Maintenance of Heavy

Equipment
Through Lubricant
Monitoring

Maintenance
Principle

Maintenance
Maintenance: kegiatan yang dilakukan
berulang-ulang untuk mengembalikan
standar prestasi dan kehandalan peralatan
agar memenuhi tuntutan operasi saat ini
Maintenance Management:
pengelolaan kegiatan perawatan yang
meliputi perencanaan, penjadwalan,
pelaporan, pengawasan, perbaikan
berkelanjutan & organisasi pelaksana
kegiatan perawatan
Maintenance Technique: kegiatan
pengawasan dan perbaikan peralatan
yang dilakukan secara berulang-ulang
agar prestasi dan kehandalan peralatan
memenuhi tuntutan operasi saat ini

Kehandalan (Reliability)

Pasti: Reliability Availability

Tidak Mungkin: Reliability Availability
Reliability Productivity

Maintenance Technique
Define of maintenance technique for every
component based on failure mode
increase reliability
Define of monitoring frequency for every
component based on potential-failure
interval
increase availability
Define of monitoring tools for every
component based on failure effect
minimize risk

Maintenance Technique
Chart

Maintenance Technique
Definition

Maintenance

Downtime

Longer downtime = higher production loss

Breakdown = unplanned/unscheduled maintenance activities = higher cost

Maintenance
Maintenance

Action

Solution

Impact
High
maintenance
cost and
production loss

Breakdown

Run to Failure

Corrective
action after
breakdown

Preventive

Monitoring to
prevent the
Failure

Corrective
action after
Shutdown

Planned
maintenance
cost and
production loss

Monitoring to
predict the
Failure

Corrective
action after
predicted
Shutdown

Maintenance
cost effective
and reduce
planned
production loss

Predictive

Pro-Active

Monitoring to
reduce/avoid

Modification to
reach longer

Minimized
maintenance
cost and

Pro-Active Maintenance
Minimize Maintenance Cost
Minimize Production Loss

Pro-Active
Maintenan
ce

Pro-Active Maintenance =
Preventive/Predictive Maintenance +
Failure Analysis
Failure Analysis = Root Cause Analysis
+ Improvement

Case Example: Gas

Engine

Failure Analysis
Gas Engine
Waukesha
GE 387 C 27 May 2003
GE 387 C 3 December
2003
GE 387 B 17 January
2004
GE 387 A 8 March 2004

Running Hour by Accident

GE
GE
GE
GE

387
387
387
287

C
C
B
A

(27
(03
(17
(08

May 03) 8.027 hour

Dec 03) 2.800 hour
Jan 04) 14.000 hour
Mar 04) 2.443 hour

Typical Damage Parts

Exhaust valve broken

Inlet valve bending / broken
Piston crown surface damage
Cylinder head surface damage
Valve tulip recession
Valve seat wear / leakage

Exhaust Valve Broken

Inlet Valve Bending /

Broken

Piston Crown Surface

Damage

Cylinder Head Surface

Damage

Valve Tulip Recession

Valve Seat Wear / Leakage

Others Fact Finding

Clearance valve stem/valve guide
higher than specification (+ 0,003)
Sulfated ash on lubricant lower than
required limit (- 0,13 %wt)
Hardness different between valve
tulip and valve seat to high (200
HVN)
Engine shutdown due high intake
manifold temperature

Valve Stem-Guide
Clearance
High clearance
miss-alignment
between valve and
guide high
contact on edge of
guide only (not
uniform
distributed) very
thin film lubrication

Contact Point
Characteristics

Fn = Load
D = Valve guide inner
diameter
d = valve stem
diameter
b = stem length
n = stem rotation speed
= 2n/60
h = 0,5.(D-d)+e.cos
= (D-d)/d
So = (Fn/b.d)(/.)
= 2e/(D-d)

Thin Film Lubrication

Sommerfeldzahl
(So)

Higher clearance
higher (D-d)
lower
lower So
lower (graphics)
lower e
lower h
thinner lubricant film
excessive wear

Valve Stem Guide Wear

Excessive wear on
valve stem
guide contact
debris/abrasive
material stem
stack in guide

