8/4/2015

Plant Maintenance
Presented To : NED
Presented By : Syed Munawer Hasan

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SYED MUNAWER HASAN

ACADEMICS

2012
2009
1997

MEM - N.E.D University of Engineering & Technology Karachi

MBA Hamdard Institute of Management Sciences
BE Mechanical - N.E.D University of Engineering & Technology Karachi

PROFESSIONAL CERIFCATION & COURSES

APM Certified Management Consultant
ASNT Certified- Vibration Analyst
AIRT Certified Thermographer
Business in Solution Promotions
Basic & Advance Bearing Knowledge
Maintenance Management
Lubrication Management
Motor Management
Plant Asset Management
Implementation of Predictive Maintenance
Implementation of Pro- active Maintenance (RCFA , Laser Alignment, Balancing etc.)
Professional Presentation Skills
Six Sigma
Energy Management & Audit

PROJECTS: (All Major Industries in Pakistan)

Conduct & Implementation of Reliability Centered Maintenance Program for Enterprise Asset Management. (RCM-EAM)
Implementation of Pro-active Reliability Maintenance Program. (PRM)
Implementation of Consequence Driven Maintenance Program. (CDM)
Implementation of Condition Base Maintenance Program. (CBM)
Improvement in Preventive & Reactive Maintenance Program.
Implementation of Best practices for Energy Management ESCO ENERCON
Competency Development

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5 Ms

MEN
MACHINES
METHODS
MATERIALS
MONEY

MEN

MACHINES

Page 9

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METHODS

Page 10

MATERIALS

Page 11

MONEY

Page 12

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Industries Objectives

Increase Efficiency
Increase Capacity
Improve Quality
End User Demand
Faster Converting Equipment
Competitive Edge
Reduce Costs
Reduce Fixed Costs
Reduce Energy and Raw Material Costs

Production

Beyond Asset Management

Maintenance
Costs

Total
Costs

Asset Efficiency Optimization - improving

the efficiency and integrity of plant assets
to release capacity without large capital
Investments.

The Challenges
Economic Environment

Equipment Age

Maintenance Budget

Demand for Reliability

Personnel

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Energy Scenario in Pakistan

Pakistan energy demand had grown at an

annual rate of 4.8% and is expected to grow
at 10% per annum by 2011.

Reduction in power generation is either due

to some major faults in thermal units or
shortage of natural gas or furnace oil.

Last year Electric Short fall was from

1200MW to 6000 MW. Peak time deficit had
scored beyond 5000 MW in June09.

Decision has been taken for putting an end

to the subsidy on electricity.

We All Know What is

An asset ?
Asset Management ?
Operations Management ?
Production Management ?
Quality Management ?
Maintenance Management ?
3M?
5M?

Availability ?
Downtime ?
Types of Downtime ?
Outage ?
Shut Down ?
Efficiency ?
Productivity ?
Profitability ?
Reliability ?
MTBF ?
MTTR or MTBR ?
OEE ?

Basic Definitions

Availability
Downtime
Types of Downtime
Outage
Shut Down
Efficiency
Productivity
Profitability
Reliability
MTBF
MTTR or MTBR
OEE

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Some Plant Assets

Heat Exchanger
Turbine

Engine

Turbo charges

Purifier

Pump

Auto cone

Fans

Supply / Return Fan

Motor

Piping
Cooling Tower fan

Compressor

Circuit Breaker

Agitator
Kiln

Ring Machine

Blower

Centrifugal

DC Drives
Electrical Panels

The Evolution of Maintenance

1970s
1970
s

1990s
1990
s

2001s

Reactive

Predictive

Operator Driven Maintenance

Fix it when it Breaks

Condition Based

First line of defense maintenance

1950

1980s

2000

Preventive

Proactive Reliability Maintenance

Scheduled Overhauls

Fix the Root Cause

Future

Apply optimal level

MAINTENANCE PHILOSPHIES
Breakdown Maintenance or Operate to Failure
or Unplanned Maintenance
Preventive or Scheduled Maintenance
Predictive or Condition Based Maintenance
Proactive Maintenance Reliability

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Run To Failure, Breakdown

Can be least expensive form of maintenance!
Negatives

Inventory
Secondary damage
Labor
Planning and scheduling

When run-to-failure works

RUN TO FAILURE
Fix it when break

No measures are taken to anticipate and prevent

mechanical problems.
Expensive due to excessive downtime & collateral damage
caused when machines are allowed to fail.
Costs

Unexpected Labor Costs.

Replacement Equipment Costs.
Unexpected Production Loss.
Income Loss.

