idhammar1
Post on 16-Nov-2015
3 Views
Preview:
DESCRIPTION
TRANSCRIPT
-
Results Oriented
Reliability and Maintenance
Consulting and Training
WWW.IDCON.COM
Optimization of Preventive Maintenance and Operator Essential
Care
-
WWW.IDCON.COM Copyright IDCON
Rate your Current Operator Essential Care & Preventive Maintenance System
On a loose sheet of paper please write a number between 1 and 10. Using your personal definition of what Operator Essential Care &
preventive maintenance (PM) is in your plant. Please rate how well you currently do OBR & PM at the plant.
1 Non existent 2 3 4 5 Average in industry 6 7 8 9 10 Not cost effective to improve
-
WWW.IDCON.COM Copyright IDCON
DO
REACTREPAIR
RETURNREPEAT
TECHNICAL DATABASE &
STORES
PREVENTION & CONDITION
MONITORING
PRODUCTIONPLAN
MARKET
CONTINUOUS IMPROVEMENT
RECORD
MAINTENANCEPLANNING AND
SCHEDULING
Priorities / Backlog
-
WWW.IDCON.COM Copyright IDCON
Exercise!
How is Preventive Maintenance Defined?
How is Operator Essential Care Defined?
-
WWW.IDCON.COM Copyright IDCON
All actions to prevent a failure or
detect a failure early
Preventive Maintenance & Operator Essential Care Definition?
-
WWW.IDCON.COM Copyright IDCON
When the equipment condition reaches an unacceptable level
When the failure has developedto the point that the equipment is unable
to operate
The failure is detected and reportedFAILURE
BREAK DOWN
Failure & Break Down
SOURCEEvent that initiateFailure developing
-
WWW.IDCON.COM Copyright IDCON
IDCON Definition - Preventive Maintenance / Essential Care and Condition Monitoring ( PM/ECCM )
Essential CarePrevents Failures
Condition MonitoringDetects Failures
LubricationAlignmentBalancingDetailed CleaningOperating PracticesInstallation PracticesFiltration AdjustmentsFixed Time Maintenance
LookListenFeelSmell
MeasuringPressureFlowCurrent, VoltageDistanceVibration TemperatureDecibels
UsingInfrared CamerasVibration SensorsShock Pulse MeasurementUltrasonic Thickness TestUltrasonic Listening (leaks)Oil AnalysisGauges, etc
ObjectiveProvides a comparable reading
SubjectiveProvides no reading
-
WWW.IDCON.COM Copyright IDCON
Do We Know Exactly where We are Going?
TIME
OEC/ PM
CURRENT
The Vision
-
WWW.IDCON.COM Copyright IDCON
Communicate a Vision to the Plant
If want people to buy into the concept of OEC or PM, you must paint a picture of the future. What will this system look like when we are done.
An Example
-
WWW.IDCON.COM Copyright IDCON
What Exactly is it We Want Operations To Do?
You need to decide for your plant
Typically
1. Inspections of running equipment, mostly mechanical inspections
2. Detailed cleaning of equipment & housekeeping3. Operate equipment with reliability in mind4. Minor maintenance tasks5. Coordinate Production Schedule & Maintenance Schedule6. Joint Root Cause Elimination
-
WWW.IDCON.COM Copyright IDCON
Whats more important?
-
WWW.IDCON.COM Copyright IDCON 12
Do you see a problem?
-
WWW.IDCON.COM Copyright IDCON 13
-
WWW.IDCON.COM Copyright IDCON
Preventive Maintenance Common PM (including OEC) Before Improvement
Process Control
Electrical
Lubrication
Instrumentation
Operations
Mech.Vibration Analysis
InfraredThermogr.
Oil Testing
-
WWW.IDCON.COM Copyright IDCON
Preventive Maintenance Painting the Picture of Finished Product
Process ControlElectricalLubrication
InstrumentationOperations Mechanical
Vibration Analysis
InfraredThermogr.
