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October 8, 2010 SKF Group Slide 0
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Establishing a successfulCondition Based Maintenance programme
Presented to IMarEST Conference 2010
Prepared by Gerald Rolfe
Executive Business Manager Marine
SKF Service Division
2010-09-28
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October 8, 2010 SKF Group Slide 2
Brief introduction to SKF
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41 172 employees 124 factories 56 227 MSEK turnoverin 130 countries 450 channels >10 % operating margin7 000 distributors in 29 countriesEnvironment: Global ISO 14001 certification, OHSAS 18001 certifcation
SKF 2009
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October 8, 2010 SKF Group Slide 4
SKF Group Vision
To equip the worldwith SKF knowledge
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October 8, 2010 SKF Group Slide 5
What is SKF knowledge?
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October 8, 2010 SKF Group Slide 6
Idea or concept
Design & manufacture
Install & commission
Operate & monitor
Maintain & repair
Restore & upgrade
OEMPerspective
End UserPerspective
Overall customer & business perspective
Transferableknowledge
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October 8, 2010 SKF Group Slide 7
SKF in the Marine Segment
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October 8, 2010 SKF Group Slide 8
SKF and the ship life cycle
Maintain andimprove
Operate and monitor
Build and install
Concept and design
Product delivery
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October 8, 2010 SKF Group Slide 9October 8, 2010 SKF Group Slide 9
SKF Marine Key capabilities & Values
Concept and design
Product delivery
Build and install
Operate andmonitor
Maintain & improve
Design and engineering Calculation, simulation and verificationTesting & validation
Quality SKF products
Efficient global distribution network Wide portfolio (five platforms)
Complete propulsion line installation Supervision of alignment and installation
Mounting and alignment services andsystems
Condition based maintenance (CBM) Condition monitoring systems (CMS)
Analysis and remote monitoring (RDC)
Maintenance tools and recommendations Root Cause Failure Analysis Validation and optimisation of design
Enable new reliable designs& minimise risk of machineryfailures and warranty costs
One-stop-shop for proven
world class products,available worldwide
Ensure optimised operationalperformance through best
practice installation services
Safer and more profitableoperations with increasedavailability and streamlined
classification agency surveys
Range of maintenanceengineering and consultingservices to boost asset
uptime
End-User
OEM
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October 8, 2010 SKF Group Slide 10October 8, 2010 SKF Group Slide 10
SKF Marine Key capabilities & Values
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October 8, 2010 SKF Group Slide 11
Bringing value to the Marine End User
Availability & Reliability Reduced need for Class inspection
Improved machinery design
Reliability in operation
Health, Safety & Environment Reduced risk of severe failures
Reduced time in hazardous areas
Efficient ship operation (SOX/NOX/CO2)
Maintenance efficiency Reduced time required for maintenance
Reduced consumption of spares
A safer and more profitable End User business
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October 8, 2010 SKF Group Slide 12
Profit
Cost of Plant
(CAPEX)
Time
Operating
Cost
(OPEX)
Reve
nue
(Outp
ut)
Payback point
The basic business model
2010-10-08 SKF Slide 12 [Code]SKF [Organisation]
Cost &
Revenue
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October 8, 2010 SKF Group Slide 13
Payback point
Downtime
Payback point
Additional cost to repairmachinery
Loss of availability & revenue
Profit ?
Why should we use condition monitoring?