RUN TO FAILURE
ADVANTAGES

Non critical equipments:

Very effective on Non critical equipments
Asset having low replacement value
Very effective on Assets having low replacement cost

DISADVANTAGES

Failures:
Primary & secondary failures of machine parts which cost very high.
Quality:
production stops, resulting in delays in the delivery of the product or service, damage of the product.
Health and Safety :
The method of breakdown could be catastrophic causing injury to employees in the vicinity;
for example: natural gas leak causing an explosion.
Regulatory
If this is equipment that is legally required and then is no longer operating; for example: stack scrubbers required
by a certificate of approval for air, light curtains required to protect working entrapment.

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Preventive Maintenance
Planned, scheduled, or calendar-based
maintenance
Under and over-maintaining
Assumes normalized data that some machines
dont fit

PREVENTIVE MAINTNANCE
Fix it when its predefined life-time
ends

A machine or parts of the machine are overhauled on a

regular basis regardless of the condition of it/them.
Costs
Regularly Scheduled Labor Costs.
Regular Replacement Equipment Costs.
Regular Scheduled Production Loss Cost.
Percentage of Machines failing on start-up due to
installation errors.

PREVENTIVE MAINTNANCE
ADVANTAGES

Routine Inspection:
Establishment of schedules and procedures for routine inspections.
Periodic Test:
Periodic testing of plant equipment for structural soundness
Record Keeping
Use of an organized record-keeping system to schedule tests and
document inspections
DISADVANTAGES
Unforseen Plant Downtime:
The main disadvantage of preventive maintenance is that routine and periodic inspections
are carried out without taking into account the intensity at which a machine operates and, therefore,
its real condition
Additional Maintenance Cost
Greater Annual Cost if it is not applied from the beginning of the equipment installation.
Unavailability of production process:
Preventive maintenance apply to machines regardless of it condition & most of the time equipment
not required maintenance but according to OEM you have to stop the machine/process to fulfill PM task.
This situation also vice versa as well.

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PREDICTIVE MAINTENANCE
Fix it at the most opportune time
Fix it, and its root cause

Determines the condition of machinery as it operates, to

schedule the most efficient and effective repair of
problem components prior to failure.
Allows you to fix the problems root cause, preventing
problem reoccurrence.
Costs
Scheduled Labor Costs (only as needed)
Replacement Equipment Costs (as needed)
Scheduled Loss of Production Costs (as needed)

Authorized FAG Industrial Service Partner

PREDICTIVE MAINTENANCE

ADVANTAGES
Prevent catastrophic failure:
Prevents the breakdown/catastrophic/premature failure.
Availability of machine:
Safety, reliability and availability increases.
Reduce primary & secondary damages:
Cost of maintenance is less.
Shutdown Planning:
Proper planning to avoid failure.

DISADVANTAGES
Required high skills
Requires skilled personnel.
Initial Cost :
Requires costly monitoring equipments.
No KPI:
No performance measurement parameters Eg. MTBF, MTBR...etc

Authorized FAG Industrial Service Partner

PROACTIVE MAINTENANCE RELIABILITY

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10

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Proactive Maintenance
Measures taken to

Reduce rates of failure

Improve longevity
Improve machinery performance
Improve product quality

Through craftsmanship and corrective actions

Find, repair, and improve
versus find-and-replace

PROACTIVE MAINTENANCE
What is Proactive Maintenance?
Improving quality and precision on repair work to eliminate maintenance
induced failures and to maximize equipment life
Identifying the key drivers of poor reliability and set standards and
educate all in the solutions (e.g. Cool, Clean, Dry and Smooth)
Ensure there is a disciplined Condition Monitoring and inspection
system in place to give adequate warning of potential failures
Identify problems early with CM and inspection so they can be understood
and eliminated before any damage is done
High levels of reliability leadership and cooperation from operations
Identify and eliminate bad actors
Wide use by your people of Root Cause Analysis basic processes to help eliminate problems
Input reliability learning's into new equip
Ensure problems are Fixed Forever and good solutions to problems are shared widely

Page 32

PROACTIVE MAINTENANCE
PDCA(Plan-Do-Check-Act)
PROACTIVE MAINTENANCE:
Proactive maintenance has now received worldwide attention as the single
most important means of achieving savings unsurpassed by conventional
maintenance techniques.

