GE Energy

Machine
Criticality
101
Don Silcock

Why is this topic important?

Scenario
Your customer wants to expand
the System 1 on his critical machines
to manage other assets in his plant.
How would you go about deciding
which of our solutions to advocate?

Why is this important?

Customer Business Objectives
Business objectives drive
the maintenance strategy,
which in turn drives the
technologies and solutions
applied.

Maintenance Strategy
Technology / Solution

Improved Business Performance

Maintenance strategy
definition and development is
a critical success factor in the
customers value chain.
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Terminology

Terminology
The four main maintenance strategies are:

Reactive Maintenance (RM)

Preventive Maintenance (PM)

Predictive Maintenance (PdM)

Proactive Centered Maintenance (PCM)

Terminology
Reactive maintenance (RM):
Maintenance performed after a failure or after an
obvious, unforeseen threat of immediate failure.

In reactive maintenance, machines are operated in a

run-to-failure (RTF) mode
Daily maintenance activities are driven by
unforeseen problems from assets breaking down
without detection of the impending failure.

Terminology
Preventive Maintenance (PM):
Maintenance tasks conducted at regular, scheduled
intervals based on average statistical/anticipated
lifetime to avoid failure
Includes inspection, service and/or replacement
Intervals may be calendar or operating time.

Terminology
Predictive Maintenance (PdM):
Maintenance based on the actual asset condition
(objective evidence of need)

Assessment data obtained from in-situ, non-invasive

tests and operating & condition measurements
Also referred to as Condition Based Maintenance (CBM).

Terminology
Proactive-Centered Maintenance (PCM):
A program of continuous maintenance optimization
Based on feedback from Root Cause Failure Analysis
(RCFA) repairs, quantitative PMs, PdM routines, CM
systems and operations.

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Terminology other acronyms

MTBE: Mean Time Between Events
MTBF: Mean Time Between Failure
MTBR: Mean Time Between Repairs
MTTR: Mean Time To Repair
MRO: Maintenance, Repair, Overhaul

OEM: Original Equipment Manufacturer

O&M: Operating and Maintenance
ERP: Enterprise Resource Planning
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Terminology
Condition Monitoring (CM):
The process of recording measurements that define
condition without disrupting operation

Examples are vibration, fluid & electrical characteristics

and thermal gradients
Measurements are compared to their limits.

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Terminology
Reliability Centered Maintenance (RCM):
A systematic, disciplined process to ensure safety
and mission compliance that defines system
boundaries and identifies system functions, functional
failures, and likely failure modes for equipment and
structures in a specific operating context.
RCM develops a logical identification of the causes
and effects (consequences) of system and functional
failures to arrive at an efficient and effective asset
management strategy to reduce the probability of
failure.
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Terminology
Functional Failure:
The System is no longer capable of performing the
intended function.

For example, a pump that is designed to produce 100

gpm at 200 psi is considered to have functionally failed
if it can only produce 90 gpm at 200 psi.

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Maintenance strategies

(Effectiveness)
Organization & Availability

Maintenance strategies
Proactive

Type of

Preventive

>20%

0%

Data based
>45%

~12%

Preventive

>25%

~31%

<10%

~55%

Time based ~86%

Wait until it breaks..

100%

Maintenance Cost Expenditures

(Efficiency)

>65%

Predictive

Reactive

Reactive

Lower

maintenance
Proactive

Predictive

Top

Information
basedQuartile
Quartile

100%

Sources:
Society of Maintenance & Reliability
Professionals Survey
The Business Case for Reliability
Robert DiStefano, John Schultz

