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Lecture_01_Intruduction_to_Plant_Mainten.pptx
- 1. Institute of ReliabilityCentred Maintenance ASSET HEALTH MANAGEMENT (AHM)
- 2. Course Outline LECTURE 01Introduction to Plant Maintenance and its Regimes LECTURE 02 Maintenance Planning, Failure Mechanisms, SHM LECTURE 03 LECTURE 04 Corrective Techniques (Balancing, Align., Looseness) LECTURE 05 Failure Mode Analysis LECTURE 06 Vibration Analysis Experiment LECTURE 07 Oil/Lube Analysis LECTURE 08 Oil/Lube Analysis Experiment Vibration Analysis (Profile & Spectrum) LECTURE 09 Infrared Thermography & Experiment
- 3. Course Outline LECTURE 10Visual Inspection (DPT, BT) LECTURE 11 Magnetic Electric Inspection (MPI, ECT) LECTURE 12 MPI, DPT, BT Experiment LECTURE 13 Ultrasonic Testing (UT), Acoustic Emission Testing (AET) LECTURE 14 Experiments on UT & AET LECTURE 15 Radiographic Inspection & Neutron Imaging LECTURE 16 Evaluation Test, Orientation of next courses
- 4. Course Outline LECTURE 01Introduction to Plant Maintenance and its Regimes LECTURE 02 Maintenance Planning, Failure Mechanisms, SHM LECTURE 03 LECTURE 04 Corrective Techniques (Balancing, Align., Looseness) LECTURE 05 Failure Mode Analysis LECTURE 06 Vibration Analysis Experiment LECTURE 07 Oil/Lube Analysis LECTURE 08 Oil/Lube Analysis Experiment Vibration Analysis (Profile & Spectrum) LECTURE 09 Infrared Thermography & Experiment Basic Maintenance & Damage Concepts Condition Monitoring
- 5. Course Outline LECTURE 10Visual Inspection (DPT, BT) LECTURE 11 Magnetic Electric Inspection (MPI, ECT) LECTURE 12 MPI, DPT, BT Experiment LECTURE 13 Ultrasonic Testing (UT), Acoustic Emission Testing (AET) LECTURE 14 Experiments on UT & AET LECTURE 15 Radiographic Inspection & Neutron Imaging LECTURE 16 Evaluation Test, Orientation of next courses Non-Destructive Testing
- 6. Introduction to Plant Maintenanceand its Regimes LECTURE 01
- 7. Lecture Outline Structures &Machines Life cycle costs Maintenance strategies Reactive maintenance Preventive maintenance Predictive maintenance Proactive maintenance Reliability centered maintenance Organizational alignment Failure defense plan
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- 10. Life Cycle Costs LifeCycle Costing (LCC) is a technique to establish total cost of ownership of a product. Material Extraction Material Processing Manufactur ing Utilization Waste Mgt. LCC
- 11. Life Cycle Costs Typicalproduct spend profile The cost of ownership of an asset or service is incurred throughout its whole life and does not all occur at the point of acquisition. Principles of LCC can be applied to both complex and simple products/projects. Acquisition Operation End of Life
- 12. Procurement Implementationand acceptance Initial training Documentation Facilities Transition from supplier Changes to business processes Withdrawal from service Life Cycle Costs Retaining Operating costs Service charges Supplier management costs Downtime/Non-availability Maintenance & repair Transportation & Handling Recurring cost Costs Involved One-off Costs Fixed Costs
- 13. Maintenance The combination ofall technical and administrative actions, including supervision actions, intended to retain an item in, or restore it to, a state in which it can perform a required function. Definition Maintenance is a set of organised activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired. Activities Repair Replacement Important for an item to reach its acceptable productivity conditions Should be carried out with lowest possible cost
- 14. History of IndustrialRevolution 1750-1830: Industrial Revolution was confined to UK Britain strictly prohibited the export of machinery, skilled workers & Techniques beyond their island empire Their monopoly couldn’t last forever, specially when some Britain's envisioned highly profitable opportunities abroad Continental European Businessmen sought to Lure British know how to their countries & offered significant incentives
- 15. History of IndustrialRevolution Industrial Revolution in Europe: ◦ William Cockerill & John Cockerill brought industrial revolution to continental Europe in Belgium by developing machine shops ◦ Belgium became the 1st country in continental Europe to be transformed economically by industrial Revolution France was slow because of his engagement with the internal Revolution In 1848: France became industrial power The Game Moves Onward… &