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PROACTIVE MAINTENANCE

ADVANTAGES
KPI:
Key performance indicators will be clearly measured in Proactive maintenance.
Root Causes:
RCA to fix problems at the root cause
Strategy:
Process and equipment design using RCM, RCD.
Precision technique:
Precision Maintenance skills, Alignment, Balance.
Maintenance Management Program:
Maintenance Policy
Control of materials
Preventive Maintenance
Condition Monitoring
Work Order
Job planning
Priority and backlog control
Data recording system
Performance measurement measures or indices

PROACTIVE MAINTENANCE

PROACTIVE MAINTENANCE HELPS TO IMPLEMENT:

EFFECTIVE MAINTENANCE MANAGEMENT

Maintenance Policy
Control of materials
Preventive Maintenance
Condition Monitoring
Work Order
Job planning
Priority and backlog control
Data recording system
Performance measurement measures or indices

DISADVANTAGES
COST:
High initial cost to implement Proactive maintenance program.
Skilled Man Power:
Skilled man power to measure and assign proactive maintenance tasks.
Time:
Atleast 2 years required to implement proper structure for Proactive maintenance

PROACTIVE MAINTENANCE RELIABILITY

VIBRATION ANALYSIS :
1. Vibration analysis to be done on critical & semi critical machines to identify the health condition .
2. Select the most critical machines to be monitored at regular basis.
3. Other predictive maintenance activities can be executed but in first step only VA will execute.
KPI (Key Performance Indicators) Monitoring :
KPIs to be set on critical equipments to gauge the performance of equipments.
RCFA (Root Cause Failure Analysis) :
During the implementation of Proactive Maintenance Reliability Program ; RCFA should be done on every failure and document
accordingly.
CRITICALTY MATRIX :
During the implementation of Proactive Maintenance Reliability Program ; RCFA should be done on every failure and document
accordingly.

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Maintenance Strategies

Corrective

Total Uptime

Preventive
Total Uptime

Predictive
Total Uptime

Proactive Reliability
Maintenance

Maximum Uptime
= Uptime
periods

= Planned
downtime

= Unplanned downtime
(breakdowns)

Manager Maintenance Old Practices

Normal Practice- Run to Failure

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Normal Practice- Run to Failure

The Alignment Specialist
State of Art
Alignment Instrument

Maintenance Practices- Preventive

What is Condition Monitoring?

Condition Monitoring is the process of determining machine
behavior and dynamics as it operates.
Machines physical parameters are monitored, trended and studied.
Any
deviation from the pre-set normal range indicates the presence of
machine
abnormality that could eventually trigger stoppage and downtime.
Physical parameters can be:
v Vibration
v Temperature
v Bearing Condition
v Oil/lubrication condition
v Other process parameters, e.g. speed, flow rate and amperage

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Selecting Machinery to Monitor

Problem Machinery
Affect on Production
Probability of Failure
Personnel Safety

The Predictive Maintenance Cycle

Proactive Reliability Maintenance

Diagnostic & Root Cause
Analysis (RCFA)

Predictive Maintenance
(PdM)

PRM

Correction & KPIs

Operational Review

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Key Performance
Indicators !
(KPIs)

Key Performance Indicators ???

Those key result areas where you are not achieving the desired
results and have a room of improvement.

For achieving the maximum efficiency of the particular area or

machine,management make certain criteria and keep on finding
areas where to improve reliability.

Key Performance Indicators

Maintenance man-hours
Production overtime hours
Production output (per period)

Market demand, pre and post-processing interruptions, quality

concerns related to machinery problems or process problems, etc.
Unscheduled downtime / outages

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Key Performance Indicators

Predicted versus unpredicted failures

Bearing and seal costs or annual usage
Energy costs
Number of hours, shifts, or days of operation without incident
Number of incident outages per time period

Key Performance Indicators

Mean Time Between Failures

Mean Time Between Repairs
Ratios of Corrective, Reactive, and Preventive Repairs
Condition monitoring generated work order closure rate

Best Practice- Predictive

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How Can Operators Contribute?

1st Monthly Measurement
by Vibration Analyst
Machine
Reliability

2nd Monthly
Measurement by
Vibration Analyst
Time

Operator inspections provide increased opportunities for failure detection.

Trending the inspection results identifies even small incremental changes.
Sharing the results improves teamwork and proactive decision making.
Operator Input Can Make A Crucial Difference!
Overview

What is Reliability?
Plant

People

Mechanical
Electrical

Process

Reliability Definition
Purposeful actions designed to obtain maximum functionality from a
machine or process with a low incidence of failure at the lowest
possible cost.

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Mechanical Reliability

Ishikawa Diagram

The Basic '4 M's' Framework of an Ishikawa Diagram

Assets - 5 M

Men
Machines
Materials
Methods
Money

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Production managements responsibilities are

summarized by the five Ms:

Men, Machines, Methods, Materials and money.

Men refers to the human element in operating systems.