Higher Valve Stem Guide

Clearance
higher lubricant temperature higher
oxidation carbonizing/debris valve
sticking
valve miss-alignment leakage on valve-seat
contact high temperature gas torching
higher lubricant temperature & lower material
strength valve broken
valve miss-alignment leakage on valve-seat
contact high temperature gas torching
valve diameter expansion valve sticking

Sulfated Ash in Lubricant

Required limit = 0,35% wt >< Mysella R40 = 0,22% wt

Wear of both valve face and valve seat by metal abrasion, high
temp, corrosion frictional sliding and adhesion mechanisms
Recession causes the valve to sink or recede into the head
Recession measurable by monitoring valve stem head

Hardness of Valve Head Seat

New valve head = 500 HVN
Broken valve head (GE 387 C by
accident on 27 May 03) = 650 HVN
Valve seat (GE 387 B by accident on
17 Jan 04) = 700 HVN
to many variant of material strength
by supplied valves quality
control ?

Intake Manifold Temperature

Shutdown
Present on all gas engine
Higher clearance higher valve
miss-alignment higher valve-seat
leakage more hot gas flow to
intake manifold by compression
stroke higher intake manifold
temperature engine shuttdown

Influence to Combustion
Valve-seat leakage combustion
chamber pressure changes timing
ignition setting changes (by DSM)
timing ignition fault detonation

Explanation
GE 387 C (27 May 03) 8.027 hour
original valve from engine
manufacturer
low sulfated ash lube oil
GE 387 C (03 Dec 03) 2.800 hour
valve material out of spec ?
GE 387 B (17 Jan 04) 14.000 hour
original valve from fabricator
GE 287 A (08 Mar 04) 2.443 hour
?

Root Cause Analysis

Detonation Sensor Module:
Random timing fluctuation advanced
ignition timing until 40 before TDC

Material:
Valve tulip to soft, 200 HVN under specification
Valve seat hardness comply to specification

Lubricant:
Ash content in lubricant 0,13 %wt under
requirement

Root Cause Analysis

Destructive test:

No beach mark
Valve broken due
to static impact
Microstructure of
piston no
excessive heating

Root Cause Analysis

Recomendation
Check clearance between valve stem
valve guide (max 0,0045 or spec of
stem diameter = 0,558 & valve guide
inner diameter = 0,5625)
Use lubricant with sulfated ash content
more than 0,35% wt
Indication of leakage on valve head-seat
can be monitored by :

Intake manifold temperature

Lube oil consumption
Compression test (by top overhaul)
Valve-seat recession (by top overhaul)

Failure Symptom Detection

Air inlet temperature:
Indicate hot gas
torching
Indicate valve seat
leaking
Indicate valve recession

TBN of Lubricant:
Indicate oxidation level
Indicate deposits form
in valve stem-guide

Total Base Number

Life Extention Cost

Effective

How to Improve
Reliability and Cost
Effectiveness

Reliability Centered Maintenance

(RCM)
Metode untuk:
merencanakan (planning) maintenance
secara terstruktur
mendefinisikan maintenance technique
(breakdown / preventive / predictive /
pro-active) secara tepat

guna mendapatkan reliability (dan

availability) tinggi yang cost effective

Prinsip Dasar RCM

Reliability tinggi tercapai jika mesin tidak
pernah breakdown
Breakdown dapat dicegah jika mesin
dimonitor dan diperbaiki sebelum kegagalan
terjadi (predictive / preventive maintenance)
Monitor dapat mendeteksi tanda-tanda akan
terjadinya kegagalan (failure symphtom)
Pemilihan alat inspeksi harus
mempertimbangkan kemampuannya untuk
mendeteksi failure sympthom

7 Pertanyaan Dasar RCM

1.Apa fungsi dan standar prestasi yang terkait dengan
aset dalam konteks operasinya saat ini ?
2.Dengan jalan apa saja aset ini bisa gagal dalam
memenuhi fungsinya ?
3.Apa yang menyebabkan setiap kegagalan fungsional ?
4.Apa yang terjadi pada setiap kegagalan yang timbul ?
5.Apa saja pengaruh dari kegagalan ini ?
6.Apa yang dapat dilakukan untuk mencegah setiap
kegagalan ?
7.Apa yang sebaiknya dilakukan bila tugas pencegahan
yang sesuai tidak dapat ditemukan ?