- 16. History of Maintenance Manufacturing machinery of that time was subject to rapidly increasing failure rates with age When failures occurred, Production would be halted for repairs and some other manufacturer would steal away the merchants who have previously bought from the “down for repairs” Although repairs were made as quickly as possible to resume production, the lost buyers could not be regained This resulted in manufacturer’s deliberately overproducing & stockpiling manufactured goods When they had sufficient backlog of goods, these manufacturers would shutdown their power plant and repair production machinery
- 17. Maintenance Result In1903: Ford started its work Build several different automobile models In 1908: Ford Model T was introduced 1908: 100 Automobile / Day 728 Minutes / Automobile 1913: 1000 Automobile / Day 93 Minutes / Automobile 1908-1913 Serious Fine Tuning in Assembly
- 18. Why We DoMaintenance? Is the purpose to fix machines that are broken or damaged? Does this describe the real purpose of maintenance? Can we view maintenance as being a way of preventing machines from failing? Do we do maintenance simply to comply with regulations or for insurance reasons? Do we overhaul machines because they are “due for overhaul” whether they need it or not? Do we need to meet production goals and thus increase profitability? When you are replacing the bearings in a motor, are you thinking of plant profitability? Understand the Goals First!
- 19. Do maintenance efficiently Domaintenance to produce the product efficiently Two Maintenance Perspectives These are not mutually exclusive goals How we view the goal ? Need to Understand Organization’s Philosophy
- 20. Understanding Organization’s Philosophy Each Organization has different Structure Priorities Success Criterion Youmust understand your organization's priorities so that you can do your part to help meet the goals.
- 21. Understanding Organization’s Philosophy Batch • Tokeep equipment running during that process is paramount. • A failure can cause huge production costs. Fishing • Fishing fleets may have a very short season. • Any problem in their factory ships can result in lost of million dollars. Power • Loss of generation can not only affect revenue, but incur penalties. • Subsidiary services are also affected. US Navy • Their concern is “ship readiness“. • Their ability to get under way when duty calls. Since it is important to detect a problem before a failure occurs, we must understand why machines fail in the first place.
- 22. Designers drafting board Poormaintenance practices and operating conditions Why Do Machines Fail? Machine Failure Start End The way machine is: Manufactured Installed Overhauled Failure starts with: Specifications Purchase Procurement & Although not all BUT Some of these factors can be controlled
- 23. Maintenance Objectives Maintenance objectivesshould be consistent with the production goals The relation between maintenance objectives and production goals is reflected in the action of keeping production machines and facilities in the best possible condition Maximising production at the lowest cost and at the highest quality and safety standards Reducing breakdowns and emergency shutdowns Optimising resources utilisation Improving spares stock control Minimizing Energy Usage Optimizing useful life of equipment
- 24. Maintenance Objectives M a i n t e n a n c e Maximising Production MinimisingEnergy Usage Optimising Useful Life of Equipment Providing Budgetary Control Optimising Resources Utilisation Reduce Breakdowns Reduce Downtimes Improving Equipment Efficiency Improving Inventory Control Implementing Cost Reduction
- 25. Importance of Maintenance Depending on industry, maintenance costs can represent between 15 and 60% of production. Estimated that one-third of all maintenance costs is wasted due to unnecessary or improperly carried out maintenance. (~$60bn out of $200bn). Difficult to compete with countries like Japan who have more advanced maintenance strategies.
- 26. Importance of Maintenance Maintenancespend is significant cost driver in today’s aircraft industry 70m hours per annum, equivalent to £7bn/annum, is invested in civil aircraft maintenance 6000 man-hours per aircraft costing about US$5.5 billion/year for the US air force and navy In 1993, inspection effort on T-38 cost US$29 per flight hour and for the F-18 US$88 per flight hour Maintenance becomes even more important with machine ageing problem!