Oil Testing
Many PMs moved from off-line to on-the-runCoordinated PM process between skills reduces PM process sizeEssential Care reduces amount corrective work , not necessarily Preventive
-
WWW.IDCON.COM Copyright IDCON
Operator Essential Care, Preventive Maintenance, Root Cause, Planning and Scheduling, Spare Parts Management
Making any of the above an isolated effort is a mistake. Focus on one temporarily can work They have to be integrated
-
Results Oriented
Reliability and Maintenance
Consulting and Training
WWW.IDCON.COM
Essential Care - Prevent
-
WWW.IDCON.COM Copyright IDCON
DO
REACTREPAIR
RETURNREPEAT
TECHNICAL DATABASE &
STORES
PREVENTION & CONDITION
MONITORING
PRODUCTIONPLAN
MARKET
CONTINUOUS IMPROVEMENT
RECORD
MAINTENANCEPLANNING AND
SCHEDULING
Priorities / Backlog
-
WWW.IDCON.COM Copyright IDCON
Motor Life in Relation to Cleanliness
0.5
3.2
8
20
02468
101214161820
Heavy Cov / 50%airintakeLight Cov /50%airintakeClean / 50% airintake
Clean 100% airintake
Years
20 HP, 1800 rpm, frame class F (155F)
-
WWW.IDCON.COM Copyright IDCON
185 F
Dirty Motor
Rule of Thumb:An 18 F Increase In TemperatureReduces Motor Life by 50%
-
WWW.IDCON.COM Copyright IDCON
135 F
Cleaner Motor
-
WWW.IDCON.COM Copyright IDCON
Make a Visible Change Early in the Project
-
WWW.IDCON.COM Copyright IDCON
Make a Visible Change Early in the Project
-
WWW.IDCON.COM Copyright IDCON
Operate Equipment with Reliability in Mind
The current load is 4-7 times the full operating load at starting the motor.
Operators should therefore not try to start Motors several times quickly together.
It will burn the motor
-
WWW.IDCON.COM Copyright IDCON
Bearings BrinellingCorrosion of moving partsAged Lubricant Seals dry up / sag
Operating Procedures - Parallel Systems
-
WWW.IDCON.COM Copyright IDCON
Bearing Life Reduction An Example
0
20
40
60
80
100
120
1 2 3 4 5
Mills / inch
% Bearing life
Roller bearings
Maintenance Technology Feb. 2000
-
WWW.IDCON.COM Copyright IDCON
Poorly aligned Probably Well Aligned
Other Signs: Hot bearings Hot Couplings Vibrating Equipment
Signs of Poor Alignment
-
WWW.IDCON.COM Copyright IDCON
The Micrometer mMicron = Micrometer = 0.000001m1 Micron = 0.000 039 inch
Grain of salt 100 m Thickness of paper 75 m Human hair 70 m Naked eye can see 40 m White blood cells 25 m Red blood cells 8 m Bacteria (cocci) 2 m
Human Hair 75 m particles 10 m
Measurement of Particle Size
-
WWW.IDCON.COM Copyright IDCON
Bearing Life & Filtration
0
2
4
6
8
10
12
14
3 6 9 12 15 18 21 24 27 31 33 36 39
Filter rating [m], =200
Bea
ring
life
in m
illio
ns o
f cyc
les
Reference: Dr. P.B Macphereson, U.K
-
WWW.IDCON.COM Copyright IDCON
-
WWW.IDCON.COM Copyright IDCON
Maintainability
-
WWW.IDCON.COM Copyright IDCON
Design for Reliability
-
WWW.IDCON.COM Copyright IDCON
Design for Maintainability
-
WWW.IDCON.COM Copyright IDCON
Design For Maintainability
-
WWW.IDCON.COM Copyright IDCON
Motor Shelf
-
Results Oriented
Reliability and Maintenance
Consulting and Training
WWW.IDCON.COM
Condition Monitoring Finding Failures
-
WWW.IDCON.COM Copyright IDCON
DO
REACTREPAIR
RETURNREPEAT
TECHNICAL DATABASE &
STORES
PREVENTION & CONDITION
MONITORING
PRODUCTIONPLAN
MARKET
CONTINUOUS IMPROVEMENT
RECORD
MAINTENANCEPLANNING AND
SCHEDULING
Priorities / Backlog
-
WWW.IDCON.COM Copyright IDCON
How would you inspect the Zinc anodes?
