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FEDERAL ENERGY MANAGEMENT PROGRA

Release 3.0

Operations &MaintenanceBest Practices

A Guide to AchievingOperational Efficiency

August 2010


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isclaier3his report as sponsored % the /nited States epartent o+ -nerg1 O0ce o+ -nerg -0cienc and

Renea%le -nerg1 ,ederal -nerg Manageent Progra. either the /nited States Governent nor anagenc or contractor thereo+1 nor an o+ their eploees1 a4es an arrant1 e5press or iplied1 or assuean legal lia%ilit or responsi%ilit +or the accurac1 copleteness1 or use+ulness o+ an in+oration1 apparatuproduct1 or process disclosed1 or represents that its use ould not in+ringe privatel oned rights. Re+erenceherein to an speci'c coercial product1 process1 or service % trade nae1 ar41 anu+acturer1 orotherise1 does not necessaril constitute or ipl its endorseent1 recoendation1 or +avoring % the /niStates Governent or an agenc or contractor thereo+. 3he vies and opinions o+ authors e5pressed hereindo not necessaril state or re6ect those o+ the /nited States Governent or an agenc or contractor thereo+


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Pre+ace7

3his Operations and Maintenance (O&M) Best Practices Guide as developed under tdirection o+ the /.S. epartent o+ -nerg8s ,ederal -nerg Manageent Progra (,-M

3he ission o+ ,-MP is to +acilitate the ,ederal Governent8s ipleentation o+ sound1 e:ective energ anageent and investent practices to enhance the nation8s energsecurit andenvironental steardship. -ach o+ these activities is directl related to achievingre;uireents set+orth in?">1Strengthening Federal Environmental, Energy, and TransportaManagement(signed in @anuar "##). 3his set ore challenging goals than -PAct "#andsuperseded e5isting e5ecutive orders $>$"> and $>$?C.

= 3heEnergy Independence and Secrity Act of 200!1 hich +urther esta%lished energ1

ater1 and%uilding coissioning anageent goals and re;uireents and also aended porto+

-PAct "## and -2PA. -DSA as signed into la in ece%er "##.= -5ecutive Order $>$?1Federal "eadership in Environmental, Energy and Economic

Performance

(signed in Octo%er o+ "##C) directs ,ederal agencies to +urther address energ1 ateroperational e0cienc %eond -.O. $>?"> ith targeted goals and actions.

Release >.# o+ this guide provides updates to Release ".# in the areas o+ O&M technoe;uipent per+orance1 and costs. 3his ne release also addresses ater use and theipacts thatrecoended O&M practices can have on ater e0cienc.

Overall1 this guide highlights O&M progras targeting energ and ater e0cienc thestiated to save E to "#E on energ %ills ithout a signi'cant capital investent.ependingon the ,ederal site1 these savings can represent thousands to hundreds9o+9thousands doeachear1 and an can %e achieved ith inial cash outlas. Dn addition to energFresoursavings1 aell9run O&M progra ill".?".

Dntroduction ...................................................................................................................... ".$7e'nitions ........................................................................................................................ ".$7Motivation ....................................................................................................................... ".$7O&M Potential1 -nerg Savings1 andBeond ........................................................................... ".>7Re+erences ....................................................................................................................... ".J7

2hapter > O&MManageent........................................................................................................... >.$ 7

>.$Dntroduction ........................................................................................................................

>.$7>." eveloping theStructure ............................................................................................................ >.$ 7>.> O%tain ManageentSupport ..................................................................................................... >.> 7

>.>.$ 3he O&M MissionStateent........................................................................................... >.> 7

>.? Measuring the Kualit o+ Lour O&MProgra .......................................................................... >.?7>. Selling O&M toManageent .................................................................................................... >. 7>.J Progra

Dpleentation ............................................................................................................ >.J>. Progra


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Persistence..................................................................................................................... >.J>. O&M2ontracting ...................................................................................................................... >

>..$ O&M 2ontract3pes........................................................................................................ >.7>.." 2ontractDncentives ........................................................................................................... >.C 7

>.C O&M< 3he -SP2Perspective...................................................................................................... >.$" 7

>.C.$ O&M eeds +or Neri'ed and PersistentSavings .............................................................. >.$"7

>.C." eterination and Neri'cation o+ O&M Savings in -SP2s ..................................>.$?7>.$#Re+erences .........................................................................................................................>.$7

2hapter ? 2oputerized Maintenance ManageentSste ........................................................... ?.$7

?.$?."?.>?.??.?.J

Dntroduction ...................................................................................................................... ?.$72MMS eedsAssessent .......................................................................................................... ?.$ 2MMS2apa%ilities...................................................................................................................72MMSBene'ts .......................................................................................................................72MMSResources ....................................................................................................................7Re+erence ........................................................................................................................... ?.>7

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Contents

2hapter 3pes o+ MaintenanceProgras ....................................................................................... .$ 7

B.$

7B."

7

B.>7B.?

7B.B

7B.J7B.A

7

Dntroduction ...................................................................................................................... .$7Reactive

Maintenance ................................................................................................................ .PreventiveMaintenance ............................................................................................................. .> PredictiveMaintenance .............................................................................................................. .?Relia%ilit 2entered Maintenance......................................................................................7!o to Dnitiate Relia%ilit 2entered Maintenance..............................................................J7Re+erences.......................................................................................................................... .C7

2hapter J Predictive Maintenance 3echnologies ....................................................................J.$7

J.$7Dntroduction ............................................................................................................................7J."7

3herograph .......................................................................................................................J."7

J.".$Dntroduction .............................................................................................................. J."7

J."."3pes o+ -;uipent .................................................................................................J."7J.".>SsteApplications ........................................................................................................... J.? 7

J.".>.$ -lectrical Sste Applications ......................................................................J.?7J.".>." Mechanical Sste Applications ...................................................................J.7J.".>.> Roo+ 3herograph ......................................................................................J.7

J.".?-;uipent2ostFPa%ac4 .................................................................................................... J. 7

J.".3raining Availa%ilit .................................................................................................J.C7J.".J2aseStudies ........................................................................................................................ J.CJ.".Resources................................................................................................................... J.$#7

J."..$ Dn+rared Service 2opanies...........................................................................J.$$7J.".." Dn+rared Dnternet Resource Sites ...................................................................J.$$7

J.>7 *u%ricant and Wear Particle

Analsis ........................................................................................ J.$" 7J.>.$Dntroduction .............................................................................................................. J.$"7


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J.>."3est3pes ........................................................................................................................... J.J.>.>3pes o+-;uipent ............................................................................................................ J.$ 7J.>.?SsteApplications ........................................................................................................... J.$ 7J.>.-;uipent2ostFPa%ac4 .................................................................................................... J.$J 7J.>.J3raining Availa%ilit .................................................................................................J.$J7J.>.2ase

Studies ........................................................................................................................ J.J.>.Re+erencesFResources ............................................................................................... J.$7

J.>..$ Analsis -;uipent Resources .....................................................................J.$7J.>.." Oil Analsis *a%oratories................................................................................J.$7J.>..> Dnternet Resource Sites .................................................................................J.$7

J.? /ltrasonicAnalsis....................................................................................................................... J.$C 7

J.?.$Dntroduction .............................................................................................................. J.$C7J.?."3pes o+-;uipent ............................................................................................................ J."# 7J.?.>SsteApplications ........................................................................................................... J."$ 7

J.?.>.$ PressureFNacuu *ea4s.................................................................................J."$7J.?.>." Mechanical Applications.................................................................................J."$7J.?.>.> -lectrical Applications....................................................................................J.""7

