Introduction and how to use CMS : simplebooklet.com

Page 1 of 16 Condition Monitoring Standards – What They Are and How to Use Table of Contents 1. Availability...................................................................................................................................... 2 2. Origins of the CMS ......................................................................................................................... 2 3. List of Condition Monitoring Standards ......................................................................................... 3 Bearings .......................................................................................................................................... 3 Blowers and Fans ........................................................................................................................... 3 Control Devices .............................................................................................................................. 3 Conveyor ........................................................................................................................................ 3 Compressors ................................................................................................................................... 3 Couplings........................................................................................................................................ 4 Filtration ......................................................................................................................................... 4 Hydraulics ...................................................................................................................................... 4 Lubrication ..................................................................................................................................... 4 Miscellaneous Electrical / Electronic and Instrumentation ............................................................ 5 Miscellaneous Mechanical ............................................................................................................. 5 Motors and Turbines ...................................................................................................................... 5 Piping.............................................................................................................................................. 6 Pneumatics...................................................................................................................................... 6 Power Transmission ....................................................................................................................... 6 Pulp-Refiners .................................................................................................................................. 6 Pumps ............................................................................................................................................. 7 Screens............................................................................................................................................ 7 Switches and Sensors ..................................................................................................................... 7 Tanks and Accumulators ................................................................................................................ 8 Valves ............................................................................................................................................. 8 4. CMS Document Fields ................................................................................................................... 9 5. How to Use the Books .................................................................................................................. 11

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Page 2 of 16 Condition Monitoring Standards – What They Are and How to Use 1. Availability 100 Condition Monitoring Standards are available, either in a 25 each book format Volumes I through IV, or electronically. For book purchases, or electronic licensing please contact IDCON, 2. Origins of the CMS The condition monitoring standards (CMS) were a central part of one of the first PM/ECCM projects for Idhammar Konsult AB in Sweden 1972. An example of a CMS documents used at that time is shown to the left. It is a CMS for a chain conveyor. When Idhammar Konsult AB started a company in the USA 1985 under the name IDCON, INC. (Idhammar Consulting), the CMS’s were translated into English for use on the North American market. IDCON decided to update the CMS documents to their current format when new computer technology became available in the 1990’s. The CMS documents are usually edited, formatted in publishing software, and printed during projects in plants. The CMS documents have been developed in actual projects working with craftspeople, supervisors, engineers and IDCON representatives. The development continues in current IDCON projects. Figure 1 – Early Swedish version of CMS´s

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Page 3 of 16 Condition Monitoring Standards – What They Are and How to Use 3. List of Condition Monitoring Standards Bearings CMS 167 R – Bearing, Oil Cooled CMS Volume III CMS 129 R – Bearing, Pillow Block CMS Volume II Blowers and Fans CMS 154 R – Blower, Rotary Lobe CMS Volume III CMS 142 R – Fan, Radial CMS Volume II CMS 120 R – Fan, Axial CMS Volume I Control Devices CMS 170 R – Governor CMS Volume III CMS 195 R – Limit Switch, Linear CMS Volume IV CMS 196 R – Limit Switch, Rotary CMS Volume IV CMS 152 R – Regulator, Air CMS Volume III Conveyor CMS 118 R – Conveyor, Belt CMS Volume I CMS 119 R – Conveyor, Drag CMS Volume I CMS 113 R – Conveyor, Screw CMS Volume I CMS 190 R – Conveyor, Small Production CMS Volume IV Compressors CMS 122 R – Compressor, Rotary-Quincy CMS Volume I

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Page 4 of 16 Condition Monitoring Standards – What They Are and How to Use Couplings CMS 105 R – Coupling, Atra Flex CMS Volume I CMS 185 R – Coupling, ELCO CMS Volume IV CMS 165 R – Coupling, Fluid CMS Volume III CMS 106 R – Coupling, Gear CMS Volume I CMS 103 R – Coupling, Grid CMS Volume I CMS 107 R – Coupling, Jaw CMS Volume I CMS 108 R – Coupling, Magnetic CMS Volume I CMS 184 R – Coupling, Safeset CMS Volume IV CMS 102 R – Coupling, Sure Flex CMS Volume I CMS 104 R – Coupling, Thomas CMS Volume I CMS 101 R – Coupling, Tire CMS Volume I CMS 109 R – Coupling, Torus CMS Volume I Filtration CMS 115 R – Air Breather, Des Case CMS Volume I CMS 171 R – Pneumatic Filter and Oil Mist CMS Volume III CMS 199 R – Lubrication, Single Point Units CMS Volume IV Hydraulics CMS 166 R – Cylinder, Hydraulic CMS Volume III CMS 131 R – Hydraulic Unit CMS Volume II CMS 168 R – Motor, Hydraulic CMS Volume III Lubrication CMS 141 R – Lubrication, Reservoir CMS Volume II CMS 199 R – Lubrication, Single Point Units CMS Volume IV