-
WWW.IDCON.COM Copyright IDCON
Solution?
-
WWW.IDCON.COM Copyright IDCON
Exercise 8-B
Heat ExchangerOil OutOil In
Water in Water out
Temp. gauge
-
WWW.IDCON.COM Copyright IDCON
Heat Exchanger Valve
-
WWW.IDCON.COM Copyright IDCON
Expensive Ratio 200:1Cheap Ratio 3:1
D=20 in
L= 400 in
RATIO = L/D = 400/20 = 20:1
Infrared Temperature Guns
-
WWW.IDCON.COM Copyright IDCON
Possible Inspection Tools
Vibration Pen
Inspection Mirrors
Stroboscope
IR Gun
Industrial Stethoscope
Flashlight
-
WWW.IDCON.COM Copyright IDCON
Flashlight
285 Lumens, size of a Marker
218 Lumens / 4D Batteries about a foot long
-
WWW.IDCON.COM Copyright IDCON
Temperature Crayons
-
WWW.IDCON.COM Copyright IDCON
Infrared Camera
-
WWW.IDCON.COM Copyright IDCON
-
WWW.IDCON.COM Copyright IDCON
-
WWW.IDCON.COM Copyright IDCON
Leaking Steam System Relief Valve
-
WWW.IDCON.COM Copyright IDCON
-
WWW.IDCON.COM Copyright IDCON
Wet Insulation Saturated with Water Due to Leak
-
Results Oriented
Reliability and Maintenance
Consulting and Training
WWW.IDCON.COM
The Basics of Reliability and Document tasks
-
WWW.IDCON.COM Copyright IDCON
Paper Inspection Route Example
175
-
WWW.IDCON.COM Copyright IDCON
CMS (100 Available)
-
WWW.IDCON.COM Copyright IDCON
Fahrenheit
Handheld Example
-
WWW.IDCON.COM Copyright IDCON
Common Mistakes (A Few Examples)
Make a route for only one component or equipment type, for example pumps routes or valve routes Because inspector will have to walk around the plant 30-50 times
to reach all equipment
No use of standard job plans for inspections Makes maintenance of inspection lists very cumbersome if a new
inspection tool or new technique is established
Separate routes for different inspection intervals Often a daily, a weekly, a monthly, a semi annually route for each
trade make scheduling cumbersome and maintenance of routes very maintenance intensive.
Set up of too many measuring points that are collected but not analyzed
We dont fix what we find
-
WWW.IDCON.COM Copyright IDCON
Work Order PM
-
WWW.IDCON.COM Copyright IDCON
What is the Final Documentation Product of OEC and PM
Usually Inspection Routes for on-the-run PM/OEC
Usually less than 5 minutes per equipment number
Work orders for off line PM/OEC Often longer jobs 30 min 16 hrs
-
WWW.IDCON.COM Copyright IDCON
Reliability Basics
Maintenance Methods Available
Life of Components
Failure Developing Period (FDP)
-
WWW.IDCON.COM Copyright IDCON
Maintenance Methods Existing Equipment
OTB Operate To Break-Down Often Too Expensive
FTM - Fixed Time Maintenance Dont Know Life Most of the Time
CBM Condition Based Maintenance 70-85% Will Therefore Need CBM
-
WWW.IDCON.COM Copyright IDCON
Random or not?
It is unnecessary to know which of the traditional six life expectancy. You need to estimate if the failure IS Random or NOT. All failures are somewhat random and 5 11% somewhat predictable (C & possibly A & B).
