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M6 BLACKBELT PROJECT Rev 6.4

This document provides details of a Six Sigma project aimed at reducing maintenance interruptions and increasing the mean time between failures (MTBF) of critical equipment at a refinery. The project focuses on pumps in critical units like crude distillation and residue manufacturing plant. The document defines the problem statement, goals, scope and assumptions. It presents analysis of failure data to identify the top 3 pumps for study based on number of repeat failures and their impact. Process flow, stakeholder mapping, communication plan and initial measurement efforts like fishbone diagrams and 5 whys are also included. The project aims to improve reliability and availability of critical pumps through root cause analysis and elimination of repeat failures.

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Reducing Maint Interruptions / Increasing MTBF of Critical Equipment ( Six Sigma Black Belt Project)
2 Start Date : April 2010 Black Belt : Vijay S.Dhonde Master Black Belt : Naveen Narayanan Project sponsor : DGM Maintenance Team Members : K K Nanduri / John Bosco Neelesh Bhagwat & RC Agarwal (BB) for guidance ControlImproveAnalyzeMeasureDefine
DMAIC • Focus on reducing variation • Involving cross functional teams • Concentration on processes rather than isolated events • Share the experience Define Measure Analyze Improve Control Opportunity / project Current performance Root causes To eliminate root causes To sustain gains
4 Key Lessons Learned • Importance of working in Cross-Functional Team • Concentration on processes rather than isolated events gives sustained solutions (May be the word process generates Fear and Resistance). • Visibility through out the implementation process makes acceptability of the project by majority. • DMAIC Methodology as problem solving technique could be applied to all critical issues. • Opportunity to practice powerful analytical tools like FMEA, Cause & Effect, SCAMPER etc.
5 Project SIPOC VOC Diagrams1 DEFINE ControlImproveAnalyzeMeasureDefine
Present Definition of Failure Failure starts here Equipment Condition P Potential Failure F Functionally failed Today’s definition of failure Equipment Broken Time The inspection and correctiveThe inspection and corrective task must be completed withintask must be completed within the P-F interval.the P-F interval.P-F Interval Maximize interval between Potential Failure and Functional Failure Importance of This Project
Importance of This Project P P-F Interval Failure Equipment not performing intended function “Functionally failed” “Normal state” Potential Failure Intended Function Design Risk to business (consequence) increase as we move along P-F Curve
8 Project Assumptions ControlImproveAnalyzeMeasureDefine What is meant by Critical Equipment? An Equipment is considered critical where either it does not have any standby or it’s non-availability would greatly affect plant throughput and it’s failure will have potential threat to safety & environment. What is Maintenance interruption? An event or condition in which the equipment is taken out of service or stopped for attending an abnormal state or part by maintenance however small may the condition be is termed as an interruption. What is MTBF and its interpretation? Mean Time Between Failure is an average uptime available for an equipment. In other words it is the average time an asset will function before it fails. In Refinery the MTBF is considered for equipments overhauled at Machine Shop only.
9 Project Assumptions ControlImproveAnalyzeMeasureDefine Why consider only equipment overhauled at shop for MTBF? • When pump is overhauled at shop it will be critically examined and assembled. • Also Machine shop follows standard procedures laid down by Original Equipment Manufacturer and Overhauling activity is carried out by skilled Maint personnel. How failure of rotary equipment is recorded? An equipment failure is recorded through basically in two modes in SAP. • One by malfunction report generated by Operations through SAP Notification type M2. • Another by Rotary Recommendation generated by Rotary Cell through SAP Notification type M6.
10 Project Assumptions ControlImproveAnalyzeMeasureDefine What base line data is being considered for the analysis? Notifications or Job generation by Rotary Cell through SAP type M6 is being considered for analysis. Why Rotary Reco (SAP Type M6) alone is considered for analysis? • Data in type M6 is highly authenticated, precise and created by a trained professional. • Data in type M2 majority of times incomplete and sometimes duplicate in nature created by working level person. • Type M2 notification data is more of descriptive in nature, while M6 data comprises measurable data. • While generating notification through M6 analysis would be conducted based on condition monitoring of the equipment by the in charge. • Also, data shows over 90% of cases bearing failures were captured in M6 Data
Failure Pattern Identification (Equipment Wise) Frequency 596 254 34 Percent 67.4 28.7 3.8 Cum % 67.4 96.2 100.0 Equipment Comp/FansMotorsPumps 900 800 700 600 500 400 300 200 100 0 100 80 60 40 20 0 Frequency Percent Pareto Chart of Equipment Pumps contribution in failure pattern being higher study will be carried out on pumps only ControlImproveAnalyzeMeasureDefine
12 • As per above Pareto diagram more recurring failures are observed in Primary, Secondary Processing and RMP units. • It is evident process units cover more than 80% of failure list. Failure Pattern Identification (Complex wise) ControlImproveAnalyzeMeasureDefine C2 168 161 154 79 24 9 Percent 28.2 27.1 25.9 13.3 4.0 1.5 Cum % 28.2 55.3 81.2 94.5 98.5 100.0 C1 Other Offsites Utilities RM P Secondary Processing Prim ary Processing 600 500 400 300 200 100 0 100 80 60 40 20 0 C2 Percent
  Project Charter Project Description Reducing Maintenance Interruptions and Increasing MTBF of Critical Pumps of Crude Distillation Unit and RMP Business Case Improved equipment availability through reduction in repeat failures can greatly contribute to cost reduction, throughput gain and compliance to environmental and safety standards. Also availability of the Rotary equipments is essential to achieve MOU target of Crude processing of the refinery. Cost of repeat failure alone contributes to over Rs 64 lakh which is around 13% of total expenditure for subject period of 3 year this besides loss of through put on account of non availability of Eqpt. Problem Statement In the 36 month period under study (April 2007-March 2010), 103 out of 594 pumps in plant areas have been taken out of service more than twice for maintenance purposes, leading to reliability and availability issues in plant operation. Such repeated maintenance activities would lead to lower MTBF values( the present benchmark of 5.2 years) and will be a potential threat to plant uptimes. Process Owner DGM Maintenance Scope Start: Stop: Excludes : Condition Monitoring and Notification generation Recheck and closure of notification.. Failures based on malfunction reports   Project Goals Metric MTBF Baseline Data Repeat Failure list of Pumps through M6 Current Average MTBF of selected list = 7.2 Months Goal Increase Average from 7.2 to 12 months Entitlement MTBF 36 months             ControlImproveAnalyzeMeasureDefine
15 Expected Tangible Benefits Top 3 critical tags for different failure modes out of identified list will be taken up for root cause analysis. Such process of avoiding repeat failures would not only result in lower maintenance cost but also help maintain optimum plant through put. One day shutdown of CCU on account of non-availability of critical bottom pump would result in loss of over Rs.2.1 Cr direct cost (CCU Value addition Rs 7000 per MT Waxy processing), can be avoided. Expected Intangible Benefits With higher equipment availability, Process can have flexible operation. Once time spent on repeat jobs reduced, better focus can be given to other reliability improvement initiatives. Also improvement plans can be extended to other parts of the refinery. Team members KK Nanduri, John Bosco, Neelesh Bhagwat & RC Agarwal ( BB for guidance) Support Required Rotary Cell, Operations and Technology Risks/ Constraints Environmental conditions and operating at Turn down due to non availability of plant through put can greatly affect MTBF of rotary equipments. ControlImproveAnalyzeMeasureDefine Project Charter