Implementasi RCM

Konsensus

Standar Prestasi
Fungsi Pompa:
mengalirkan air dari
tanki X ke tanki Y
Standar Prestasi:
800 liter per menit
Kapasitas Bawaan:
1000 liter/menit
Desain operasi:
800/1000 x 100% =
80%

Karakteristik Peralatan
Setiap peralatan
dirancang untuk
suatu kebutuhan
tertentu
Setiap peralatan
mempunyai
kemampuan tertentu
Setiap peralatan
dioperasikan pada
kondisi tertentu
(design operation)

Perawatan
Perawatan :
kegiatan yang
dilakukan
berulang-ulang
agar suatu
peralatan selalu
memiliki kondisi
yang sama dengan
keadaan awalnya

Perawatan
Perawatan rutin
(reactive/pro-active
maintenance) tidak
dapat meningkatkan
kemampuan inheren
yang dimiliki peralatan
Corrective
Maintenance dapat
meningkatkan
kemampuan inheren
dengan cara modifikasi
/ up-rating

Pertanyaan-1

Definisikan FUNGSI dan

STANDAR PRESTASI
secara jelas dan
lengkap !

50

Pertanyaan-2

Definisikan
KEGAGALAN
untuk setiap
FUNGSI secara
jelas dan
lengkap !

Pertanyaan-3

Definisikan
MODE untuk
setiap
KEGAGALAN
secara jelas
dan lengkap !

Pertanyaan-4

Definisikan EFEK
untuk setiap mode
KEGAGALAN
secara jelas dan
lengkap !

53

54

Pertanyaan-5 s/d 7
EFEK
KEGAGALA
N
LANGKAH
PENCEGAHA
N

LANGKA
H
DEFAULT

Hidden Multiple Failure

56

Hidden Multiple Effect

Pertanyaan-5
Pergunakan
Diagram
Keputusan
RCM untuk
mendefinisik
an
PENGARUH
KEGAGALA
N

Pertanyaan-6
Pergunakan
Diagram
Keputusan
RCM untuk
mendefinisik
an langkah
pencegaha
n

Preventive Task

Pertanyaan-7
Pergunakan
Diagram
Keputusan
RCM untuk
mendefinisik
an langkah
default

Redesign
Kapan
redesign
layak untuk
dilakukan ?

63

Proposed Task
Defined from failure effect minimize failure
effect avoid failure increase reliability

Initial Interval
Defined from targeted availability
minimize breakdown avoid failure
increase availability

Can be Done by
Minimum required competency of
craft man

Reliability & Cost

Effectiveness
Melakukan equipment criticality rating
Menetapkan work priority
Menetapkan spare parts service level
Melakukan / mengatur monitoring frequency
Mengoptimasi monitoring tools
Menganalisis failure mode (sesuai operasi
saat ini)
Mengoptimasi maintenance technique

Failure Mode Pattern

A=B+F
B = wear-out
C = fatigue
D = random failure
(electrical/instrument)

E = random failure
(mechanical)

F = infant mortality

Failure Mode Pattern B & C

Failure Mode Pattern E & F

Maintenance Technique

Maintenance Technique
Failure
Mode
Pattern

Maintenance Technique

Combination of corrective maintenance and

optimized time based preventive maintenance

Optimized time based preventive maintenance

Time based preventive maintenance refer to

instruction manual

Predictive maintenance (condition based

preventive maintenance) for
electrical/instrumentation equipment

Predictive maintenance (condition based

preventive maintenance) for mechanical
equipment

Corrective maintenance

Initial Interval based on P-F

P-F Interval pendek:
Makin sempit waktu
untuk persiapan
tenaga kerja,
analisis dan
penyediaan spare
parts
Kemungkinan
terjadi breakdown
makin besar
Downtime akan
lebih panjang
(kerugian produksi
lebih besar)

Infra-Red Thermography
31,0C

AR01

30
SP01
25

20

15
14,3C

Object parameter
Value
Emissivity
0,96
Object distance
75,0 m
Ambient temperature 28,1C

