Reliability and Integrity Management 1

7/30/2019 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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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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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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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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Reliability Tools and Techniques

maintenance costreduction

RCM 30%CBM 30%TPM 30%Total 90%


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A Five Letter Abbreviation

S

O

C

E

E

nake

il

ures

very

vil


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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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Most Management Process also needfeedback!

PLAN

DOIMPROVE

MEASURE


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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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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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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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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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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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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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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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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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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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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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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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Reliability Data


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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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Reliability and Integrity Management

PLAN

DOIMPROVE

MEASURE

Maintenance and


Manage and executedai ly activi t ies

Reliabi l i ty and

integr i ty KPIs

RCA and s trategyreview


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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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Condition monitoring toolkit

Vibration

Lube Oil

PerformanceWatchkeeper data

Themography

Electrical measurements

Etc.


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Condition Based Maintenance Process

Collect Data

Analyse and diagnose

Look at the context

Action focusedrecommendations

Implement

Close out

Strategy


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PLAN

DOIMPROVE

MEASURE

Maintenance and



Reliabi l i ty and

integr i ty KPIs



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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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PLAN

DOIMPROVE

MEASURE

Maintenance and



Reliabi l i ty and

integr i ty KPIs



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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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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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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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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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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

Reliability and Integrity Management 1

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