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Page 5 of 16 Condition Monitoring Standards – What They Are and How to Use Miscellaneous Electrical / Electronic and Instrumentation CMS 194 S – Motor Starter (Shutdown) CMS Volume IV CMS 186 R – Gauge, Magnetic Flow CMS Volume IV See also under Switches and Sensors Miscellaneous Mechanical CMS 126 R – Backstop CMS Volume II CMS 158 R – Bolts and Nuts CMS Volume III CMS 157 R – Brake Disc CMS Volume III CMS 156 R – Doctor Blade CMS Volume III CMS 180 R – Debarker, Drum CMS Volume IV CMS 123 R – Dryer System, Air desiccant CMS Volume I CMS 132 R – Feeder CMS Volume II CMS 116 R – Flinger CMS Volume I CMS 128 R – Heat Exchanger CMS Volume II CMS 133 R – Mechanical Seal CMS Volume II CMS 134 R – Packing CMS Volume II CMS 174 P – Caterpillar Dozer Pre-Operational Checks CMS Volume III CMS 197 R – Strander, Disc (On-the-run) CMS Volume IV CMS 198 S – Strander, Disc (Shutdown) CMS Volume IV Motors and Turbines CMS 100 R – Motor, AC CMS Volume I CMS 161 R – Motor, DC CMS Volume III CMS 168 R – Motor, Hydraulic CMS Volume III CMS 173 R – Turbine, Steam (Small) CMS Volume III

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Page 6 of 16 Condition Monitoring Standards – What They Are and How to Use Piping CMS 164 R – Expansion Joint CMS Volume III CMS 172 R – Piping and Pipe Hangers CMS Volume III CMS 146 R – Steam Trap Mechanical CMS Volume II CMS 148 R – Steam Trap Thermodynamic CMS Volume II CMS 147 R – Steam Trap Thermostatic CMS Volume II CMS 124 R – Steam Joint – Valmet CMS Volume I Pneumatics CMS 159 R – Cylinder, Air CMS Volume III CMS 171 R – Pneumatic Filter and Oil Mist CMS Volume III CMS 152 R – Regulator, Air CMS Volume III Power Transmission CMS 163 R – Clutch, Centrifugal CMS Volume III CMS 130 R – Drive, Chain CMS Volume II CMS 155 R – Drive, Cog Belt CMS Volume III CMS 137 R – Drive, V-Belt CMS Volume II CMS 117 R – Gear Reducer CMS Volume I CMS 191 R – Index Drive, Rotary CMS Volume IV CMS 151 R – Rope Sheaves CMS Volume III CMS 150 R – Universal Joint CMS Volume III Pulp-Refiners CMS 179 R – Pulp Refiner, Beloit Double Disc CMS Volume IV CMS 177 R – Pulp Refiner, Classic Conical CMS Volume IV CMS 176 R – Pulp Refiner, Conical-disc CMS Volume IV CMS 178 R – Pulp Refiner, Single Disc CMS Volume IV

