SUMMARY OF PhD. Thesis

FACULTY OF MACHINE BUILDING Eng. Ancuţa Carmen COSTEA SUMMARY OF PhD. Thesis CONTRIBUTIONS REGARDING THE IMPLEMENTATION OF THE COMPUTERIZED MAINTENANCE SYSTEMS Committee for Public Upholding: PhD Supervisor, Acad.Prof.dr.ing.Csaba GYENGE PRESIDENT: MEMBERS: - Prof.dr.ing. Petru BERCE - Dean, Faculty of Machine Building, Technical University of Cluj-Napoca; - Prof.dr.ing. Csaba GYENGE PhD Supervisor, Technical University of Cluj-Napoca; - Prof.dr.ing. Octavian PRUTEANU Reviewer, Gheorghe Asachi Technical University of Iaşi; - Prof.dr.ing Traian GRĂMESCU Reviewer, Gheorghe Asachi Technical University of Iaşi - Prof.dr.ing Marian BORZAN Reviewer, Technical University of Cluj-Napoca

CONTENTS INTRODUCTION 5 TERMINOLOGY AND NOTATION 11 CHAPTER 1 - CURRENT STATUS OF RESEARCH AND ACHIEVEMENTS IN THE MAINTENANCE FIELD 15 1.1. DEFINITION OF THE MAINTENANCE CONCEPT 15 1.2. GENERAL TERMS 16 1.3. THE EVOLUTION OF MAINTENANCE METHODS 22 1.4. LIFETIME OF THE EQUIPMENT 23 1.5. RESEARCH FOR IMPLEMENTING THE MAINTENANCE SYSTEMS 25 1.5.1. Research on the application of the predictive maintenance 27 1.5.1.2. The vibrations control in operation of the equipment 27 1.5.1.3. The prediction bearing wear by measuring the vibrations 28 1.5.2. The analysis of the vibrations 30 1.5.3. Applications of the predictive maintenance in the paper industry 32 1.5.4. Applications of the monitoring system on-line and off-line 35 1.5.5. The implementation of the Integrated Maintenance Solution 40 1.5.6. Computerized systems of automatic diagnostic for equipment functioning 41 1.5.7. Preventive maintenance by thermo vision 44 1.5.8. Application of risk-based maintenance of the steam boiler components of a power station 45 1.6. CONCLUSIONS 49 CHAPTER 2 OBJECTIVES OF THE PhD THESIS 51 CHAPTER 3 - THEORETICAL BASE OF THE MAINTENANCE 53 3.1. INTRODUCTION 53 3.2. THE NEED, PURPOSE AND ROLE OF MAINTENANCE ACTIVITIES 54 3.3. MAINTENANCE SYSTEMS 55 3.3.1. Corrective maintenance 57 3.3.2. Preventive maintenance 57 3.3.3. Predictive maintenance 59 3.3.4. Palliative maintenance 63 3.3.5. Proactive maintenance 64 3.3.6. Total productive maintenance 66 3.3.7. Reliability Centered Maintenance 70 3.3.8. Risk based maintenance 80 3.4. INTERACTION OF THE SYSTEMS MAINTENANCE 83 3.5. FACTORS OF INFLUENCE ON MAINTAINABILITY 85 3.6. CATEGORY OF TIMES FROM THE CONCEPT OF MAINTAINABILITY 87 3.7. QUANTIFICATION OF THE MAINTAINABILITY INDICATORS 88 3.8. MAINTAINABILITY INDICATORS 90 3.9. THE COSTS OF MAINTENANCE 92 3.10. THE OPTIMUM DURATION OF RELIABLE SERVICE 93 3.11. CONCLUSIONS 96 eng. Costea Ancuţa Carmen 1