- 27. Importance of Maintenance AircraftCost Breakdown Fuel Flight Crew Depriciation Insurance Maintenance Source: Introduction to Aircraft Design (chapter on Why do aircraft cost so much?), J.P.Fielding
- 28. Importance of Maintenance CivilAircrafts Delay Causes Passengers Government Authorities Technical (Maintenance) Ramp Handling Passengers Source: Introduction to Aircraft Design (chapter on Why do aircraft cost so much?), J.P.Fielding
- 29. Importance of Maintenance TechnicalDelay Causes Engine (Turbine) Maintenance Avionics & Electric Passenger Accomodation Landing Gear Flying Control MISC Hydraulics Structure Source: Introduction to Aircraft Design (chapter on Why do aircraft cost so much?), J.P.Fielding
- 30. Maintenance Plan On Failure Fixit when it fails Fixed Time Maintain Based upon Calendar Condition Based Maintain Based Upon known Condition Design Out Identify & design Out root cause of failure
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- 33. Reactive Maintenance If itisn't broke, don’t fix it No money spent on maintenance until machine or structure stops working Sounds Interesting ..... BUT AT THE COST OF HUGE MAINTENANCE BUDGET!
- 34. Breakdown Maintenance asReactive Maintenance ?? Control is lost when breakdown maintenance is employed. This is why it is often termed“ reactive” maintenance. The plant reacts or responds to equipment failures rather than anticipating them, planning for them or avoiding them altogether.
- 35. Reactive Maintenance Reactive Maintenanceis: Unplanned Disruptive Interruption Costly ineffective response option Allowing this to prevail as an existing response increases the overall cost and complexity of managing the system. Highly Undesirable
- 36. Reactive Maintenance Objectives Maximisation ofthe effectiveness of all critical plant systems Elimination of Breakdowns Elimination of Unnecessary Repairs Reducing deviations from optimum operating conditions Steps involved Fault Detection Fault Isolation Fault Elimination Verification of Fault Elimination Several actions should be taken, like adjusting, aligning, calibration, removing, or replacing
- 37. Prerequisites Reactive Maintenance Accurate identification ofProblems Effective planning Adequate time to repair Proper Repair Procedures
- 38. Prerequisites Reactive Maintenance Effective Planning Depends On Skillsof the planners Well developed maintenance database Complete repair procedures Required labour skills, specific tools
- 39. A Plant inReactive Mode When a plant is primarily using run to failure maintenance we can say they are caught in a reactive mode They are always reacting to problems and situations. When visiting a plant in this mode one will find it to be dirty and disorganized. Employees will complain that they are over worked or always “too busy” to change how they do things. There will likely be a high rate of injuries, spills, fires and other damage caused by unexpected failures.
- 40. A Plant inReactive Mode Due to reactive mode, Plant is always behind and trying to catch up to meet production demands. They are not running the plant, the plant is running them and this is a frustrating environment to work in. Most of us prefer to work in a predictable environment in which we feel we are in control of the situation. A plant in reactive mode is clearly not that type of environment. Morale will likely be low.
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- 43. Reactive Maintenance Requiresno pre-care of the plant Little management apart from organizing labor and stores If applied correctly, it can be very cost effective Advantages of Reactive Maintenance are Outraged by its Disadvantages ADVANTAG ES:
- 44. Reactive Maintenance Mostexpensive maintenance method No Failure warning: Safety threat Environmental Risk High spare parts inventory High overtime costs Long machine downtime Spare machines required Low production availability Large standby maintenance team Knock-on effects on other machines and overall loss of production Secondary/Consequential damage may occur DISADVANT AGES: Bearing Shaft Pump
- 45. Preventive Maintenance Time DrivenMaintenance Time between maintenance decided on statistical data Hour of Operations Based On Elapsed Time Bath Tub Curve
- 46. Preventive Maintenance Preventative maintenanceis defined as regularly scheduled repair of components and equipment. It may consist of: Scheduled inspection Cleaning, lubrication Parts replacement Repair of components Preventative maintenance is time based intervention according to a prescribed schedule.
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- 48. The unfortunate realityis that there is a high probability of failure immediately after an overhaul due to: Infant Mortality Infant Mortality Poor lubrication Incorrect parts being installed Poor alignment and balance
- 49. Estimated Life VsProbable Life The probability of failure increases before it "should" fail, so the length of the flat section needs to change. The reality of a failure rate is that it is random. Failure of a component occurs after a time that cannot be predicted. The task is to schedule the maintenance within the "probable life" period. Unfortunately, we do not know what that period is, or how quickly the machine may fail once the wear-out phase begins.
