

Bearing Oil Level

PUMP BEARING LOCATION & OIL RINGS