16 CTQ Drill Down Tree ControlImproveAnalyzeMeasureDefine Enhance Availability of Critical Equipment for Ops By Reducing MTTR By Improving MTBF Increase Equipment uptime Reduce No of Failures Reduce No of Repeat failures Reduce No of repeat failures or increase MTBF from 7.2 to 12
17 Customer Output Process Input Supplier 1. WHO are your primary customers? (From Step A) 2. WHAT does the customer receive? (Think of their CTQ’s) 3. What STEPS are Included in the Process today? (high level) 4. What is provided to START the process? 5. Who PROVIDES the input? (Who) (Nouns) (Verbs) (Nouns) (Who) Equipment in Operation / Condition Monitoring Analysis and Release of type M6 Notification Equipment Isolation and Handover for Maint Activity Completion by Area Maintenance History / Data Updation by Area Maintenance Notification Closure Recheck / Condition Monitoring Availability of equipment Operations Route Readings / Plant Calls Area Operations C O P I S ControlImproveAnalyzeMeasureDefine
18 ControlImproveAnalyzeMeasureDefine Process Flow of Notification Generation Data AnalysisRecommendation release (SAP M6) Start Data Collection Site activities based on Reco Close Data (history) Updation Reading acceptable ? NOYES Follow up reading Route / Plant Call
19 X = Where this Stakeholder IS TODAY on the Project O = Where this Stakeholder NEEDS TO BE on the Project * When Populating the Stakeholder, consider the ARMI: • A= Approver of team decisions • R= Resource or subject matter expert (ad hoc) • M= Member of team • I= Interested Party who will need to be kept informed Stakeholder ARMI* Strongly Opposed Opposed Neutral Supportive Strongly Supportive DGM Maint A X/O Ops PP R X/O Ops SP R X/O Ops RMP R X/O Rotary Cell R X/O Technology I X/O Stakeholder Analysis ControlImproveAnalyzeMeasureDefine
Target Audience Content Frequency Delivery Method Top Management Project Progress Report As per Project Road Map Steering Committee Review Meeting Project Sponsor / Champion. DGM (Maint.) Project Progress, Issues, Milestones Achieved, Next Steps. End of Each Phase Project Review Meeting. Key Stakeholders as Chief Ops Mgr (SP) / Chief Ops Mgr (PP) Project Status, Issues, Barriers, Milestone Achieved, Next Steps. Bi-weekly Status by e-mail Operators / Technicians Project Needs, Issues, Barriers, Progress Done, Changes Done, Next Steps Need based As and When required discussion at site Engineering Team Members Project Needs, Issues, Barriers, Performance of Machines. weekly Co-ordination Meeting. Communication Plan ControlImproveAnalyzeMeasureDefine DMAIC
Data Pareto Patterns Capability MEASURE DEFINE ANALYZE IMPROVE 21 ControlImproveAnalyzeMeasureDefine
Identification Process for Top 3 Critical Pumps for Study Total Repeat Failures List of Over two Failures List segregated based on criticality index Actions yet to be initiated Reduced list based on severity index Top 3 source of failures 594 103 23 16 8 3 ControlImproveAnalyzeMeasureDefine
Focused pumps for Study Equipment Failure Cost (in Lakhs) MTBF (Months) 001G10S - CRUDE OIL SEAL 6.8 5.1 001G11S - LONG RES BRG / OTHER 145 4.0 132P266 – EXCS WAXY BRG 36 4.0 Process Sigma for above 3 Critical Equipments 3.2 ControlImproveAnalyzeMeasureDefine
List of Top 8 Equipments for Study Equipment Failure COST MTBF 001G10S - D3 BOTTO SEAL 541,453 5.1 001G1 - CRUDE OIL SEAL 984,054 7.2 001G11 - LONG RESI BRG 3,394,683 7.2 001G11S - LONG RES BRG / OTHER 14,437,919 4.0 001G12 - H.G.O. SEAL 533,272 7.2 001G31 - HEAVY KER OTHER 620,711 5.1 098P803B - FLASHED SEAL 546,555 6.0 132P266B BRG 3,613,592 4.0 BRG Bearing Failure OTHER SEAL Mechanical Seal Failure HIGH VIBRATION, PIPING, Internals, Seizure, Accessories ETC ControlImproveAnalyzeMeasureDefine
Back ground analysis For Identifying top 3 Critical pumps for study Back Up Slides for Measure Phase ControlImproveAnalyzeMeasureDefine
Process Capability Index Number of defect opportunities per unit (Failure Modes) O 3 Number Of Units (Notifications for pumps under study) N 16 Number Of actual defects (No. of Pumps under study) D 3 Defects per opportunity DPO=D/(N*O) 3/(3*16) = 0.042 DPMO DPO * 1000000 42000 Process Sigma (From table) 3.2 ControlImproveAnalyzeMeasureDefine DMAIC
FM EA Regression DOE MASURE DEFINE ANALYZE IMPROVE 2 MEASURE ControlImproveAnalyzeMeasureDefine
ControlImproveAnalyzeMeasureDefine Applicable Failure Modes in Centrifugal pump are • Insufficient Capacity • Insufficient Pressure • No liquid delivery • Vibration and Noise • Short Bearing Life • Short Mechanical Seal Life Applicable Modes being analyzed for present case are • Vibration and Noise • Short Bearing Life • Short Mechanical Seal Life Failure Modes in Pumps
ControlImproveAnalyzeMeasureDefine Cause & Effect Fishbone – Seal Failure Seal Failure Mechanical Environment Measurements Methods Material Machines Personnel Contaminated lube oil assembly procedure Non adhering to bearing assembly procedure Non adhering to seal Use of incorrect BOM reconditioned spares Use of Defective Spares / Improper bearing CW system Incorrect support / piping installation Pump Failure out of improper pump assembly Incorrect lube oil level - brg guard/ leveler Misalignment in Hot condition Frequent Pump Change over -No defined policy Improper Seal Flushing - NA to checklist Improper Seal Flushing - Orientation of piping Improper Seal Flushing - Chocking of piping Incorrect Seal Design Lower flow operation - lower plant throughput Lower flow operation - ignorance about P-Q Cavitation - process upset Use of non-calibrated instruments
ControlImproveAnalyzeMeasureDefine Cause & Effect Fishbone – Bearing Failure Failure Bearing Environment Measurements Methods Material Machines Personnel Pump cavitation / Process upset Dirt/Moisture in housing Distorted casing Bent Shaft / Run Out Un Balance - Pump Defective Spares Improper bearing CW system External Corrosion Excessive Load on the pump Deviation from design conditions Incorrect Bearing Design Absence of Lubrication Improper Lubrication Improper Pump Installation Improper Brg Installation Misalignment Lower flow operation Measurement Improper Vibration
Mechanical Seal Failure Analysis ControlImproveAnalyzeMeasureDefine
ControlImproveAnalyzeMeasureDefine Main Cause Why-Why Analysis ( 1st ) Why-Why Analysis (2nd ) Misalignment 1. Alignment does not take process conditions 2. Excessive piping strain 3. Erratic instrument reading 1. Improper skill or knowledge on Hot service 2. Improper piping / support installation 3. Absence of Instrument Calibration Wrong Mechanical Seal assembly 1. Improper personnel skill 2. Use of Non-Standard Materials 1. Lack of awareness or focused training 2. Not adhering to Standard Procedure / spare parts Damage to bearings during installation 1. Improper use of tools and tackles 2. Use of defective bearing 1. Not adhering to Standard Procedure 2. Use of Non-Inspected (by SKF) bearing Bearing Failure while in operation 1. Improper Lube oil Level 2. Improper Lube Oil Quality 3. Excessive Cooling or Heating of housing 1. Defective bearing isolator / leveler 2. Use of contaminated oil / Handling issue 3. Improper cooling system / Choice of lubricant / defective oil ring or splasher Suction Pressure variations / Low flow / Pump Cavitations 1. Operation outside acceptable range 2. Operation much lesser than design point 3. Deviation in operating parameter/ Cavitations 1. Absence of suction surge vessel 2. Pump too big to handle lower throughput 3. Process upset Improper flushing of seal 1. Connected piping is chocked 2. Improper piping orientation 1. Not adhering to procedure / checklist 2. Ignorance or insufficient knowledge Frequent change over of the pump 1. Plant follow 15 day cycle it is too frequent to adopt. 1. No defined practice available Root Cause Analysis (Mechanical Seal Failure)