J.?.?-;uipent2ostFPa%ac4 .................................................................................................... J."" 7J.?.3raining Availa%ilit .................................................................................................J.""7J.?.J2aseStudies ........................................................................................................................ J."J.?.Re+erencesFResources ............................................................................................... J.">7

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Contents

J.B7

J.J7

J.A7

J.M

7

J.?..$ -;uipentResources ............................................................................................. J."> 7J.?.." Service2opanies................................................................................................. J."? 7J.?..> Dnternet ResourceSites .......................................................................................... J."? 7

Ni%rationAnalsis....................................................................................................................... 7J..$Dntroduction .............................................................................................................. J."7J.."3pes o+-;uipent ............................................................................................................ J."JJ..>SsteApplications ........................................................................................................... J."J..?-;uipent2ostFPa%ac4 .................................................................................................... J." 7

J..3rainingAvaila%ilit .......................................................................................................... J." J..J2aseStudies ........................................................................................................................ 7J..Re+erencesFResources ............................................................................................... J."7

J...$ 3raining -;uipentResources.............................................................................. J."C 7J..." Service2opanies................................................................................................. J."C 7J...> 3rainingFDnternet Resource Sites................................................................

J."C7MotorAnalsis .......................................................................................................................J.>#7J.J.$Dntroduction .............................................................................................................. J.>#7J.J."Motor Analsis

3est............................................................................................................ J.>#7J.J.".$ -lectrical Surge2oparison.................................................................................. J.>#7J.J."." Motor 2urrent Signature Analsis .............................................................J.>#7

J.J.>SsteApplications ........................................................................................................... J.>J.J.?-;uipent2ostFPa%ac4 .................................................................................................... J.>$ 7J.J.3rainingAvaila%ilit .......................................................................................................... J.>$ J.J.JRe+erencesFResources ............................................................................................... J.>"7

J.J.J.$ -;uipentResources ............................................................................................. J.>" 7J.J.J." Service

2opanies................................................................................................. J.>" 7J.J.J.> Dnternet Site


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Resources .......................................................................................... J.>"7orance

nding.........................................................................................J.>>7

$Dntroduction ..................................................

.......................................................... J.>>7J.."!o to -sta%lish a Per+orance 3rendingProgra .......................................................... J.>>7J..>SsteApplications ........................................................................................................... J.>J..?-;uipent2ostFPa%ac4 .................................................................................................... J.>? 7J..3rainingAvaila%ilit .......................................................................................................... J.>? J..J2aseStudies ........................................................................................................................

7Re+erences.......................................................................................................................... J.>7

2hapter 2oissioning -5istingBuildings.................................................................................... .$ 7

A.$7A."7A.>7A.B

7A.J7A.A7A.M

7A.C7

Dntroduction ...................................................................................................................... .$7e'nitions ......................................................................................................................... ."7

3pical ,indings +ro -5isting Building2oissioning .......................................................... .?7

3rac4ing 2oissioningBene'ts ............................................................................................. .J 7

3he 2oissioningProcess ....................................................................................................... . 72oissioning ProviderKuali'cations ..................................................................................... . 7

3he ,uture o+ Building2oissioning...................................................................................... . 72aseStudies..........................................................................................................................C7

.C.$Sste Shutdon uring /noccupiedPeriods.................................................................. .C7.C."Dn9!ouse Recoissioning at a O- ational *a%orator....................................$#7

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Contents

.$# AdditionalResources .................................................................................................................. .$" 7.$$Re+erences...............................................................................................................................$"7

2hapter Metering +or Operations and Maintenance .............................................................$7

M.$

7M."7M.>7M.?7

M.B

7

M.J

7M.A7

M.M

7

M.C

7M.$#

Dntroduction ...................................................................................................................... .$7Dportance o+ Metering and the Business 2ase................................................................."7Metering Applications .......................................................................................................>7MeteringApproaches .................................................................................................................. ..?.$One93ieFSpot Measureents...................................................................................?7.?."Run93ie Measureents............................................................................................7.?.>Short93er MeasureentsFMonitoring ......................................................................7.?.?*ong93er MeasureentsFMonitoring .......................................................................J7.?.3he Metering !ierarch ............................................................................................J7Metering Sste 2oponents...........................................................................................7

..$Meters........................................................................................................................ .7.."ata 2ollection..........................................................................................................7..>ataStorage........................................................................................................................ ...?ataAnalsis ...................................................................................................................... .CMetering -conoics..........................................................................................................C7Metering ,inancing Options...............................................................................................$$7

..$Metering ,inancing !ierarch ...................................................................................$$7Steps in Meter Planning.....................................................................................................$>7..$-sta%lish Progra Goals and O%ectives ...................................................................$>7.."Ddenti+ eeds to Support Selected Analsis Approaches .........................................$>7..>evelop and Appl -valuation 2riteria .....................................................................$?7..?Dpleentation1 esign1 and Dnstallation.................................................................

.$

7..Per+orance Nalidation and Persistence ...................................................................$7


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e Stud Heral Services

inistration8s

asteneier ,ederal 2ourthouse ................. .$7Re+erences.......................................................................................................................... .$7

2hapter C O&M Ddeas +or Maor -;uipent 3pes ..................................................................C.$7

C.$7Dntroduction ............................................................................................................................7

C.$.$*oc4 and 3ag.............................................................................................................

C.$7C."7Boilers ....................................................................................................................................7

C.".$ Dntroduction ............................................................................................................C.>7

C.".".$ ,ire93u%e Boilers.............................................................................................C.>7C."."." Water93u%e Boilers.........................................................................................C.>7C.".".> -lectric Boilers ..............................................................................................C.?7

C.".> e 2oponents .....................................................................................................C.7

C.".>.$ 2ritical 2oponents ......................................................................................C.7C.".>." Other 2oponents ........................................................................................C.7

C.".? Sa+etDssues ....................................................................................................................... C.

C."..$ -0cienc1 Sa+et1 and *i+e o+ the -;uipent................................................C.C7C.".." Boiler -nerg Best Practices..........................................................................

C.C7C.".2ost and -nergFWater -0cienc ...........................................................................C.C7

C."..$ -0cienc1 Sa+et1 and *i+e o+ the -;uipent................................................C.C7C.".." Boiler -nerg Best Practices..........................................................................C.C7



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Contents

C.".JMaintenance o+Boilers ....................................................................................................... C.$" 7C.".iagnostic

3ools ................................................................................................................. C.$" 7C.".Availa%le So+tare

3ools.................................................................................................... C.$>7C.".CRelevant OperationalF-nerg -0ciencMeasures............................................................. C.$?7

C.".C.$ Boiler Measure $< Boiler *oading1 Se;uencing1 Scheduling1 and 2ontrolC.$?7C.".C." Boiler Measure "< Boiler 2o%ustion -0cienc......................................C.$7C.".C.> Boiler Measure >< 3rending Boiler Stac4 3eperature.............................C."#7C.".C.? OpportunitDdenti'cation..................................................................................... C."# 7

C.".$# Boiler Rules o+3hu% .................................................................................................. C."?7

C.".$#.$ Boiler Water9/se Best Practices ..............................................................C."7

C.".$$ 2aseStudies.................................................................................................................... C."C.".$" Boiler 2hec4list1 Saple Boiler Maintenance *og1 and Water Kualit 3est .......C."J7C.".$>Re+erences....................................................................................................................C.>"7

