Download - Reliability and Integrity Management 1
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2013-05-10 SKF Slide 1 [Code]SKF [Organisation]
Reliability and Integrity
Management
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2013-05-10 SKF Slide 2 [Code]SKF [Organisation]
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2013-05-10 SKF Slide 3 [Code]SKF [Organisation]
Bearings
Steel
Sealsprevent foreign particles coming inor lubricants leaking out
Minimize friction and carry loads
cleanest in the world
ServiceCreating synergiesandvalueforeach unique cl ient
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2013-05-10 SKF Slide 4 [Code]SKF [Organisation]
SKF Reliability Systems
SKF Reliability Systems is a business unit within SKFAB, committed to providing reliability solutions
Currently active across many industry sectors
throughout the world over 1,400 personnel and salesof US$150m/annum
The organisation has been built from the combinationof internal growth and acquired Companies withmany years experience in the fields of reliabilitymanagement
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2013-05-10 SKF Slide 5 [Code]SKF [Organisation]
RCM
Will reduce maintenance cost by 30%
and eliminate unscheduled downtime
TPMWill empower workforce and reduce
costs by 30% and reduce down time
year on year
PRM
Will proactively eliminate
failures
CBM
Will reduce maintenance cost by 30% and
eliminate unscheduled downtime
PdM
Will ensure reliability of rotatingequipment
RCA
Will reduce down time year
on year
TQM
Will proactively eliminatefailures
APMWill transform business
performance
Reliability Tools and Techniques
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2013-05-10 SKF Slide 6 [Code]SKF [Organisation]
Reliability Tools and Techniques
maintenance costreduction
RCM 30%CBM 30%TPM 30%Total 90%
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2013-05-10 SKF Slide 7 [Code]SKF [Organisation]
A Five Letter Abbreviation
S
O
C
E
E
nake
il
ures
very
vil
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2013-05-10 SKF Slide 8 [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
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2013-05-10 SKF Slide 10 [Code]SKF [Organisation]
Most Management Process also needfeedback!
PLAN
DOIMPROVE
MEASURE
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2013-05-10 SKF Slide 11 [Code]SKF [Organisation]
Applied to maintenance?Firefighting
PLAN
DOIMPROVE
MEASURE
How to f ix the problem
Mobi l ise resou rces
and get i t done!
Cost , dow nt ime
How could we do to
bett er, faster?
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2013-05-10 SKF Slide 12 [Code]SKF [Organisation]
Maintenance and Integrity Loop
PLAN
DOIMPROVE
MEASURE
Maintenance and
Integ ri ty Strategy
Manage and execute
dai ly activi t ies
Reliabi l i ty and
integr i ty KPIs
RCA and s trategy
review
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2013-05-10 SKF Slide 13 [Code]SKF [Organisation]
The Reliability and Integrity ManagementProcess- 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 senseWherever possible maintain on the basis of the condition of
equipment
Optimisation of maintenance effort
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2013-05-10 SKF Slide 14 [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
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2013-05-10 SKF Slide 15 [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
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2013-05-10 SKF Slide 16 [Code]SKF [Organisation]
What is RCM ?
RCM - A process used to determine what must be
done to ensure that any physical asset continues tofulfil its intended functionsin its presentoperating context
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2013-05-10 SKF Slide 17 [Code]SKF [Organisation]
Identify functional failures
What is an equipment item for? Identify its functions
How can it fail to perform those
functions?
Does it matter if any of these
things happen?N
Y
stop
What would cause them to
happen?
Identify failures that
must be defended
Is there an appropriate maintenance
action to defend against that event? plan maintenance task
RedesignN
Y
A Simplified RCM Decision LogicRCM overview
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2013-05-10 SKF Slide 18 [Code]SKF [Organisation]
Traditional ViewHow Things Fail
0
20
40
1 2 3 4 5 6 7 8
Tradit ion al View o f Failure
Basis of Scheduled Maintenance
Challenged by Av iat ion Exper ience
I d K l d f
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2013-05-10 SKF Slide 19 [Code]SKF [Organisation]
Improved Knowledge of
How Things Fail
0
20
40
1 2 3 4 5 6 7 8
0
20
40
1 2 3 4 5 6 7 8
0
20
40
1 2 3 4 5 6 7 8 0
50
1 2 3 4 5 6 7 8
Bathtub 4%
Wearout 2%
Random 26%
Early Life Fail 68%
Failure characteristics matterbecause they determine the
correct type of maintenance!
The only defence against a random
failure is a condition monitoring task.
Hence RCM and condition monitoring
are interdependent
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2013-05-10 SKF Slide 20 [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.
