Reliability and Integrity Management

2013-05-10 SKF Slide 1 [Code] SKF [Organisation]

2013-05-10 SKF Slide 2 [Code] SKF [Organisation]

Bearings
Minimize friction and carry loads

Seals
prevent foreign particles coming in or lubricants leaking out

Steel
cleanest in the world

Service
Creating synergies and value for each unique client
2013-05-10 SKF Slide 3 [Code] SKF [Organisation]

SKF Reliability Systems

SKF Reliability Systems is a business unit within SKF AB, committed to providing reliability solutions

Currently active across many industry sectors throughout the world over 1,400 personnel and sales of US$150m/annum
The organisation has been built from the combination of internal growth and acquired Companies with many years experience in the fields of reliability management

2013-05-10 SKF Slide 4 [Code] SKF [Organisation]

Reliability Tools and Techniques

CBM RCM
Will reduce maintenance cost by 30% and eliminate unscheduled downtime Will reduce maintenance cost by 30% and eliminate unscheduled downtime

TQM

PRM
Will proactively eliminate failures

PdM

RCA

Will proactively eliminate Will ensure reliability of rotating failures equipment

Will reduce down time year on year

TPM
Will empower workforce and reduce costs by 30% and reduce down time year on year
2013-05-10 SKF Slide 5 [Code] SKF [Organisation]

APM
Will transform business performance

Reliability Tools and Techniques

RCM CBM TPM Total

maintenance cost reduction 30% 30% 30% 90%

2013-05-10 SKF Slide 6 [Code] SKF [Organisation]

A Five Letter Abbreviation

S nake

Oil
C ures

E very
E vil

2013-05-10 SKF Slide 7 [Code] SKF [Organisation]

Objective- go back to first principles

The big picture- what are we trying to achieve
Apply Reliability Engineering principles to meet corporate goals

Go into a little detail on the key elements

-Set a strategy -Execute the strategy -Measure performance -Address issues

2013-05-10 SKF Slide 8 [Code] SKF [Organisation]

Most Management Process also need feedback!

PLAN

IMPROVE

DO

MEASURE

2013-05-10 SKF Slide 10 [Code] SKF [Organisation]

Firefighting Applied to maintenance?

PLAN

How to fix the problem

IMPROVE

How could we do to better, faster?

Mobilise resources and get it done!

DO

Cost, downtime

MEASURE

2013-05-10 SKF Slide 11 [Code] SKF [Organisation]

Maintenance and Integrity Loop

PLAN

Maintenance and Integrity Strategy RCA and strategy review Manage and execute daily activities

IMPROVE

DO

Reliability and integrity KPIs

MEASURE

2013-05-10 SKF Slide 12 [Code] SKF [Organisation]

The Reliability and Integrity Management Process- PLAN

Matching Maintenance and Inspection effort to business needs

Planned maintenance is done where there is a business case A conscious decision to run to failure where it makes business sense Wherever possible maintain on the basis of the condition of equipment Optimisation of maintenance effort

2013-05-10 SKF Slide 13 [Code] SKF [Organisation]

Approaches to Maintenance Strategy Development

Good Practice past experience

Reliability Centred Maintenance

Streamlined Reliability Centred Maintenance Risk Based Maintenance Each has its place

2013-05-10 SKF Slide 14 [Code] SKF [Organisation]

Established Practice

Capitalise on (and contribute to) Corporate knowledge

Quick! BUT

Need to address operating context

Need to address criticality Need to understand why
Reliance on good practice is ideal for low criticality equipment and high criticality equipment where maintenance is driven by statute or Company standard

2013-05-10 SKF Slide 15 [Code] SKF [Organisation]

What is RCM ?
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

2013-05-10 SKF Slide 16 [Code] SKF [Organisation]

A Simplified RCM Decision Logic RCM overview

Identify its functions Identify functional failures

What is an equipment item for? How can it fail to perform those functions?

