October 8, 2010 SKF Group Slide 0

Establishing a successful Condition Based Maintenance programme

Presented to Prepared by IMarEST Conference 2010 Gerald Rolfe Executive Business Manager Marine SKF Service Division

2010-09-28

Brief introduction to SKF

October 8, 2010 SKF Group Slide 2

SKF 2009

41 172 employees 124 factories 56 227 MSEK turnover in 130 countries 450 channels >10 % operating margin 7 000 distributors in 29 countries Environment: Global ISO 14001 certification, OHSAS 18001 certifcation

SKF Group Vision

To equip the world with SKF knowledge

October 8, 2010 SKF Group Slide 4

What is SKF knowledge?

October 8, 2010 SKF Group Slide 5

Overall customer & business perspective

Idea or concept OEM Perspective Design & manufacture Install & commission End User Perspective Operate & monitor Maintain & repair Restore & upgrade
Transferable knowledge

October 8, 2010 SKF Group Slide 6

SKF in the Marine Segment

October 8, 2010 SKF Group Slide 7

SKF and the ship life cycle

Concept and design Product delivery

Maintain and improve Build and install Operate and monitor

October 8, 2010 SKF Group Slide 8

SKF Marine Key capabilities & Values

Concept and design

Design and engineering Calculation, simulation and verification Testing & validation

Enable new reliable designs & minimise risk of machinery failures and warranty costs One-stop-shop for proven world class products, available worldwide

OEM

Product delivery

Quality SKF products Efficient global distribution network Wide portfolio (five platforms)

Build and install

Complete propulsion line installation Supervision of alignment and installation Mounting and alignment services and systems Condition based maintenance (CBM) Condition monitoring systems (CMS) Analysis and remote monitoring (RDC)

Ensure optimised operational performance through best practice installation services Safer and more profitable operations with increased availability and streamlined classification agency surveys Range of maintenance engineering and consulting services to boost asset uptime

Operate and monitor End-User Maintain & improve

Maintenance tools and recommendations Root Cause Failure Analysis Validation and optimisation of design

October 8, 2010 SKF Group Slide 9

SKF Marine Key capabilities & Values

October 8, 2010 SKF Group Slide 10

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

October 8, 2010 SKF Group Slide 11

The basic business model

Cost & Revenue

Profit Payback point

ost C g n i at Oper PEX) (O

Cost of Plant (CAPEX)

ue n ve t) Re utpu (O

Time

2010-10-08 SKF Slide 12 [Code] SKF [Organisation] October 8, 2010 SKF Group Slide 12

Why should we use condition monitoring?

Cost & Revenue

Payback point

Payback point
Additional cost to repair machinery

Profit ?
Cost of Plant (CAPEX)

Loss of availability & revenue

Time

Downtime
October 8, 2010 SKF Group Slide 13

Condition based maintenance

October 8, 2010 SKF Group Slide 14

Condition Based Maintenance process

Maintenance strategy
Business impact 1 3 2

System set-up

4 Maintenance complexity

AEO Upgrade and improvement

Data collection

Remote analysis Correction

October 8, 2010 SKF Group Slide 15

Asset Efficiency Optimisation (AEO) process

Maintenance Strategy Project Business Goals
PM = Preventive Maintenance ( time based ) PRM = Proactive Reliability Maintenance ( includes Predictive Maint. ) ODR = Operator Driven Reliability ( RTF = observation ) RCFA = Run to Failure ( reactive maintenance ) Root Cause Failure Analysis

Pre-Defined Priorities

PRM/ODR Collection and Analysis

Work Identification

Information Integration and Decision Work Order Generation Corrective Maintenance Operator s Initiators

Work Control

Standard Job Plans and Procedures

RCFA

Maintenance Strategy

Reliability Issues (Design)

Plant Asset Management and Maintenance Program (Living Program) PM PRM ODR RTF

Planning Rolling Schedule

Spare Parts Alignment

Work Execution

Work Execution
October 8, 2010 SKF Group Slide 16

Post Maintenance Testing Update Program

Client needs analysis - output

This provides an objective basis for the future improvement plan

October 8, 2010 SKF Group Slide 17

Condition monitoring strategy

Examples: Turbo machines: Compressors Generators Critical Machines: Turbochargers IG Fans Inaccessible Machines: Hazardous pumps & fans Auxiliary machines: Motors, Pumps, Fans LO & HFO Purifiers, etc
Fast Sudden onset failure