ControlImproveAnalyzeMeasureDefine MECHANICAL SEAL FAILURE - CAUSE Category Severity Occurrence Detection RPN Improper Seal Flushing - Chocking of piping Method 9 9 9 729 Improper Seal Flushing - Orientation of piping. Method 9 9 9 729 Pump Suction Pressure Variation Method 9 9 9 729 Frequent Pump Change over -No defined policy Method 9 9 9 729 Misalignment in Hot condition Method 9 5 7 315 Cavitations out of process upset Method 9 4 8 288 Lower flow operation – Design Limitations Method 9 4 8 288 Lower flow operation - lower plant throughput Method 9 4 8 288 Incorrect lube oil level - Brg guard/ leveller Person 9 4 8 288 Cause Prioritization (Mechanical Seal Failure)
Cause “For Improper Mechanical Seal Flushing Plans” Cause Validation (Mechanical Seal Failure) ControlImproveAnalyzeMeasureDefine
Improper Seal Flushing Plans in CDU G10/10S/G2/G2S/G11/G11S Original Seal Flushing Plan API 31 Present Seal Flushing Plan API 12 Cyclone Separator Replaced by Strainer ControlImproveAnalyzeMeasureDefine
Improper Seal Flushing Plans Cyclone Separator Dirt goes back to suction Strainer dirt remains and chocks the path in due course ControlImproveAnalyzeMeasureDefine
CYCLONE SEPARATOR API 31 Process liquid is recirculated through a cyclone separator to the seal. Solid particles are centrifuged through cyclone separator and sent back to suction. The Plan is specified for services containing solids with a specific gravity at least twice that of the process fluid. Normally cyclone separators do require preventive Maintenance checks otherwise finer particles reach to the seal faces. The finer particles can enter between the seal faces and cause damage to the seal. Improper Seal Flushing Plans STRAINER API PLAN 12 Process liquid is recirculated through a strainer to the seal. Solid particles are separated through fine filter element or mesh. This plan is used generally with clean liquids. Normally strainers do require periodic preventive Maintenance checks. Otherwise strainer element gets chocked during course of time and restricts liquid movement. Such scenario makes dry run of seal faces and cause damage to the seal. ControlImproveAnalyzeMeasureDefine
Bearing Failure Analysis ControlImproveAnalyzeMeasureDefine
Bearing Failure Modes ControlImproveAnalyzeMeasureDefine Major Causes
ControlImproveAnalyzeMeasureDefine Main Cause Why-Why Analysis ( 1st ) Why-Why Analysis (2nd ) Misalignment 1. Alignment does not take process conditions 2. Excessive piping strain 3. Erratic instrument reading 1. Improper skill or knowledge on Hot service 2. Improper piping / support installation 3. Absence of Instrument Calibration Oil Contamination 1. Improper personnel skill 2. Non-Standard Methods / Oil Handling 1. Lack of awareness or focused training 2. Not adhering to Standard Procedure / tools Damage to bearings during installation shop 1. Improper use of tools and tackles 2. Use of defective bearing 1. Not adhering to Standard Procedure 2. Use of Non-Inspected (by SKF) bearing Lubrication 1. Improper Lube oil Level 2. Improper Lube Oil Quality 3. Excessive Cooling or Heating of housing 1. Defective bearing isolator / leveler 2. Use of contaminated oil / Handling issue 3. Improper cooling system / Choice of lubricant / defective oil ring or splasher Suction pressure variations / Low flow or Cavitation 1. Operation outside acceptable range 2. Operation much lesser than design point 3. Deviation in operating parameter/ Cavitation 1. Absence of suction surge vessel 2. Pump too big to handle lower throughput 3. Process upset Overloading 1. Casing distortion 2. Improper piping orientation 1. Improper pump nozzle load design 2. Ignorance or insufficient knowledge Frequent change over of the pump 1. Plant follow 15 day cycle it is too frequent to adopt. 1. No defined practice available Root Cause Analysis (Bearing Failure)
ControlImproveAnalyzeMeasureDefine BEARING FAILURE - CAUSE Category Severity Occurrence Detection RPN Misalignment in Hot condition Method 9 9 9 729 Improper Lubrication – Defective ring or splasher Method 9 9 9 729 Improper Lubrication – Choice of lubricant Method 9 9 9 729 Improper Lubrication – Handling issues Method 9 9 9 729 Frequent Pump Change over -No defined policy Method 9 9 9 729 Lower flow operation – Suction pressure variations Method 9 9 9 729 Incorrect lube oil level - Brg guard/ leveller Method 9 4 8 288 Lower flow operation – Design issues Pers 9 4 8 288 Incorrect lube oil level - Brg guard / leveller Method 9 4 8 288 Cause Prioritization (Bearing Failure)
Cause Mis-Alignment in Hot Condition & Improper Lubrication Cause Validation (Bearing Failure) ControlImproveAnalyzeMeasureDefine
Mis - Alignment in Hot Condition (G11 of CDU)
Mis - Alignment in Hot Condition (G11 of CDU) ControlImproveAnalyzeMeasureDefine CDU -001G11** 001G11** -P1H PumpInboardHorizontal RouteSpectrum 09-Apr-10 11:47:31 OVERALL=10.23V-DG PK = 10.13 LOAD =100.0 RPM=2949.(49.16Hz) 0 10000 20000 30000 40000 50000 0 1 2 3 4 5 6 7 FrequencyinCPM PKVelocityinmm/Sec Freq: Ordr: Spec: 2887.5 .979 3.385 1XRPM 2XRPM 3XRPM
Improper Lubrication (132P266B of LOBS)
2-3mmabove OilLevel Incorrect Oil ring or Splash Disc • Under - Lubrication • Poor lube oil circulation • Improper bearing cooling • Improper level or overheating • Oil blackening • Premature bearing failure Improper Lubrication (Bearing Failure) ControlImproveAnalyzeMeasureDefine Oil ring position as of now in some of the LOBS Pumps DMAIC
SCAM PER MASURE DEFINE ANALYZE IMPROVE 2 MEASURE Sol. Proi. Cost benefit. Ana. FMEA – Pilot Sol’n. ControlImproveAnalyzeMeasureDefine
ControlImproveAnalyzeMeasureDefine ROOT CAUSE Improper Seal Flushing Frequent Pump Change over Policy Improper Lubrication – Defective ring Lower flow operation - lower plant throughput Substitute Replace Strainer with Cyclone separator Change over with 3 month period as pilot With OIL RING with splasher disc Replace the pump with lower capacity Combine Adopt Oil Mist Lubrication System Arrange Minimum Circulation Line Modify MOC of seal with superior seal design Standby pump warm up procedure - Modify Modify / Trim impeller Put to use Use an external flushing compatible with process New filtration system New Impeller to suit Process conditions Eliminate Use of open cans / bottle lubrications Lower throughput operation of unit Rearrange Existing pump change over policy Increase Balancing Hole diameter SCAMPER Analysis For Solution Generation Mechanical Seal Leak
ControlImproveAnalyzeMeasureDefine ROOT CAUSE Improper Hot Alignment Frequent Pump Change over policy Improper Lubrication – Defective ring Lower flow operation - lower plant throughput Substitute Replace pump with heavy duty API 610(8th) Change over with 3 month period as pilot With splasher ring Replace the pump with lower capacity Combine Combine all suction streams into a surge vessel Adopt Zero Piping stresses Oil Mist Lubrication System Arrange Minimum Circulation Line Modify Present alignment practice Standby pump warm up procedure - Modify Modify / Trim impeller Put to use Always take external help or vendor for support Ensure vibration data collection before pump put on load (long C/V) New filtration system New Impeller to suit Process conditions Eliminate Use of open cans / bottle lubrications Lower throughput operation of unit Rearrange Correction based on 10 min run of the pump. Existing pump change over policy Increase Balancing Hole diameter SCAMPER Analysis For Solution Generation Bearing Failure