CHAPTER 4 - ACHIEVEMENTS REGARDING THE METHODS OF RISK BASED MAINTENANCE 99 4.1. INTRODUCTION 99 4.2. ACCIDENT IDENTIFICATION TECHNIQUES 100 4.3. IDENTIFICATION OF MECHANISMS OF FAILURE AND TYPES OF DAMAGES 102 4.4. RISK ANALYSIS 104 4.4.1. Probability and consequences of failure occurrence of the breakdown or accidents 105 4.4.2. The method stages of the risk evaluation 106 4.5. THE METHODS OF RISK BASED MAINTENANCE 113 4.5.1. RIMAP procedure 113 4.5.1.1. The stages of RIMAP procedure 114 4.5.1.2. Conclusions 122 4.5.2. HAZOP method 122 4.5.2.1. Principle of HAZOP method 123 4.5.2.2. The stages of HAZOP method 125 4.5.2.3. Conclusions 127 4.5.3. The method of HAZROP risk analysis 128 4.6. CONCLUSIONS 130 CHAPTER 5 - THEORETICAL AND PRACTICAL RESEARCH REGARDING THE MONITORING BY VIBRATION AND TEMPERATURE 133 5.1. INTRODUCTION 133 5.2. MONITORING THE DYNAMIC EQUIPMENT BY THE VIBRATION ANALYSIS 136 5.2.1. The vibrations equipment 136 5.2.2. Types of defects made through the analysis the of vibrations of the dynamic equipment 142 5.3. MONITORING THE DYNAMIC EQUIPMENT BY TERMOGRAPHY 162 5.3.1. Applications of the termography 162 5.3.2. The level of risk of defects caused by the temperature increase 172 5.4. CONCLUSIONS CHAPTER 6 - EXPERIMENTAL RESEARCH REGARDING THE VIBRATIONS MEASUREMENT OF DYNAMIC EQUIPMENT 175 6.1. INTRODUCTION 175 6.2. GENERAL ASPECTS REGARDING THE COMPUTERIZED SYSTEMS OF AUTOMATED DIAGNOSTICS 175 6.3. THE PROCEDURE FOR MEASURING THE VIBRATION OF DYNAMIC EQUIPMENT 179 6.4. EXAMPLES OF SETTINGS USED ON DIFFERENT TYPES OF EQUIPMENT 158 6.5. REPORT OF VIBRO-DIAGNOSIS 199 6.6. CONCLUSIONS eng. Costea Ancuţa Carmen 2

CHAPTER 7 - EXPERIMENTAL RESEARCH REGARDING THE APPLICATION OF THE MAINTENANCE SYSTEMS 209 7.1. EXPERIMENTAL RESEARCH REGARDING THE IMPLEMENTATION OF RISK BASED MAINTENANCE AT S.C. SOMEŞ S.A. DEJ COMPANY 209 7.1.1. INTRODUCTION 209 7.1.2. PRESENTATION OF THE COMPANY, OF THE USED EQUIPMENT AND INSTALLATIONS WITH HIGH LEVEL OF RISK 211 7.1.3. STUDY OF SYSTEMS TIME EVOLUTION WITHIN THE SC. SOMEŞ DEJ SA. COMPANY 213 7.1.4. EXPERIMENTAL RESEARCH ON IMPROVING THE RELIABILITY OF THE REGENERATION BOILER BY THE APPLICATION OF RISK BASED MAINTENANCE 218 7.1.4.1. The evaluated system: black lye pump of the regeneration boiler 220 7.1.4.2. The evaluation form of the work system 221 7.1.4.3. Determination of global level risk of the work system 227 7.1.4.4. The interpretation of results regarding the risk assessment of the system 227 7.1.4.5. The working sheet of the measures proposed 228 7.1.4.6. Proposed solutions and their implementation within the company 237 7.2. EXPERIMENTAL RESEARCH REGARDING THE IMPLEMENTATION OF PROACTIVE MAINTENANCE SYSTEM 238 7.2.1. INTRODUCTION 238 7.2.2. THE IMPLEMENTATION OF PROACTIVE MAINTENANCE SYSTEM 239 7.2.3. DESCRIPTION OF THE USED EVALUATING METHOD 241 7.2.4. THE VIBRATION MEASURING DEVICE MICROLOG CMVA60 ULS 243 7.2.5. DATA PROCESSING BY USING THE PRISM 4 SOFTWARE 244 7.2.6. CASE STUDIES REGARDING THE IMPLEMENTATION OF PROACTIVE MAINTENANCE SYSTEM WITHIN THE PULP AND PAPER DEPARTMENT OF SC Somes SA Dej 246 7.2.6.1. The analysis of the vibrations for the superior press and the proposed solutions 251 7.2.6.2. The analysis of the vibrations for the black lye pump C 2 and the proposed solutions 253 7.3. CONCLUSIONS CHAPTER 8 FINAL CONCLUSIONS AND FUTURE PERSPECTIVES IN THE FIELD OF MAINTENANCE 261 BIBLIOGRAPHY 265 APPENDICES 273 eng. Costea Ancuţa Carmen 3