- 50. Risk is BalancedAgainst Cost If the maintenance is put off too long, the machine may fail If the overhaul is performed too early, it becomes too expensive, in labor, lost production and parts
- 51. Preventive Maintenance The machinesare as likely to fail after two months as they were in 22 months. The concept of Calendar-Based Maintenance contains flaws
- 52. A Plant inPreventive Mode Machines will still fail due to the fact that 89% of failure modes are random Because machines are still failing, the plant is still in reactive mode, however, they also have a huge amount of preventive maintenance work scheduled that they have to do. There will be stress, overtime and probably some resentment towards planned maintenance tasks These planned maintenance tasks are also costly in terms of manpower, spare parts and downtime – even if it is planned downtime.
- 53. Preventive Maintenance Types Preventive Maintenance Routine Maintenance Running Maintenance Opportunity Maintenance Window Maintenance Shutdown Preventive Maintenance •Maintenanceactivities that are repetitive and periodic in nature •Lubrication, cleaning, and small adjustment •Maintenance activities that are carried out while the machine or equipment is running •Activities that are performed before the actual preventive maintenance activities take place. Set of maintenance activities that are performed on a machine or a facility when an unplanned opportunity exists during the period of performing planned maintenance activities to other machines or facilities. Set of activities that are carried out when a machine or equipment is not required for a definite period of time. Maintenance activities that are carried out when the production line is in total stoppage situation.
- 54. Preventive Maintenance Factors affectingefficiency of PM Need for adequate staff in order to perform maintenance Right choice of production equipment & machinery that is suitable for the work environment & capable of tolerating the workload Required staff qualifications and skills, which can be gained through training Support and commitment from executive management to the PM programme Proper planning and scheduling of PM programme Ability to proper apply the PM Programme
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- 56. Good Examples ofPreventive Maintenance
- 57. Preventive Maintenance Reducesfailures (compared to the on-failure strategy) It uses the workforce cost-effectively with planned work schedules Allows work to be planned well in advance It can only be applied effectively on fixed time intervals where the deterioration is age related Scheduled maintenance costs are around one-third of run-to-failure costs ADVANTAG ES:
- 58. Preventive Maintenance Themaintenance activity and associated costs will increase Generally based on bathtub curve – not reliable in many cases. The actual maintenance activity can sometimes cause failures itself May be replacing a component that still has useful life Treats all similar machines as same. DISADVANT AGES:
- 59. Predictive Maintenance Regular Machine Monitoring TechnologySkills Diagnostic Data Performance Data Maintenance Histories Operations Data Design Data
- 60. Machines warn abouttheir failure
- 61. 80 82 84 86 88 90 92 94 25 30 3540 55 60 65 % Predictive maintenance improves production line performance Predictive maintenance in % of total maintenance Machine availability in %
- 62. This include mostrotating machines with rolling element bearings. We don’t know when the bearings will fail but they do let us know when they are damaged or failing. Plant in Predictive Mode The plant is no longer in a reactive mode, so most work is planned Less overtime and workers are not stressed out They come in to work every day and they know what they need to do, there are few surprises Neat and clean workplaces
- 63. Predictive Maintenance Designof system Monitoring equipment Staff training Labor costs for measurement and analysis COSTS: Elimination of unexpected & Secondary breakdowns Increased time between services Reduction of spare part stock Reduction in insurance premium SAVINGS:
- 64. Predictive Maintenance ADVANTAG ES: Equipmentcan be shut-down before severe damage occurs Alternatively, equipment can be run to failure if desired Production can be modified to extend the unit life – For example: Decrease the load on equipment so that it can continue to run until the next planned plant shutdown The required maintenance work can be planned, with labor organized, spares assembled, etc. Reliability Quality Profitability Productivity
- 65. Predictive Maintenance Extremely Costlyif Implemented Incorrectly! The drawback of predictive maintenance is that it depends heavily on information and the correct interpretation of the information. DISADVANT AGES:
- 66. Proactive Maintenance Elimination ofconditional failures through the identification of the root cause condition that initiates the failure cycle. GETTING TO THE ROOT OF PROBLEM It commissions corrective actions aimed at the sources of failure. Designed to extend the life of mechanical machinery
- 67. Justification of ProactiveMaintenance • A predictive maintenance program gives a warning of bearing failure, and then the replacement can be ordered and a repair scheduled. • That's great, but why did the bearing fail?