Sr. No Solution Generation COST Easy to Implement Easy to Control Total 1 Install a suction surge vessel to re-arrange all streams 1.8 10.8 5.4 18 2 Replace existing pumps with sturdier API design pumps 0.4 10.8 5.4 16.6 3 Modify (Trim / balancing hole size etc) / Replace impeller 1.8 10.8 5.4 18 4 Replace existing lube oil ring with Splasher Disc and use filtered lube oil. 1.8 10.8 5.4 18 5 Adopt new pump change over policy as a pilot study with a period of 3 month duration 1.8 10.8 5.4 18 6 Keep constant watch on pump suction conditions all the time for ensuring positive suction pressure. 0.4 10.8 5.4 16.6 7 Modify existing seal flushing plan from API Plan 11 to API Plan 32 (external flushing) 1.8 10.8 5.4 18 8 Always operate pump at designed conditions 0.4 10.8 5.4 16.6 Solution Prioritization Matrix Pumps in Train III / LOBS ControlImproveAnalyzeMeasureDefine
Sr. No Solution Generation COST Easy to Implement Easy to Control Total 1 Replace existing strainer on seal flushing line with cyclone separator. 1.8 10.8 5.4 18 2 Modify existing seal flushing plan from API Plan 12 to API Plan 21 (with energy efficient cooler) or Double seal 0.4 10.8 5.4 16.6 3 Always use filtered and quality lube oil 1.8 10.8 5.4 18 4 Replace existing lube oil ring with Splasher Disc 1.8 10.8 5.4 18 5 Adopt new pump change over policy as a pilot study with a period of 3 month duration 1.8 10.8 5.4 18 6 Modify existing alignment practice by including run alignment technique. 1.8 10.8 5.4 18 7 Always avail vendor or external help for all overhauls and installations at site. 0.4 10.8 5.4 16.6 8 Always operate pump at designed conditions 0.4 10.8 5.4 16.6 Solution Prioritization Matrix Pump in CDU Complex ControlImproveAnalyzeMeasureDefine
Solution Implementation Action Plan SR NO DESCRIPTION OF SOLUTION ACTION POINTS BY WHOM BY WHEN SUPPORT REQD 1 Installation of Cyclone Separators in place of existing strainers – CDU PUMPS 1. Codification and Stock Proposal 2. Procurement and Binning of items 3. Installation at site 4. On Job Training on Seals Rotary Cell / P&CS / Area Maintenance 1. Stock Proposal Completed. 2. Procurement action initiated. 3. Material expected in 6 weeks. 4. Area wise Training Jun 2010 – Nov 2010 2 Conversion of existing flushing plan 11 into plant 32 in P266 A/B 1. MOC / Drawing Preparation 2. Procurement 3. Site installation and commissioning Rotary Cell / LOBS Maint / Operations Completed LINK 3 Installation of suction Surge Vessel – P266A/B 1. MOC / Drawing Preparation 2. Procurement Action 3. Site installation and commissioning Rotary Cell / LOBS Maint / Operations By next RMP Shutdown LINK 4 Trim impeller and increase balancing hoe dia of P266 1. Vendor consultancy 2. Modification of impeller Rotary Cell / Machine shop Completed 5 Adopt 3 month pump change over policy on pilot project 1. Study tag wise effect for pump change over 2. Change present process 3. Implement as a pilot Rotary Cell / LOBS Ops 1. Study to be completed by 20.09.2010 2. Implementation by 01. 10.2010 ControlImproveAnalyzeMeasureDefine
Solution Tree – Bearing / Seal Failures Y REDUCING MAINT INTERRUPTIONS AND INCREASE MTBF OF PUMPS PROBLEM Lower flow operation / Suction Pressure Variations Frequent pump change over Improper lubrication Improper Seal Flushing Alignment variations in hot condition ROOTCAUSE Pump Designed for higher capacity / Multiple suction streams For checking integrity of standby pump Use of incorrect splash ring and unfiltered lube oil Chocking of lines and limitations in direct flushing from discharge Differential expansion due to high temp service EFFECT Creates reverse thrust on pump bearings when pump operates at low flow Each start/ stop starves seal flushing liquid and potential for seal leak Premature bearing failure on account of overheating Premature Mech seal failure on account of over heating Substantial change in shaft alignment value SOLUTION Modify impeller Replace pump Modify existing pump change over procedure on pilot project Replace ring with splash disc / Install filtration unit Replace Plan 12 with Plan 31(CDU) / Replace Plan 11 with API Plan 32(RMP) and On Job Training Carry out RUN alignment after 10 min pump run ControlImproveAnalyzeMeasureDefine
1 Install Cyclone separators on flushing line connections in place of strainers – G10/10S/G2/G2S 2 Modify existing practice of hot alignment and include Run Alignment Technique – G10/11 3 Trim and increase balancing hole dia of Impeller - 132P266 A/B 4 Modify existing mechanical seal flushing plan from API Plan 11 with API plan 32 – 132P266 A/B 5 Adopt 3 month pump change over policy on pilot study in LOBS Unit 6 Install a suction surge vessel to re-arrange all streams – 132P266 A/B 7 Replace existing Lube oil ring with Splasher Disc – All pumps i.e. G11/G11S/ G10/G10S/ 132P266A&B 8 Change existing flushing plans in G11/G11S / G10/G10S with API Plan 21 (installation of Cooler) 9 Always operate pumps at designed conditions 10 Replace existing pumps considering present operating conditions with sturdier design. 11 Install double seals in all pumps i.e. G11/G11S/ G10/ G10S/ 132P266A&B Effort Benefit Analysis ControlImproveAnalyzeMeasureDefine 6, 7, 8 9, 10, 11 1, 2, 3, 4, 5 DMAIC
61 CO NTR O L PLAN FM EA MASURE DEFINE ANALYZE IMPROVE 2 MEASURE ControlImproveAnalyzeMeasureDefine
Process Management ControlImproveAnalyzeMeasureDefine Metrics Y=O/P & X = I/P Unit of measure Responsibility Periodicity Type of Chart What to respond Corrective action Y1: Mechanical Seal Failure Nos Rotary Once in Month I Chart Every incident Analysis of failure X1: Flushing of Mechanical Seal Temp / Pressure Maint Officer / Operator / Ops Officer Seal Temp / Pressure once every day Trend Temp below 160 deg C / Pressure below 14 Kg/cm2 Clean flushing circuit X2: Bearing Loading Flow / Vibration / Lube Oil Condition Maint Officer / Ops Officer / Rotary Pump Flow rates - Daily / Vibration - 15 days / LO Decolourization - weekly Aspen / Vibview Operate pump at least 60% BEP & Replace LO Monitor failure symptoms Y2: Bearing Failure Nos Rotary Once in Month I Chart Every incident Analysis of failure X1: Bearing Loading Flow / Vibration / Lube Oil Condition Maint Officer / Ops Officer / Rotary Pump Flow rates - Daily / Vibration - 15 days / LO Decolourization - weekly Aspen / Vibview Operate pump at least 60% BEP & Replace LO Monitor failure symtoms X2: Suction pressure variation Pressure Maint Officer / Ops Officer / Rotary On every day Aspen Maintain suction above 4.2 Kg/cm2 Monitor failure symptoms
63 Key Lessons Learned • Importance of working in Cross-Functional Team • Concentration on processes rather than isolated events gives sustained solutions (May be the word process generates Fear and Resistance). • Visibility through out the implementation process makes acceptability of the project by majority. • DMAIC Methodology as problem solving technique could be applied to all critical issues. • Opportunity to practice powerful analytical tools like FMEA, Cause & Effect, SCAMPER etc.
End of Presentation Thank You
Centrifugal Pump Failure Pattern for years 2008 & 2009 ## Others includes Low Flow / Low pressure / Casing repairs etc. ** Internals like wear ring, shaft shear / Pump seizure / Unbalance etc. ControlImproveAnalyzeMeasureDefine
Rotary Recommendations – Category wise Back to Definitions ControlImproveAnalyzeMeasureDefine
Solution Tree – Bearing / Seal Failures Back 2 Imp
STRAINER ORIFICE PRESSURE GAUGE EXTERNAL FLUSH TO SEAL Modified to API Plan 32 Original Pump Flushing Plan 11 Solution Tree – Bearing / Seal Failures Back 2 Imp

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M6 BLACKBELT PROJECT Rev 6.4

  • 1.
    Reducing Maint Interruptions/ Increasing MTBF of Critical Equipment ( Six Sigma Black Belt Project)
  • 2.
    2 Start Date :April 2010 Black Belt : Vijay S.Dhonde Master Black Belt : Naveen Narayanan Project sponsor : DGM Maintenance Team Members : K K Nanduri / John Bosco Neelesh Bhagwat & RC Agarwal (BB) for guidance ControlImproveAnalyzeMeasureDefine
  • 3.
