1、 Guidance Notes on Equipment Condition Monitoring Techniques GUIDANCE NOTES ON EQUIPMENT CONDITION MONITORING TECHNIQUES APRIL 2016 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2016 American Bureau of Shipping ABS Plaza 16855 Northchase Drive
2、 Houston, TX 77060 USA Foreword Foreword Since the late 1970s, marine and offshore operators have increasingly applied various proactive maintenance techniques to prevent failures before they occur, detect the onset of failures, or discover failures before they impact system performance. There have
3、been numerous advances in condition monitoring technology, trending, and increasingly more powerful planned maintenance software and machine diagnostics solutions as a result of increased computing power and networking. Beginning in 1978, ABS cooperated with Owners on developing and implementing pre
4、ventative maintenance programs incorporating condition monitoring techniques. In 1984, ABS issued its first Guide for Survey Based on Preventative Maintenance Techniques with subsequent updates in 1985, 1987, 1995, and then inclusion in the ABS Rules for Survey After Construction (Part 7) in mid-200
5、2. Since that date, updates have been made periodically with the most recent in the 2012 Rules. Machinery systems continued to become larger and more complex, requiring operators with more specialized knowledge of the machinery and systems onboard. Accordingly, ABS published the Guide for Survey Bas
6、ed on Reliability-Centered Maintenance (RCM Guide) in December 2003 to provide vessel and other marine installation owners, managers and operators with requirements for the development of a maintenance program using techniques successfully applied in other industries for machinery systems within a m
7、aintenance philosophy referred to as Reliability-Centered Maintenance (RCM). Subsequently, ABS published the Guidance Notes on Reliability-Centered Maintenance (RCM Guidance Notes) in July 2004 to provide supplementary information for the more effective application of the requirements of the RCM Gui
8、de. The RCM Guidance Notes provide information related to equipment failure, maintenance strategies, risk considerations, conducting and documenting an RCM analysis and sustaining an RCM program. The purpose of these Guidance Notes on Equipment Condition Monitoring Techniques is to provide a single
9、ABS document containing information related to the subject and to be used as a resource (supplement) for choosing appropriate condition monitoring techniques where referred to in Appendix 7-A-14 of the ABS Rules for Survey After Construction (Part 7) or the ABS Guide for Surveys Based on Machinery R
10、eliability and Maintenance Techniques. Topics addressed include a summary of condition-monitoring techniques used in the marine industry, guidance on the selection of an appropriate technique, measurement frequency, personnel skills, company resources, and risk assessment. Also available is an elect
11、ronic spreadsheet listing organized by the type and condition of the equipment being monitored. Through the application of condition-monitoring techniques, Owners/managers/operators should be able to expect improved equipment and system reliability onboard their vessels or other marine installations
12、. ABS recommends consideration is given to enrolling these vessels in either the Reliability-Centered Maintenance Program or the Preventative Maintenance Program to take advantage of the additional cost saving benefits for equipment maintenance together with receiving credit towards the ABS Continuo
13、us Survey Machinery. These Guidance Notes become effective on the first day of the month of publication. Users are advised to check periodically on the ABS website www.eagle.org to verify that this version of these Guidance Notes is the most current. We welcome your feedback. Comments or suggestions
14、 can be sent electronically by email to rsdeagle.org. Terms of Use The information presented herein is intended solely to assist the reader in the methodologies and/or techniques discussed. These Guidance Notes do not and cannot replace the analysis and/or advice of a qualified professional. It is t
15、he responsibility of the reader to perform their own assessment and obtain professional advice. Information contained herein is considered to be pertinent at the time of publication, but may be invalidated as a result of subsequent legislations, regulations, standards, methods, and/or more updated i
16、nformation and the reader assumes full responsibility for compliance. This publication may not be copied or redistributed in part or in whole without prior written consent from ABS. ii ABSGUIDANCE NOTES ON EQUIPMENT CONDITION MONITORING TECHNIQUES .2016 Table of Contents GUIDANCE NOTES ON EQUIPMENT
17、CONDITION MONITORING TECHNIQUES CONTENTS SECTION 1 General 1 1 Application 1 2 Objective . 1 3 Defining Condition-Monitoring Tasks 1 4 Definitions . 2 5 Machinery Condition Monitoring Techniques 5 TABLE 1 Machinery Condition Monitoring Applications . 6 SECTION 2 Equipment Failure 9 1 Introduction .