The Predictive Maintenance Cycle

Diagnostic & Root Cause

Analysis (RCFA)

Predictive Maintenance

Proactive

Correction & KPIs

Maintenanace

Operational Review

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How Can Operators Contribute?

1st Monthly Measurement
by Vibration Analyst
Machine
Reliability

2nd Monthly
Measurement by
Vibration Analyst
Time

Operator inspections provide increased opportunities for failure detection.

Trending the inspection results identifies even small incremental changes.
Sharing the results improves teamwork and proactive decision making.
Operator Input Can Make A Crucial Difference!

Key Performance Indicators ???

Those key result areas where you are not achieving the desired
results and have a room of improvement.

For achieving the maximum efficiency of the particular area or

machine,management make certain criteria and keep on finding
areas where to improve reliability.

Key Performance Indicators

Predicted versus unpredicted failures

Bearing and seal costs or annual usage
Energy costs
Number of hours, shifts, or days of operation without incident
Number of incident outages per time period

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KPI - WORLD CLASS

Maintenance Costs = Total Maintenance
Costs/Total Production Cost

4 14%

Maintenance Productivity = Maintenance Costs

Year /Original Plant Assets

2 - 3%

Planned Maintenance

>90%

Reactive Maintenance

<10%

Maintenance Downtime

<4%

MTBR Pumps = Time Between Repairs/# Repairs

3+ Years

DMAIC
DMADV

Production

DFSS

Maintenance
Costs

Total
Costs

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Engineering Solutions

Plant Efficiency Management

1. Do you know, why
you do, what you do?

2. Does it
matter?

5. Do you learn
and improve?

3. Did you do what

you should, well?
4. Do you know
what it means?

Plant Management for Optimization

Maintenance Strategy Project

Reliability Issues (Design)

Pre-Defined Priorities

Work
Identification
(when)

Plant Asset Management and

Maintenance Program (Living Program)
PM
PRM
ODR
RTF

Work
Execution
(how)

PM = Preventive Maintenance (time-based)

PRM = Proactive Reliability Maintenance
(predictive and corrective)
ODR = Operator Driven Reliability (observe)
RTF = Run to Failure (reactive maintenance)
RCA = Root Cause Analysis

Standard Job Plans

and Procedures

Planning

Corrective
Maintenance

Spare Parts
Alignment

Operators
Initiators

Optimize (why)

PRM/ODR Collection and Analysis

Information Integration and Decision
Work Order Generation

Work
Control
(who)

Business Goals

RCA

Maintenance
Strategy
(what)

Rolling Schedule

Work Execution
Post Maintenance Testing
Update Program

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Plant Assessments
Plant Assessments helps us understand the plant maturity compared to industry benchmarks

Plant Assessments

Energy Assessments
House keeping
Inventory
Spares
Maintenance
Stores
Workshop
Skill

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Plant Asset Management

Company Business Goal

KPIs

RCFA

Reliability, Availability, Maintainability, Safety

(Mechanical Integrity)

RCM (Fouling)

RBI

Planned
Inspection
Maintenance Program (NDT)

Operator
Planned
Inspection Maintenance

Operator
Inspection

Condition
Monitoring

Task
Rationalization
Task
Rationalization

Task, Discipline, Freq, Job Plan

BOM, Inventory Optimization

EAM / ERP
SAP / ORACLE

Work Notification
Work Acknowledgement

Decision
Support

What is RCM?

Reliability Centred Maintenance (RCM) - A process used to determine

what must be done to ensure that any physical asset continues to fulfil its
intended functions in its present operating context

Why Do RCM?

The Right Maintenance, on

The Right Equipment, at

The Right Time, by

The Right People, for

The Right Reasons

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RCM Team Composition

CORE TEAM: Dedicated RCM analyst(s)
Plant Personnel
Resource Team
Core
Team
(analysts)

Team Composition is
CRITICAL to success

RESOURCE TEAM: Plant staff available for

reviews /interviews - Ops, Elec., Mech., I&C,
Engineering
PLANT PERSONNEL: Support reviews /
interviews as needed and implementation
TYPICAL RESOURCE REQUIREMENTS PER
ANALYSIS (700-1000 tags):
Ops - <60 hrs.
Elec - <4 hrs.
Mech - <8 hrs.
I&C - <12 hrs.
Eng - <60 hrs.
TOTAL PROJECT PERIOD: 3 months

The RCM Process as a

Funneling Process

How can the way people think and react be changed when
there is no consistent starting point?
Paradigm 1: OPS
Paradigm 2: Maint.

Desired
Paradigm

RCM

Paradigm 3: Eng.