    DMAIC • Focus onreducing variation • Involving cross functional teams • Concentration on processes rather than isolated events • Share the experience Define Measure Analyze Improve Control Opportunity / project Current performance Root causes To eliminate root causes To sustain gains
  • 4.
    4 Key Lessons Learned •Importance of working in Cross-Functional Team • Concentration on processes rather than isolated events gives sustained solutions (May be the word process generates Fear and Resistance). • Visibility through out the implementation process makes acceptability of the project by majority. • DMAIC Methodology as problem solving technique could be applied to all critical issues. • Opportunity to practice powerful analytical tools like FMEA, Cause & Effect, SCAMPER etc.
  • 5.
  • 6.
    Present Definition ofFailure Failure starts here Equipment Condition P Potential Failure F Functionally failed Today’s definition of failure Equipment Broken Time The inspection and correctiveThe inspection and corrective task must be completed withintask must be completed within the P-F interval.the P-F interval.P-F Interval Maximize interval between Potential Failure and Functional Failure Importance of This Project
  • 7.
    Importance of ThisProject P P-F Interval Failure Equipment not performing intended function “Functionally failed” “Normal state” Potential Failure Intended Function Design Risk to business (consequence) increase as we move along P-F Curve
  • 8.
    8 Project Assumptions ControlImproveAnalyzeMeasureDefine What ismeant by Critical Equipment? An Equipment is considered critical where either it does not have any standby or it’s non-availability would greatly affect plant throughput and it’s failure will have potential threat to safety & environment. What is Maintenance interruption? An event or condition in which the equipment is taken out of service or stopped for attending an abnormal state or part by maintenance however small may the condition be is termed as an interruption. What is MTBF and its interpretation? Mean Time Between Failure is an average uptime available for an equipment. In other words it is the average time an asset will function before it fails. In Refinery the MTBF is considered for equipments overhauled at Machine Shop only.
  • 9.
    9 Project Assumptions ControlImproveAnalyzeMeasureDefine Why consideronly equipment overhauled at shop for MTBF? • When pump is overhauled at shop it will be critically examined and assembled. • Also Machine shop follows standard procedures laid down by Original Equipment Manufacturer and Overhauling activity is carried out by skilled Maint personnel. How failure of rotary equipment is recorded? An equipment failure is recorded through basically in two modes in SAP. • One by malfunction report generated by Operations through SAP Notification type M2. • Another by Rotary Recommendation generated by Rotary Cell through SAP Notification type M6.
  • 10.
    10 Project Assumptions ControlImproveAnalyzeMeasureDefine What baseline data is being considered for the analysis? Notifications or Job generation by Rotary Cell through SAP type M6 is being considered for analysis. Why Rotary Reco (SAP Type M6) alone is considered for analysis? • Data in type M6 is highly authenticated, precise and created by a trained professional. • Data in type M2 majority of times incomplete and sometimes duplicate in nature created by working level person. • Type M2 notification data is more of descriptive in nature, while M6 data comprises measurable data. • While generating notification through M6 analysis would be conducted based on condition monitoring of the equipment by the in charge. • Also, data shows over 90% of cases bearing failures were captured in M6 Data
  • 11.
    Failure Pattern Identification(Equipment Wise) Frequency 596 254 34 Percent 67.4 28.7 3.8 Cum % 67.4 96.2 100.0 Equipment Comp/FansMotorsPumps 900 800 700 600 500 400 300 200 100 0 100 80 60 40 20 0 Frequency Percent Pareto Chart of Equipment Pumps contribution in failure pattern being higher study will be carried out on pumps only ControlImproveAnalyzeMeasureDefine
  • 12.
    12 • As perabove Pareto diagram more recurring failures are observed in Primary, Secondary Processing and RMP units. • It is evident process units cover more than 80% of failure list. Failure Pattern Identification (Complex wise) ControlImproveAnalyzeMeasureDefine C2 168 161 154 79 24 9 Percent 28.2 27.1 25.9 13.3 4.0 1.5 Cum % 28.2 55.3 81.2 94.5 98.5 100.0 C1 Other Offsites Utilities RM P Secondary Processing Prim ary Processing 600 500 400 300 200 100 0 100 80 60 40 20 0 C2 Percent
  • 13.
      Project Charter Project Description ReducingMaintenance Interruptions and Increasing MTBF of Critical Pumps of Crude Distillation Unit and RMP Business Case Improved equipment availability through reduction in repeat failures can greatly contribute to cost reduction, throughput gain and compliance to environmental and safety standards. Also availability of the Rotary equipments is essential to achieve MOU target of Crude processing of the refinery. Cost of repeat failure alone contributes to over Rs 64 lakh which is around 13% of total expenditure for subject period of 3 year this besides loss of through put on account of non availability of Eqpt. Problem Statement In the 36 month period under study (April 2007-March 2010), 103 out of 594 pumps in plant areas have been taken out of service more than twice for maintenance purposes, leading to reliability and availability issues in plant operation. Such repeated maintenance activities would lead to lower MTBF values( the present benchmark of 5.2 years) and will be a potential threat to plant uptimes. Process Owner DGM Maintenance Scope Start: Stop: Excludes : Condition Monitoring and Notification generation Recheck and closure of notification.. Failures based on malfunction reports   Project Goals Metric MTBF Baseline Data Repeat Failure list of Pumps through M6 Current Average MTBF of selected list = 7.2 Months Goal Increase Average from 7.2 to 12 months Entitlement MTBF 36 months             ControlImproveAnalyzeMeasureDefine
  • 14.
    15 Expected Tangible Benefits Top 3critical tags for different failure modes out of identified list will be taken up for root cause analysis. Such process of avoiding repeat failures would not only result in lower maintenance cost but also help maintain optimum plant through put. One day shutdown of CCU on account of non-availability of critical bottom pump would result in loss of over Rs.2.1 Cr direct cost (CCU Value addition Rs 7000 per MT Waxy processing), can be avoided. Expected Intangible Benefits With higher equipment availability, Process can have flexible operation. Once time spent on repeat jobs reduced, better focus can be given to other reliability improvement initiatives. Also improvement plans can be extended to other parts of the refinery. Team members KK Nanduri, John Bosco, Neelesh Bhagwat & RC Agarwal ( BB for guidance) Support Required Rotary Cell, Operations and Technology Risks/ Constraints Environmental conditions and operating at Turn down due to non availability of plant through put can greatly affect MTBF of rotary equipments. ControlImproveAnalyzeMeasureDefine Project Charter
  • 15.
    16 CTQ Drill Down Tree ControlImproveAnalyzeMeasureDefine EnhanceAvailability of Critical Equipment for Ops By Reducing MTTR By Improving MTBF Increase Equipment uptime Reduce No of Failures Reduce No of Repeat failures Reduce No of repeat failures or increase MTBF from 7.2 to 12
  • 16.
    17 Customer Output ProcessInput Supplier 1. WHO are your primary customers? (From Step A) 2. WHAT does the customer receive? (Think of their CTQ’s) 3. What STEPS are Included in the Process today? (high level) 4. What is provided to START the process? 5. Who PROVIDES the input? (Who) (Nouns) (Verbs) (Nouns) (Who) Equipment in Operation / Condition Monitoring Analysis and Release of type M6 Notification Equipment Isolation and Handover for Maint Activity Completion by Area Maintenance History / Data Updation by Area Maintenance Notification Closure Recheck / Condition Monitoring Availability of equipment Operations Route Readings / Plant Calls Area Operations C O P I S ControlImproveAnalyzeMeasureDefine
  • 17.
    18 ControlImproveAnalyzeMeasureDefine Process Flow ofNotification Generation Data AnalysisRecommendation release (SAP M6) Start Data Collection Site activities based on Reco Close Data (history) Updation Reading acceptable ? NOYES Follow up reading Route / Plant Call
  • 18.