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Maintenance Cost $/hp/yr

Comparative maintenance spend

$20

From EPRI Power

Generation Study

$15

$10

$5

RM

PM

PdM

PCM

Maintenance Strategies

Note: This chart represents established programs

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Asset criticality ranking

Asset criticality ranking

Asset Criticality ranking helps determine the right level of asset management
resources (technology, parts, and people) for each asset. This enables the business
risk of each asset to be managed in an appropriate manner.
The criticality ranking process produces a balanced ranking of All Assets in the plant
each with a 4-digit numerical criticality number.
A cross-functional team is usually assembled to agree on criteria weighting and asset
evaluation.
The Primary criticality ranking
criteria are:
Safety,
Environment & Regulatory
Compliance,
Production,
Maintenance & Operating Costs
Product quality
Plus other criteria if relevant
Typical Asset Criticality
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Ranking Tool

Asset criticality ranking

On the Asset Criticality Pareto Chart, natural break points appear to
segregate the assets into identifiable criticality classifications

Criticality Ranking

For the most critical assets (typically 10-15% of assets),

a Reliability Centered Maintenance (RCM) approach is
used to determine the appropriate maintenance
strategy.
Critical assets are assessed using Failure
Modes & Effects Analysis (FMEA) process.
Less Critical assets are assigned a
strategy using standard Templates
Non-Critical assets
Run-to-failure

15%

30% (typical)

50% (typical)

Distribution of Assets

5%

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The P-F interval

Mechanical Asset Example (Centrifugal Pump)
The P-F interval is
the interval between
the occurrence of a
potential failure and
the decay into a
functional failure
Time can be
measured in seconds,
minutes, days,
months or years.
P1-Px indicate
detectability intervals
by various techniques
or technologies.

Process Performance Data (highly

dependent on tuning of system /
instruments) ~1 week 6 months

Vibration P-F interval 1-9

months
Wear Debris in oil P-F
interval 1-6 months

IR Thermography P-F
interval 3-12 weeks

P1

P2

P = Potential Failure
Is an identifiable condition which indicates
that a functional failure is either about to
occur or is in the process of occurring

Quantitative PM P-F
Interval 5-8 weeks
Audible noise P-F
interval 1-4 weeks

P3
P4

Heat by touch P-F

interval 1-5 days

P5

P6
P7

Relays

F = Functional Failure
The point at which the asset fails to
deliver to its intended purpose

Time
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Maintenance Management
Maintenance Management is the process of
managing failure modes to ensure the asset
performs its intended function. This is an
integral part of our Customers asset
management and business processes, directly
related to their key performance indicators.
There are four Maintenance Strategies
commonly employed, each with particular
attributes and suited to certain applications.

The P-F Curves illustrate progression of multiple

failure modes on one machine - from Potential
Failure Initiation (P), to Functional Failure (F)
P1

Failure Mode #1

F1

Time
P2

Selection of the maintenance strategy should

support the objectives of our customers
business.
Today, the top performers in industry are
deploying effective maintenance strategies,
supported by technologies, resources and
sound procedures to keep their assets
performing high on the P-F curve.

Failure Mode #2

F2

Time
P3
Failure Mode #3

F3

Time

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Plant equipment criticality

Technology
Protection, on-line diagnostics,
process data, performance &
Decision Support

Maintenance Strategy

RCM

Protection, on-line
diagnostics & process data
On-line scanning &
process data
Off-line portable &
process data

Process data

FMEA

PM
Templates
Run to
Failure

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Plant equipment criticality

Bently Nevada Solutions
3500 & 3701, System 1,
Bently Performance/EMAP &
Decision Support

Maintenance Strategy

RCM

3500 & 3701 & System 1

Trendmaster DSM
& wireless
Snapshot PDC

FMEA

PM
Templates
Run to
Failure

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System 1

System 1 asset management platform

Online - Continuous

Online Periodic

Offline Periodic

monitoring & protection

(scanning) monitoring

walk-around monitoring

Switch/Hub

3500 & TDI

3300 &
TDXNet
or TDE

Wired

Wireless
Snapshot
PDC

BOP Assets

Critical Assets

Essential Assets

Gas Turbines

Fans

Vibration

Steam Turbines

Pumps

Portable Devices

Compressors

Blowers

Lube Oil

Main line Pumps

Etc

Thermography

MCA, etc
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Questions?