2%
4%
5%
7%
14%
68%Picture Courtesy: www.weibull.com
-
WWW.IDCON.COM Copyright IDCON
L10 L90
Bearing life under the same operating conditions, can vary from 1 to 25 years
Component Life
-
WWW.IDCON.COM Copyright IDCON
Car tires life under the same operating conditions, may vary from 35,000 to 45,000 miles
(6000-6500 mil)
35 K 45 K
Back
Component Life
-
WWW.IDCON.COM Copyright IDCON
Cha
nge
in C
ondi
tion
Bre
ak D
own
FDP
A belt will show signs of deterioration before breaking down
Failure Developing Period
-
WWW.IDCON.COM Copyright IDCON
When the equipment condition reaches an unacceptable level
When the failure has developedto the point that the equipment is unable
to operate
The failure is detected and reportedFAILURE
BREAK DOWN
Failure/ Break Down
SOURCEEvent that initiateFailure developing
Source: klla till feletBreak down: Haveri
-
WWW.IDCON.COM Copyright IDCON
Bre
ak D
own
A light bulb will break instantaneously without any
signs of deterioration
Failure Developing Period
-
WWW.IDCON.COM Copyright IDCON
1. Prevent failures2. Most cost effective maintenance method3. Implement the most cost effective method
Selecting Maintenance Method
-
WWW.IDCON.COM Copyright IDCON
Detailed CleaningLubricationAlignmentAdjustmentOperating ProceduresFiltrationBalancingInstallation Procedures
Preventing Problems
-
WWW.IDCON.COM Copyright IDCON
Maintenance Methods Existing Equipment
OTB Operate To Break-Down Often Too Expensive
FTM - Fixed Time Maintenance Dont Know Life Most of the Time
CBM Condition Based Maintenance 70-85% Will Therefore Need CBM
-
WWW.IDCON.COM Copyright IDCON
What will happen if the function Break down?1. Environmental damage or personal injury2. High cost (lost production or damages)3. Preserve value (Life)
Obvious P & ID Ask operator
99%
ANSWER BY:
What is the Function?
Selecting Maintenance Method
-
WWW.IDCON.COM Copyright IDCON
ESSENTIAL CARE (EC)lubricationalignmentbalancingdetailed cleaningoperating proceduresfiltration CBM
Inspection lists on component level1. Running objective2. Running subjective3. Shutdown objective4. Shutdown subjective
For Existing Equipment
-
WWW.IDCON.COM Copyright IDCON
Decide What, Who, and When
Decide what inspections/ PM to Do
Decide who Should do the tasks
How often should the task be done?
-
WWW.IDCON.COM Copyright IDCON
How does this component work?
How can this component fail?
How can I predict the failure?
Alternative to RCM (Reliability Centered Maintenance)
-
WWW.IDCON.COM Copyright IDCON
Example: Belt
How does it work?
How does it fail?
Check:Slippage/ oil, waterBelt tightnessAlignment of BeltSheave WearNoise
E!
-
WWW.IDCON.COM Copyright IDCON
Motor InspectionOn-The-Run Cleanliness (fins, plugged airflows, etc) Fan with strobe Temperatures with (IR Temperature - Max? 170F (75C) Vibration (feel or with Pen Alarm 0.25 in/sec 6.35 mm/sec?) Hold down bolts Base Condition of Junction Box and wires Noise Load (Current Reading)
ShutdownWinding test
CMS 100 R
-
WWW.IDCON.COM Copyright IDCON
Exercise 5-B
-
WWW.IDCON.COM Copyright IDCON
Exercise 5-B
Temperatures Bolts and Fasteners Noise and Vibration & cavitation Oil - Level and Condition Leaks Pressures Cleaning Breather Piping to and from Pump
CMS 127R
-
WWW.IDCON.COM Copyright IDCON
Do they know how?Is it practical?
N
Can they be trainedin < X min?