Cost of Plant
(CAPEX)
Time
Cost &
Revenue
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October 8, 2010 SKF Group Slide 14
Condition based maintenance
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October 8, 2010 SKF Group Slide 15
Condition Based Maintenance process
System set-up
Data collection
Maintenancestrategy
Maintenance complexity
Bu
sinessimpact
1
23
4
Upgrade andimprovement
Remote analysis
Correction
AEO
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October 8, 2010 SKF Group Slide 16
Reliabilit y Issues
(Design)
Pre-Defined Prioriti es
Maintenance Strategy Project Business Goals
Preventive Maintenance ( time based )
Proactive Reliability Maintenance
( includes Predictive Maint. )
Operator Driven Reliability (
observation )
Run to Failure ( reactive maintenance )
Root Cause Failure Analys is
PM =
PRM =
ODR =
RTF =
RCFA =
Maintenance
StrategyPlant Asset Management and
Maintenance Program (Living
Program)
PM PRM ODR RTF
RCFA
PRM/ODR Collection and Analysis
Information Integration and Decision
Work Order Generation CorrectiveMaintenance
Operators
Initiators
Planning
Rolling Schedule
Standard Job Plans
and Procedures
Spare Parts
Al ignment
Work Execution
Post Maintenance Testing
Update Program
Work
Identification
Work
Control
Work
Execution
Asset Efficiency Optimisation (AEO) process
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October 8, 2010 SKF Group Slide 17
Client needs analysis - output
This provides an objective basis for the future improvement plan
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October 8, 2010 SKF Group Slide 18
Auxiliary machines:
Motors, Pumps, FansLO & HFO Purif iers, etcPeriodic data
Inaccessible Machines:Hazardous pumps & fans
Semi-Online
Condition monitoring strategy
Critical
Medium
Sudden onset
failure
Gradual
degradation
Finan
cialRisk
Time to machine failure
Examples:
Required Scan Rate FastSlowLow
High
Costp
erPoint
Critical Machines:
TurbochargersIG FansOnline
Turbo machines:
Compressors
GeneratorsCritical Online
A I t t CBM l ti
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October 8, 2010 SKF Group Slide 19
Citrix/Application Server
Citrix Server@ptitude Analyst ApplicationSKF Transaction Server
Database Server
Oracle 10g@ptitude Analyst Database
CBM Service Provider
Citrix ClientVPNTCT application
Internet
Direct connection
available only toauthorised SKF
users
Workstation onboard
Citrix Client
VPNTCT application
-
Citrix ClientVPNTCT application
SKFNetwork
Citrix/Application Server
Citrix Server@ptitude Analyst ApplicationSKF Transaction Server
Database Server
Oracle 10g@ptitude Analyst Database
SKF Data Hosting Centre
Citrix ClientVPNTCT application
Internet
Direct connection
available only toauthorised SKF
users
Workstation onboard
Visualisation ClientTCT application
RemoteShip systems
Ship Operator
Shore based personnel
-
Citrix ClientVPNTCT application
SKFNetwork
An Internet CBM solution
Oth C diti M it i t h i
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October 8, 2010 SKF Group Slide 20
Other Condition Monitoring techniques
Online monitoring:
Oil Particle count - e.g. Gearbox wear & contamination
Process data analysis - to identify abnormal operating conditions
Periodic monitoring:
Oil & Grease - for Oil condition (e.g.Transformer), Component wear
Thermographic - for Temperature checks & Electrical system faults
Ultrasonic - for Air leaks, Steam leaks, NDT, etc
Online oil particle sensor
A i hi diti
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October 8, 2010 SKF Group Slide 21
Assessing machine condition
To assess machine condition, the CM engineer requires: Knowledge of machinery & its operation
Knowledge of how to apply CM technology
Knowledge of CM analysis & decision-making
Usual Ships engineer situation: Itinerant workforce
CM is outside normal area of expertise
Lack of own central CM technical support
Difficulty to sustain quality & effectiveness
The Marine CBM solution:
Efficient CBM process using Remote Monitoring
Powerful CM technology - simple to use on board
ISO Certified & Marine experienced CM engineers
Application Engineering - support with RCFA & Improvement
Effective Contract Management Compliance, Performance & ROI
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October 8, 2010 SKF Group Slide 22
Key issues to be considered
Critical Success Factors
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October 8, 2010 SKF Group Slide 23October 8, 2010 SKF Group Slide 23
Critical Success Factors
1) Strategy: Select the right machines & systems (criticality review) Right data, right time, right quality
2) Resources: Data collection staff (disciplines, top management support) Analysis staff (onboard or remote)
3) Technology: Capable CM hardware & software technology Marine Industry acceptability & suitability
4) Activity planning: Planning & scheduling work Schedule compliance (collection, analysis, reporting)
Critical Success Factors
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October 8, 2010 SKF Group Slide 24October 8, 2010 SKF Group Slide 24
Critical Success Factors
5) Data management: Effective data transfer - reliable IT systems Centralised database with routine maintenance
6) Analysis: Quality of analysis competent staff, quality assurance process Speed & efficiency CM tools & techniques