- 68. Plant in ProactiveMode Similar behavior as in care of predictive maintenance The condition of most of the plants assets is known because CM technologies are being employed. Machines should not fail unexpectedly - at least not frequently. One removes the root causes of many failures thus increasing reliability and extending the life of the machines
- 69. Proactive Maintenance One-offmaintenance activity It reduces failures It will lead to increased production It will remove or reduce the need for maintenance ADVANTAG ES:
- 70. Proactive Maintenance Largedesign changes can be costly Plant outages may be required to effect design changes Unless root causes of failure are fully understood, changes may be ineffectual, or potentially detrimental There are sometimes unknown ‘knock-on’ effects of design changes that can cause further difficulties later on DISADVANT AGES:
- 71. Condition-Based Maintenance Condition-Based Maintenance ProactiveMaintenance Predictive Maintenance Root Causes Failure Symptoms & Faults Balancing/Alignment Tools Viscosity/Contamination Monitoring Wear Debris Analysis Vibration Analysis Thermography/MCS Fault Free Machine Life Extension Early detection of Faults & Failures Strategy It Looks For! Example Technologies Employed Benefits Sought
- 72. Maintenance Strategy Technique Needed HumanBody Parallel Proactive Maintenance Monitoring and correction of failing root causes, e.g., contamination Cholesterol and blood pressure monitoring with diet control Predictive Maintenance Monitoring of vibration, heat, alignment, wear dibris Detection of heart disease using EKG or ultrasonics Preventive Maintenance Periodic component replacement By-pass or transplant surgery Breakdown Maintenance Large maintenance budget Heart attack or stroke Maintenance Strategy – Human Body Parallel
- 73. Key Facts Allfour maintenance strategies are required to make an effective Maintenance Plan. All four maintenance strategies have advantages when implemented correctly. All four maintenance strategies have disadvantages when implemented incorrectly. The appropriate strategy can only be chosen when the reasons and consequence for equipment failures are fully understood.
- 74. 0 10 20 30 40 50 60 US $ Realtive Cost51 30 12 7 Breakdown Planned Predictive Proactive
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- 76. Maintenance Regimes Comparison MaintenanceStrategies Reactive Maintenance Preventive Maintenance Predictive Maintenance Others
- 77. 0 10 20 30 40 50 60 Reactive Preventive PredictiveProactive % Maintenance Efforts Focus – Currently Time Spent on Each Maintenance Type All Industry Now
- 78. 0 10 20 30 40 50 60 Reactive Preventive PredictiveProactive % Source: Deloitte & Touche , CSI Survey Maintenance Efforts Focus – In Future All Industry in 5 years Time Spent on Each Maintenance Type All Industry Now
- 79. 0 10 20 30 40 50 60 Reactive Preventive PredictiveProactive % All Industry in 5 years Benchmark Now Time Spent on Each Maintenance Type All Industry Now Maintenance Efforts Focus – Benchmark Source: Deloitte & Touche , CSI Survey
- 80. 80 Respond to Events Plan all work Organisational Discipline Reactive Domain Planned Domain Proactive Domain Benchmark (abilityto predict, plan, schedule) (defect elimination) (differentiation, integration & alignment) (improve fix it capabilities) Don’t Fix it Fix it after it Breaks Fix it before it breaks Improve it Differentiate Organisational Learning Where are you along that journey? Journey to Success
- 81. RM PM RM = ReactiveMaintenance PM = Preventive Maintenance In the past - “fix-it-when-it-breaks” concept Highly reactive coupled with time-based preventive maintenance and overhauls – whether machines needed it or not Conventional Maintenance Culture
- 82. RM PM RM PdM PM RM = ReactiveMaintenance PM = Preventive Maintenance PdM = Predictive Maintenance Today, more plants are reducing maintenance by adding predictive technologies to help eliminate unscheduled downtime Present Day Maintenance Culture