Does it matter if any of these things happen?

Y

stop

What would cause them to happen?

Is there an appropriate maintenance action to defend against that event?
N Y

Identify failures that must be defended

plan maintenance task

Redesign

2013-05-10 SKF Slide 17 [Code] SKF [Organisation]

Traditional View How Things Fail

40 20 0 1 2 3 4 5 6 7 8

Traditional View of Failure Basis of Scheduled Maintenance Challenged by Aviation Experience

2013-05-10 SKF Slide 18 [Code] SKF [Organisation]

Improved Knowledge of How Things Fail

40 20 0 1 2

Bathtub 4%

50

Random 26%

40 20 0 1 2

The only defence against a random Failure characteristics matter 0 monitoring 3 4 failure 5 6 is 7 a condition 8 1 2 the 3 4 task. 5 6 7 8 because they determine correct type and of maintenance! Hence RCM condition monitoring are2% interdependent40 Early Life Fail 68% Wearout
20 0

2013-05-10 SKF Slide 19 [Code] SKF [Organisation]

Value of RCM
When carried out properly, formal RCM is Rigorous process to define the correct maintenance Audit trail Documented strategy BUT It can be time consuming Does not blend well into a continuous improvement process Other approaches do these things more efficiently Choosing the right approach is a critical issue, machine by machine.

2013-05-10 SKF Slide 20 [Code] SKF [Organisation]

Streamlined RCM techniques

SRCM- SKF developed technique, that utilises a streamlined process to rapidly structure and optimise maintenance. Risk Based Maintenance- a similar SKF developed technique, that determines the applicability of tasks by measuring the risk reduction they provide. Both rely on templates to accelerate the analysis and bring consistency and structure to the maintenance plan

2013-05-10 SKF Slide 21 [Code] SKF [Organisation]

Reliability Data

2013-05-10 SKF Slide 23 [Code] SKF [Organisation]

2013-05-10 SKF Slide 24 [Code] SKF [Organisation]

Role of Maintenance Strategy Development

To define an optimised task set -planned activities via CMMS -Condition monitoring strategy -Watchkeeping/first line maintenance strategy

To establish baseline for performance - failure codes -quantitative performance standards -equipment classification in line with ISO 14224

2013-05-10 SKF Slide 25 [Code] SKF [Organisation]

Reliability and Integrity Management

PLAN

Maintenance and Integrity Strategy RCA and strategy review Manage and execute daily activities

IMPROVE

DO

Reliability and integrity KPIs

MEASURE

2013-05-10 SKF Slide 40 [Code] SKF [Organisation]

Strategy Execution

Planned maintenance compliance Effectiveness of Condition monitoring Effectiveness of Watchkeeping Resource and Competence Management

Accurate capture of failure and maintenance close-out data

2013-05-10 SKF Slide 41 [Code] SKF [Organisation]

Condition monitoring toolkit

Vibration Lube Oil Performance Watchkeeper data

Themography
Electrical measurements Etc.

2013-05-10 SKF Slide 42 [Code] SKF [Organisation]

Condition Based Maintenance Process

Strategy

Collect Data
Analyse and diagnose Look at the context

Action focused recommendations

Implement Close out
2013-05-10 SKF Slide 43 [Code] SKF [Organisation]

Reliability and Integrity Management

PLAN

Maintenance and Integrity Strategy RCA and strategy review Manage and execute daily activities

IMPROVE

DO

Reliability and integrity KPIs

MEASURE

2013-05-10 SKF Slide 45 [Code] SKF [Organisation]

Reliability KPIs
Lagging indicators- tell as what we have achieved to date MTBFs Plant uptime OEE Leading indicators tell us of our Reliability Management process is working.
HP FLARE PS V 550 0

Quantity of oil shipped- lagging indicator Level in vessel tells us that part of plant is working -leading indicator

