Development of a reliability centered maintenance based early warning systems for a zinser 660 speed frame machine/ Ociti Innocent Olur

Table of Contents
ABSTRACT................................................................................................................................................................i
DECLARATION.......................................................................................................................................................ii
APPROVAL..............................................................................................................................................................iii
TABLE OF FIGURES............................................................................................................................................. vi
CHAPTER ONE: INTRODUCTION.....................................................................................................................11.0 Title...................................................................................................................................................................11.1
Background of the study................................................................................................................................ 11.2
problem statement.......................................................................................................................................... 21.3
Objectives of the study....................................................................................................................................21.3.1
Main objective........................................................................................................................................... 21.3.2
Specific objectives..................................................................................................................................... 21.4
Justification of the study................................................................................................................................ 31.5
Significance of the study.................................................................................................................................31.6
Scope of the study............................................................................................................................................31.6.1
Conceptual scope....................................................................................................................................... 31.6.2
Geographical scope....................................................................................................................................31.6.3
Time scope................................................................................................................................................. 3
CHAPTER THREE: LITERATURE REVIEW....................................................................................................42.0 Introduction.....................................................................................................................................................42.1
Reliability Centered Maintenance.................................................................................................................42.1.1
Key speed frame machine components......................................................................................................52.1.2
Failure modes of the components.............................................................................................................. 52.1.3
Detection of the failures.............................................................................................................................52.1.4
Instrumentation for monitoring the parameters......................................................................................... 6
v2.2 Early Warning Systems..................................................................................................................................72.2.1
Techniques for developing Early Warning Systems..................................................................................72.2.1.1
Support Vector Machine (SVM)..........................................................................................................72.2.1.2
Hierarchical Clustering........................................................................................................................ 82.2.1.3
Fuzzy c-Means.......................................................................................................................................82.2.1.4 k-Means..................................................................................................................................................82.2.1.5
Self-Organizing Maps...........................................................................................................................82.2.1.6
Principal Component Analysis (PCA)................................................................................................ 92.2.1.7
Time Synchronous Averaging (TSA).................................................................................................. 92.2.3
Needs for Early Warning Systems...........................................................................................................10
CHAPTER THREE: METHODOLOGY.............................................................................................................113.0 Introduction...................................................................................................................................................113.1
Materials and Equipment.............................................................................................................................113.2
Establishing the various failure modes of the Speed frame...................................................................... 113.2.1
Age-Related Failure Mode.......................................................................................................................113.2.2
Non-Age-Related Failure Mode.............................................................................................................. 113.2.3
Infant Mortality Failure Mode................................................................................................................. 123.3
Developing a Reliability Centered Maintenance based Early Warning System.....................................123.3.1
Data acquisition, preparation and preprocessing..................................................................................... 133.3.2
Performing Time-Synchronous Averaging and Envelope Spectra..........................................................133.3.3
Recognizing patterns in data....................................................................................................................153.3.4
Validation of the early warning system................................................................................................... 163.3.5 Implementation........................................................................................................................................ 163.4
Performing a Cost Benefit Analysis of implementing the Early Warning System.................................16
CHAPTER FOUR: RESULTS AND DISCUSSION...........................................................................................17
vi
4.0 Introduction...................................................................................................................................................174.1
Failure mode of the critical speed frame parts.......................................................................................... 174.2
Reliability Centered Maintenance based Early Warning System for Zinser 660 speed frame machine.
...............................................................................................................................................................................194.3
Cost Benefit Analysis of implementing the Early Warning System.........................................................24
CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS..............................................................255.0 Conclusion..................................................................................................................................................... 255.1 Recommendation...........................................................................................................................................25
REFERENCE LISTS AND APPENDICES......................................................................................................... 26 Introduction.........................................................................................................................................................26
Appendices...........................................................................................................................................................26
Reference lists......................................................................................................................................................33

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