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2013-05-10 SKF Slide 21 [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 andbring consistency and structure to the maintenance plan
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2013-05-10 SKF Slide 23 [Code]SKF [Organisation]
Reliability Data
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2013-05-10 SKF Slide 24 [Code]SKF [Organisation]
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2013-05-10 SKF Slide 25 [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
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2013-05-10 SKF Slide 40 [Code]SKF [Organisation]
Reliability and Integrity Management
PLAN
DOIMPROVE
MEASURE
Maintenance and
Integ ri ty Strategy
Manage and executedai ly activi t ies
Reliabi l i ty and
integr i ty KPIs
RCA and s trategyreview
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2013-05-10 SKF Slide 41 [Code]SKF [Organisation]
Strategy Execution
Planned maintenance compliance
Effectiveness of Condition monitoring
Effectiveness of WatchkeepingResource and Competence Management
Accurate capture of failure and maintenance close-out
data
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2013-05-10 SKF Slide 42 [Code]SKF [Organisation]
Condition monitoring toolkit
Vibration
Lube Oil
PerformanceWatchkeeper data
Themography
Electrical measurements
Etc.
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2013-05-10 SKF Slide 43 [Code]SKF [Organisation]
Condition Based Maintenance Process
Collect Data
Analyse and diagnose
Look at the context
Action focusedrecommendations
Implement
Close out
Strategy
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2013-05-10 SKF Slide 45 [Code]SKF [Organisation]
Reliability and Integrity Management
PLAN
DOIMPROVE
MEASURE
Maintenance and
Integ ri ty Strategy
Manage and executedai ly activi t ies
Reliabi l i ty and
integr i ty KPIs
RCA and s trategyreview
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2013-05-10 SKF Slide 46 [Code]SKF [Organisation]
Reliability KPIs
Lagg ing indicators- tel l as wh at we have achieved to date
MTBFs
Plant uptime
OEE
Leading indicators tell us of our Reliability Management
process is working.
QAF 51 Rev
02
P0502
B
P0502
A
FT551
1
P0501
L
I
C5511
PRODUCED
WATER
TREATMENT
HP FLARE
GAS
COMPRESSOR
PSV
5500
SE-55000
LSHH
5512
LIT
5511
ESD
ESD
E0505B
FCV5511
A
FCV5511
B
LSLL
5513
8
E0505A
8 LCV5511
F
I
C5511
Quantity of oil shipped- lagging indicator
Level in vessel tells us that part of plant is working-leading indicator
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2013-05-10 SKF Slide 47 [Code]SKF [Organisation]
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2013-05-10 SKF Slide 50 [Code]SKF [Organisation]
Reliability and Integrity Management
PLAN
DOIMPROVE
MEASURE
Maintenance and
Integ ri ty Strategy
Manage and executedai ly activi t ies
Reliabi l i ty and
integr i ty KPIs
RCA and s trategyreview
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2013-05-10 SKF Slide 51 [Code]SKF [Organisation]
Failure codes- Centrifugal Pump
EXL FTS FWR LOU
Externalleakage
Failedtostart
Failedwhilerunning
Lowoutput
BEAUF Bearingfailure
X X Vibrationmonitoring
CASUF Couplingfault
X Vibrationmonitoring
COUUF Impellerwear/damage
X Watchkeeping/Performancemonitoring
IMPUF Thrustbearingfailure
Watchkeeping
INTUP Seal failure X X X Watchkeeping
SEAUD Casingcorrosion X X X Inspection
BEATF Internalblockage
X Watchkeeping/Performancemonitoring
Apparent
causeTechnicalCause
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2013-05-10 SKF Slide 54 [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.
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2013-05-10 SKF Slide 55 [Code]SKF [Organisation]
Case study
LNG flash
drum
To storage
strainer strainer
LNG pumpsNegative suction pressure
During routine 6 monthly strainer
inspection:A pump runningB pump shut down for maintenancePump isolation valve passing
Air enters system via strainerA pump cavitatesLoss of level controlPlant 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
BUT need tools and processes to ensureresponse to failure
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2013-05-10 SKFSlide 56 [Code]SKF [Organisation]
PLAN
DOIMPROVE
MEASURE
Calculate Leading/lagging KPIs
Compare wi th Strategy
Develop strategy
Develop KPIs
Human and
organisat ional
performance
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2013-05-10 SKFSlide 61 [Code]SKF [Organisation]
Optimise Inspection and MaintenanceOur objective is
Optimise planned activitiesIdentify anomalies
And bad actors
Through these activi ties
Capture opportunityLoss events, identify
and eliminate
Root cause
investigate excessiveunplanned
maintenance, identify
and eliminate root
cause
Capture failures/trips of critical
equipment and
eliminate root
cause
Which we address
through Identifyexcessive
backlog and
eliminate root
cause
Continually challenge
maintenance and inspection
strategy:-Criticality correct?
-Reliability assumptions
correct?
-Best use of technology? -
Opportunities to reduced
scheduled shutdowns?
Accurate and timely
reporting of
opportunity loss
Accurate assignment
and description of
corrective work
orders
Accurate
reporting of
failures of critical
equipment
Needinginformation Accurate
maintenance
man-hour records
Actual Opportunity
loss
Excessive
unplanned
maintenance
Potential
Opportunity loss
Which breaks
into:
Non-
conformance in
planned
maintenance
R li bilit d I t it M t
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2013-05-10 SKFSlide 63 [Code]SKF [Organisation]
Reliability and Integrity Management
The message..
PLAN
DOIMPROVE
MEASURE
Maintenance and Integrity Strategy
Manage and execute daily
activit ies
Reliabi l i ty and integrity K PIs
RCA and strategy review
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