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7/19/22©2020 - 2022 IDCON INC1Documenting Preventive Maintenance/ Essential Care and Condition MonitoringTorbjörn IdhammarCEO and PresidentIDCON INC1WWW.IDCON.COM© IDCON INC2Industries Worked In• Wood, Building Products• Steel and Metals• Pharmaceutical• Power Plants• Mining• Food• Chemical• Oil and Gas• Pulp and Paper• Manufacturing2

7/19/22©2020 - 2022 IDCON INC2WWW.IDCON.COM© IDCON INC3Ongoing Contracts• Norbord/ WestFraser• Louisiana Pacific• Novo Nordisk, USA• Ingredion • Domtar• Billerudkorsnäs• Softys/ CMPC Tissue• Oji Paper• Resolute Forest Prod.• NicePak• Nitta Gelatin• Centinela• Cascades• Fatima, PakistanOur ClientsRecent Clients:3WWW.IDCON.COM© IDCON INC4International Presence 4

7/19/22©2020 - 2022 IDCON INC3WWW.IDCON.COM© IDCON INC5Areas of ExpertiseReliability & Maintenance for the Process Industry• Advice• Leadership Organization• Reliability Assessments• Planning & Scheduling• Shutdown/ Turnaround• Preventive Maintenance• Operator Essential Care• Root Cause Problem Elimination• Spare Parts Management• Technical DatabaseIn Plants, Mills & MinesPublic Training/Seminars5WWW.IDCON.COM© IDCON INC6Recap from Seminar 1• Definition of Preventive Maintenance/ Essential Care & Condition Monitoring• Preventing Failures• Condition Monitoring• Life of Components• Failure Developing Period• Maintenance Methods Available• Available: XXXXXX6

7/19/22©2020 - 2022 IDCON INC4WWW.IDCON.COM© IDCON INC7Productivity Circle7WWW.IDCON.COM© IDCON INC8Common PM Before ImprovementLubricationOil TestingMechanicalInfrared ThermographyElectricalOperationsProcess ControlInstrumentationVibration Analysis8

7/19/22©2020 - 2022 IDCON INC5WWW.IDCON.COM© IDCON INC9Painting the Picture of the Finished ProductOperationsOil TestingVibration AnalysisLubricationElectricalProcess ControlInstrumentationInfrared ThermographyMechanical• Many PMs moved from off-line to on-the-run• Coordinated PM process reduces PM process size• Essential Care reduces amount Corrective Work 9The Logic of documenting PM’s10

7/19/22©2020 - 2022 IDCON INC6WWW.IDCON.COM© IDCON INC111. Do we understand how the component/equipment works, what is the function?2. Divide the Equipment into Components3. Select Maintenance Method (OTB, FTM, CBM)4. How does the component fail?5. What can be done to prevent failures?6. What can be done to find failures early?7. If 4 & 5 are insufficient, are there critical parts we need?8. Inspection frequency for each inspection?9. Tools and Who should do the inspection?Summary of Documentation Steps11WWW.IDCON.COM© IDCON INC121. How does it Work?Grid Coupling12

7/19/22©2020 - 2022 IDCON INC7WWW.IDCON.COM© IDCON INC131. How does it Work (a little more complex example)13WWW.IDCON.COM© IDCON INC142. Dive into componentsPump - CentrifugalSeal - PackingCoupling - GridMotor - AC14

7/19/22©2020 - 2022 IDCON INC8WWW.IDCON.COM© IDCON INC153. Maintenance Methods: Existing Equipment OTB – Operate To BreakdownFTM – Fixed Time MaintenanceCBM – Condition Based Maintenance15WWW.IDCON.COM© IDCON INC164. How Does Component Fail?Grid Coupling – Symptom modes• Noise (“pinging” or vibrating)• Leaking seal/ gasket• Increase in temperature• Missing/ damaged bolts/ set screws• Missing/ damaged keyway16