Relative humidity
0, 84
Label
Value
o

LNG Temperature
-160
C
SP01
23,1C
AR01 : min
23,1C
AR01 : avg
26,1C

Infra-Red Thermography
melokalisir daerah kritis
Ultrasonic
mengukur ketebalan dinding tanki pada bagian
kritis
Life Assessment
menetapkan umur sisa tanki

Monitoring Interval define

Availability

Monitoring frequency harus dioptimasi untuk

menjamin tuntutan availability dan cost effectiveness

Maintenance Technique
1. Correct maintenance technique increase
reliability
2. Correct maintenance interval increase
availability
3. Correct monitoring tools reduce failure
risk
Correct managing of the 3 factors:
increase availability, reliability and cost
effectiveness

maintenance excellence

Integrated Maintenance
System
Maintenan
ce Activity

Man
Power
TPM

CMMS

WO

Spare
Parts

ECR

RCM

Register
System

RBI

Integrated
Maintenance System

Modern Maintenance
Principle

Maxim 1
OLD
Maintenance is
about preserving
physical assets
NEW
Maintenance is
about preserving
the functions of
assets

Maxim 2
OLD
Routine maintenance is about
preventing failures
NEW
Routine maintenance is about
avoiding, reducing or eliminating
the consequences of failures

Maxim 3
OLD
The primary objective of the
maintenance function is to optimise
plant availability at minimum cost
NEW
Maintenance affects all aspects of
business effectiveness and risk - safety,
environmental integrity, energy
efficiency, product quality and customer
service, not just plant availability and
cost

Maxim 4
OLD
Most equipment
becomes more
likely to fail as it
gets older
NEW
Most failures are
not more likely to
occur as
equipment gets
older

Pattern of Failure

Pattern A is the well-known

bathtub curve
Pattern B suggests that most
items can be expected to
operate reliably for a period
"X", and then wear out.
Pattern C shows slowly
increasing probability of failure
with no specific wearout age
Pattern D shows low failure
probability to begin with then a
rapid increase to a constant
level
Pattern E shows a constant
probability of failure at all ages
Pattern F starts with high infant
mortality and drops eventually
to a constant or very slowly
increasing failure probability.

Studies on civil aircraft

4% of the items conform to pattern A
2% to B
5% to C
7% to D
14% to E
68% to pattern F
(The distribution of these patterns in aircraft
is not necessarily the same as in industry,
but as equipment grows more complex, more
and more items conform to patterns E and F.)

Overhaul

it leads to the belief that if we

don't have any hard evidence
at all about the existence of
an age-related failure-mode,
it is wise to overhaul the item
anyway from time to time
"just-in-case" such a failure
mode does exist. This ignores
the fact that overhauls are
extraordinarily invasive
undertakings that massively
upset stable systems. As
such, they are highly likely to
induce infant mortality, and
so cause the very failures
which they seek to prevent

Maxim 5
OLD
Comprehensive data about failure rates
must be available before it is possible to
develop a really successful maintenance
program
NEW
Decisions about the management of
equipment failures will nearly always have
to be made with inadequate hard data
about failure rates

Maxim 6
OLD
There are three basic types of
maintenance:
- predictive
- preventive
- corrective
NEW
There are four basic types of maintenance:
- predictive
- preventive
- corrective
- detective

Maxim 7

OLD
The frequency of
condition-based
maintenance tasks should
be based on the frequency
of the failure and/or
failure the criticality of
the item
NEW
The frequency of
condition-based
maintenance tasks should
be based on the failure
period (also known as the
"lead time to failure" or
"P-F interval")

P-F Interval

The P-F interval governs the

frequency with which the
predictive task must be done.
The checking interval must be
significantly less than the P-F
interval if we wish to detect
the potential failure before it
becomes a functional failure.
The P-F interval can be
measured in any units relating
to exposure to stress (running
time, units of output, stopstart cycles, etc), but it is
most often measured in terms
of elapsed time. For different
failure modes, the P-F interval
can vary from fractions of a
second to several decades.

P-F and Nett P-F Interval

Unless there is a good reason to do

otherwise, it is usually sufficient to
select a checking interval equal to
half the P-F interval. This ensures
that the task will detect the
potential failure before the
functional failure occurs, while
providing a net interval of at least
half the P-F interval to do
something about it. However, it is
sometimes necessary to select a
checking interval which is some
other fraction of the P-F interval.
If the P-F interval is too short for it
to be practical to check for the
potential failure, or if the nett P-F
interval is too short for any
sensible action to be taken once a
potential failure is discovered, then
the condition-based task is not
appropriate for the failure mode
under consideration.