GAS COMPRESSOR L I 5511 C

ESD

ESD

LS HH 551 2 LS LL 551 3

SE-55000

LIT 551 1

F I 5511 C

FT 551 1

P0502 A

E0505A

FCV5511 A

LCV5511

PRODUCED WATER TREATMENT

P0501

P0502 B

E0505B

FCV5511 B

2013-05-10 SKF Slide 46 [Code] SKF [Organisation]

QAF 51 Rev 02

2013-05-10 SKF Slide 47 [Code] SKF [Organisation]

Reliability and Integrity Management

PLAN

Maintenance and Integrity Strategy RCA and strategy review Manage and execute daily activities

IMPROVE

DO

Reliability and integrity KPIs

MEASURE

2013-05-10 SKF Slide 50 [Code] SKF [Organisation]

Failure codes- Centrifugal Pump

Technical Cause
BEAUF CASUF

Apparent cause

Bearing failure

EXL FTS External Failed leakage to start X

FWR LOU Failed Low while output running X Vibration monitoring X X Vibration monitoring Watchkeeping/ Performance monitoring Watchkeeping Watchkeeping Inspection X Watchkeeping/ Performance monitoring

Coupling fault COUUF Impeller wear/damage IMPUF Thrust bearing failure INTUP Seal failure SEAUD Casing corrosion BEATF Internal blockage

X X

X X

X X

2013-05-10 SKF Slide 51 [Code] SKF [Organisation]

An Example
The pump tripped on high vibration, causing an expensive plant shutdown.
Vibration was caused by bearing failure Bearing failure caused by false brinelling Machine subject to vibration while shut down.. Operators did not bar over. No procedure Loss of experienced personnel due to.. This incident gave the Company an excellent opportunity to LEARN.
2013-05-10 SKF Slide 54 [Code] SKF [Organisation]

Case study
During routine 6 monthly strainer inspection: A pump running B pump shut down for maintenance Pump isolation valve passing Air enters system via strainer To storage A pump cavitates Loss of level control Plant trip- cost $2m ISSUES: Competence/ procedures Valve Maintenance Why inspect the strainer anyway? Run to failure inappropriate BUT how often to inspect? ANSWER Maintain on condition via seal pressure

LNG flash drum

strainer

strainer

LNG pumps
Negative suction pressure

BUT need tools and processes to ensure response to failure

2013-05-10 SKF Slide 55 [Code] SKF [Organisation]

PLAN
IMPROVE
Develop strategy Develop KPIs

DO

MEASURE
Calculate Leading/lagging KPIs Human and organisational performance Compare with Strategy

2013-05-10 SKF Slide 56 [Code] SKF [Organisation]

Our objective is Through these activities

Identify anomalies And bad actors

Optimise Inspection and Maintenance

Optimise planned activities

Which breaks into:

Actual Opportunity loss

Potential Opportunity loss

Nonconformance in planned maintenance

Excessive unplanned maintenance

Which we address through Capture opportunity

Loss events, identify and eliminate Root cause

Capture failures/ trips of critical equipment and eliminate root cause

Identify excessive backlog and eliminate root cause

investigate excessive unplanned maintenance, identify and eliminate root cause

Continually challenge maintenance and inspection strategy: -Criticality correct? -Reliability assumptions correct? -Best use of technology? Opportunities to reduced scheduled shutdowns?

Needing information

Accurate and timely reporting of opportunity loss

Accurate reporting of failures of critical equipment

Accurate maintenance man-hour records

Accurate assignment and description of corrective work orders

2013-05-10 SKF Slide 61 [Code] SKF [Organisation]

Reliability and Integrity Management The message..

PLAN
Maintenance and Integrity Strategy

IMPROVE
RCA and strategy review

DO
Manage and execute daily activities

Reliability and integrity KPIs

MEASURE

There are no magic bullets It is a simple process in concept But hard work in detail SKF can help at each stage in the process You need to start the journey form where you are
2013-05-10 SKF Slide 63 [Code] SKF [Organisation]