Integrated
Plant
Philosophy

Paradigm n

Each disciplines paradigms are funneled to create a

consistent approach to plant maintenance

BRIEF OVERVIEW
RCM

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Maintenance management system

Item

Requirements
Objectives
Constraints
Resources
Structures
Accountabilities
Job scheduling
Job execution
Provision of spares
Use of technology

Feedback Loop. Learning..

Strategy & Policy

Organization

Planning & Control

Exception reporting

Management Information Plant history file

Trends
Value of money
analysis

RCM process model

Business Goals

Select System
Boundaries

Identify what
is important

System Functions
System
Components

FMEA
(Criticality Analysis)

Failure Modes
Failure Effects

Critical
Evaluation Criteria

Identify
Failure Causes

AET?

Define
Proactive
Tasks

Perform
Non-Critical
Evaluation

Component
Critical?

Implement
Design
Change

RTF?

Define Simple
Tasks

Define what
PMs should
be done
Y
Recommend
RTF

Task Comparison

Feedback Loop

Implement
Decisions

Existing PM
Program

Change PM
program

Execute Living
Program

What are failure modes?

BURN OUT
ERODES
EXTERNALLY LEAKS
FAILS AS IS
FAILS TO ACTUATE
FAILS TO CHANGE STATE UPON DEMAND
FAILS TO CLOSE
FAILS TO DE-ENERGIZE
FAILS TO ENERGIZE
FAILS TO OPEN
FAILS TO OPERATE PROPERLY
FAILS TO PERFORM CONTROL FUNCTION
FAILS TO PROVIDE POWER
FAILS TO PROVIDE PROPER OUTPUT
FAILS TO REMAIN CLOSED
FAILS TO REMAIN ENERGIZED
FAILS TO REMAIN OPEN
FAILS TO RUN (INCLUDES DEGRADED
OPERATION)

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What are failure effects?

RESULTS IN MACHINE UNAVAILABLE > 8 HOURS
RESULTS IN MACHINE UNAVAILABLE BETWEEN 2 HOURS & 8 HOURS
RESULTS IN MACHINE UNAVAILABLE < 2 HOURS
RESULTS IN A SIGNIFICANT IMPACT ON PRODUCTION
RESULTS IN A MODERATE IMPACT ON PRODUCTION
RESULTS IN NO IMPACT ON PRODUCTION
RESULTS IN FAILURE TO MEET QUALITY STANDARDS
COMPROMISES QUALITY STANDARDS
RESULTS IN NO QUALITY IMPACT
RESULTS IN A RECORDABLE INJURY OR NEAR MISS
RESULTS IN A NON-RECORDABLE INJURY
RESULTS IN NO RISK
RESULTS IN AN EXTERNAL RELEASE OR PERMIT VIOLATION
RESULTS IN A ON-SITE RELEASE
RESULTS IN NO RELEASE
RESULTS IN A >$35,000 KRONOR REPLACEMENT OR REPAIR IF RTF

What are failure effects

Component ID &
description
155-1-11---> Hydrostatic slide PL72055

RESULTS IN MACHINE UNAVAILABLE > 8

HOURS

FAILS TO OPERATE PROPERLY

RESULTS IN A SIGNIFICANT IMPACT ON

PRODUCTION

HAS PREMATURE/DELAYED
OPERATION

Failure modes

RESULTS IN FAILURE TO MEET QUALITY

STANDARDS
RESULTS IN A >$35,000 KRONOR
REPLACEMENT OR REPAIR IF RTF

Failure effect

Criticality analysis (FMEA)

01.01--->FAILS TO ROTATE AND POSITION THE RING ACCORDING TO SPECIFICATIONS
155-1-1--->Workhead spindle Accumulator n-2 (15 bar)
ACCUMU--->ACCUMULATOR
EXTERNALLY LEAKS

RESULTS IN MACHINE UNAVAILABLE BETWEEN 2

HOURS & 8 HOURS

No

EXTERNALLY LEAKS

RESULTS IN MACHINE UNAVAILABLE < 2 HOURS

No

FAILS TO OPERATE PROPERLY

RESULTS IN A <$10,000 KRONOR REPLACEMENT OR

REPAIR IF RTF

BETWEEN 2-8 HOURS FOR

REPLACEMENT IF SPARE IS
AVAILABLE

INTERNALLY LEAKS
155-1-10--->stop and start the hydraulic motor Hydraulic valve YV-547
VALHYD--->VALVE, HYDRAULIC OPERATED