18、9 2 Equipment Failure . 9 3 Equipment Failure Rate and Patterns . 9 3.1 Failure Rate . 9 3.2 Failure Rate . 10 3.3 Conditional Probability Failure Rate 10 3.4 Equipment Failure Models and Failure Patterns 10 4 Failure Management Strategy 12 4.1 Proactive Maintenance Tasks . 12 4.2 Run-to-failure . 1
19、3 4.3 One-time Changes 13 4.4 Servicing and Routine Inspection 14 TABLE 1 Six Classic Failure Rate Patterns . 11 FIGURE 1 Equipment Life Periods . 11 SECTION 3 Condition-monitoring (Predictive) Maintenance . 15 1 Potential Failure (P-F) Diagram 15 2 Selection of Task Frequency 15 3 Condition-monitor
20、ing Maintenance Categories. 16 4 Condition-monitoring Maintenance Task Applicability and Effectiveness . 16 ABSGUIDANCE NOTES ON EQUIPMENT CONDITION MONITORING TECHNIQUES .2016 iii 5 Determining Condition-monitoring Maintenance Task Intervals . 17 5.1 Condition-monitoring Task Interval 17 5.2 Initia
21、l Condition-monitoring Task Intervals . 17 5.3 Improving the Understanding of P-F Intervals . 17 5.4 Additional Guidance . 17 6 Condition Monitoring Technician Skill Level . 18 7 Establishing Condition-monitoring Maintenance Task Action Limits . 18 FIGURE 1 P-F Diagram 15 SECTION 4 Temperature Measu
22、rements 19 1 Introduction . 19 2 Temperature Measurement Techniques . 19 2.1 Point Temperature Overview . 19 2.2 Installation Considerations . 19 2.3 Point Temperature Devices . 20 2.4 Infrared Thermography 22 TABLE 1 Comparison of Temperature Measurement Techniques 19 FIGURE 1 Infrared Thermograph
23、Coupler Alignment . 24 FIGURE 2 Infrared Thermograph Electric Motor Bearing . 24 FIGURE 3 Infrared Thermograph Hot Electric Motor 25 FIGURE 4 Infrared Thermograph Belts Slipping . 25 FIGURE 5 Infrared Thermograph Boiler Valve 26 FIGURE 6 Infrared Thermograph Boiler Refractory 26 FIGURE 7 Infrared Th
24、ermograph Heater Block 27 FIGURE 8 Infrared Thermograph Variable Speed Drive . 27 SECTION 5 Dynamic Monitoring . 28 1 Introduction . 28 1.1 Vibration Parameters . 28 1.2 Baseline Measurement 28 1.3 Measurement Data Collection . 30 1.4 Data Collection Equipment Calibration 30 1.5 Vibration and Balanc
25、ing Limits 30 1.6 External Specialist . 31 2 Dynamic Monitoring Techniques. 31 2.1 Time Waveform Analysis . 31 2.2 Broad Band Vibration Analysis 31 2.3 Spectrum Analysis . 32 2.4 Shock Pulse Analysis 36 2.5 Ultrasonic Analysis 36 2.6 Other Techniques 37 2.7 Vibration Limits Resources 40 iv ABSGUIDAN
26、CE NOTES ON EQUIPMENT CONDITION MONITORING TECHNIQUES .2016 TABLE 1 Vibration Parameter Comparison for a Sinusoidal Wave . 29 TABLE 2A Criteria for Overall Condition Rating Overall Velocity rms (mm/s) . 34 TABLE 2B Criteria for Overall Condition Rating Overall Velocity Peak (in/s) 35 TABLE 3 Additio
27、nal Dynamic Monitoring Techniques 37 FIGURE 1 Relationships for Vibration Amplitude for Sinusoidal Wave 29 SECTION 6 Oil Analysis . 44 1 Introduction . 44 1.1 Aspects of Oil Analysis 44 2 Oil Analysis Condition-monitoring Techniques . 45 2.1 Atomic Emissions Spectroscopy . 45 2.2 Dielectric Strength
28、 Tests . 45 2.3 Ferrography . 46 2.4 Infrared and Ultraviolet Spectroscopy (ASTM E2412) . 46 2.5 Moisture Measurement 47 2.6 Kinematic Viscosity Test 48 2.7 Microbial Analysis 48 2.8 Particle Counter . 49 2.9 Potentiometric Titration Total Acid Number (TAN) (ASTM D664) and Total Base Number (TBN) (A