C.>7 Stea

3raps................................................................................................................................. CC.>.$Dntroduction .............................................................................................................. C.>?7C.>."3pes o+ Stea

3raps.......................................................................................................... C.>?7C.>.".$ Mechanical Stea

3rap......................................................................................... C.>? 7C.>."." 3herostatic Stea

3rap ...................................................................................... C.> 7C.>.".> 3herodnaic Stea

3raps................................................................................ C.>J7C.>.".? Other Stea

3raps................................................................................................. C.>7C.>.>Sa+etDssues......................................................................................................................... C

C.>.?.$ Other2osts ............................................................................................................ C.>

C.>.?2ost and -nerg-0cienc ................................................................................................. C.> 7C.>.Maintenance o+ Stea

3raps.............................................................................................. C.>C 7C.>..$ 2haracteristics o+ Stea 3rap,ailure ................................................................... C.>C7

C.>.JPer+oranceAssessent..................................................................................................... C.?$ 7C.>.iagnostic


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-;uipent......................................................................................................... C.?> 7C.>.Relevant OperationalF-nerg -0ciencMeasures............................................................. C.?>7

C.>..$ Stea 3rap Water9/se BestPractices.................................................................... C.?7

C.>.C2aseStudies ........................................................................................................................ 7C.>.$# Stea 3raps2hec4list .................................................................................................... C.? 7C.>.$$

Re+erences....................................................................................................................C.?7C.?72hillers ...............................................................................................................................C.?7

C.?.$Dntroduction .............................................................................................................. C.?7C.?."3pes o+2hillers ................................................................................................................. C.?

C.?.".$ Mechanical 2opression2hiller .......................................................................... C.?7C.?."." A%sorption 2hiller.......................................................................................C.?C7

C.?.>e2oponents.................................................................................................................7

C.?.>.$ Mechanical 2opression 2hillers...............................................................C.?C7C.?.>." A%sorption2hiller.................................................................................................. C.?C 7

C.?.?Sa+etDssues...........................................................................................................................

. C.?.2ost and -nerg

-0cienc.....................................................................................................C.# . C.?.JMaintenance o+2hillers.........................................................................................................C.# . C.?.iagnostic

3ools ................................................................................................................. C." 7C.?.Availa%le So+tare

3ool ..................................................................................................... C."7C.?.CRelevant OperationalF-nerg -0ciencMeasures ............................................................ C.>7

C.?.C.$ 2hiller Water9/se BestPractices ........................................................................... C.7

C.?.$# 2hillers

2hec4list............................................................................................................ C. 7C.?.$$ Saple 2hiller Operation*og ....................................................................................... C.C 7


i


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C.J.$$Re+erences........................................................................................................................7

C.7 Air !andlingSstes ................................................................................................................ C." 7

C..$ Dntroduction ............................................................................................................C."7C.." 3pes o+ Air !andling Sstes................................................................................C."7C..> e 2oponents ....................................................................................................C."7

C..? 2ost and -nerg -0cienc......................................................................................C."7C..Maintenance ....................................................................................................................7

C...$ iagnostic 3ools ............................................................................................C.>7C..." 2ase Stud ....................................................................................................C.>7

C..J Air !andling Sste 2hec4lists...............................................................................C.?7C..Re+erences........................................................................................................................7

C.7,ans .......................................................................................................................................7

C..$ Dntroduction ............................................................................................................C.7C.." 3pes o+,ans. .........................................................................................................................C.

. . C..".$ A5ial ,an.............................................................................................................7

C.."." 2entri+ugal ,ans ............................................................................................C.7C..> e 2oponents ....................................................................................................C.C7C..? Sa+etDssues........................................................................................................................ C.CC.. 2ost and -nerg -0cienc......................................................................................C.C7C..J Maintenance o+ ,ans ...............................................................................................C.C7C.. iagnostic 3ools.......................................................................................................C.C#7

C.. Availa%le So+tare 3ools .........................................................................................C.C#7

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Contents

C..C Relevant OperationalF-nerg -0ciencMeasures .......................................................... C.C$7C..$# 2aseStudies..................................................................................................................... C.C..$$ ,ans

2hec4list ................................................................................................................. C.CC..$"Re+erences....................................................................................................................C.C7

C.CPups ................................................................................................................................C.CJ7

C.C.$Dntroduction .................................................................................................................C.CJC.C." 3pes o+Pups.................................................................................................................. C.C

C.C.".$ naic Pup (2entri+ugalPup) .........................................................................C.C

. . C.C."." Positive isplaceentPup......................................................................................C.C. C.C.> e2oponents ............................................................................................................... C.C

C.C.>.$ 2entri+ugalPup........................................................................................................C.C

. . C.C.>." Positive isplaceent Pups ........................................................................C.C

C.C.?Sa+et

Dssues............................................................................................................................ C.C.2ost and -nerg-0cienc ................................................................................................. C.$##

C.C.JMaintenance o+Pups............................................................................................................C.$##

. C.C.iagnostic3ools ................................................................................................................. C.$#$

C.C.Availa%le So+tare3ools.................................................................................................... C.$#"C.C.CRelevant OperationalF-nerg -0ciencMeasures ............................................................ C.$#"

C.C.C.$Pup Sste Water9/se Best

Practices ................................................................. C.$#C.C.$# 2aseStud. ..........................................................................................................................

. C.C.$$ Pups2hec4list.............................................................................................................. C.$#

C.C.$"Re+erences....................................................................................................................C.$#7

C.$#Motors ................................................................................................................................C.$#C7

C.$#.$Dntroduction .................................................................................................................C.$#C7


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C.$#." 3pes o+Motors .............................................................................................................. C.$#C

C.$#.".$ 2Motors ........................................................................................................... C.$#C.$#."." A2Motors................................................................................................................C.$

. C.$#.> e2oponents ............................................................................................................. C.$$#

C.$#.>.$ 2Motor..................................................................................................................C.$

. . C.$#.>." A2 Motor.......................................................................................................

C.$$$7C.$#.? Sa+etDssues..........................................................................................................................C

. C.$#. 2ost and -nerg-0cienc..................................................................................................C.$$" . C.$#.J Maintenance o+Motors ................................................................................................... C.$$> 7

C.$#. iagnostic-;uipent ..................................................................................................... C.$$? 7C.$#. Availa%le So+tare

3ools ................................................................................................ C.$$?7C.$#.C Relevant OperationalF-nerg -0cientMeasures ........................................................... C.$$7C.$#.$# -lectric Motors2hec4list.............................................................................................. C.$$ 7C.$#.$$Re+erences....................................................................................................................C.$$C7

C.$$ Air2opressors ......................................................................................................................C.$"#7

C.$$.$Dntroduction .................................................................................................................

C.$"#7C.$$." 3pes o+ Air2opressors....................................................................................................C.$"#

. . C.$$.".$ Positive isplaceent...................................................................................C.$"#7

C.$$."." 2entri+ugal2opressor ....................................................................................... C.$"$ 7

C.$$.> e2oponents.................................................................................................................

. C.$$.? Sa+etDssues..........................................................................................................................C.$"". . C.$$.?.$ General Sa+et Re;uireents +or 2opressed Air........................................

C.$""7C.$$. 2ost and -nerg-0cienc..................................................................................................C.$">

. . C.$$..$ Ddenti+ the -lectrical 2ost o+ 2opressed Air..............................................C.$">7

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Contents

C.$$.." Waste !eat Recovered +ro 2opressors can %e /sed +or!eating. ...................C.$"?