155-1-11---> Hydrostatic slide PL-72055

SLIDE--->SLIDE
FAILS TO OPERATE PROPERLY

RESULTS IN MACHINE UNAVAILABLE > 8 HOURS

HAS PREMATURE/DELAYED OPERATION

RESULTS IN A SIGNIFICANT IMPACT ON PRODUCTION

Yes

RESULTS IN FAILURE TO MEET QUALITY STANDARDS

RESULTS IN A >$35,000 KRONOR REPLACEMENT OR
REPAIR IF RTF
155-1-14--->adjust the driven plate position (feed unit) Indramat motor + enconder
MTOR--->MOTOR
FAILS TO RUN (INCLUDES DEGRADED OPERATION)

RESULTS IN MACHINE UNAVAILABLE < 2 HOURS

FAILS TO START

RESULTS IN FAILURE TO MEET QUALITY STANDARDS

Yes

MOTOR NUMBER M11. 1hp ????? USED

FOR SETUP AND INITIAL STAGES OF
MACHINE RUNNING

RESULTS IN A $10,000-$35,000 KRONOR

REPLACEMENT OR REPAIR IF RTF

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Maintenance standard
F AN S

Component type:

Component Classification Category:

Critical

Environment

YES
NO
Harsh
Non-Harsh
Usage Frequently
Seldom

Co nd itio n M o nito ring T a sks:

Provide for continuous on-line vibration monitoring
with alarm indication

Frequency

COM M E N T S
T a sks id e ntifie d fo r N o n-Critica l sho uld ON LY b e
p e rfo rme d o n e xp e nsive / la rg e fa ns. Othe rwise ,
cho o se fro m the T ime -D ire cte d listing .
On-line monitoring and alarming is valid for critical
machinery. In addition, perform full vibration analysis at the
recommended frequencies, and upon receiving an alarm.
Sampling and analysis of lube oil to include initial
evaluation of contamination, chemistry, and wear. Further
diagnostics to be directed by intial test results. Oil Analysis
provides indication of lubricant and machine conditon. Do
not limit to large

OL

OL

OL

OL

NA

NA

NA

NA

Perform lube oil analysis. Establish action levels.

T rend results.

3M

3M

3M

3M

3M

6M

3M

6M

Perform full spectrum vibration monitoring. Establish

baseline and action levels. T rend results.

1M

1M

1M

1M

Perform Infrared T hermography scan on couplings

1Y

1Y

1Y

1Y

1Y

2Y

1Y

2Y

Detects need for greasing and some degradations.

Monitor and trend fan performance indicators (speed,

flow, inlet & outlet pressures, damper positions,
process temperatures, bearing temperatures).
Establish action levels, trend results.

1D

1D

1D

1D

1W

1W

1W

1W

Perform component performance test over full range

of operation. Establish baseline and action levels.
T rend results.
T ime D ire cte d T a sks:
Lubricate the fan bearings (grease).

CD

CD

CD

CD

CD

CD

CD

CD

Data log and trend either daily or weekly. On-line

monitoring recommended for critical machinery. Monitor
and trend during daily Operator rounds if on-line not
available. Also monitor and trend in conjunction with
vibration analysis frequency
T his test should include pressures, temperatures, flows,
etc.

3M

3M

3M

3M

6M

18M

6M

18M

9M

24M

9M

24M

CD
/18M

CD
/18M

CD
/18M

CD
/18M

CD
/18M

CD
/18M

CD
/18M

CD
/18M

12M

24M

12M

24M

18M

36M

18M

36M

Lube oil change out.

CD

CD

CD

CD

24M

36M

24M

36M

Inspect/replace fan bearings.

CD

CD

CD

CD

CD

CD

CD

CD

Perform a visual inspection of the fan element.

BO

BO

BO

BO

NN

NN

NN

NN

1D

1D

1D

1D

1W

1W

1W

1W

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

NA

NA

NA

NA

Lubricate coupling on direct drive applications.

Inspect fan belts and sheaves.

S urve illa nce T a sks:

Monitor vibration, bearing temperatures, and fan
performance.
Check lube oil level, add where necessary (oil
lubricated bearings). Record and trend amounts
Verify proper operation and observe condition.
Document abnormalities.
E co no mic Co nsid e ra tio ns:
Run until corrective maintenance is required

T his task should be condition directed UNLESS you

cannot implement ALL the Condition-Monitoring tasks.

Use these frequencies if not performing lube oil sampling.

T his task should be condition directed when possible.

Review in control room. Spot check with pyrometer as

needed.

T he qualitative observation of a component's condition or

performance. [Look, Listen, T ouch]

Note 1: Daily when operated

Note 2: Performed ONLY on expensive/large pumps

The P-F interval

What is the P-F interval?

What characteristic will

indicate reduced failure
resistance?
B POTENTIAL

100
%
FAILURE

DEFINED
POTENTIAL

DEFINED
FUNCTIONAL
10%

C
FUNCTIONAL

0%
Time

Inspection Interval

TASK INTERVAL FEASIBLE?