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Page 7 of 16 Condition Monitoring Standards – What They Are and How to Use Pumps CMS 127 R – Pump, Centrifugal CMS Volume II CMS 160 R – Pump, Diaphragm CMS Volume III CMS 188 R – Pump, Diaphragm Metering CMS Volume IV CMS 175 R – Pump, Double Suction Centrifugal CMS Volume IV CMS 144 R – Pump, Gear CMS Volume II CMS 169 R – Pump, Multistage Centrifugal CMS Volume III CMS 187 R – Pump, Peristaltic CMS Volume IV CMS 145 R – Pump, Piston CMS Volume II CMS 153 R – Pump, Progressive Cavity CMS Volume III CMS 110 R – Pump, Vacuum Nash CMS Volume I CMS 143 R – Pump, Vane CMS Volume II CMS 111 R – Pump, Vertical Multistage CMS Volume I CMS 189 R – Pump, Vertical Sump CMS Volume IV Screens CMS 140 R – Screen, Centrifugal CMS Volume II CMS 139 R – Screen, Disc CMS Volume II CMS 136 R – Screen, Reciprocating CMS Volume II CMS 138 R – Screen, Vibrating CMS Volume II Switches and Sensors CMS 125 R – Motion Detector CMS Volume II CMS 195 R – Limit Switch, Linear CMS Volume IV CMS 196 R – Limit Switch, Rotary CMS Volume IV CMS 181 R – Proximity Switch, Capacitive CMS Volume IV CMS 182 R – Proximity Switch, Acoustic CMS Volume IV CMS 183 R – Proximity Switch, Inductive CMS Volume IV

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Page 9 of 16 Condition Monitoring Standards – What They Are and How to Use 4. CMS Document Fields The header of the document includes the name of the CMS and a reference number. For example, the reference number for an AC motor is “CMS 100R” and is found in red in the upper right corner of the document. 100 is just a reference number identifying this particular CMS, the “R” means that this CMS concerns condition monitoring tasks that can be done when equipment is running. Basic Function gives the reader a short introduction of how the component works. Figure 2 - CMS first page. The document has three columns, KEY, HOW, and WHY. The KEY is meant to be a reference for someone using an inspection checklist. The checklist could contain just the KEY words. If the

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Page 10 of 16 Condition Monitoring Standards – What They Are and How to Use person doing the inspection does not know why, or how, the inspections are done, the CMS is available as a reference. Read the section “using this book as a reference” below for more information. IDCON’s philosophy strongly supports focusing on telling people WHY a task is important before asking someone to perform a task. Understanding WHY something is done, and WHY it is important, is a major contributor to gaining acceptance for change. The HOW column tell the reader HOW to do a specific inspection. The matching WHY-section is displayed directly to the right of the HOW-section for each task. Figure 3 - CMS Columns are KEY, HOW and WHY. If you are building an inspection program, you can use all keywords (left column) as instructions in your route list. If the person doesn’t know how, or why an inspection is done, the CMS will serve as a reference.

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Page 11 of 16 Condition Monitoring Standards – What They Are and How to Use 5. How to Use the Books The CMS standards are training and reference material for the basic function and basic condition monitoring (inspections) of common components found in industry. The documents can be used as: • Reference when building or enhancing a preventive maintenance system. • Reference when executing condition monitoring inspections. • Training material for teaching basic function of components. • Training material for how and why to do condition monitoring/ inspections. The first part of setting up a preventive maintenance system is to decide which maintenance method is the most cost effective for each component. The periodic maintenance methods available for existing equipment are: • Maintenance Prevention (MP) – to prevention failures (for example: lubrication, alignment, cleaning, balancing, filtration, adjustments, operating procedures, and installation procedures) • Condition Based Maintenance (CBM) – to detect failures early (for example vibration analysis, look, listen, feel, smell, current readings, pressure readings, and temperature readings) • Fixed Time Maintenance (FTM) – to avoid unplanned failures (works for component with known life) • Operate To Break Down (OTB) – OTB is cost effective if cost of the consequence of the failure is smaller than the cost of doing the inspection. Selecting maintenance method is usually obvious, but the theory behind selecting maintenance method can be found in IDCON’s PM/ECCM manuals. The second step is to decide on the execution frequency of the tasks. All components should eventually have a lubrication interval, an inspection interval, a cleaning interval etc. The interval is decided by different factors depending on what the task is. For example, lubrication life and/or