7/19/22©2020 - 2022 IDCON INC9WWW.IDCON.COM© IDCON INC174. FMEA or SMEA?Grid BreaksKey BreaksCoupling FailsMotor Control SystemMisalignmentStress OverloadStress High-Cycle FatigueMechanical Wear on GridNot Enough LubricationVibrationVibrationMisalignmentEngine Control SystemIncreased Resistance-Driven EndStress High-Cycle FatigueStress OverloadIncreased Resistance-Driven EndSet Screw Loose17WWW.IDCON.COM© IDCON INC184. SMEA (Symptom Mode Effect Analysis)? Pinging NoiseKey BreaksCoupling FailsLeaking OilVibrating NoiseCoupling HotBolt/Screw loose/ missing18

7/19/22©2020 - 2022 IDCON INC10WWW.IDCON.COM© IDCON INC195. What Can be Done to PREVENT Failures?Grid Coupling• Lubrication (type, volume, frequency)• Alignment*• Buy high quality coupling*• Install coupling correctly*• Change gasket • Change seal• (Even drive from control system)*Not done on a set frequency (Therefore not a typical “PM”). Do it right the first time.19WWW.IDCON.COM© IDCON INC206. What Can be Done to Find Failures?Grid Coupling• Tempe ra tu re• Noise• Vibration• Load check on motor• Visually inspect keyway - seals, lub. leakage with strobe20

7/19/22©2020 - 2022 IDCON INC11WWW.IDCON.COM© IDCON INC217. Critical Parts Needed? PM is good in this case, but part is not very expensive to store.• Actual carrying costVS• Risk of failure [%] x cost of consequence not having the part [$]21WWW.IDCON.COM© IDCON INC228. Inspection Frequency• Estimate failure developing period (FDP) - See PM Seminar 1• Divide by 2• Grid Coupling estimated to 4 week, inspect bi-weekly.22

7/19/22©2020 - 2022 IDCON INC12WWW.IDCON.COM© IDCON INC239. WhoImplement taskGo to next groupIs it practical? Do they know how?Can they be treated in < x min?Groups:1. Operator2. Area Maintenance3. In-house Maintenance Expert4. Outside ExpertYYYNNN23WWW.IDCON.COM© IDCON INC24Typical Operator InspectionsMotor temperature/vibrationWeep hole regulatorBelt and coupling condition with stroboscopeOil level in hydraulic unitHeat exchanger function hydraulic unitOil level in pump24

7/19/22©2020 - 2022 IDCON INC13WWW.IDCON.COM© IDCON INC25Typical Maintenance InspectionsPlaces impractical for operators to get toComplex systems Vibration analysisComponents that require experienceInfrared camera25WWW.IDCON.COM© IDCON INC26ESSENTIAL CARE (EC)Installation/ DesignAlignmentBalancingDetailed CleaningOperating ProceduresFiltrationLubricationCBMInspection lists on component level1. Running objective2. Running subjective3. Shutdown objective4. Shutdown subjectiveFor Existing Equipment26

7/19/22©2020 - 2022 IDCON INC14WWW.IDCON.COM© IDCON INC27© 1 of 1COMPONENT ON-THE-RUN INSPECTION Frequency SHUTDOWN INSPECTION/ FTM Frequency Coupling Gear CMS106R Operators: Noise Temperature Visual Guards Mech. Maint.: Noise Temperature Visual Guards Weekly Monthly Lubricator: Take apart, inspect, clean all parts, change seals, re lubricate, check alignment. 2 years Motor AC CMS 100R Operations: Air intake detailed cleaning water humidity Temperature Noise and Vibration Motor Base Electrical Greasing. Mech. Maint.: Air intake detailed cleaning water humidity Temperature Noise and Vibration Motor Base Electrical Greasing. Vibration analysis Lubrication (if applicable). Frequency depends on rpm and grease. Weekly Weekly- monthly 2-3 Weeks 3 months E/I Maint. For critical motors, it’s suggested to run a winding test. A winding test can be done with a number of different tools, use the mill standard tool. If there is a maintenance opportunity, do detailed cleaning of unit, remove junction box cover and inspect connections. Follow required safety procedures. Yearly Pump Centrifugal Packing CMS127R Operations: Temperature Bolts and fasteners seal noise and vibration oil level oil condition leaks in piping pressure gague detailed cleaning breather cavitation Mech Maint. Temperature Bolts and fasteners seal noise and vibration oil level oil condition leaks in piping pressure gague detailed cleaning breather cavitation tighten packing if needed. Weekly Monthly Lubricator: Oil change yearly for mineral oil, every 3 years for synthetic oil. 1-3 years 27WWW.IDCON.COM© IDCON INC28PM Database28