29、STM D4739) 50 2.10 Sediment Tests (ASTM D1698-03)(2008) (Withdrawn 2014) 50 2.11 Other Techniques 50 3 Additional Resources 63 3.1 Acronyms 63 3.2 Standards Listing . 63 TABLE 1 Oil Analysis and Tribology 51 TABLE 2 Contaminants in Fluids . 55 TABLE 3 Additional Oil Analysis Monitoring Techniques .
30、57 SECTION 7 Corrosion Monitoring . 65 1 Introduction . 65 2 Corrosion Monitoring Techniques . 65 2.1 Coupon Testing . 65 2.2 Corrometer (Electrical Resistance) 66 2.3 Potential Monitoring . 66 2.4 Ultrasonic Thickness and Gauging 66 SECTION 8 Nondestructive Testing . 67 1 Introduction . 67 2 Nondes
31、tructive Testing Techniques . 67 2.1 X-ray Radiography 67 2.2 Liquid Dye Penetrants . 69 ABSGUIDANCE NOTES ON EQUIPMENT CONDITION MONITORING TECHNIQUES .2016 v 2.3 Ultrasonic Leak Detection 69 2.4 Ultrasonic Flaw Detection 70 2.5 Ultrasonic Phased Array 70 2.6 Magnetic Particle Inspection 71 2.7 Edd
32、y Current Testing . 71 2.8 Acoustic Emission 72 2.9 Hydrostatic and Pneumatic Testing . 72 2.10 Visual Inspection Borescope 73 2.11 Other Techniques 73 TABLE 1 Nondestructive Techniques and Applications . 68 TABLE 2 Additional Nondestructive Monitoring Techniques 74 SECTION 9 Electrical Testing 76 1
33、 Introduction . 76 2 Electrical Testing and Monitoring Techniques 76 2.1 Megohmmeter Testing . 76 2.2 High Potential Testing 76 2.3 Surge Testing 77 2.4 Power Signature Analysis 77 2.5 Motor Circuit Analysis 77 2.6 Battery Impedance Testing 78 SECTION 10 Observation and Surveillance . 79 1 Introduct
34、ion . 79 2 Observation and Surveillance Techniques . 79 2.1 Visual Inspection 79 2.2 Audio Inspections 79 2.3 Touch Inspections 80 SECTION 11 Process Variable and Performance Trending 81 1 Introduction . 81 1.1 Data Collection 81 2 Performance Technique 82 2.1 Performance Trending . 82 SECTION 12 En
35、gine and System Performance Monitoring and Diagnostics . 83 1 Introduction . 83 2 Data Collection and Transmittal 84 2.1 Vessel Level Data 84 2.2 Vessel Data Capture 85 2.3 Analysis and Qualification Software . 86 2.4 State Trending . 86 2.5 From Client to Fleet Management Software 86 2.6 Data Revie
36、w and Governance . 87 vi ABSGUIDANCE NOTES ON EQUIPMENT CONDITION MONITORING TECHNIQUES .2016 3 Performance Monitoring 87 3.1 Performance Parameters 87 3.2 Performance Reporting . 87 3.3 Remote Monitoring 88 4 Future Trends . 89 FIGURE 1 Simplified Process. 83 FIGURE 2 ISO 13374 Functional Blocks 84
37、 FIGURE 3 Remote Monitoring and Data Transmission . 88 FIGURE 4 Vessel Systems Monitoring and Data Transmission 89 SECTION 13 Evaluating New Condition Monitoring Techniques . 90 1 Introduction . 90 2 Applicability of Technique . 90 3 Consistency/Repeatability of Measurements 90 4 Statutory Regulatio
38、ns 90 5 Cost Effectiveness 90 TABLE 1 Evaluating Cost Effectiveness of a Condition-Monitoring Technique . 91 APPENDIX 1 Additional References . 93 ABSGUIDANCE NOTES ON EQUIPMENT CONDITION MONITORING TECHNIQUES .2016 vii This Page Intentionally Left Blank Section 1: General SECTION 1 General 1 Applic
39、ation Condition-monitoring tasks may be applied to any equipment and machinery systems for which they are applicable. Both Appendix 7-A-14 of the ABS Rules for Survey After Construction (Part 7) and the ABS Guide for Surveys Based on Machinery Reliability and Maintenance Techniques should be referen