. . C.$$..> /se o+ ,lo 2ontrollers ....................................................................................C.$"

C.$$..? Dportance o+ Maintenance to -nerg Savings............................................

C.$"C.$$.. *ea4 -valuation Procedure .........................................................................C.$"C.$$.J Maintenance o+ Air2opressors.................................................................................. C.$"J

. . C.$$.J.$ General Re;uireents +or a Sa+e and -0cient Air 2opressor......................C.$"J

C.$$. iagnostic 3ools.....................................................................................................C.$"7C.$$. Availa%le So+tare 3ools .......................................................................................C.$"7C.$$.C Relevant OperationalF-nerg -0cienc Measures ...............................................C.$"C7

C.$$.C.$ Air 2opressor Water9/se Best Practices....................................................C.$"C7

C.$$.$# 2aseStud .................................................................................................................... C.$>$ C.$$.$$ Air 2opressors 2hec4list...................................................................................C.$>"7C.$$.$" Re+erences..........................................................................................................C.$>>7

C.$"*ighting...................................................................................................................................

C.$>7C.$".$ Dntroduction ..........................................................................................................C.$>7C.$"." Sstes and 2oponents ....................................................................................C.$>7

C.$".".$ *ight Sources ..............................................................................................C.$>7C.$"."." Ballasts1 3rans+orers1 and Poer Pac4s.....................................................C.$>7C.$".".> *uinaire !ousing ......................................................................................C.$>C7C.$".".? *ighting 2ontrol evices .............................................................................

C.$?#7C.$".> Sa+etDssues .................................................................................................................... C.$?J

C.$".>.$ -lectrical and -;uipent Sa+et .................................................................C.$?J7C.$".>." !azardous Materials !andling ....................................................................C.$?7

C.$".? -nerg -0cienc1 Savings1 and 2ost ....................................................................C.$?7

C.$".?.$ Planned versus Reactive Maintenance........................................................C.$?7

C.$".?." Response to 2oplaints .............................................................................C.$#7C.$".?.> Retro't versus Redesign..............................................................................


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C.$#7C.$".?.? -nerg 2odes .............................................................................................C.$>7

C.$". Maintenance Procedures ......................................................................................C.$>7

C.$"..$ 2oissioning ...........................................................................................C.$>7C.$".." 2oon 2auses o+ Poor Per+orance.........................................................C.$?7C.$"..> 2leaning......................................................................................................C.$?7

C.$"..? *ap and Ballast 3rou%leshooting...............................................................C.$7C.$".. *ighting 2ontrols 2ali%ration and 3rou%leshooting......................................C.$J7C.$"..J iagnostic 3ools ..........................................................................................C.$7C.$".. -conoics...................................................................................................C.$C7

C.$".J *ighting 2hec4list..................................................................................................C.$J#7C.$". Re+erences............................................................................................................C.$J$7

2hapter $# O&M,rontiers...................................................................................................................$#.$ 7

$#.$$#."$#.>$#.?$#.B$#.J

A2R5 !andtoolF!oneell !NA2 ServiceAssistant ................................................................$#.$7ecision Support +orO&M............................................................................................................$#."7-,ORMAQPorta%le iagnosticSolutions..................................................................................$#." 7Per+orance and 2ontinuous Re92oissioning Analsis

3ool .................................................$#.>7

-nerg-5pert ..............................................................................................................................7Re+erence ..............................................................................................................................$#.?7

2hapter $$ 3en Steps to Operational-0cienc ..................................................................................$$.$7

iv



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..* -MS* %uildingg per+orance %l.............................................

cal utilit soc4et9

er..............................................................................

tric eteringarch...................................................................................

cal electrical su%el used in long9tertoring ...........................................

etering 'nancingarch ...................................................

........................elopent processeter sstening .....................................................

".7.$7J."7J.>7J.?7J.7

J.

J.J

J.J7J.J7

J.J

J.

J.

J.J."7J."J7J."J7J.>7.7

.$#7.$$7.$7

.7.7

.$"7.$?7

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Contents

.C.$7 Dnstalled ireless onitoring sste +or WB-9%asedsste................................................. .$7.C."7 Saple screen capture +or a generic %uilding shoing an alar or high9energ

using condition...............................................................................................................$

.C.>7 ata +ro the onitoring device provides a coparison o+ " das o+electricit.................. .$7C.$.$7 3pical +olding loc4 and tag scissorclap ............................................................................. C." 7C.".$7 !orizontal return 're9tu%e%oiler........................................................................................... C.> 7C.".>7 -lectric%oiler ......................................................................................................................... C.? 7C."."7 *ongitudinal9dru ater9tu%e%oiler..................................................................................... C.? 7C.".?7 Adapted +ro $CCC ational Board o+ Boiler and Pressure Nessel Dnspectors

incident report suar. ..............................................................................................C.

C.".7 -:ect o+ +ouling on aterside................................................................................................ C.C 7C.".J7 2o%ustionanalzer.............................................................................................................. C.$ 7C.".7 -5aple locations H co%ustionanalsis.............................................................................. C.$ 7C.".7 Boiler tu%e H scaledeposit...................................................................................................... C."$ 7C.".C7 Boiler tu%e H +ailure(rupture)................................................................................................ C."$ 7

C.".$# ,eed9ater pipe H o5gen pitting.................................................................................C.""7C.".$" 2ondensate pipe H o5gen pitting ...............................................................................C.""7C.".$? Boiler energ losses versus scalethic4ness............................................................................. C.""7C.".$$ Boiler tu%e H +ailure (rupture).......................................................................................C.""7C.".$> 2ondensate pipe H acidic corrosion .............................................................................C.""7C.>.$7 Dnverted %uc4et steatrap .................................................................................................... C.>? 7

C.>."7 Bietallic steatrap ............................................................................................................. C.> 7C.>.>7 Bellos steatrap.................................................................................................................. C.> 7C.>.7 isc steatrap ....................................................................................................................... C.>J 7C.>.?7 ,loat and therostatic steatrap ......................................................................................... C.>J 7C.>.J7 -nerg loss +ro lea4ing steatraps...................................................................................... C.> 7C.>.7 *ive stea (le+t) versus 6ash stea(right)............................................................................ C.?$ 7C.>.7 ,ailed gas4et on %lind6ange.................................................................................................. C.? 7


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C.?.$7 3pical chillerplant ............................................................................................................... C.? 7C.."7 irect or open coolingtoer ................................................................................................. C.J$ 7C..$7 2oolingtoer......................................................................................................................... C.J$ 7C.J.$7 General Services Adinistration8s 2usto !ouse1 Philadelphia1 PA .........................C.7C..$7 2ooling coil re;uiringcleaning ............................................................................................. C.? 7C.."7 aper ;uic4 '5 H not

recoended................................................................................... C.? 7C..$7 Propeller direct9drive +an (+ront and rearvie). ................................................................... C.?7C.."7 Propeller %elt9drive +an (+ront and rearvie). ...................................................................... C.7C..>7 3u%e9a5ial+an......................................................................................................................... C. 7C..?7 Nane a5ial+an......................................................................................................................... C. 7C..7 2entri+ugal+an ....................................................................................................................... C. 7C.C.$7 3echnolog tree +or pups.........................................................................................C.7C.C."7 Rotar lo%epup ................................................................................................................. C.CJ 7C.C.>7 Positive displaceentpups. .............................................................................................. C.C 7C.C.?7 2entri+ugalpup. ................................................................................................................ C.C 7C.C.7 Scheatic o+ pup and relie+ valve...........................................................................C.CC7C.C.7 Retro't cost savings (1## annuall). ....................................................................C.$#J7

C.C.J7 Pup sste energ use andsavings.................................................................................... C.$#J7

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31/574

Contents

C.$#.$ 2otor.............................................................................................................................. C.C.$#." A2otor................................................................................................................................CC.$#.> Parts o+ a direct current

otor................................................................................................C.$$$ 7C.$#.? Parts o+ an alternating currentotor .....................................................................................C.$$$7C.$$.$ Rotar screcopressor.........................................................................................................C.$"# 7C.$$.". 3pical single acting to9stagecopressor ..........................................................................C.$"$ 7C.$$.> !elical9lo%erotors ..................................................................................................................C.$"" 7C.$".$ ,luorescent lapF%allaste0cac ............................................................................................C.$> 7C.$"." Wall9%o5 occupanc sensor uses hidden internal dip9sitches to set anual9on1

auto9o:. ............................................................................................................................$?$7

C.$".> Photosensor and 6uorescent diing %allast +or continuous dalightdiing ..................C.$?