ABSTRACT In the last years, due to some major changes that occurred in the international and national market, the application of modern methods of maintenance became necessary. The maintenance activity must be considered as a future investment that can be converted as source of benefit for companies. The Ph.D. thesis entitled Contributions Regarding the Implementation of the Computerized Maintenance Systems, structured in 8 chapters, references and 8 appendixes, is presented briefly as following. Chapter 1 entitled The Actual Stage of the Research and Contribution in the Field of Maintenance presents briefly the evolution of the maintenance methods and the current research activities related to the implementation of different types of maintenance concepts (predictive, proactive, risk base maintenance) within different companies in the world. By combining different types of maintenance, according to the main objectives and policy of each company, new methods of maintenance has been developed, such as: risk base maintenance, total productive maintenance and reliability centered maintenance. The case studies presented within this chapter confirm the tendency of implementing the predictive maintenance, the risk base maintenance and integrated maintenance solutions, in this filed. The Chapter 2 presents the main objectives of the Ph.D. thesis as following: experimental research regarding the benefits and the implementation of the proactive and risk base maintenance system within SC Somes SA Dej Company; experimental research regarding the determination of vibrations on different dynamic equipment, by using performance measuring apparatus and dedicated software, in cooperation with SC Rulmenti Suedia SRL Cluj; research regarding the evolution of the equipment and installations with high level of risk, within SC Somes SA Dej Company; the realization of the database and the elaboration of forms and procedure for the implementation of the risk base maintenance concept; experimental research regarding the implementation of risk-based maintenance concept in order to improve the reliability of the regeneration boiler from the Cellulose division of the SC Somes SA Dej Company; experimental research regarding the implementation of the proactive maintenance method in order to improve the reliability of the black lye pump and the superior press from of the Cellulose division of SC Somes SA Dej Company; eng. Costea Ancuţa Carmen 4

Chapter 3 of the thesis entitled The Theoretical Base of the Maintenance presents the types of maintenance used at national and international level, including the application, necessary equipment, their advantages and disadvantages. The types of maintenance systems studied are: corrective maintenance or reactive maintenance, preventive maintenance or maintenance based on time, predictive maintenance and proactive maintenance. Also, in this chapter are presented the modern methods of maintenance that were approached, such as risk based maintenance, total productive maintenance and reliability-centered maintenance of the equipment. This chapter still refers to terms used in the field of maintenance, such as maintainability, reliability, availability etc. Also, there are presented the categories of time associated with the technical equipment: operating time and down-time, waiting time and actual time of maintenance. The chapter concludes with a brief presentation of the annual maintenance cost terms related to the type of the used maintenance. Because of the proactive maintenance and the risk-based of maintenance benefits, in the following chapters assigned to the experimental research conducted in the PhD thesis, the main advantages of these types of maintenance to the SC Somes S.A. Dej Company will be presented. In Chapter 4, entitled "Achievements of the Methods of Risk-based Maintenance", there are presented the theoretical considerations of the risk concept and the main techniques used to identify the accidents and the maintenance methods based on the risk assessment. Within this chapter the risk based maintenance methods are presented in detail, such as: Risk based Inspection and Maintenance Procedure for European Industry RIMAP; HAZard and OPerability methodology - HAZOP; HAZop Reliability Operability methodology HAZROP. In the method of quantitative determination of the risk level, the stages of the evaluation method and the application forms and procedures necessary for the analyzed system are presented detailed within this chapter. The main techniques studied that may be used in order to identify the possible accidents are the following methods: Hazards and Operability Study HAZOPS Failure Modes and Effects Analysis FMEA Fault Tree Analysis FTA Event Tree Analysis ETA Human Reliability Analysis HRA By following the steps proposed in this chapter regarding the experimental research conducted in the PHD thesis, the method of risk assessment of the breakdown has been applied, by using the RIMAP procedure at the equipment within the SC Somes SA Dej Company. eng. Costea Ancuţa Carmen 5