Maxim 8
OLD
If both are technically appropriate, fixed
interval overhauls/replacements are
usually both cheaper and more effective
than condition-based maintenance
NEW
If both are technically appropriate,
condition-based maintenance is nearly
always both cheaper and more effective
fixed interval overhauls/ replacements
throughout the life of the asset

Use Fuel Life and MTBF

The Figure shows hypothetical failure data

for such a fleet which show that most of
the tyres last between 30 000 miles and
50 000 miles. If a fixed-interval retreading
policy designed to prevent all failures due
to normal wear is adopted on the basis of
this information, all the tyres will be
retreaded at 30 000 miles. However, this
policy also means that many tyres would
be retreaded long before it was really
necessary. In some cases, tyres which
could have lasted as long as 50 000 miles
would be retreaded at 30 000 miles, so
they could lose up to 20 000 miles of
useful life.
On the other hand, it is possible to define
a potential failure condition for tyres
related to tread depth. Checking tread
depth is quick and easy, so it is a simple
matter to check the tyres (say) every
2000 miles and to arrange for them to be
retreaded only when they need it. This
would enable the fleet operator to get an
average of 40 000 miles out of his tyres
without endangering his drivers, instead
of the 30 000 miles which he gets if he
does the scheduled restoration task
described above - an increase in useful
tyre life of 33%. So in this case a
predictive task is much more costeffective than scheduled restoration

Maxim 9
OLD
Serious incidents/catastrophic accidents
which involve multiple equipment
failures are usually the result of "bad
luck" or "acts of God", and are hence
unmanageable

NEW
To a considerable extent, the likelihood
of a multiple failure is a manageable
variable, especially in protected systems

Maxim 10
OLD
The quickest and surest way to improve
the performance of an existing
"unreliable" asset is to upgrade the design
NEW
It is nearly always more cost-effective to
try to improve the performance of an
unreliable asset by improving the way it is
operated and maintained, and only to
review the design if this cannot deliver the
required performance

Maxim 11
OLD
Generic maintenance policies can be
developed for most types of physical
asset
NEW
Generic policies should only be applied
to identical assets whose operating
context, functions and desired
standards of performance are also
identical

Stand by - Duty

However, if pump B fails, the

operators simply switch to
pump C, so the only
consequence of the failure of
pump B is that it must be
repaired. As a result, it is
probable that the operators of
B would at least consider
letting it run to failure
(especially if the failure of B
does not cause significant
secondary damage.)
On the other hand, if pump C
fails while pump B is still
working (for instance if
someone cannibalises a part
from C), it is likely that the
operators will not even know
that C has failed unless or until
B also fails. To guard against

Maxim 12
OLD
Maintenance policies should be formulated
by managers and maintenance schedules
drawn up by suitably qualified specialists or
external contractors (a top-down approach)
NEW
Maintenance policies should be formulated
by the people closest to the assets. The role
of management is to provide the tools to
help them make the right decisions, and to
ensure that the decisions are sensible and
defensible

Maxim 13
OLD
The maintenance department on
its own can develop a successful,
lasting maintenance programme
NEW
A successful, lasting maintenance
program can only be developed
by maintainers and users of the
assets working together

Maxim 14
OLD
Equipment manufacturers are in the
best position to develop
maintenance programs for new
physical assets
NEW
Equipment manufacturers can only
play a limited (but still important)
role in developing maintenance
programs for new assets

Maxim 15
OLD
It is possible to find a quick, one-shot
solution to all our maintenance
effectiveness problems
NEW
Maintenance problems are best solved
in two stages: (1) change the way
people think (2) get them to apply their
changed throught processes to
technical/ process problems - one step
at a time

Tribology Principle

Tribolog
y
Definition-1: Science and technology of
interacting surface in relative motion and of
the practices related thereto
Definition-2: Lubrication, friction, and wear of
moving or stationery parts
Impact: Industry could save considerable
money by improving their lubrication, friction,
and wear practices

