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Peruvian International Maintenance Conference 2010 The Maintenance Engineering and Reliability Pillars of Productivity
Terry Harris, CMRP 656 Ridgeway Dr. Sidney, Ohio 45365 937-371-1644 tkharris10@woh.rr.com reliableprocesssolutions.com
Competition
We are all involved in competition.
We compete with companies in our business lines. We compete with new processes that may make ours inefficient. We are competing around the world! Can LAM be more competitive in the future?
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112 90 77 71 67 54 44 42 40
Africa & Middle East Bahrain 1 Botswana 1 Kuwait 1 South Africa 78 Nigeria 5 UAE 9 Qatar 14 Saudi Arabia 8 Zambia 1
Asia India Indonesia Japan Malaysia Thailand Papa N.G. Philippines Singapore Trinidad Yemen
3 10 2 1 3 1 1 2 3 1
PF Interval
Equipment Performance
FF
Time
UF
Reactive 10-15 PP
Inability to perform precision maintenance More spare parts Expediting of spare parts Unplanned maintenance Unplanned downtime Quality issues E,H,&S issues Inefficient use of maintenance time Inefficient use of operations time Extremely short equipment life Work practices dont extend equipment life
Predictive Maintenance
90% of all equipment failures can be predicted months before the failure! 90% of all bearing failures can be predicted at least 3 months before failure! 90% of all motor failures can be predicted 6-12 months before failure!
Predictive 30-50 PP
Reactive 10-15
Predictive Maintenance
Reduces collateral damage Time to plan the work Time to do the correct maintenance Time to have correct parts (no expediting) Time to do precision maintenance Less spare parts 30% less More efficient use of maintenance time Less Emergency Downtime Repair work can extend equipment life Safer work conditions
Proactive
70-100 PP Lubrication Excellence Precision Maintenance Alignment, Balance, etc. Select Suppliers Supplier Specifications Metrics Equipment Ranking RCM/PMO TPM RCA/FMEA RCD Training Programs
Predictive 30-50
Reactive 10-15
Equipment Performance
PM Tasks
Written Procedures
Job Planning/Scheduling CMMS System
Time
FF RCA
Proactive Maintenance
Maximizes precision work techniques Minimum spare parts, 50% reduction Maximum Runtime, Minimal downtime 80% of maintenance tasks proactive Minimal E, H, &S exposure Very Low quality Issues Maximum Equipment Life Lower MRO costs Reduction of Predictive Maintenance Costs Elimination of equipment failure modes Allows you to perform Lean Maintenance
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Engineering/Design
25-35% of equipment reliability issues are engineering and design related. Poor equipment selection
Motors, Pumps, Couplings, Equipment Options, Pump Bases, Gear Reducers, Fans, Conveyors, Packing Equipment, Etc
Engineering/Design
Who makes the best motor? Who makes the best pump? Who makes the best membranes? Who makes the best cartridge filter? Who makes the best actuators/valves? Who makes the best coupling? Who makes the best pump base?
Knowing the answer to these questions is what adds life and reliability to the equipment.
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Ref: DT
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Ref: DT
Fabrication
10-20% of failures are contributed to equipment fabrication Improper Piping Practices
Elbows on inlet flanges Pipe strain on equipment Torque methods on fasteners Improper welding procedures on steel Improper welding procedures on plastic
Fabrication
Improper Handling of Completed Equipment
Pick points, Shipping points, Tie Down Points, Support Points
Installation
15-25% of failures are poor installation practices Improper Handling Practices
Pick points, Moving practices, Storing
Coupling Alignment
Poor or no alignment methods
Installation cont.
Installation Failures
Operations
10-20% of failures are from operational issues Starting equipment under full load
Could be equipment or programming
Closing discharges valves to quickly Not monitoring thermal conditions Not monitoring physical vibration Not monitoring visual oil changes Operating equipment in manual Lack of fluid to pump on startup Water on components Lack of a TPM program
Maintenance
20-30% of all failures are directly contributed to maintenance before/after startup. Improper inspection of components Improper lubrication practices
Improper/contaminated lube Too much lube No lube analysis, Visual/Testing
No/poor Preventive Maintenance Program No/poor Predictive Maintenance Program No/poor Proactive Maintenance Process No/Improper training of maintenance
No procedures, training programs, follow up, retraining
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How important is precision balance to equipment component life cycles? Using precision balance specifications can add 23 times the life to the bearings.
Precision Balance
A real life example of a loss of bearing life due to unbalance is as follows: Lets use the example of a 12 pump impellor turning at 3600 RPM. This impellor is out of balance by only 1 oz. The 1 oz. out of unbalance equals 275 lbs of additional force on a bearing designed for 1000 lbs. This reduces the bearing life by 48%.
F=Force m=imbalance (lbs) r=radius of imbalance (in) f=rotational speed (Hz) g=386.4 in/sec2 Substitute 1 oz. (1/16 lb.), 12", 3600 RPM (60 Hz):
F = 0.102 x (
Thus, 1 oz. of imbalance on a 12" radius at 3600 RPM creates an effective centrifugal force of 275 lbs. Now calculate the effect of this weight on bearing life. Suppose that the bearings were designed to support a 1000 lb. rotor. The calculated bearing life is less than 50% of the design life as shown below.
Actual L 10 Life = (Design L 10 Life) x ( 1000 3 ) 1000 + 275 = 0.48 Design L 10 Life
Precision Balance
When you buy or rebuild a motor, pump, or any rotating equipment specify a balance standard of .05in/sec.
Precision Balance can be affected by not cutting keyways in shafts the correctly. The correct method is as follows using the drawing below. Measure from the end of the shaft to the edge of the taper of the keyway slot. This is A. Measure the length of the coupling, this is B. A + B / 2 is the proper length of the key. You are trying to replace the weight of the metal remove in the keyway slot
If keyways not precision cut then have 180 degrees apart
Misalignment Failures
A study in the petrochemical industry realized the following results: Average bearing life increases by a factor of 8.0.
Implementing
Implementing precision alignment means having written procedures and methods to verify that it is actually happening in the plant.
Measure
Examples of Measurements Maintenance costs/RAV OEE (Overall Equipment Effectiveness) MTBF (Mean Time Between Failure) Reduced downtime
Questions