Chapter 5 of the PhD thesis entitled "Theoretical and Practical Research on Vibration and Temperature Monitoring" presents some theoretical considerations and practical aspects of the modern diagnostic equipment used, such as vibration analysis and monitoring by thermography. In this chapter are presented the most common types of defects used to analyze the vibration of the equipment with the spectrum analysis and different applications of the thermography method. There are presented mechanical and electrical defects, as there were recorder by analyzing the vibration spectrums, such as: mechanical or electrical disequilibria, misalignment, wear of bearings, wear of transmission components (gears, belts), eccentricities, clearance, wear loose, lubrication problems, winding defects. This chapter concludes with a brief presentation of the several applications of dynamic monitoring equipment, by using the termography method. Currently is not conceivable the application of proactive maintenance or risk based maintenance concepts without knowing in detail the vibrations analysis of dynamic equipment and the termography, or by not having the specific equipment for measuring the vibrations and temperatures. In Chapter 6 entitled "Experimental Research on Vibration Measurement at the Dynamic Equipment" is presented in what consists the automatic diagnosis system that is able to structure the decisions, when process parameters together with their own decision tree are added, as more parameters related to monitoring the operation condition of equipment. In this chapter is presented the procedure of setting the measurement points in the vibration analysis by using the Microlog CMW A60 ULS portable apparatus and the software PRISM 4, for different types of equipment: electrical engines, fans, pumps, gearboxes, couplings with belt and compressors, which generally are used in the critical equipment or have a major impact on the production level of an enterprise. The experimental research conducted in this chapter were carried out in collaboration with SC Rulmenţi Suedia SRL (SKF dealer and Certified Partner for Maintenance), and presents the vibration measurement procedure that was applied to various dynamic equipment: electric motors, fans, pumps, gearboxes, couplings and belts, compressors, generally elements that are used in the critical equipment or have a major impact on the production level of an enterprise. The test results were needed in order to obtain qualitative diagnostic information within the implementation of a predictive or proactive maintenance system. This has made a suitable combination of measurement parameters of the machine operating conditions and characteristics of failure. By knowing the peculiarities of the procedure for measuring the vibration at different dynamic equipment, some experimental research were performed in collaboration with SC eng. Costea Ancuţa Carmen 6

Rulmenţi Suedia SRL, and finally different diagnosis reports of vibrations for SAPA Chisinau Chris Company were successfully obtained. Therefore, by using the analysis of spectrums vibrations and the thermography method, the optimum operating conditions of the equipment were obtained, by using the time of measurement and the measuring devices and dedicated software provided by SC Rulmenţi Suedia SRL. The obtained results, obtained from the research developed at the SC Rulmenţi Suedia SRL Company, are comparable to those achieved in the field at the international level. Chapter 7 of the PhD thesis entitled "Experimental Research on the Application of the Maintenance" presents two types of maintenance systems that were successfully implemented in the pulp and paper factory at the SA Somes SC Dej company, by establishing the stages and the implementation of some case studies, by applying the general method of risk identification and by monitoring the vibration analysis, within the implemented concept of risk-based maintenance and proactive maintenance. In this chapter, the performed research is presented, by pointing out the main achievements obtained in order to improve the benefits of the proactive maintenance system and the risk based maintenance methods that were successfully implemented, through a series of experimental research that have been conducted since 2005, at the SA Somes SA Dej Company, in collaboration with the Bay Zoltan Institute of Miskolc, Hungary, and the company SKF SC Rukmenti Suedia SRL. Within the proactive maintenance performed at the SC SOMEŞ S.A. Dej Company the risk-based maintenance concept has been successfully implemented at the equipment with a high level of risk. The case studies presented in Chapter 7 underlines the main contributions of the author within the PhD thesis, consisting in: the experimental research performed regarding the implementation of the risk based maintenance system, by using the RIMAP procedure, in order to improve the reliability of the regeneration boiler from the Cellulose division of the SC Somes SA Dej Company, and the experimental research regarding the implementation of the proactive maintenance system in order to improve the reliability of the black lye pump and the superior press of the paper machine. By following the reorganization of the maintenance activities, based on the modern principles that were presented, the allocated time to the planned repairs was decreased at approximately 1 month/year, and the cost savings by implementing these methods of maintenance (risk based maintenance and the proactive maintenance) are substantial. The Chapter 8 of the thesis, entitled "Final Conclusions and Future Perspectives of the Research in the Maintenance Field" underlines the main contributions of the author within the eng. Costea Ancuţa Carmen 7

PhD thesis. The future perspectives of continuing the research in the maintenance field are also briefly presented within this chapter. The main research results presented in the PhD thesis entitled Contributions Regarding the Implementation of the Computerized Maintenance Systems were published in different journals and proceedings of prestigious conferences from the country and abroad, within the 20 scientific papers, including 8 as first author. Cluj-Napoca, October 2011 Assist.eng. Costea Ancuţa Carmen eng. Costea Ancuţa Carmen 8