Hamrock: Fluid Film

Lubrication

Applied
Tribology
Principle
Engine cant start
without fuel, but
without lubricant
engine run to
damage:
o No relative motion no friction
o Friction related to
efficiency
o No friction - no wear
o Wear related to
endurance
www.s3.images.com &
www.mitsubishi.com

Application
Friction can be
optimized depend on
requirement through
adjusting of:
o Adhesion
o Deformation
o Weld Shear - Plow

Coulomb
Theory
Macro Friction Analysis

Ff

FN

Ff
FN

Balance Condition :
F f W sin
FN W cos
f tan

Holland:

Micro Friction
Analysis

Deformation (fd)
Adhesion (fa)
Weld-Shear-Plow (fwsp)

Satryo Soemantri Brodjonegoro:

Tribologi

can be
optimized
to build
lowest or
highest friction
coefficient

Deformati
on
Soft materials
deform when under
pressure
increased resistance to
motion
Materials deform
"plow" through to move
creating a resistive force
higher friction
www.school-forchampions.com

Adhesio
n

Two objects into contact:

many atoms or molecules from one object are in such
close proximity to
those in the other object
molecular or electromagnetic forces attract the molecules
of the
two materials together
adhesion
slide one object across the other
breaking these adhesive bonds
essence of friction
www.school-forchampions.com

Weld Shear Plow

WELDING

SHEARING

PLOWING

www.gulfoil.co
m

Pressing on contact
surface of two object
+ Sliding motion
Welding
Surface roughness +
Sliding motion
Shearing
Surface roughnes +
deformation + Sliding
motion Plowing

Increase
Efficiency

INPUT

SYSTEM

OUTPU
T

Output = Input - Losses

Efficiency = Output/Input
Losses Efficiency
Friction Losses
Lubrication
Friction

Lubrication reduce deformation + adhesion + (weld + shear

+ plow)

Lubrication
Principles
wedge

squeeze

hydrodyna
mic
Hamrock: Fluid Film
Lubrication

Lubricant &
Lubrication

Lubricant = 3rd Body (solid / fluid / gas)

Lubricant &
ClearanceF
So

b d
So : Sommerfeld Number
(Bearing Characteristic)
Practice : 5 So 20
FN : Load
b : Bearing Width
d : Shaft Diameter
Endurance Constant Bearing
Characteristic
Efficiency Lowest Friction
Lowest Friction Lowest Viscosity
Endurance + Efficiency Finest
Clearance
Holland:
Tribologie

Dd
: Clearance
d
: Absolute Viscosity

2 n

: Angular Speed
60

Tribology Solution for

3E

Principle of
Design
World Wide Fuel
Charter
(WWFC):
Category1
Category2
Category3
CategoryFuel
4

Specificati
on

Emission
Regulatio
n
Low
Emission
Engine
Technolo
gy

Lubricant
Classifica-tion:
API
Service
JASO
ISO VG
ACEA

Lubricant
Specificati
on

Principle of
Implementation

Lower
Emissio
n

CxHy + O2 CO2 + H2O +

Heat

Lubricant Conservation &

Diversification
Low Base
Oil
Viscosity

Additive

Qualified
Lubricant

Longer
Service
Interval

Used
Lubricant

Recycling
Process
Mineral /
Synthetic
Virgin Base
Oil

Bio Virgin
Base Oil

Refined Base
Oil

Waste

Trend
Future trend:
Endurance
Efficiency
Environment

Tribology Solution:
Finest Clearance
Minimize Moving
Parts
Lowest Viscosity

Better
Quality and
Sustainabilit
y of Life

Resume
Pemenuhan target produksi akan tercapai jika
reliability dan availability tinggi
Reliability tinggi dapat diwujudkan dengan
menerapkan maintenance technique berdasarkan
mode kegagalan setia komponen kritis alat berat
Availability tinggi dapat diwujudkan dengan
mengatur interval monitoring
Reliability Centered Maintenance (RCM) dapat
dipergunakan untuk mewujudkan Availability dan
Reliability tinggi secara Cost Effective
Lubricant monitoring dapat dipergunakan untuk
menurunkan resiko kegagalan
Pro-Active Maintenance dapat dipergunakan untuk
menaikkan target reliability, availability dan cost
effectiveness