40、ced, as applicable, for equipment that is not permitted to be enrolled in the respective programs for reasons of statutory regulations or ABS survey policy. If the machinery is intended to be enrolled in a Machinery Maintenance Program or the Preventative Maintenance Program, it is a prerequisite th
41、e machinery be on a Special Continuous Survey of Machinery (CMS) cycle. 2 Objective These Guidance Notes provide supplementary information for condition monitoring, trending and diagnostics which can be used in conjunction with Appendix 7-A-14 of the ABS Rules for Survey After Construction (Part 7)
42、and the ABS Guide for Surveys Based on Machinery Reliability and Maintenance Techniques. Condition-monitoring tasks are scheduled activities used to monitor machine condition and to detect a potential failure in advance so that action can be taken to prevent that failure. These Guidance Notes summar
43、ize: i) The various condition-monitoring techniques applied to machinery ii) The condition-monitoring tasks most applicable for particular machinery iii) The effectiveness of condition-monitoring tasks iv) The failure condition monitored v) The framework for network based data collection Improved eq
44、uipment and machinery system reliability onboard vessels and other marine structures may be expected through the proper application of condition-monitoring tasks where condition-monitoring techniques are appropriate, applicable, and correctly implemented. The principles summarized in these Guidance
45、Notes follow the same principles as those applied in Appendix 7-A-14 of the ABS Rules for Survey After Construction (Part 7) and the ABS Guide for Surveys Based on Machinery Reliability and Maintenance Techniques. 3 Defining Condition-Monitoring Tasks A condition-monitoring task is a scheduled task
46、used to detect the potential onset of a failure so that action can be taken to prevent such failure. A potential failure is an identifiable condition that indicates that a functional failure is either about to occur or is in the process of occurring. Condition-monitoring tasks should only be chosen
47、when a detectable potential failure condition will exist before failure and the applicable task has a reasonable probability of detecting the failure. The first maintenance types that should be considered are those recommended by the manufacturer. Condition monitoring tasks should only be considered
48、 if they can be proven to be applicable and effective. ABSGUIDANCE NOTES ON EQUIPMENT CONDITION MONITORING TECHNIQUES .2016 1 Section 1 General Some condition-monitoring tasks may be identified from previous risk studies such as, HAZOPs, HAZIDs and FMEAs conducted during a system design. Failure-fin
49、ding tasks may be considered to supplement some of the identified condition-monitoring tasks for increased robustness of the maintenance scheme. (See Appendix 5 of the ABS Guide for Surveys Based on Machinery Reliability and Maintenance Techniques.) Note: At times condition-monitoring tasks are referred to by practitioners in some countries as “predictive maintenance” tasks. Section 3 provides additional details. 4 Definitions The following definitions are applied to the terms used in these Guidance Notes. ABS Recognized Condition Monitoring Company: This te