7C.$".? Repair and reiring ust %e done % a licensedelectrician. .................................................C.$?J7C.$". ,luorescent lap ortalitcurve ...........................................................................................C.$?C7C.$".J *ighting uni+orit and '5ture spacingcriteria.....................................................................C.$$7

C.$". 2ali%rations +orcontrols .........................................................................................................C.$J 7C.$". 2eiling occupancsensor........................................................................................................C.$ 7

3a%les

>.$.$ Dndustr O&M etrics and%enchar4s ................................................................................ >. 7

>."." Overvie o+ 4e O&M issues1 tiing1 and supportingdocuents ........................................ >.$>7..$ Relia%ilit centered aintenance eleentapplications ........................................................ .J7J.$.$ 2oon predictive technologapplications......................................................................... J.$ 7.$.$ 2oissioning tpe consideration % +acilitcondition....................................................... .$7C.".$ Boiler ccling energloss........................................................................................................ C.$? 7C."." Optiu e5cessair................................................................................................................. C.$ 7

C.".> Recoended liits +or %oiler9aterconcentrations ........................................................... C."$7


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2hapter $ Dntroduction and Overvie

3he purpose o+ this guide is to provide ou1 the Operations and Maintenance (O&M)F-anager and practitioner1 ith use+ul in+oration a%out O&M anageent1 technologieenergand ater e0cienc1 and cost9reduction approaches. 3o a4e this guide use+ul and to reour needs and concerns1 the authors et ith O&M and -nerg anagers via ,ederal -Manageent Progra (,-MP) or4shops. Dn addition1 the authors conducted e5tensiveliteraturesearches and contacted nuerous vendors and industr e5perts. 3he in+oration and castudiesthat appear in this guide resulted +ro these activities.

Dt needs to %e stated at the outset that this guide is designed to provide in+oration oe:ective

O&M as it applies to sstes and e;uipent tpicall +ound at ,ederal +acilities. 3his gunotdesigned to provide the reader ith step9%9step procedures +or per+oring O&M on anspeci'cpiece o+ e;uipent. Rather1 this guide 'rst directs the user to the anu+acturer8sspeci'cationsand recoendations. Dn no a should the recoendations in this guide %e used in po+anu+acturer8s recoendations. 3he recoendations in this guide are designed tosuppleentthose o+ the anu+acturer1 or1 as is all too o+ten the case1 provide guidance +or sstes ae;uipent

+or hich all technical docuentation has %een lost.As a rule1 this guide ill 'rst de+er to the anu+acturer8s recoendations on e;uip

operation and aintenance.

Actions and activities recoended in this guide shou!d

on!" #e attepted #" trained and certi$ied personne!% $ suchpersonne! are not avai!a#!e' the actions recoended hereshou!d not #e initiated%

(%( A#out This Guide3his guide is designed to serve as a resource +or O&M anageent and technical sta

Dt does not tr to represent the universe o+ O&M9related aterial. Rather1 it attepts to.$.$ %elo can serve asguide +or

trac4ing and trending etrics against industr %enchar4s (ASA "###).

3a%le >.$.$. Dndustr O&M etrics and %enchar4s

*%5 4e!!ing O&M to Manageent

3o success+ull interest anageent in O&M activities1 O&M anagers need to %e 6uthe language spo4en % anageent. Proects and proposals %rought +orth to anageneed tostand on their on erits and %e copetitive ith other +unding re;uests. While evaluat

criteriaa di:er1 generall soe level o+ econoic criteria ill %e used. O&M anagers need thave aor4ing 4noledge o+ econoic etrics such as. e'ne di:erent conditions under hich Repair and

Replaceent (R&R) or4 ill %e per+ored1 hoill %e

,inal Proposal Section 2. o+ DDK

?. e'ne reporting re;uireent +or O&M activitiesand its

,inal Proposal DDK M&N Plan Outline(Sections ".?.$1 >..)

. Su%ission o+ the -2M9speci'c O&M chec4lists %the -S2O.

,inal Proposal Recoended1 %ut notre;uired % DDK contract

J. -S2O provides O&M training & su%its theOperations and

Maintenance Manual +or -2Ms1 including# ears1 di:erent approto ho aintenance can %e per+ored to ensure e;uipent reaches or e5ceeds its design have%een developed in the /nited States. Dn addition to aiting +or a piece o+ e;uipent to +ail

(reactiveaintenance)1 e can utilize preventive aintenance1 predictive aintenance1 or relia%ilitcenteredaintenance.

5%) Reactive Maintenance

Reactive aintenance is %asicall

theUrun it till it %rea4sV aintenanceode.

o actions or e:orts are ta4en to aintainthe e;uipent as the designeroriginallintended to ensure design li+e is reached.Studies as recent as the inter o+"###indicate this is still the predoinant odeo+ aintenance in the /nited States.

3here+erenced stud %rea4s don the averageaintenance progra as +ollos$E Preventive

= $"E Predictive

= "E Other.

ote that ore than E o+ aintenance resources and activities o+ an average +acilit

stillreactive.

Advantages to reactive aintenance can %e vieed as a dou%le9edged sord. D+ e aredealing


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ith ne e;uipent1 e can e5pect inial incidents o+ +ailure. D+ our aintenance prograpurel reactive1 e ill not e5pend anpoer dollars or incur capital cost until soething%rea4s.Since e do not see an associated aintenance cost1 e could vie this period as savingone.

3he donside is realit. Dn realit1 during the tie e %elieve e are saving aintenance acapital cost1 e are reall spending ore dollars than e ould have under a di:erentaintenanceapproach. We are spending ore dollars associated ith capital cost %ecause1 hile aitingthe e;uipent to %rea41 e are shortening the li+e o+ the e;uipent resulting in ore +re;ureplaceent. We a incur cost upon +ailure o+ the priar device associated ith its +ailu

causingthe +ailure o+ a secondar device. 3his is an increased cost e ould not have e5perienced aintenance progra as ore proactive. Our la%or cost associated ith repair ill pro%a

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catastrophic +ailures1 e ill decrease the nu%er o+ +ailures. Miniizing +ailures translaaintenance and capital cost savings.

O&M Best Practices Guide, Release 3.0'.3

3he /.S. av pioneered preventive

isadvantages

conduct aintenance activities intended %the e;uipent designer1 e;uipent li+e is


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urn onstent< $#

esuction inntenances< "E to

Eination o+

%rea4dons< #E to EReduction in dontie< >E to ?EDncrease in production< "#E to "E.


state)1 there% alloing causal stressors to %eeliinated or controlled prior to an signi'cantdeterioration in the coponent phsical state.Results indicate current and +uture +unctionalcapa%ilit.

