DCS Consultants' approach to developing a predictive maintenance program for turbo-machinery, including its associated load and support equipment, is to design an individual program for each piece of equipment that will attack the major contributors to downtime and losses of production while simultaneously increasing the reliability and optimizing efficiency and capacity of the equipment.
DCS utilizes a comprehensive approach to implementing a PM program that is optimized for each individual piece of equipment and is designed to attack the major contributors to downtime and losses of production while simultaneously increasing the reliability and optimizing efficiency and capacity of the equipment. The following technologies are among those utilized to achieve these goals.
- Precision Component Repair
- Proper Installation Procedure
- Repetitive Problem Identification
- Root Cause Failure Analysis
- Detailed Vibration Analysis and Trending
- Performance Analysis and Calibration Trending
A master data sheet to be used for each inspection will be developed for each unit. A separate, but similar report data sheet also will be developed for each unit. During each inspection, the turbo-machinery specialist will:
- Review and council with the operators.
- Check calibration of the instruments and controls.
- Review log book entries since last inspection.
- Record all operating parameters, both local & remote.
As the data is collected the technician checks for:
- Piping and equipment are inspected leaks.
- All oil system components and expansion joints are checked for deterioration.
- The combustion system is inspected for hot crossfire tubes.
- The inlet filter system is inspected for proper operation and filter conditions.
- Any other abnormal or undesirable conditions are documented.
- Any values outside of normal tolerance are noted.
Once the data is collected a computer analysis of the data is performed. DCS has developed a system of data trending and analysis that optimizes the indication of probable oncoming failures. This allows calibration work to be performed on a time available basis prior to its causing outages or malfunctions in the operation of the equipment. This also allows the turbine specialist to anticipate nonstandard spare parts needs before an overhaul.
After the data is collected, it will be input into a custom computer program developed specifically for that unit. This program will perform all calculations, calculate all calibration errors and compare readings to acceptable levels. A proprietary program will generate an exhaust temperature profile from the data collected and compare this profile to the standard and past profiles on the same unit. This data can then be easily manipulated by the turbine specialist as needed to evaluate any situations that may occur.
The data is added to the historical database for the unit. A proprietary data analysis program is then used to analyze the data. This program uses methods of data trending and analysis developed by DCS personnel and proven over the years in actual preventive maintenance programs. A Full computer assisted analysis of all of the vibration data collected is performed.
Following each inspection DCS Consultants will prepare and submit a formal report containing, but not limited to, the following:
- Comments and recommendations on additional modifications, changes and improvements, if any, that might enhance or further improve the reliability, availability and/or efficiency of the equipment.
- Comments and recommendations on operating and maintenance practices.
- A summary of problems and concerns outstanding on the unit. Summary of down time, causes, running time, total running time to date, etc. Summary of adjustments made and any corrective actions taken during the inspection.
- The Report Data Sheet.
- Copies of any graphs or charts deemed necessary by the specialist to provide further information on the condition or status of the unit
- Copies of vibration readings taken and any analysis charts or graphs deemed necessary to provide additional information on problems or trends occurring.
- A Problem Progress Report will be issued with the report that will detail and track all outstanding maintenance items on the equipment.