DEGRADATION

Criticality Matrix example

LEVEL

AVAILABILITY

RATE

QUALITY

SAFETY

ENVIRONMENT

COST

External
Release
Results in
Permit
Violation

>X
$$Replacem
ent or
Repair if
RTF

High

Results in
Machine
Unavailable
X Hours

Production
Rate
Decrease >
X%

Failure to
Meet
Standards

Recordable
Injury or
Higher,
Includes
Near Miss

Moderat
e

Results in
Machine
Unavailability
between X
Hours Y
Hours

Production
Rate
Decrease
between X%
- Y%

Compromise
s Standards

Nonrecordable

On-site
Release

XY$
Replacemen
t or Repair if
RTF

Low

Results in
Machine
Unavailability
< Y Hours

No Impact on
Production
Rate

No Impact

No Risk

No Release

<Y$
Replacemen
t or Repair if
RTF

Manufacturing Criticality Matrix

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Critical Evaluation Criteria - Example

CONSEQUENCE DESCRIPTION

CRITICAL
HEALTH / SAFETY

EXTREMELY
HIGH

HIGH

FINANCIAL IMPACT

S-1

S-2

F-2

S-3

F-3

E-3

Local emergency response.

Cleanup for days/weeks.
Potential short-term minor adverse effects on the environment
(including soil and groundwater) or a few members of the
public.

100k$ to 0.5m$
impact.

S-4

F-4

E-4

Less than 100k$

impact.

First aid.

E-2

Unit emergency response.

Significant cleanup for weeks/months.
Potential localized, medium term significant adverse effects
on the environment (including soil and groundwater) or a
small community.

0.5m$ to 1m$
impact.

Medical aid injury.

Restricted work.

LOW

E-1

Major Plant wide emergency response.

Major cleanup for months/years.
Potential widespread, long-term significant adverse effects on
the environmental (including soil and groundwater) or a large
community.

Greater than 1m$

impact.

Disabling Injury.
Lost time injury.

MEDIUM

ENVIRONMENTAL IMPACT

F-1

Fatalities.
Long-term health impact
on public.

Resource Availability
PM/CM Cost History
Outage/Downtime History
Safety/Environmental
Impact History

Confined to close proximity.

Inconsequential or no adverse effects.

Select System(s) & Identify

Boundaries

Design Information
Equipment List
P&IDs, Electrical
Schematics

Collect Pertinent Data

Identify Key Important
Functions and Boundaries

Design Information
(including Performance Standards)

Criticality Analysis
Equipment List

Operating History
Design Information
Expert Judgment

Failure Modes & Effects

Analysis (FMEA)

Critical and NonCritical Criteria

Yes

Critical Criteria
Met?

Organization Goals
and Objectives

No
Non-Critical
Criteria Met?

Yes

No
Task Selection
Design
Information
Operating
History

Component Critical

Run-to-Failure
Component Non-Critical

Identify Failure Causes

Assign Applicable, Cost-Effective
Tasks Commensurate with Component
Criticality
Task Comparison
Implementation

RCM Process

Living Program

Vibration Analysis

Basic Over all meter

Portable Vibration Analyzer
Off Line System / Online system
Surveillance / Protection system

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Thermography examples ..

Equipment #: HT Bushing Bleaching Transformer

Overall Classification: Serious
Thermal abnormality is found in the middle phase. Repair in the immediate
future (1-2 days). Replace component and inspect the surrounding
components for probable damage.

Thermography examples ..

Equipment #: Base Motor # 5 Right Side

Overall Classification: Good / Moderate
Heat distribution across the motor windings showing
some excess. Maximum temperature on both sides of the
motor is 90.5 C. Close observation recommended.

Thermography examples ..

Equipment #: Pulleys Base Motor # 11 (Misalignment)

Overall Classification: Serious
Thermal abnormality detected in heat distribution across the
pulley. Indication of heavy misalignment. Precision align pulley
& belt to minimize equipment damage.

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Thermography examples ..

Equipment #: HRSG C East Side Duct A Top

Maximum temperature recorded: 360.4 C

Thermography examples ..

GENERATOR# 1 RIGHT SIDE INSULATION

No abnormality detected in heat distribution of the windings. Operating
temperatures of the windings are within limits. Maximum temperature on
both sides of the core is 106 C.

Thermography examples ..

MAIN STEAM PIPE

Inspect for insulation damage.