Basicall1 predictive aintenance di:ers+ro preventive aintenance % %asingaintenance need on the actual condition o+ theachine rather than on soe preset schedule.


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$-es o Maintenance Progra)s

On the don side1 to initiall start into the predictive aintenance orld is not ine5pMuch o+ the e;uipent re;uires cost in e5cess o+ #1###. 3raining o+ in9plant personnele:ectivel utilize predictive aintenance technologies ill re;uire considera%le +unding.Progradevelopent ill re;uire an understanding o+ predictive aintenance and a 'r coit

toa4e the progra or4 % all +acilit organizations and anageent.

5%5 Re!ia#i!it" 6entered Maintenance

Relia%ilit centered aintenance (R2M) agazine provides the +olloing de'nition o+Ua process used to deterine the aintenance re;uireents o+ an phsical asset in itsoperatingconte5t.V

Basicall1 R2M ethodolog deals ithsoe 4e issues not dealt ith % other Advantages

aintenance progras. Dt recognizes that = 2an %e the ost e0cient aintenance prograall e;uipent in a +acilit is not o+ e;ual = *oer costs % eliinating unnecessariportance to either the process or +acilit aintenance or overhauls.sa+et. Dt recognizes that e;uipent design and = Miniize +re;uenc o+ overhauls.

= Reduced pro%a%ilit o+ sudden e;uipent +ailures.

= A%le to +ocus aintenance activities on criticalcoponents.

= Dncreased coponent relia%ilit.

= Dncorporates root cause analsis.

resources and that the use o+ %oth need to %e isadvantages

prioritized and optiized. Dn a nutshell1 R2M = 2an have signi'cant startup cost1 training1is a ssteatic approach to evaluate a +acilit8s e;uipent1 etc.e;uipent and resources to %est ate the to = Savings potential not readil seen % anagand result in a high degree o+ +acilit relia%ilitand cost9e:ectiveness. R2M is highl relianton predictive aintenance %ut also recognizes that aintenance activities on e;uipenis ine5pensive and uniportant to +acilit relia%ilit a %est %e le+t to a reactive ainteapproach. 3he +olloing aintenance progra %rea4dons o+ continuall top9per+oring+acilitiesould echo the R2M approach to utilize all availa%le aintenance approaches ith thepredoinantethodolog %eing predictive.

= ^$#E Reactive

= "E to >E Preventive

= ?E to E Predictive.

Because R2M is so heavil eighted in utilization o+ predictive aintenance technolo

itsprogra advantages and disadvantages irror those o+ predictive aintenance. Dn addittheseadvantages1 R2M ill allo a +acilit to ore closel atch resources to needs hile iprelia%ilit and decreasing cost.


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3a%le ..$ %elo highlights guidance on R2M developent % e;uipent application(adapted

+ro ASA "###). Dt is iportant to %oth de'ne the e;uipent criticalit and cost o+ don9hen deterining the optial i5 o+ aintenance eleents. Once de'ned1 the e;uipent%e

prioritized in the developing a +unctional R2M progra.

3a%le ..$. Relia%ilit centered aintenance eleent applications

5%8 >o- to nitiate Re!ia#i!it" 6entered Maintenance

3he road +ro a purel reactiveprogra to a R2M progra is notan eas one. 3he +olloing is a listo+ soe %asic steps that ill helptoget oving don this path (ASA"###).

Maintenance Priorit Matri5 +or R2Mevelopent

Priorit

Weighting escription Application

$.7 evelop a Master e;uipentlist identi+ing the e;uipent inour +acilit.

$

"

>

-ergenc

/rgent

Priorit

*i+e1 health1 sa+et ris49ission criticalit

2ontinuous operation o+ +acilit at ris4

Mission supportFproect deadlines

".7 Prioritize the listed coponents%ased on iportance orcriticalit to operation1 process1or ission H see te5t %o5highlighting priorit schee.

?

J

Routine Prioritized< 'rst coeF'rst served

iscretionar esired %ut not essential

e+erred Accoplished onl hen resources allo

2oparison o+ ,our Maintenance Progras(Piotros4i "##$)

Reactive Maintenance (Brea4don or Run9to9,ailure Maintenance)Basic philosoph

= Allo achiner to run to +ailure.

= Repair or replace daaged e;uipent hen o%vious pro%les occur.

2ost< $FhpFr

3his aintenance philosoph allos achiner to run to +ailure1 providing +or the repair or replaceent o+daaged e;uipent onl hen o%vious pro%les occur. Studies have shon that the costs to operate in this+ashion are a%out $ per horsepoer (hp) per ear. 3he advantages o+ this approach are that it or4s ell i+

e;uipent shutdons do not a:ect production and i+ la%or and aterial costs do not atter.'.(


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=eliability -entered Maintenance $ierarchy

#eactiveElement PreventiveElement PredictiveElement Applications

Sall parts and e;uipent -;uipent su%ect to ear -;uipent ith rando +ailure

on9critical e;uipent 2onsua%le e;uipent 2ritical e;uipent

-;uipent unli4el to +ail -;uipent ith 4non +ailure -;uipent not su%ect to ear

Redundant sstes Manu+acturer recoendations Sstes hich +ailure a %einduced %


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>. Assign coponents into logical groupings.

?. eterine the tpe and nu%er o+ aintenance activities re;uired and periodicit us

a. Manu+acturer technical anuals

%. Machiner histor

c. Root cause analsis 'ndings 9 Wh did it +ailI

d. Good engineering udgent

. Assess the size o+ aintenance sta:.

J. Ddenti+ tas4s that a %e per+ored % operations aintenance personnel.

. Analze e;uipent +ailure odes and ipacts on coponents and sstes.

. Ddenti+ e:ective aintenance tas4s or itigation strategies.

3he re+erences and resources provided %elo are % no eans all9inclusive. 3he liste

organiza9tions are not endorsed % the authors o+ this guide and are provided +or our in+oration

3olocate additional resources1 the authors o+ this guide recoend contacting relevant tragroups1data%ases1 and the orld9ide e%.

An 9ntroduction to =eliability andMaintainability EngineeringB< 2harles -. -%elingPu%lished %< McGra !ill 2ollege

ivisionPu%lication date< Septe%er $CCJ

Maintenance Engineering $andboo1B< *indle R. !iggins1 ale P. Brautiga1

7and R. eith Mo%le (-ditor)7Pu%lished %< McGra !ill 3e5t1 th -dition 7Pu%lication date< Septe%er $CC?7

-ondition";ased Maintenance andMachine 2iagnostics

B< @ohn !. Willias1 Alan avies1 andPaul R. ra4ePu%lished %< 2hapan & !allPu%lication date< Octo%er $CC?

Maintenance /lanning andScheduling$andboo1B< Richard . (oc) PalerPu%lished %< McGra !illPu%lication date< March "C1 $CCC



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ntainability and Maintenance Managementoseph . Patton1 @r.7ished %< Dnstruent Societ o+ Aerica1Revision7ication date< ,e%ruar $CC?7

ability"-entered Maintenanceohn Mou%raished %< Dndustrial Press1 "nd -ditionication date< April $CC

ability"-entered Maintenance

Anthon M. Sithished %< McGra !illication date< Septe%er $CC".