- 83. RM = ReactiveMaintenance PM = Preventive Maintenance PdM = Predictive Maintenance PaM = Proactive Maintenance RM PM RM PdM PM PaM PM PdM RM With a strategically balanced approach, Maintenance Optimization drives the achievement of mission critical objectives - such as becoming the Best Cost Producer With Maintenance Optimization
- 84. Reliability Centred Maintenance Fourcomponents of Reliability Centred Maintenance Program Reliability Centred Maintenance Reactive Maintenance Preventive Maintenance Proactive Maintenance Predictive Maintenance Small items Non-Critical Inconsequential Unlikely to Fail Redundant Subject to Wear-Out Consumable Replacement Failure Pattern Known Small items Non-Critical Inconsequential Unlikely to Fail Redundant Subject to Wear-Out Consumable Replacement Failure Pattern Known
- 85. Framework of ReliabilityCentred Maintenance Is Asset’s Reliability Acceptable? Is Asset’s Mission Critical? Is the Asset expendable? Continuous Improvement Run the Asset to Failure Will improved maintenance cost effectively achieve reliability objective? Will redesign cost effectively achieve reliability objective? Deploy redundancy Deploy redesign Deploy advanced maintenance tactics YES YES YES YES NO NO NO NO NO YES
- 86. Reliability Based Maintenanceas a breakthrough strategy in Asset Improvement The function of maintenance is not to simply maintain, but provide reliable production capacity and to extend the life of plant assets at optimum cost. Reliability Centred Maintenance Objective
- 87. 1. Elimination ofplant downtime 2. Condition of equipment known. Machinery condition information provides status of existing and future plant capacity. 3. Commitment to extend the useful life of equipment through the identification and elimination of failure modes 4. Development of work teams and team goals combining maintenance and operations. 5. Maintenance & Operations are partners in providing and utilising plant capacity. 10 Goals of Reliability Centred Maintenance
- 88. 6. Maintenance isknowledge–based , providing for improved decision making. 7. Commitment to create a learning organisation where mistakes are not repeated. 8. Development of a systematic approach for each situation ( predictive, proactive, preventive and reactive). 9. Both management and operation staffs develop a plan for action and improvement. 10. Maintenance function has long term objectives, where the gains are sustained year after year. 10 Goals of Reliability Centred Maintenance
- 89. Increased Productivity(2-40%) Reduced maintenance expense (7-60%) Improved product quality (rework & scrap rates reduced 5-90%) Extend equipment life (>1- 10x life extension) Reduced spares inventory (10-60%) Increased inventory turns (up to 75%) Reduced finished goods inventory Reduced energy consumption (5-15%) Increased safety & environmental protection Key Benefits of Reliability Centred Maintenance
- 90. Work Closeout Work Execution PdM Equip. Condition Directed Feedback PAM RootCause Analysis Identifies Equip. Condition Asset Optimization RM Equipment Failures Scheduled PM Tasks Feedback Asset Optimization Process
- 91. 65 % 30 %85 % 100 % Ratio of planned to total maintenance Maintenance cost Index Impact of Planning on Maintenance Cost
- 92. Maintenance in theOrganization Traditional Maintenance Reactive /PM Maintenance Manager TPM /TQM Production Manager Investments Modifications Engineering Manager Plant manager Predictive Maintenance Proactive Maintenance Root Cause Failure Analysis Failure Defence Plan Asset Manager
- 93. To select theoptimum and most cost effective mix of maintenance tools and methods to guarantee machine reliability. Failure Defence Plan The goal of the failure defence plan is to assign techniques which will warn or defend against equipment failure.
- 94. Worth Kettle Reactor pump Heat Exchanger M Functional Failure Heavyseal leak, Hot wart coming out pump. Failure Effect Reactor must be stopped. Empty reactor. Product/Time loss. Failure Mode Carbon seal ring of single mechanical seal was broken.. Failure Mode &Effects Analysis Failure Cause Due to an unbalance of the pump seal ring has broken.. Failure Defence Task 1. Balancing/Vibration analysis every 3 months 2. Improve seal design. Reactor Pump Failure Defence Plan