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Lube Strategy Development Chart

Maintenance
Culture &
Practice

Lubrication
Strategy

Cleanliness &
Contamination
Control

Data Base
Management
& Reporting

Lubrication
Knowledge
& Application

Environmental
& Safety

Supply

Asset
Efficiency
Culture
Proactive
Lubrication
Management

Lubrication
Processes

Basic
Requirement

What is poor lubrication?

Incorrect intervals:

Incorrect lubricant selection:

under-greasing
over-greasing
poor quality lubricant
lubricant type is unsuitable for the application

Contamination:

impurities can mix with the lubricant

poor handling (e.g. dirt on grease fitting)

The Basics of a Good Lubrication Strategy

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Magnom - The Technology

Contaminant
Collection zone
Magnetic Field
Lines

Fluid flow

Magnet
Metal plates
Refraction of the fluid compacts this
contaminant and ensures that it is
held out of the flow paths, avoiding
wash off...

Lubrication

Manual (Grease Gun)

Single Point Automatic
Multi Point Automatic
Dry Lube

Savings !

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Maintenance Cost Vs. Vibration Level

Highest
Vibration

Maintenance
Cost

Lowest
Vibration

Maintenance
Cost

Pumps (1800 rpm) 3.8 mm / sec US $ 10,000 0.6 mm / sec

US $ 2,500

Pumps (3600 rpm) 6.6 mm / sec US $ 46,000 0.5 mm / sec

US $ 2,500

Fans

8.6 mm / sec US $ 16,500 1.3 mm / sec

US $ 220

Impact on Power Consumption

Misalignment

30 HP Motor /Pump
4 amp reduction after precision alignment
Substantial reduction in vibration
US $ 1,600 per year operating cost reduction

Unbalance
30 HP Motor /Fan
0.95 amp reduction after precision balancing
80% reduction in vibration

US $ 378 per year operating cost reduction

Cost Savings Calculations

KW

Savings = V(A1-A2)x P.F x 1.732/1000

Annual

Cost Savings = kW Savings x Hours Run / Year x

Unit Cost of Energy
Example:
30

HP Running 24 hrs/day 7days/week 50 weeks/year

Voltage

(V) = 440 volts , Power Factor (P.F) = 0.88

Amperage

Before Alignment (A1)= 40 Amps

Amperage

After Alignment (A2)= 35 Amps

Energy

Cost Rs 6.00 / kWHr

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Asset Management
Unplanned Mechanical Downtime in Hours
Unplanned Mechanical Downtim
in Hours

Number of Unplanned
Mechanical Failures

Number of Unplanned Mechanical Failures

20
15
10
5
0
Jan

Mar

May

Jul

Sept

Nov

120
100
80
60
40
20
0
Jan

Planned Mechanical Downtime

(Hours)

200
Other Unplanned Downtime
(Hours)

Mar

May

Jul

Sept

Nov

Planned Maintenance Downtime

Other Unplanned Downtime

150
100
50

200
150
100
50
0

0
Jan

Mar

May

Jul

Sept

Nov

Jan

Mar

May

Jul

Sept

Nov

Overall Equipment Effectiveness

Theoretical Available time (24 hrs; 7 days) = 168 hours/week maximum

Scheduled Losses

Total available time scheduled

Unplanned Planned
Downtime Downtime

Actual Availability
(plant operating time)
Performance rate
(net operating time)
Yield-quality

OEE = %

Lunch
/
break
s

Vacations Excess
weekends capacity

Speed
losses

Defect
losses
Overall Equipment Effectiveness = Availability x Performance x Quality
Benchmarks = 65% - 85% (Discrete) and 85% - 95% (Continuous Process)

Maintenance Development
Maximum Efficiency/OEE
Operator Driven Reliability (ODR)

OEE
>90%

Proactive Reliability Maintenance (PRM)

OEE
80%-90%

Predictive Maintenance (PdM)

OEE
60%-80%

Preventive Maintenance (PM)

OEE
40%-60%

Reactive/Corrective

OEE
<40%

Minimum Efficiency/OEE
(OEE = Overall Equipment Effectiveness)

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Balancing Efficiency vs. Effectiveness

Strategy Development

The Right Tasks

Continuous
Improvement
Loop

Analysis/Assessment

Effectiveness

Work Planning

Work Scheduling

Sustaining
Maintenance
Management
Cycle

Performed Well

Work History

Work Execution

Efficiency

Known Words

Financial Management
Human Resource Management
Materials Management
Inventory Management
Maintenance Management
Energy Management
Production Management
Sales Management
Marketing Management
Supply Chain Management
Operations Management

Page 111

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Implementing Change
People

Sustained
Improvement

Process

Technology
helping make
your vision a reality

Together We Move The World

Thank you

38