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Page 12 of 16 Condition Monitoring Standards – What They Are and How to Use consumption for a component should decide lubrication intervals, while cleaning interval depends on how fast equipment gets dirty, and condition monitoring (inspection) intervals must be based on the failure developing period. Detailed information on failure developing period can be found in IDCON’s PM/ECCM manual. However be aware that inspection intervals change depending on operating conditions such as: • Environment (cleanliness, temperature) • Speed (an 3600 rpm motor must be inspected more frequently than an 1800 rpm motor) • Operating condition (load, start/ stop frequency) • Lubrication practices • Hours of operation (24 hours a day, 7 days a week, or 8 hours a day five days a week) The third step is to organize all tasks into some sort of system, such as condition monitoring routes, lubrication routes, shutdown tasks etc. The documentation in this book handles basic condition monitoring done on-the-run. Most of the preventive maintenance (PM) tasks in your plant should be covered by doing condition monitoring while the equipment is running. In IDCON’s experience, 70-90% of all preventive maintenance (PM) tasks are condition monitoring tasks done on-the-run if the PM system is set up cost effectively. Condition monitoring route tasks should be organized in a logical walking path. The route should include all inspections for the area for a particular skill. An example of a route could be “basement of paper machine for mechanic” “mezzanine for operator”, or “vacuum system for instrument mechanic”. The routes should not consist of a list of one component type, for example, a route of only pumps, or only valves. If a system is set up by component type, the inspector has to go through the area 10-15 times, one time for each component that needs to be inspected. Many systems are set up by component type due to computer system limitations. The fourth step is to tie condition monitoring instructions to the route. Let the people performing the tasks in your plant modify, and agree to the inspection instructions before implementing. Working

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Page 13 of 16 Condition Monitoring Standards – What They Are and How to Use through the instructions will train people and improve your chances to get buy-in for the system. Combine the inspection texts depending on skills of people doing inspections, and what type of tools they have. The fifth step is to teach inspectors (operators or craftspeople) how and why inspections are done, using the Condition Monitoring Standards (CMS). For more detailed information about components, see IDCON’s PM/ECCM manual. The CMS books should be located in a central location for each area in the plant for all to use as a reference manual. The CMS books can for example be put in workshops or control rooms. The sixth step is to execute the inspection routes. Below follows a couple of examples of how other plants have set up their systems.

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Page 14 of 16 Condition Monitoring Standards – What They Are and How to Use Example Plant 1. The plant uses hand held computers, and CMS as a reference. This plant uses a Computerized Maintenance Management System (CMMS) that does not handle inspection routes well. This is true for most major systems on the market because they are work order driven. The example plant has therefore chosen a stand-alone system for inspection routes and works with the system as follows: 1. A work order is set up in the main CMMS system. The work order says “pick up hand held computer, and do inspections that are due for pulp mill this week”. The time and cost is captured in the main CMMS system this way. 2. Crafts Person/ operator get a rugged handheld computer from the supervisor, and follow the instruction on the screen. The instructions consist of KEY words from the CMS documents in this book. If the inspector does not know how, or why an inspection is done, the CMS is available in several places in the plant for reference. The inspector has also been trained in inspection techniques using the CMS documents. 3. Each inspection is logged in the handheld computer. Exact time for each inspection is logged, any measurements requested are logged for the particular equipment. If work orders are needed the inspector can log a work order request. 4. When the inspector is done with route, the handheld computer is put into cradle, and all information is downloaded into the computer software. 5. The supervisor has access to all data, he/she can print a list of all work order requests, look at inspection history per equipment number for Root Cause Problem Elimination, export data to Excel, make graphs etc. 6. If corrective maintenance needs to be done, a work request (notification) is issued in the main CMMS system.

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Page 16 of 16 Condition Monitoring Standards – What They Are and How to Use Example Plant 2. Uses an inspection list (paper) with CMS as reference documents. The plant Computerized Maintenance Management System (CMMS) does not handle routes well. They use the system as follows: 1. A work order is set up in the CMMS system. The work order says “go to route software, print out inspection list, and do inspections that are due for factory floor this week”. The time and cost is captured in the main CMMS this way. 2. Crafts Person/ operator get the inspection list from the supervisor, and follow the instruction on the list. The instructions in the list consist of KEY words from the CMS documents in this book. The plant has decided to add a longer explanation to each key word than the plant in example 1. If the inspector does not know how, or why an inspection is done, the CMS is available in several places in the plant for reference. The inspector has also been trained in inspection techniques using the CMS documents. 3. Each inspection is logged on the list. 4. When done with route, the list is turned in to the supervisor. 5. The supervisor goes through the list with the inspector and writes work requests in the main CMMS if any corrective maintenance needs to be done. 6. The list is filed in a filing system and becomes necessary data for Root Cause Elimination. Figure 5 - The logic is the same in this system as in the hand held system, the only difference is that this plant uses an inspection list instead of a handheld system. As you may notice, this plant has chosen to have more explicit instructions in the instruction texts.

Introduction and how to use CMS

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