'.*


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Preventive Maintenance (3ie9Based Maintenance)Basic philosoph

= Schedule aintenance activities at predeterined tie intervals.

= Repair or replace daaged e;uipent %e+ore o%vious pro%les occur.

2ost< $>FhpFr

3his philosoph entails the scheduling o+ aintenance activities at predeterined tie intervals1 heredaaged e;uipent is repaired or replaced %e+ore o%vious pro%les occur. When it is done correctl1 studieshave shon the costs o+ operating in this +ashion to %e a%out $> per hp per ear. 3he advantages o+ thisapproach are that it or4s ell +or e;uipent that does not run continuousl1 and ith personnel ho haveenough 4noledge1 s4ills1 and tie to per+or the preventive aintenance or4.

Predictive Maintenance (2ondition9Based Maintenance)Basic philosoph

= Schedule aintenance activities hen echanical or operational conditions arrant.

= Repair or replace daaged e;uipent %e+ore o%vious pro%les occur.

2ost< CFhpFr

3his philosoph consists o+ scheduling aintenance activities onl i+ and hen echanical or operationalconditions arrant9% periodicall onitoring the achiner +or e5cessive vi%ration1 teperature andForlu%rication degradation1 or % o%serving an other unhealth trends that occur over tie. When the conditiongets to a predeterined unaccepta%le level1 the e;uipent is shut don to repair or replace daagedcoponents so as to prevent a ore costl +ailure +ro occurring. Dn other ords1 Uon8t '5 hat is not %ro4eStudies have shon that hen it is done correctl1 the costs to operate in this +ashion are a%out C per hp peear. Advantages o+ this approach are that it or4s ver ell i+ personnel have ade;uate 4noledge1 s4ills1and tie to per+or the predictive aintenance or41 and that it allos e;uipent repairs to %e scheduled i

an orderl +ashion. Dt also provides soe lead9tie to purchase aterials +or the necessar repairs1 reducingthe need +or a high parts inventor. Since aintenance or4 is onl per+ored hen it is needed1 there isli4el to %e an increase in production capacit.

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Relia%ilit 2entered Maintenance (Pro9Active or Prevention Maintenance)Basic philosoph

= /tilizes predictiveFpreventive aintenance techni;ues ith root cause +ailure analsis to detect and pinpprecise pro%les1 co%ined ith advanced installation and repair techni;ues1 including potential e;uip

redesign or odi'cation to avoid or eliinate pro%les +rooccurring.

2ost< JFhpFr

3his philosoph utilizes all o+ the previousl discussed predictiveFpreventive aintenance techni;ues1 inconcert ith root cause +ailure analsis. 3his not onl detects and pinpoints precise pro%les that occur1%ut ensures that advanced installation and repair techni;ues are per+ored1 including potential e;uipenredesign or odi'cation1 thus helping to avoid pro%les or 4eep the +ro occurring. According to studiehen it is done correctl1 operating in this +ashion costs a%out J per hp per ear. One advantage to thisapproach is that it or4s e5treel ell i+ personnel have the 4noledge1 s4ills1 and tie to per+or all o+re;uired activities. As ith the predictive9%ased progra1 e;uipent repairs can %e scheduled in an order+ashion1 %ut additional iproveent e:orts also can %e underta4en to reduce or eliinate potential pro%le+ro repeatedl occurring. ,urtherore1 it allos lead9tie to purchase aterials +or necessar repairs1 threducing the need +or a high parts inventor. Since aintenance or4 is per+ored onl hen it is neededand e5tra e:orts are put +orth to thoroughl investigate the cause o+ the +ailure and deterine as to iachiner relia%ilit1 there can %e a su%stantial increase in production capacit.

5%9 Re$erences

ASA. "###.*eliaility #entered Maintenance >ide for Facilities and #ollateral Eipmational Aeronautics and Space Adinistration1 Washington1 .2.

Piotros4i1 @. April "1 "##$.ProGActive Maintenance for Pmps, Archives, Ferary 2004,

Pup9one.coZReport online[. Availa%le /R*


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2hapter J Predictive Maintenance 3echnologies

8%( ntroduction

Predictive aintenance attepts to detect the onset o+ a degradation echanis igoal

o+ correcting that degradation prior to signi'cant deterioration in the coponent ore;uipent. 3hediagnostic capa%ilities o+ predictive aintenance technologies have increased in recent ithadvances ade in sensor technologies. 3hese advances1 %rea4throughs in coponentsensitivities1size reductions1 and ost iportantl1 cost1 have opened up an entirel ne area o+ diagnto theO&M practitioner.

As ith the introduction o+ an ne technolog1 proper application and!=A9>9>5is critical iportance. 3his need is particularl true in the 'eld o+ predictive aintenancetechnologthat has %ecoe increasingl sophisticated and technolog9driven. Most industr e5pertouldagree (as ell as ost reputa%le e;uipent vendors) that this e;uipent should not %epurchased+or in9house use i+ there is not a serious coitent to proper ipleentation1 operatotraining1and e;uipent onitoring and repair. D+ such a coitent cannot %e ade1 a site is advised

to see4 other ethods o+ progra ipleentationYa pre+era%le option a %e to contrtheseservices ith an outside vendor and rel on their e;uipent and e5pertise.

3a%le J.$.$ %elo highlights tpical applications +or soe o+ the ore coon predicaintenance technologies. O+ course1 proper application %egins ith sste 4noledge predictive technolog capa%ilit H %e+ore an o+ these technologies are applied to live s

3a%le J.$.$. 2oon predictive technolog applications (ASA "###)


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ractices Guide, Release 3.0

(.1

!echnologies

Ni%ration MonitoringFAnalsis

*u%ricant1 ,uel Analsis

Wear Particle Analsis

Bearing1 3eperatureFAnalsis

Per+orance Monitoring

/ltrasonic oise etection

/ltrasonic ,lo

Dn+rared 3herograph

on9destructive 3esting

Nisual Dnspection

Dnsulation Resistance

Motor 2urrent Signature Analsis

Motor 2ircuit Analsis

Polarization Dnde5

-lectrical Monitoring

$ea

vyEqu

i

p

me

n

t:

-ranes

Elec

t

r

ica

lSy

stems

2ies

el5en

era

t

o

rs

$ea

tE

change

rs

-irc

uit

;re

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ElectricMotors

!

a

n1

s

,/iping

!rans

for

mer

s

App

li

c

a

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o

ns

-o

ndense

rs

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Predictive Maintenance echnologies

8%) Therograph"

8%)%( ntroduction

Dn+rared (DR) therograph can %e de'ned as the process o+ generating visual iages th

repre9sent variations in DR radiance o+ sur+aces o+ o%ects. Siilar to the a o%ects o+ di:erentaterialsand colors a%sor% and re6ect electroagnetic radiation in the visi%le light spectru (#.? toicrons)1an o%ect at teperatures greater than a%solute zero eits DR energ (radiation) proportioits e5isting teperature. 3he DR radiation spectru is generall agreed to e5ist %eteen ".#$ icrons. B using an instruent that contains detectors sensitive to DR electroagneticradiation1a to9diensional visual iage re6ective o+ the DR radiance +ro the sur+ace o+ an o%ect cgenerated. -ven though the detectors and electronics are di:erent1 the process itsel+ is si

thata video caera uses to detect a scene re6ecting electroagnetic energ in the visi%le lightspectru1interpreting that in+oration1 and displaing hat it detects on a li;uid crstal displa (*2screenthat can then %e vieed % the device operator.