ImplementTask
Y
N
Go to next groupYN
Y
1. Operator2. Area Maintenance3. In house maintenance expert4. Outside expert
GROUPS
Who
-
WWW.IDCON.COM Copyright IDCON
Motor Temperature
Belt and Coupling Condition with Stroboscope
Weep Hole Regulator
Typical Operator Inspections
-
WWW.IDCON.COM Copyright IDCON
Examples of Typical Maintenance Inspections
Places Impractical for Operators to Get To
Complex Systems Vibration Analysis
Components that Require Experience Infrared Camera
Typical Maintenance Inspections
-
WWW.IDCON.COM Copyright IDCON
Ref: CMS127R
Ref: CMS106R
Ref: CMS100R
-
WWW.IDCON.COM Copyright IDCON
Hydraulic Cylinder
-
WWW.IDCON.COM Copyright IDCON
MAINTENANCE PROCEDURE
FAILURE RATE
DIR. MAINT. COST REPAIR TIME +
MATERIAL = COST
COST / YEAR
DOWNTIME COST / YEAR DAMAGES MAINTENANCE COST/YEAR
OTB
FTM
CBM
0.2
1
0.2
16h * $40 = $640Parts 3,000 $728
10h *$40 = $400Parts 3,000
10h *$40 = $400Parts 3,000
3,400
680
0.2*$4,000*10 = $8,000
0
0
1,000*0.2=$200
0
0
728+8,000+200=$8,928
$3,400
$680
Consequence of Break Down Analysis
-
WWW.IDCON.COM Copyright IDCON
Summary of Documentation Setup
-
WWW.IDCON.COM Copyright IDCON
Most OrganizationsKNOW
What to do
Best OrganizationsDo it.
Results Oriented Maintenance
-
WWW.IDCON.COM Copyright IDCON
Example 1- Kiln bricksOperate To Breakdown - OTB $500,000If responded to Inspection $60,000
Lost opportunity actual example
-
WWW.IDCON.COM Copyright IDCON
Accounting
Optimization of Preventive Maintenance and Operator Essential CareRate your Current Operator Essential Care & Preventive Maintenance SystemSlide Number 3Exercise!Preventive Maintenance & Operator Essential Care Definition?Failure & Break DownIDCON Definition - Preventive Maintenance / Essential Care and Condition Monitoring ( PM/ECCM )Do We Know Exactly where We are Going?Communicate a Vision to the PlantWhat Exactly is it We Want Operations To Do? Whats more important?Do you see a problem?Slide Number 13Preventive Maintenance Common PM (including OEC) Before ImprovementPreventive Maintenance Painting the Picture of Finished ProductOperator Essential Care, Preventive Maintenance, Root Cause, Planning and Scheduling, Spare Parts ManagementEssential Care - PreventSlide Number 18Motor Life in Relation to CleanlinessDirty MotorCleaner MotorMake a Visible Change Early in the ProjectMake a Visible Change Early in the ProjectOperate Equipment with Reliability in MindOperating Procedures - Parallel SystemsBearing Life Reduction An ExampleSigns of Poor AlignmentMeasurement of Particle SizeBearing Life & FiltrationSlide Number 30MaintainabilityDesign for ReliabilityDesign for MaintainabilityDesign For MaintainabilityMotor ShelfCondition Monitoring Finding FailuresSlide Number 37How would you inspect the Zinc anodes?Solution?Exercise 8-B Heat Exchanger ValveInfrared Temperature GunsPossible Inspection ToolsFlashlightTemperature CrayonsInfrared CameraSlide Number 47Slide Number 48Leaking Steam System Relief ValveSlide Number 50Wet Insulation Saturated with Water Due to LeakThe Basics of Reliability and Document tasksPaper Inspection Route ExampleCMS (100 Available)Handheld ExampleCommon Mistakes (A Few Examples)Work Order PMWhat is the Final Documentation Product of OEC and PMReliability BasicsMaintenance Methods Existing Equipment Random or not?Component LifeComponent LifeFailure Developing PeriodFailure/ Break DownFailure Developing PeriodSelecting Maintenance MethodPreventing ProblemsMaintenance Methods Existing Equipment Selecting Maintenance MethodFor Existing EquipmentDecide What, Who, and WhenAlternative to RCM (Reliability Centered Maintenance)Slide Number 74Motor InspectionExercise 5-BExercise 5-BWhoTypical Operator InspectionsTypical Maintenance InspectionsSlide Number 81Hydraulic CylinderConsequence of Break Down AnalysisSummary of Documentation SetupResults Oriented MaintenanceLost opportunity actual exampleAccounting
top related