7/19/22©2020 - 2022 IDCON INC15WWW.IDCON.COM© IDCON INC29 KEY HOW WHY Temperature Scan clean areas of motor with an Infrared Temperature Gun (IR-Gun) 1. High temperature in the middle of the motor may indicate damaged winding, or that motor operates close to maximum output capacity. 2. Hot spots at the bearings may be caused by damaged bearings, misalignment, over- or under lubrication. Check if coupling is hot, if it is, the problem may be alignment. Noise and Vibration Listen for abnormal noise and vibration. Listen to the motor closely and try to detect any unusual noise. Vibration can be detected by: 1. feeling motor (subjectively) 2. take vibration reading with vibration pen 3. take full spectrum vibration reading 1. Try to detect unusually high vibration level by putting a hand on different spots on the motor. 2. If a vibration pen is used, it is usually enough to take the vibration reading in the horizontal plane (horizontally mounted motor). The highest vibration value will usually appear in the horizontal plane. To enable trending, mark where to take the reading on the motor. A general guideline for this type of equipment is not to exceed 0.25 in/s (about 6 mm/s). Be aware that this number is a rough guideline and is dependent on rpm, and bearing clearances. If a high vibration level is detected, lubricate the bearings while measuring the vibration level. The vibration level should go down as the grease hits the bearing. When the vibration level stops going down, make sure to stop lubrication. This will ensure that you do not over lubricate. Check the motor 2-3 days later and measure the vibration level again, if the vibration level is high, the lubricant has escaped, or the bearing is damaged. Ask vibration technician to check bearing. For motors in operation where the consequence of a failure costs at least twice as much as the cost of measuring a full vibration spectrum should be recorded every 2-3 weeks. Refer to vibration analysis tools ad procedures. Noise and vibration can be caused by looseness in mounting or coupling, misalignment, worn bearings, damaged winding, broken air intake fan. Equipment near the motor may induce vibration. Over lubrication will either: 1. Increase the heat in the bearing due to increased resistance. Heat will reduce bearing and seal life dramatically. 2. Destroy bearing seal and expose the bearing to dirt which will reduce bearing life dramatically. 1 2 © Copyright IDCON, INC. œ Do Not Copy MOTOR - AC Basic Function An Alternating Current (AC) motor has two major components, the stator and the rotor (see picture). The stator creates a rotating magnetic field. The rotating magnetic field acts on the rotor, causing it to spin due to the rotating magnetic torque. The rotating magnetic field from the stator is produced by the currents that are flowing through the stator windings. The stator windings have several “poles”. The poles are activated by the current at different times, causing the magnetic field to move (rotate). The rotor is built of a number of magnets. The rotor magnets react to the rotating magnetic field, and the rotor starts to rotate with the magnetic field. Courtesy: Reliance motors © Copyright IDCON, INC. œ Do Not Copy Training: Reference DocumentationSamples: www.idcon.com29WWW.IDCON.COM© IDCON INC30PM/ECCM Example Centrifugal FanCMS 142R Fan – Air CentrifugalCMS129R Bearings+ Temp. and vib. limitCMS 137R Belt DriveCMS 100R Motor AC+ Amp. & Temp. & vib. limit30

7/19/22©2020 - 2022 IDCON INC16WWW.IDCON.COM© IDCON INC31PM/ECCM Example31WWW.IDCON.COM© IDCON INC32FahrenheitHandheld Example32

7/19/22©2020 - 2022 IDCON INC17WWW.IDCON.COM© IDCON INC33Condition Monitoring Standards33WWW.IDCON.COM© IDCON INC34Summary• 9 Step documentation process• Use Component Standards• Use RCM/ FMEA when needed only• Speed and Value must be considered34