Because DR radiation +alls outside that o+ visi%le light (the radiation spectru to hich oees

are sensitive)1 it is invisi%le to the na4ed ee. An DR caera or siilar device allos us to esthevisi%le light spectru and vie an o%ect %ased on its teperature and its proportional

eittanceo+ DR radiation. !o and h is this a%ilit to detect and visualize an o%ect8s teperature piportant in aintaining sstes or coponentsI *i4e all predictive aintenance technoloDR tries to detect the presence o+ conditions or stressors that act to decrease a coponent8use+ul ordesign li+e. Man o+ these conditions result in changes to a coponent8s teperature. ,ore5aple1a loose or corroded electrical connection results in a%norall elevated connection teperdue to increased electrical resistance. Be+ore the connection is hot enough to result in e;ui+ailure or possi%le 're1 the patterns are easil seen through an DR iaging caera1 the condidenti'ed and corrected. Rotating e;uipent pro%les ill norall result in soe +or o++rictional

change that ill %e seen as an increase in the coponent8s teperature. ,ault or copleto+re+ractor aterial ill %e readil seen as a change in the coponents theral pro'le. *ossroo+ 8se%rane integrit ill result in oisture that can %e readil detected as di:erences in thetheral pro'le. 3hese are ust a +e general e5aples o+ the hundreds o+ possi%le applicatthistechnolog and ho it ight %e used to detect pro%les that ould otherise go unnoticeacoponent +ailed and resulted in e5cessive repair or dontie cost.

8%)%) T"pes o$ E?uipent

Man tpes o+ DR detection devices e5ist1 varing in


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capa%ilit1 design1 and cost. Dn addition1 siple teperatureeasureent devices that detect DR eissions %ut do notproduce a visual iage or DR pro'le are also anu+actured.

3he +olloing te5t and pictures provide an overvie o+ eachgeneral instruent tpe.

Spot =adiometer #9nfrared !hermometer(H

Althoughnot generall thought o+ in the orld o+therograph1DR theroeters use the sae %asic principles as

higherend e;uipent to de'ne an o%ect8s teperature %ased onDR eissions. 3hese devices do not provide aniagerepresentative o+ an o%ect8s theral pro'le1 %ut rather avaluerepresentative o+ the teperature o+ the o%ect or area o+interest.

(.2

,igure J.".$. 3pical DR spot theroeter



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9nfrared 9magerH As indicated earlier1 e;uipent capa%ilities1design1 cost1 and +unctionalit var greatl. i:erences e5ist in DRdetector aterial1 operation1 and design. At the +undaental level1DR detection devices can %e %ro4en don into to ain groups Hiagers and caeras ith radioetric capa%ilit. A siple DR

iager has the a%ilit to detect an o%ect8s DR eissions andtranslate this in+oration into a visual iage. Dt does not have thecapa%ilit to analze and ;uanti+ speci'c teperature values. 3his

,igure J.".". Dnternal house all.are uniportant and the o%ect8s teperature pro'le (represented ote dar4 area indicatincooler% the iage) is all that is needed to de'ne a pro%le. An e5aple teperatures %ecause loss.o+ such an application ould %e in detecting issing or inade;uateinsulation in a structure8s envelope. Such an application erel re;uires an iagerepresentative o+the di:erences in the theral pro'le due to a%sence o+ ade;uate insulation. -5act

teperature valuesare uniportant.

DR caeras ith +ull radioetric capa%ilit detect the DR eissions +ro an o%ect andtranslate

this in+oration into a visi%le +orat as in the case o+ an iager. Dn addition1 these devichave thecapa%ilit to analze the iage and provide a teperature value corresponding to the ainterest.

3his capa%ilit is use+ul in applications here a teperature value is iportant in de'ninpro%leor condition. ,or e5aple1 i+ an iage indicated a di:erence %eteen a pulle %elt

teperatureand an a%ient teperature1 the %elt a have orn1 %e the rong size1 or indicate aisalignentcondition. noing the appro5iate teperature di:erences ould %e iportant indeterining i+a pro%le e5isted.

,igure J.".>. 3eperature is used in de'ning %elt pro%les. ,igure shos a %elt teperature o+$?Cb,1 and a%ient teperature o+ Jb, +or a di:erence o+ "b,. 3he di:erence should %e trendedover tie to deterine slippage that ould %e indicated % a higher teperature di:erence.


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8%)%* 4"ste App!ications

8%)%*%( E!ectrica! 4"ste App!ications

3he priar value o+ therographic inspections o+ electrical sstes is locating pro%le

that the can %e diagnosed and repaired. U!o hot is itIV is usuall o+ +ar less iportance. thepro%le is located1 therograph and other test ethods1 as ell as e5perience and cosense1are used to diagnose the nature o+ the pro%le. 3he +olloing list contains ust a +e o+ thepossi%leelectrical sste9related surve applications" 4!z) can provide an earl indication o%earing

deterioration./ltrasonic detection devices are %ecoing ore idel used in detection o+ certain


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electricalsste anoalies. ArcingFtrac4ing or corona all produce soe +or o+ ionization that distheair olecules around the e;uipent %eing diagnosed and produces soe level o+ ultrasonsignature.An ultrasonic device can detect the high9+re;uenc noise produced % this e:ect and trait1 viaheterodning1 don into the audi%le ranges. 3he speci'c sound ;ualit o+ each tpe o+eission isheard in headphones hile the intensit o+ the signal can %e o%served on a eter to allo;uanti'9

cation o+ the signal.Dn addition to translating ultrasonic sound aves into +re;uencies heard % the huaor

seen on a eter +ace1 an ultrasonic sound ave detectors provide the capa%ilit to caandstore the detectors output. /tilizing displa and analsis so+tare1 a tie ave+or o+ thultrasonicsignature can then %e visuall displaed. 3his +unctionalit increases the technolog8scapa%ilit tocapture and store ;uanti'a%le data related to a coponents operating condition. /ltrasonsignature

in+oration can then %e used to %aseline1 analze1 and trend a coponent8s condition. Dncontrast toa technician8s su%ective analsis o+ a coponent8s condition using an audio signal1 anultrasonicanoalies indicative o+ coponent pro%les are ore easil de'ned using a signature p

3he+olloing iages o+ ultrasonic tie ave+ors +ro to identical gear%o5es illustrate houltrasonic

O&M Best Practices Guide, Release 3.0(.1


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signature data storage and analsis can %e used to ;uanti+ achine condition. Gear%o5 U$ave+or shos an ultrasonic signature anoal that a %e attri%uta%le to issing or ogearteeth1 hile Gear%o5 U"V signature shos a 6at pro'le.

Gear%o5 $

Gear%o5 "

Generall1 this tpe o+ diagnosis can %e per+ored on a standard personal coputer (P2progras not onl provide the spectral and tie series vies o+ the ultrasonic signature %uena%leusers to hear the translated sound saples siultaneousl as the are vieing the on thonitor.

8%3%) T"pes o$ E?uipent

/ltrasonic analsis is one o+ the less cople5 and

lesse5pensive predictive aintenance technologies. 3hee;uipentis relativel sall1 light1 and eas to use. Measureent dataarepresented in a straight+orard anner using eters ordigitalreadouts. 3he cost o+ the e;uipent is oderate and theaount

o+ training is inial hen copared to otherpredictive

aintenance technologies. 3picture to the right shos atpical ultrasonic detectiodevice.

(.20


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3pical hand9held ultrasonic detector



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Since ultrasounds travel onl a short distance1 soe scanninga

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