World Grain - February 2023 - 58
MILLING OPERATIONS
Reliability and
condition-based
maintenance
Examining equipment condition issues from design, installation to failure
by Jeff Gwirtz
In an article in the April 2022 issue of World Grain, " Reviewing
Maintenance Strategies, " the development and progression
of maintenance strategies was presented. Implementation
of those strategies vary by milling site and even within the
same milling organization. The September 2022 World Grain
article, " Where to Begin? A strategic maintenance journey for
millers, " identified the importance of maintenance goal setting,
incident analysis and identification of costs.
The purpose of this article is to consider equipment condition
issues from design, installation to failure and discuss reliability
and condition-based monitoring (CBM). Both maintenance
and operations staff must be proactive in monitoring,
reporting equipment condition to access the machines condition
and deterioration rate over time.
Planning of preventive maintenance activities is taking less
of a time-based approach, instead becoming more condition
based. The condition-based approach may require more data
handling but that has become easier to with the use of computers
and development of Computerized Maintenance Management
Systems (CMMS). Even greater amounts of information
about plant equipment, drives and control systems are being
documented and managed by CMMSs.
Advancing from time-based preventive maintenance to
predictive maintenance requires data acquisition and analysis
based on equipment condition. In addition to manual inspection
and testing methods, measurements using sensors and
perhaps devices connecting via the Internet of Things (IoT),
allow for analysis of data to develop a predictive forecast.
Collecting and analyzing historical data remains an essential
component of predictive maintenance. The data collected
must be accurate, reliable, and timely. Analysis and predictive
58
forecast strategies must be flexible to meet changing needs
allowing you to move from preventive to a predictive-based
maintenance model or industry 4.0.
I-P-F curve
Figure 1 (page 60) is a typical I-P-F curve from the point of
installation. I and P represents potential failure, the point at
which equipment is starting to deteriorate or wear moving
toward failure. F is the point of functional failure where the
useful limit of performance is reached, and the equipment is
no longer functional. The goal of I-P-F curve development is
to be prepared for equipment functional failure and maximize
equipment I-P-F interval from both an economic (cost of ownership)
and technical perspective.
The graph identifies the time interval between potential failure
and functional failure or lifespan that can be assigned to
the equipment as a whole or equipment components subject to
wear. Lifespan will vary between equipment and given operating
conditions. Examples of this include start-stop cycle or
starting empty or under load.
The time intervals will vary between pieces of equipment
and the work being accomplished by the equipment. Consider,
for example, a wheat screw conveyor starting and stopping
frequently under load delivering wheat to an undersized surge
hopper or bin above B1 compared to a screw conveyor carrying
filter dust (much lower load and product density) running
constantly delivering filter stock to a pneumatic lift system for
sifting. Within the milling system, time to failure differences
may be observed between more heavily loaded B1 roll stands
than less heavily loaded and B5 roll stands. In each of these two
comparisons time to failure would be reasonably different.
February 2023 / World Grain / World-Grain.com
http://www.World-Grain.com
World Grain - February 2023
Table of Contents for the Digital Edition of World Grain - February 2023
World Grain - February 2023 - Intro
World Grain - February 2023 - 1
World Grain - February 2023 - 2
World Grain - February 2023 - 3
World Grain - February 2023 - 4
World Grain - February 2023 - 5
World Grain - February 2023 - 6
World Grain - February 2023 - 7
World Grain - February 2023 - 8
World Grain - February 2023 - 9
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