7) Reporting: Credibility good quality advice Standardisation report format, fault codes, etc Compliance reporting on time
8) Feedback & integration: Feedback to analyst from C/E & Sperintendent Integration with CMMS where necessary
Critical Success Factors
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October 8, 2010 SKF Group Slide 25October 8, 2010 SKF Group Slide 25
Critical Success Factors
9) Reliability improvement: Availability of reliability data (event history) Focus on repetitive faults & issues Root cause analysis & elimination
10) Value for money: Contract compliance reporting - timeliness, accuracy, etc
Performance reporting - continuous improvement) Cost-Benefit analysis & reporting - cost avoidance & ROI
CBM Marine customer gap analysis
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October 8, 2010 SKF Group Slide 26
CBM - Marine customer gap analysis
CBM Marine customer gap analysis
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October 8, 2010 SKF Group Slide 27
CBM - Marine customer gap analysis
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October 8, 2010 SKF Group Slide 28
Demonstrating value
Effective CBM contract management
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October 8, 2010 SKF Group Slide 29
Effective CBM contract management
Fleet Average Overdues Since start of SKF Contract
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
01/01/07
01/02/07
01/03/07
01/04/07
01-05-07
01-06-07
01-08-07
01-09-07
01-10-07
01-11-07
01-12-07
01-01-08
01-02-08
01-03-08
01-04-08
01-05-08
01-06-08
01-07-08
01-08-08
01-09-08
01-10-08
01-11-08
01-12-08
01-01-09
01-02-09
01-03-09
01-04-09
01-07-09
Reduction in Overdue data To improve
Assurance
Effective CM system support tracking To ensure data integrity
Critical Machine
Datasheets-
To improve
Knowledge of
the Assets &
accuracy of
Analysis
Support Case Tr ends
0
5
10
15
20
25
30
35
40
45
50
1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 73 77 81 85 89 93 97 101 105 109 113 117 121 125 129 133 137 141 145 149 153 157 161 165 169 173 177 181
Week Num ber
NumberofCases
Open Cases New Cases Closed Cases
Satisfactory machines = Improved Fleet Assuranc
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October 8, 2010 SKF Group Slide 30
Satisfactory machines Improved Fleet Assuranc
Cost-Benefit reporting
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October 8, 2010 SKF Group Slide 31
Cost Benefit reporting
What information should be included in Cost-Benefit calculations?Time saved = planned versus unplanned maintenance?
Less component damage = reduced / no catastrophic failures?
Reduction in maintenance spend/budget?
Avoidance of Equipment downtime or Ship off-hire event? HS&E risk (penalty) avoided?
Historical methods for cost-benefit reporting of CBM programmes:
Estimate the cost saving for each CM recommendation (fault/event) Normally too time consuming to collect all necessary data
Range of opinion/interpretation of actual savings
Estimate the overall cost saving due to CBM contract Needs meaningful measures for Maint. & Equipment performance e.g. MTBF
Relies on accurate baselines - to measure any improvement
Requires agreement between Customer & Vendor on who delivered any savings
Benefit reporting Marine Fleet CBM
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October 8, 2010 SKF Group Slide 32
Benefit reporting Marine Fleet CBM
Total Benefits per Class
Total= $855,260
$0
$50,000
$100,000
$150,000
$200,000
$250,000
$300,000
$350,000
Class
Per Vessel
Class $289,890 $8,300 $41,670 $120,410 $68,320 $102,890 $192,000 $19,300 $12,480Per Vessel $24,158 $2,767 $10,418 $30,103 $17,080 $12,861 $8,727 $19,300 $12,480
Bird Border C_LPG P's Trader TreeE's and
Virtues
Loch
RannochGem
Total Benefits per Vessel
Total= $855,260
$0
$5,000
$10,000
$15,000
$20,000
$25,000
$30,000
$35,000
Bird Border C_LPG P's Trader TreeE's and Loch
Gem
Cost BenefitVessel Class
Total Average per vessel Average permachine per vessel
P's $120,410 $30,103 $284
Bird $289,890 $24,158 $244
Tree $102,890 $12,861 $153Loch Rannoch $19,300 $19,300 $145
Gem $12,480 $12,480 $139
Trader $68,320 $17,080 $132
C_LPG $41,670 $10,418 $104
E's and Virtues $192,000 $8,727 $95
Border $8,300 $2,767 $54
Total $855,260 $14,496 $148
SKF cost-benefit model
(CM event) adapted to
large scale report ing
Class 1
Class 2
Class 3Class 4
Class 5
Class 6
Class 7
Class 8
Class 9
C1 C2 C3 C4 C5 C6 C7 C8 C9
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October 8, 2010 SKF Group Slide 33
So how does vibration analysisactually work then?
How does Vibration Analysis actually work?
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October 8, 2010 SKF Group Slide 34
y y
Bearing Outer Ring defect
A proven technique: Especially good for steady-state conditions
Key issues: Data Quality: Variable machine speeds & loadsReliability: Operating environmentEase of use: Remote monitoring
Vibration facts of life
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October 8, 2010 SKF Group Slide 35
Static vs. Dynamic Data
Amplitude
Time
Each machine component
generates its own
characteristic Vibration
Signature
Bearing
coupling
Gear
meshGenerator
Rotor Hub
Amplitude
Frequency & Range
FFT Processing
Dynamic data(Spectra)
4 kb of data
2 bytes of
data
Static Value
(RMS)
What can we see with Vibration Analysis?