    19 X = Wherethis Stakeholder IS TODAY on the Project O = Where this Stakeholder NEEDS TO BE on the Project * When Populating the Stakeholder, consider the ARMI: • A= Approver of team decisions • R= Resource or subject matter expert (ad hoc) • M= Member of team • I= Interested Party who will need to be kept informed Stakeholder ARMI* Strongly Opposed Opposed Neutral Supportive Strongly Supportive DGM Maint A X/O Ops PP R X/O Ops SP R X/O Ops RMP R X/O Rotary Cell R X/O Technology I X/O Stakeholder Analysis ControlImproveAnalyzeMeasureDefine
  • 19.
    Target Audience ContentFrequency Delivery Method Top Management Project Progress Report As per Project Road Map Steering Committee Review Meeting Project Sponsor / Champion. DGM (Maint.) Project Progress, Issues, Milestones Achieved, Next Steps. End of Each Phase Project Review Meeting. Key Stakeholders as Chief Ops Mgr (SP) / Chief Ops Mgr (PP) Project Status, Issues, Barriers, Milestone Achieved, Next Steps. Bi-weekly Status by e-mail Operators / Technicians Project Needs, Issues, Barriers, Progress Done, Changes Done, Next Steps Need based As and When required discussion at site Engineering Team Members Project Needs, Issues, Barriers, Performance of Machines. weekly Co-ordination Meeting. Communication Plan ControlImproveAnalyzeMeasureDefine DMAIC
  • 20.
  • 21.
    Identification Process for Top3 Critical Pumps for Study Total Repeat Failures List of Over two Failures List segregated based on criticality index Actions yet to be initiated Reduced list based on severity index Top 3 source of failures 594 103 23 16 8 3 ControlImproveAnalyzeMeasureDefine
  • 22.
    Focused pumps forStudy Equipment Failure Cost (in Lakhs) MTBF (Months) 001G10S - CRUDE OIL SEAL 6.8 5.1 001G11S - LONG RES BRG / OTHER 145 4.0 132P266 – EXCS WAXY BRG 36 4.0 Process Sigma for above 3 Critical Equipments 3.2 ControlImproveAnalyzeMeasureDefine
  • 23.
    List of Top8 Equipments for Study Equipment Failure COST MTBF 001G10S - D3 BOTTO SEAL 541,453 5.1 001G1 - CRUDE OIL SEAL 984,054 7.2 001G11 - LONG RESI BRG 3,394,683 7.2 001G11S - LONG RES BRG / OTHER 14,437,919 4.0 001G12 - H.G.O. SEAL 533,272 7.2 001G31 - HEAVY KER OTHER 620,711 5.1 098P803B - FLASHED SEAL 546,555 6.0 132P266B BRG 3,613,592 4.0 BRG Bearing Failure OTHER SEAL Mechanical Seal Failure HIGH VIBRATION, PIPING, Internals, Seizure, Accessories ETC ControlImproveAnalyzeMeasureDefine
  • 24.
    Back ground analysis ForIdentifying top 3 Critical pumps for study Back Up Slides for Measure Phase ControlImproveAnalyzeMeasureDefine
  • 25.
    Process Capability Index Numberof defect opportunities per unit (Failure Modes) O 3 Number Of Units (Notifications for pumps under study) N 16 Number Of actual defects (No. of Pumps under study) D 3 Defects per opportunity DPO=D/(N*O) 3/(3*16) = 0.042 DPMO DPO * 1000000 42000 Process Sigma (From table) 3.2 ControlImproveAnalyzeMeasureDefine DMAIC
  • 26.
  • 27.
    ControlImproveAnalyzeMeasureDefine Applicable Failure Modesin Centrifugal pump are • Insufficient Capacity • Insufficient Pressure • No liquid delivery • Vibration and Noise • Short Bearing Life • Short Mechanical Seal Life Applicable Modes being analyzed for present case are • Vibration and Noise • Short Bearing Life • Short Mechanical Seal Life Failure Modes in Pumps
  • 28.
    ControlImproveAnalyzeMeasureDefine Cause & EffectFishbone – Seal Failure Seal Failure Mechanical Environment Measurements Methods Material Machines Personnel Contaminated lube oil assembly procedure Non adhering to bearing assembly procedure Non adhering to seal Use of incorrect BOM reconditioned spares Use of Defective Spares / Improper bearing CW system Incorrect support / piping installation Pump Failure out of improper pump assembly Incorrect lube oil level - brg guard/ leveler Misalignment in Hot condition Frequent Pump Change over -No defined policy Improper Seal Flushing - NA to checklist Improper Seal Flushing - Orientation of piping Improper Seal Flushing - Chocking of piping Incorrect Seal Design Lower flow operation - lower plant throughput Lower flow operation - ignorance about P-Q Cavitation - process upset Use of non-calibrated instruments
  • 29.
    ControlImproveAnalyzeMeasureDefine Cause & EffectFishbone – Bearing Failure Failure Bearing Environment Measurements Methods Material Machines Personnel Pump cavitation / Process upset Dirt/Moisture in housing Distorted casing Bent Shaft / Run Out Un Balance - Pump Defective Spares Improper bearing CW system External Corrosion Excessive Load on the pump Deviation from design conditions Incorrect Bearing Design Absence of Lubrication Improper Lubrication Improper Pump Installation Improper Brg Installation Misalignment Lower flow operation Measurement Improper Vibration
  • 30.
  • 31.
    ControlImproveAnalyzeMeasureDefine Main Cause Why-WhyAnalysis ( 1st ) Why-Why Analysis (2nd ) Misalignment 1. Alignment does not take process conditions 2. Excessive piping strain 3. Erratic instrument reading 1. Improper skill or knowledge on Hot service 2. Improper piping / support installation 3. Absence of Instrument Calibration Wrong Mechanical Seal assembly 1. Improper personnel skill 2. Use of Non-Standard Materials 1. Lack of awareness or focused training 2. Not adhering to Standard Procedure / spare parts Damage to bearings during installation 1. Improper use of tools and tackles 2. Use of defective bearing 1. Not adhering to Standard Procedure 2. Use of Non-Inspected (by SKF) bearing Bearing Failure while in operation 1. Improper Lube oil Level 2. Improper Lube Oil Quality 3. Excessive Cooling or Heating of housing 1. Defective bearing isolator / leveler 2. Use of contaminated oil / Handling issue 3. Improper cooling system / Choice of lubricant / defective oil ring or splasher Suction Pressure variations / Low flow / Pump Cavitations 1. Operation outside acceptable range 2. Operation much lesser than design point 3. Deviation in operating parameter/ Cavitations 1. Absence of suction surge vessel 2. Pump too big to handle lower throughput 3. Process upset Improper flushing of seal 1. Connected piping is chocked 2. Improper piping orientation 1. Not adhering to procedure / checklist 2. Ignorance or insufficient knowledge Frequent change over of the pump 1. Plant follow 15 day cycle it is too frequent to adopt. 1. No defined practice available Root Cause Analysis (Mechanical Seal Failure)
  • 32.
    ControlImproveAnalyzeMeasureDefine MECHANICAL SEAL FAILURE- CAUSE Category Severity Occurrence Detection RPN Improper Seal Flushing - Chocking of piping Method 9 9 9 729 Improper Seal Flushing - Orientation of piping. Method 9 9 9 729 Pump Suction Pressure Variation Method 9 9 9 729 Frequent Pump Change over -No defined policy Method 9 9 9 729 Misalignment in Hot condition Method 9 5 7 315 Cavitations out of process upset Method 9 4 8 288 Lower flow operation – Design Limitations Method 9 4 8 288 Lower flow operation - lower plant throughput Method 9 4 8 288 Incorrect lube oil level - Brg guard/ leveller Person 9 4 8 288 Cause Prioritization (Mechanical Seal Failure)
  • 33.
    Cause “For Improper Mechanical SealFlushing Plans” Cause Validation (Mechanical Seal Failure) ControlImproveAnalyzeMeasureDefine
  • 34.
    Improper Seal FlushingPlans in CDU G10/10S/G2/G2S/G11/G11S Original Seal Flushing Plan API 31 Present Seal Flushing Plan API 12 Cyclone Separator Replaced by Strainer ControlImproveAnalyzeMeasureDefine
  • 35.
    Improper Seal FlushingPlans Cyclone Separator Dirt goes back to suction Strainer dirt remains and chocks the path in due course ControlImproveAnalyzeMeasureDefine
  • 36.