Critical

High Critical Online

Cost per Point

Financial Risk

Online

Semi-Online

Periodic data Medium Low Slow Gradual degradation

Required Scan Rate Time to machine failure

October 8, 2010 SKF Group Slide 18

An Internet CBM solution

Internet
Remote Ship systems

CBM Service Provider

Citrix Client VPN TCT application SKF Network Workstation onboard Workstation onboard Citrix Client Visualisation Client VPN TCT application TCT application

Direct connection available only to authorised SKF users

Citrix/Application Server Citrix Server @ptitude Analyst Application SKF Transaction Server

Database Server Oracle 10g @ptitude Analyst Database

Ship Operator Shore based personnel

Citrix Client VPN TCT application

SKF Data Hosting Centre

October 8, 2010 SKF Group Slide 19

Other Condition Monitoring techniques

Periodic monitoring:
Oil & Grease Thermographic Ultrasonic - for Oil condition (e.g.Transformer), Component wear - for Temperature checks & Electrical system faults - for Air leaks, Steam leaks, NDT, etc

Online monitoring:
Oil Particle count - e.g. Gearbox wear & contamination - to identify abnormal operating conditions Process data analysis

Online oil particle sensor

October 8, 2010 SKF Group Slide 20

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

October 8, 2010 SKF Group Slide 21

Key issues to be considered

October 8, 2010 SKF Group Slide 22

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)

October 8, 2010 SKF Group Slide 23

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

October 8, 2010 SKF Group Slide 24

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

October 8, 2010 SKF Group Slide 25

CBM - Marine customer gap analysis

October 8, 2010 SKF Group Slide 26

CBM - Marine customer gap analysis

October 8, 2010 SKF Group Slide 27

Demonstrating value

October 8, 2010 SKF Group Slide 28

Effective CBM contract management

Effective CM system support tracking To ensure data integrity
Support Cas e Tre nds Open Cases New Cases Closed Cases

50 45 40 N u m b e ro fC a s e s 35 30 25 20 15 10 5 0 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 We e k Num be r

Reduction in Overdue data To improve Assurance

Fleet Average Overdues Since start of SKF Contract 30.00% 25.00%

20.00%

15.00%

Critical Machine Datasheets To improve Knowledge of the Assets & accuracy of Analysis

10.00%

5.00%

0.00%
01 /0 1/ 07 01 /0 2/ 07 01 /0 3/ 07 01 /0 4/ 07 01 -0 507 01 -0 607 01 -0 807 01 -0 907 01 -1 007 01 -1 107 01 -1 207 01 -0 108 01 -0 208 01 -0 308 01 -0 408 01 -0 508 01 -0 608 01 -0 708 01 -0 808 01 -0 908 01 -1 008 01 -1 108 01 -1 208 01 -0 109 01 -0 209 01 -0 309 01 -0 409 01 -0 709

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Satisfactory machines = Improved Fleet Assurance

October 8, 2010 SKF Group Slide 30

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

October 8, 2010 SKF Group Slide 31

Benefit reporting Marine Fleet CBM

Total Benefits per Class Total= $855,260
$350,000 $300,000 $250,000 $200,000 $150,000 $100,000 $50,000 $0 Class Per Vessel

C1
Bird Class Per Vessel $289,890 $24,158

Border

C2

C_LPG

C3

P's

C4

Trader

C5

Tree

C6

E's and Virtues

C7

Loch Rannoch $19,300 $19,300

C8

Gem

SKF cost-benefit model (CM event) adapted to C9 large scale reporting

$8,300 $2,767

$41,670 $10,418

$120,410 $30,103

$68,320 $17,080

$102,890 $12,861

$192,000 $8,727

$12,480 $12,480

C ost Benefit Vessel Class

P's Class

1 Bird $35,000 Class 2 Tree Class 3 $30,000 Loch Rannoch Class 4 $25,000 Gem Class 5 Trader $20,000 Class 6 C_LPG Class 7 $15,000 E's and Virtues Class 8 $10,000 Border Class 9
Total $5,000
October 8, 2010 SKF Group Slide 32 $0

$120,410 $289,890

Total Average per vessel Total Benefits per Vessel Total= $855,260

Average per machine per vessel

$30,103 $12,861

$284 $244 $153 $145 $139 $132 $104 $95 $54 $148

$24,158 $19,300 $12,480 $17,080 $10,418 $8,727 $2,767 $14,496

E's and

$102,890 $19,300 $12,480 $68,320 $41,670 $192,000 $8,300 $855,260

Bird

Border

C_LPG

P's

Trader

Tree

Loch

Gem

So how does vibration analysis actually work then?

