Threat Based Maintenance (TBM) - NREL
Threat Based Maintenance (TBM) - NREL
Threat Based Maintenance (TBM) - NREL
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New Approach<strong>TBM</strong>!<strong>Threat</strong> <strong>Based</strong> <strong>Maintenance</strong>4
What is <strong>TBM</strong>?Find and Eliminate SmallProblems before they BecomeBig Ones… in Real Time
What are the Benefits?Improved availabilityLowered maintenance costImproved efficiency6
Why Conventional Approaches Come up ShortSystems are complexExternal events damage or degrade equipmentGradual, but variable wearAccumulated stresses over time7
Complexity and Reliability?!?!?!?!?!?!?!?!?!?!?!?!?!?!?!?!?!?!?! ?! ?!?! ?!?!?!?!?! ?!?!?!?!?!?!?!?!?!?!?!?!?!?!?!
It Gets WorseProbofFailureTime9
What Does this Mean?In Complex Systems, Failure is EffectivelyRandom!10
However, the PF Curve is not InevitableMost failures start with something small… thenprogress…the leaky oil seal……the small cooler leak……the failed sensor……the minor operator error…11
What if you Could…?Detect and Eliminate the <strong>Threat</strong>ProbofFailureReset the PF Curve!Emerging Problem<strong>Maintenance</strong> InterventionTime12
How? It’s All in the DataHistorianVolume of data and alarmsoverwhelms:— Resources— Analysis capabilitiesResult:— Surprises still happen— Unplanned outages— Excessive maintenance costDCSSensors1313
How? It’s All in the DataAdvancedAnalyticsHistorianAdvanced Analytics:— Find the “needles in thehaystack”— Leverage investment inexisting data infrastructureResult:— Detect and eliminate threatsto generation— Reduce unplanned outages— Reduce maintenance costDCSSensors1414
The SmartSignal SolutionStarts withData fromYour EquipmentRemoves theEffects of NormalOperationPersonalized Empirical ModelsPosts Emerging <strong>Threat</strong>sto WatchListPulls every 5-10 minutesEPI*Center15
Leader in Predictive Analytics
<strong>TBM</strong> in Action…
Minor Problem-Bearing Temperature <strong>Threat</strong>Plant Notified on Increasing Bearing Temps—Possible Air FilterFouling
Minor Problem-Bearing Temperature <strong>Threat</strong>Plant Confirmed---Added External Blower to Maintain Cooling
Minor Problem-Bearing Temperature <strong>Threat</strong>Excessive Bearing Temperature Reduces Life andIncrease Possibility of a Future ProblemAnother <strong>Threat</strong> To Generation Eliminated!
Major Problem—Cracked Generator ShaftEntergy’s Waterford Two Gas/Steam Unit411 MW
Early Data Showed No Problems22
First Indication of Problem on 12/13/07Bearing 8H (Exciter bearing) Vibration on the rise and posted to theWatchList at 12:59:30
Increasing Indications
M&D Center ActionsContacted plant—take local vibes dataBrought in vibes specialistPlan to investigate that eveningDecided to bring down early and faster thennormalInvestigation found:
Crack in Generator Shaft
Rough Indication of Crack Depth
<strong>TBM</strong> & SmartSignal in Wind
In Summary<strong>TBM</strong>- Eliminate <strong>Threat</strong>sto GenerationAvailability<strong>Maintenance</strong> CostPeace of Mind29
For Further InformationDave Bell, VP Application Engineering– drbell@smartsignal.com– 630-829-4006
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