    CYCLONE SEPARATOR API31 Process liquid is recirculated through a cyclone separator to the seal. Solid particles are centrifuged through cyclone separator and sent back to suction. The Plan is specified for services containing solids with a specific gravity at least twice that of the process fluid. Normally cyclone separators do require preventive Maintenance checks otherwise finer particles reach to the seal faces. The finer particles can enter between the seal faces and cause damage to the seal. Improper Seal Flushing Plans STRAINER API PLAN 12 Process liquid is recirculated through a strainer to the seal. Solid particles are separated through fine filter element or mesh. This plan is used generally with clean liquids. Normally strainers do require periodic preventive Maintenance checks. Otherwise strainer element gets chocked during course of time and restricts liquid movement. Such scenario makes dry run of seal faces and cause damage to the seal. ControlImproveAnalyzeMeasureDefine
  • 37.
  • 38.
  • 39.
    ControlImproveAnalyzeMeasureDefine Main Cause Why-WhyAnalysis ( 1st ) Why-Why Analysis (2nd ) Misalignment 1. Alignment does not take process conditions 2. Excessive piping strain 3. Erratic instrument reading 1. Improper skill or knowledge on Hot service 2. Improper piping / support installation 3. Absence of Instrument Calibration Oil Contamination 1. Improper personnel skill 2. Non-Standard Methods / Oil Handling 1. Lack of awareness or focused training 2. Not adhering to Standard Procedure / tools Damage to bearings during installation shop 1. Improper use of tools and tackles 2. Use of defective bearing 1. Not adhering to Standard Procedure 2. Use of Non-Inspected (by SKF) bearing Lubrication 1. Improper Lube oil Level 2. Improper Lube Oil Quality 3. Excessive Cooling or Heating of housing 1. Defective bearing isolator / leveler 2. Use of contaminated oil / Handling issue 3. Improper cooling system / Choice of lubricant / defective oil ring or splasher Suction pressure variations / Low flow or Cavitation 1. Operation outside acceptable range 2. Operation much lesser than design point 3. Deviation in operating parameter/ Cavitation 1. Absence of suction surge vessel 2. Pump too big to handle lower throughput 3. Process upset Overloading 1. Casing distortion 2. Improper piping orientation 1. Improper pump nozzle load design 2. Ignorance or insufficient knowledge Frequent change over of the pump 1. Plant follow 15 day cycle it is too frequent to adopt. 1. No defined practice available Root Cause Analysis (Bearing Failure)
  • 40.
    ControlImproveAnalyzeMeasureDefine BEARING FAILURE -CAUSE Category Severity Occurrence Detection RPN Misalignment in Hot condition Method 9 9 9 729 Improper Lubrication – Defective ring or splasher Method 9 9 9 729 Improper Lubrication – Choice of lubricant Method 9 9 9 729 Improper Lubrication – Handling issues Method 9 9 9 729 Frequent Pump Change over -No defined policy Method 9 9 9 729 Lower flow operation – Suction pressure variations Method 9 9 9 729 Incorrect lube oil level - Brg guard/ leveller Method 9 4 8 288 Lower flow operation – Design issues Pers 9 4 8 288 Incorrect lube oil level - Brg guard / leveller Method 9 4 8 288 Cause Prioritization (Bearing Failure)
  • 41.
    Cause Mis-Alignment in HotCondition & Improper Lubrication Cause Validation (Bearing Failure) ControlImproveAnalyzeMeasureDefine
  • 42.
    Mis - Alignmentin Hot Condition (G11 of CDU)
  • 43.
    Mis - Alignmentin Hot Condition (G11 of CDU) ControlImproveAnalyzeMeasureDefine CDU -001G11** 001G11** -P1H PumpInboardHorizontal RouteSpectrum 09-Apr-10 11:47:31 OVERALL=10.23V-DG PK = 10.13 LOAD =100.0 RPM=2949.(49.16Hz) 0 10000 20000 30000 40000 50000 0 1 2 3 4 5 6 7 FrequencyinCPM PKVelocityinmm/Sec Freq: Ordr: Spec: 2887.5 .979 3.385 1XRPM 2XRPM 3XRPM
  • 44.
  • 45.
    2-3mmabove OilLevel Incorrect Oil ringor Splash Disc • Under - Lubrication • Poor lube oil circulation • Improper bearing cooling • Improper level or overheating • Oil blackening • Premature bearing failure Improper Lubrication (Bearing Failure) ControlImproveAnalyzeMeasureDefine Oil ring position as of now in some of the LOBS Pumps DMAIC
  • 46.
    SCAM PER MASURE DEFINE ANALYZE IMPROVE 2 MEASURE Sol. Proi. Cost benefit.Ana. FMEA – Pilot Sol’n. ControlImproveAnalyzeMeasureDefine
  • 47.
    ControlImproveAnalyzeMeasureDefine ROOT CAUSE ImproperSeal Flushing Frequent Pump Change over Policy Improper Lubrication – Defective ring Lower flow operation - lower plant throughput Substitute Replace Strainer with Cyclone separator Change over with 3 month period as pilot With OIL RING with splasher disc Replace the pump with lower capacity Combine Adopt Oil Mist Lubrication System Arrange Minimum Circulation Line Modify MOC of seal with superior seal design Standby pump warm up procedure - Modify Modify / Trim impeller Put to use Use an external flushing compatible with process New filtration system New Impeller to suit Process conditions Eliminate Use of open cans / bottle lubrications Lower throughput operation of unit Rearrange Existing pump change over policy Increase Balancing Hole diameter SCAMPER Analysis For Solution Generation Mechanical Seal Leak
  • 48.
    ControlImproveAnalyzeMeasureDefine ROOT CAUSE ImproperHot Alignment Frequent Pump Change over policy Improper Lubrication – Defective ring Lower flow operation - lower plant throughput Substitute Replace pump with heavy duty API 610(8th) Change over with 3 month period as pilot With splasher ring Replace the pump with lower capacity Combine Combine all suction streams into a surge vessel Adopt Zero Piping stresses Oil Mist Lubrication System Arrange Minimum Circulation Line Modify Present alignment practice Standby pump warm up procedure - Modify Modify / Trim impeller Put to use Always take external help or vendor for support Ensure vibration data collection before pump put on load (long C/V) New filtration system New Impeller to suit Process conditions Eliminate Use of open cans / bottle lubrications Lower throughput operation of unit Rearrange Correction based on 10 min run of the pump. Existing pump change over policy Increase Balancing Hole diameter SCAMPER Analysis For Solution Generation Bearing Failure
  • 49.
    Sr. No SolutionGeneration COST Easy to Implement Easy to Control Total 1 Install a suction surge vessel to re-arrange all streams 1.8 10.8 5.4 18 2 Replace existing pumps with sturdier API design pumps 0.4 10.8 5.4 16.6 3 Modify (Trim / balancing hole size etc) / Replace impeller 1.8 10.8 5.4 18 4 Replace existing lube oil ring with Splasher Disc and use filtered lube oil. 1.8 10.8 5.4 18 5 Adopt new pump change over policy as a pilot study with a period of 3 month duration 1.8 10.8 5.4 18 6 Keep constant watch on pump suction conditions all the time for ensuring positive suction pressure. 0.4 10.8 5.4 16.6 7 Modify existing seal flushing plan from API Plan 11 to API Plan 32 (external flushing) 1.8 10.8 5.4 18 8 Always operate pump at designed conditions 0.4 10.8 5.4 16.6 Solution Prioritization Matrix Pumps in Train III / LOBS ControlImproveAnalyzeMeasureDefine
  • 50.