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October 8, 2010 SKF Group Slide 36
y
What Defects can be identified?
Misalignment & Unbalance
Looseness & clearances
Gear defects - lube, wear, damage
Bearing defects - lube, wear, damage
Process faults Temp, Pressure, etc
And many more
What Parameters can we monitor?
Component defect frequencies
Trends (Vel, Accel, Freq. Band, gE)
Normal level
Increasing
Unacceptable
Normal FFT spectra
Defect FFT spectra
Marine CM technology
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October 8, 2010 SKF Group Slide 37
Application software: Powerful data management & analysis features Flexible, intuitive: Easy to learn and use
Robust, proven CM system for multiple users
Wide interconnectivity, unlimited expansion Continuous investment and development
Portable hardware: Suitable for ATEX and non-ATEX use
Test signal generator (1st route point)
>200-off Quick Connect Studs & Glue
Effective calibration cycle (12-24 months)
Fixed sensors for inaccessible & hazardousareas
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October 8, 2010 SKF Group Slide 38
areas
Cargo pump room
Engine room
Pumproom
Vacpumps
Ballastpumpstbd
Ballastpumpport
Cargopumpport
Cargopumpstbd
Cargopumpcentre
Mainjunction
box
Exhaustfan
Exhaustfan
Switch box
Fixedsensors Multi-core cables
SAFETY
BARRIER
S
Online condition monitoring
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October 8, 2010 SKF Group Slide 39
Machine
signalsConvert
signal
Processing of
data & FFTsSignals, FFT data
and Trends
Analysis of
Trends & FFT
ACC
Machine Multilog IMXSensors CM Database @ptitude Software
Signal processing &data capture Data storage(1,5Mb/Machine/day) Data management& analysis
Shaft speed (rpm)
Vibration
Steering angle
Oil particles, Water, Temp Oil Pressure (gravity tanks)
Remote database access for different users
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October 8, 2010 SKF Group Slide 40
SKF CM Engineer
System conf iguration
Database management
Machine data & history
Analysis & Reporting
Contract management
Ship operator
Fleet/Class status
Ship status
Machine trend
Machine history
Web
Server
Database Server& Virtualisation
Application Server(@ptitude)
SKF Remote Monitoring CentreLive access (e.g. Citrix)
Ship operator/manager
Application-specific condition monitoring
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October 8, 2010 SKF Group Slide 41
Turbocharger
SKF Turbocharger monitor
Speedswitch
Accelerometers with separate
chargeamplifiers
DigitalControlSystem
MachineCondition
Transmitters
Onboard PC
Vibration levels& Alarm relays
T/C Efficiency & Performance:
T/C compressor intake temperatureT/C compressor air flowTemperature before T/C turbineT/C turbine gas flowCharging air pressureBarometric pressureExhaust gas pressure before T/C turbine
T/C Condition:
Vibration levels
Engine speedT/C speedSea state
Status/condition
Alarm
4-20 mAmp
O
PC
SKF remote monitoring
Internet
(Citrix/VPN)
Satellite/GPRS,
etc..
Status reportsWork orders
Alarmsetc.
Condition dataNotes/commentsetc.
PC with applicationinstalled to automaticallystore and transfer data to
SKF
Monitoring centrewith T/C reliability
database, efficiencyformulas, reportingtools and formats
etc.
Example: Turbocharger monitoring
BNC connection forPortable MicrologFFT
Benefits of CBM - Gearbox problem
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October 8, 2010 SKF Group Slide 42
Acceleration trend shows an increaseSpectrum identif ies IMS/LSS gear mesh frequency
with sidebands.
Recommendation: Inspect & replace gears
Root Causes: Lubrication, Alignment, Excess loads
Benefits of CBM - Coupling problem
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October 8, 2010 SKF Group Slide 43
Increase in velocity at both ends of generator,with dominant frequency at 1x shaft rpm.
Overall vibration and 1x shaft rpm trends show
an almost identical prof ile.
Recommendation: Inspect the coupling
(damaged)
Root causes: Excess misalignment, Shock
loads
Benefits of CBM Motor bearing problem
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October 8, 2010 SKF Group Slide 44
Increase in Enveloped Acceleration (gE)
trend. Spectra shows bearing outer race
frequency with harmonics.
Recommendation: Change the bearing
Root Cause: Electrical damage, poorinsulation
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October 8, 2010 SKF Group Slide 45
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