October 8, 2010 SKF Group Slide 33

How does Vibration Analysis actually work?

A proven technique: Especially good for steady-state conditions Key issues: Data Quality: Variable machine speeds & loads Reliability: Operating environment Ease of use: Remote monitoring

Bearing Outer Ring defect

October 8, 2010 SKF Group Slide 34

Vibration facts of life

Static vs. Dynamic Data
Bearing Gear Generator mesh Each machine component generates its own characteristic Vibration Signature

Dynamic data (Spectra)

Amplitude

4 kb of data

Frequency & Range

coupling

Rotor Hub

FFT Processing
Amplitude Time

October 8, 2010 SKF Group Slide 35

Static Value (RMS)

2 bytes of data

What can we see with Vibration Analysis?

What Parameters can we monitor? Component defect frequencies Trends (Vel, Accel, Freq. Band, gE)
Normal level Unacceptable Increasing

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
Defect FFT spectra Normal FFT spectra

October 8, 2010 SKF Group Slide 36

Marine CM technology
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)

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

October 8, 2010 SKF Group Slide 37

Fixed sensors for inaccessible & hazardous areas

Cargo pump room
Fixed sensors
Vac pumps
Exhaust fan

Pump room

Exhaust fan

Multi-core cables

Ballast pump stbd

Engine room
Cargo pump stbd

Main junction box

SAFETY BARRIER S

Cargo pump centre

Switch box

Cargo pump port

Ballast pump port

October 8, 2010 SKF Group Slide 38

Online condition monitoring

Signal processing & data capture
Machine signals Convert signal Processing of data & FFTs

Data storage (1,5Mb/Machine/day)

Signals, FFT data and Trends

Data management & analysis

Analysis of Trends & FFT

ACC

Shaft speed (rpm) Vibration Steering angle Oil particles, Water, Temp Oil Pressure (gravity tanks)

Machine

Sensors

Multilog IMX

CM Database

@ptitude Software

October 8, 2010 SKF Group Slide 39

Remote database access for different users

SKF Remote Monitoring Centre Live access (e.g. Citrix) Application Server (@ptitude) Database Server & Virtualisation

Web Server

Ship operator/manager

SKF CM Engineer System configuration Database management Machine data & history Analysis & Reporting Contract management
October 8, 2010 SKF Group Slide 40

Ship operator Fleet/Class status Ship status Machine trend Machine history

Application-specific condition monitoring

SKF Turbocharger monitor
Speed switch 4-20 mAmp
Machine Condition Transmitters

Example: Turbocharger monitoring

Digital Control System
Status/condition Alarm OPC T/C Efficiency & Performance: T/C compressor intake temperature T/C compressor air flow Temperature before T/C turbine T/C turbine gas flow Charging air pressure Barometric pressure Exhaust gas pressure before T/C turbine T/C Condition: Vibration levels Engine speed T/C speed Sea state

Vibration levels & Alarm relays

BNC connection for Portable Microlog FFT

Onboard PC

Turbocharger
Internet (Citrix/VPN) Satellite/GPRS, etc..
Accelerometer s with separate charge amplifiers PC with application installed to automatically store and transfer data to SKF

Status reports Work orders Alarms etc.

Condition data Notes/comments etc.

SKF remote monitoring

Monitoring centre with T/C reliability database, efficiency formulas, reporting tools and formats etc.

October 8, 2010 SKF Group Slide 41

Benefits of CBM - Gearbox problem

Acceleration trend shows an increase Spectrum identifies IMS/LSS gear mesh frequency with sidebands. Recommendation: Inspect & replace gears Root Causes: Lubrication, Alignment, Excess loads

October 8, 2010 SKF Group Slide 42

Benefits of CBM - Coupling problem

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 profile. Recommendation: Inspect the coupling (damaged) Root causes: Excess misalignment, Shock loads

October 8, 2010 SKF Group Slide 43

Benefits of CBM Motor bearing problem

Increase in Enveloped Acceleration (gE) trend. Spectra shows bearing outer race frequency with harmonics. Recommendation: Change the bearing Root Cause: Electrical damage, poor insulation

October 8, 2010 SKF Group Slide 44

October 8, 2010 SKF Group Slide 45