    Sr. No SolutionGeneration COST Easy to Implement Easy to Control Total 1 Replace existing strainer on seal flushing line with cyclone separator. 1.8 10.8 5.4 18 2 Modify existing seal flushing plan from API Plan 12 to API Plan 21 (with energy efficient cooler) or Double seal 0.4 10.8 5.4 16.6 3 Always use filtered and quality lube oil 1.8 10.8 5.4 18 4 Replace existing lube oil ring with Splasher Disc 1.8 10.8 5.4 18 5 Adopt new pump change over policy as a pilot study with a period of 3 month duration 1.8 10.8 5.4 18 6 Modify existing alignment practice by including run alignment technique. 1.8 10.8 5.4 18 7 Always avail vendor or external help for all overhauls and installations at site. 0.4 10.8 5.4 16.6 8 Always operate pump at designed conditions 0.4 10.8 5.4 16.6 Solution Prioritization Matrix Pump in CDU Complex ControlImproveAnalyzeMeasureDefine
  • 51.
    Solution Implementation Action Plan SR NO DESCRIPTIONOF SOLUTION ACTION POINTS BY WHOM BY WHEN SUPPORT REQD 1 Installation of Cyclone Separators in place of existing strainers – CDU PUMPS 1. Codification and Stock Proposal 2. Procurement and Binning of items 3. Installation at site 4. On Job Training on Seals Rotary Cell / P&CS / Area Maintenance 1. Stock Proposal Completed. 2. Procurement action initiated. 3. Material expected in 6 weeks. 4. Area wise Training Jun 2010 – Nov 2010 2 Conversion of existing flushing plan 11 into plant 32 in P266 A/B 1. MOC / Drawing Preparation 2. Procurement 3. Site installation and commissioning Rotary Cell / LOBS Maint / Operations Completed LINK 3 Installation of suction Surge Vessel – P266A/B 1. MOC / Drawing Preparation 2. Procurement Action 3. Site installation and commissioning Rotary Cell / LOBS Maint / Operations By next RMP Shutdown LINK 4 Trim impeller and increase balancing hoe dia of P266 1. Vendor consultancy 2. Modification of impeller Rotary Cell / Machine shop Completed 5 Adopt 3 month pump change over policy on pilot project 1. Study tag wise effect for pump change over 2. Change present process 3. Implement as a pilot Rotary Cell / LOBS Ops 1. Study to be completed by 20.09.2010 2. Implementation by 01. 10.2010 ControlImproveAnalyzeMeasureDefine
  • 52.
    Solution Tree –Bearing / Seal Failures Y REDUCING MAINT INTERRUPTIONS AND INCREASE MTBF OF PUMPS PROBLEM Lower flow operation / Suction Pressure Variations Frequent pump change over Improper lubrication Improper Seal Flushing Alignment variations in hot condition ROOTCAUSE Pump Designed for higher capacity / Multiple suction streams For checking integrity of standby pump Use of incorrect splash ring and unfiltered lube oil Chocking of lines and limitations in direct flushing from discharge Differential expansion due to high temp service EFFECT Creates reverse thrust on pump bearings when pump operates at low flow Each start/ stop starves seal flushing liquid and potential for seal leak Premature bearing failure on account of overheating Premature Mech seal failure on account of over heating Substantial change in shaft alignment value SOLUTION Modify impeller Replace pump Modify existing pump change over procedure on pilot project Replace ring with splash disc / Install filtration unit Replace Plan 12 with Plan 31(CDU) / Replace Plan 11 with API Plan 32(RMP) and On Job Training Carry out RUN alignment after 10 min pump run ControlImproveAnalyzeMeasureDefine
  • 53.
    1 Install Cyclone separatorson flushing line connections in place of strainers – G10/10S/G2/G2S 2 Modify existing practice of hot alignment and include Run Alignment Technique – G10/11 3 Trim and increase balancing hole dia of Impeller - 132P266 A/B 4 Modify existing mechanical seal flushing plan from API Plan 11 with API plan 32 – 132P266 A/B 5 Adopt 3 month pump change over policy on pilot study in LOBS Unit 6 Install a suction surge vessel to re-arrange all streams – 132P266 A/B 7 Replace existing Lube oil ring with Splasher Disc – All pumps i.e. G11/G11S/ G10/G10S/ 132P266A&B 8 Change existing flushing plans in G11/G11S / G10/G10S with API Plan 21 (installation of Cooler) 9 Always operate pumps at designed conditions 10 Replace existing pumps considering present operating conditions with sturdier design. 11 Install double seals in all pumps i.e. G11/G11S/ G10/ G10S/ 132P266A&B Effort Benefit Analysis ControlImproveAnalyzeMeasureDefine 6, 7, 8 9, 10, 11 1, 2, 3, 4, 5 DMAIC
  • 54.
  • 55.
    Process Management ControlImproveAnalyzeMeasureDefine Metrics Y=O/P &X = I/P Unit of measure Responsibility Periodicity Type of Chart What to respond Corrective action Y1: Mechanical Seal Failure Nos Rotary Once in Month I Chart Every incident Analysis of failure X1: Flushing of Mechanical Seal Temp / Pressure Maint Officer / Operator / Ops Officer Seal Temp / Pressure once every day Trend Temp below 160 deg C / Pressure below 14 Kg/cm2 Clean flushing circuit X2: Bearing Loading Flow / Vibration / Lube Oil Condition Maint Officer / Ops Officer / Rotary Pump Flow rates - Daily / Vibration - 15 days / LO Decolourization - weekly Aspen / Vibview Operate pump at least 60% BEP & Replace LO Monitor failure symptoms Y2: Bearing Failure Nos Rotary Once in Month I Chart Every incident Analysis of failure X1: Bearing Loading Flow / Vibration / Lube Oil Condition Maint Officer / Ops Officer / Rotary Pump Flow rates - Daily / Vibration - 15 days / LO Decolourization - weekly Aspen / Vibview Operate pump at least 60% BEP & Replace LO Monitor failure symtoms X2: Suction pressure variation Pressure Maint Officer / Ops Officer / Rotary On every day Aspen Maintain suction above 4.2 Kg/cm2 Monitor failure symptoms
  • 56.
    63 Key Lessons Learned •Importance of working in Cross-Functional Team • Concentration on processes rather than isolated events gives sustained solutions (May be the word process generates Fear and Resistance). • Visibility through out the implementation process makes acceptability of the project by majority. • DMAIC Methodology as problem solving technique could be applied to all critical issues. • Opportunity to practice powerful analytical tools like FMEA, Cause & Effect, SCAMPER etc.
  • 57.
  • 58.
    Centrifugal Pump FailurePattern for years 2008 & 2009 ## Others includes Low Flow / Low pressure / Casing repairs etc. ** Internals like wear ring, shaft shear / Pump seizure / Unbalance etc. ControlImproveAnalyzeMeasureDefine
  • 59.
    Rotary Recommendations –Category wise Back to Definitions ControlImproveAnalyzeMeasureDefine
  • 60.
    Solution Tree –Bearing / Seal Failures Back 2 Imp
  • 61.
    STRAINER ORIFICE PRESSURE GAUGE EXTERNAL FLUSH TO SEAL Modifiedto API Plan 32 Original Pump Flushing Plan 11 Solution Tree – Bearing / Seal Failures Back 2 Imp

Editor's Notes

  • #17 To use the the CTQ Drill Down Tree above: 1. Drill-down into your CTQ (Big Y) to determine key drivers (little y’s) and their process and input drivers (X’s) 2. Evaluate the amount of IMPACT each driver (y) has on your CTQ, and the CONTROL you have to change each driver (y) 3. Select the key driver (y) to focus on for the rest of the project. Note, “y” is measurable could be a characteristic about the main process could be a characteristic of a sub-process For the CTQ Translation Matrix:
  • #18 You may need more / less boxes than highlighted on this template. You can add / delete as necessary for your project. When identifying Supplier(s), consider who starts and/or provides input to the process. When identifying Customer(s), consider who ends the process and/or is the recipient of the output.
  • #19 To use the the CTQ Drill Down Tree above: 1. Drill-down into your CTQ (Big Y) to determine key drivers (little y’s) and their process and input drivers (X’s) 2. Evaluate the amount of IMPACT each driver (y) has on your CTQ, and the CONTROL you have to change each driver (y) 3. Select the key driver (y) to focus on for the rest of the project. Note, “y” is measurable could be a characteristic about the main process could be a characteristic of a sub-process For the CTQ Translation Matrix:
  • #20 These Change tools are optional. Another alternative you can use is a “Threat / Opportunity” matrix.