Professional Documents
Culture Documents
- A business case
Mahomed Chothia
Slide 1 [RS MFC] 2008-10-10 SKF SKF [MENA]
Reliability / Maintenance
The purchase price of rotating equipment represents only about 10 to 25 % of its total cost of ownership, . while energy, maintenance and operating costs represent 75 to 90 %.
Source: Lee Culbertson, Royal Purple Ltd., "Justify Lubricant Upgrades with Energy Savings". Machinery Lubrication Magazine. July 2001
Operator-Driven Reliability
Planning for a shift to an integrated proactive maintenance strategy starts with understanding where you are today in process for maintaining and managing capital assets. Use a mix of strategies
Safety/ Environment
Management
Finance
Engineering
Re-design current assets Coordinate maintenance needs Control projects Reduce capital outlay.
PLANT PERFORMANCE
Reliability
Increase asset efficiency Increase machine uptime Reliability systems
Operations
Increased production Production quality Comply w/ maintenance schedules Cost effective
Purchasing
Ensure product life cycle costs Increase service level Quality services Reduce inventory
Maintenance
Service response Perform precision work Maintain asset Control costs
COST
$10,000 / hour $10,000 / hour $15,000 / hour $100,000 / hour Millions of $ 1 stop = 3 to 4 days $1,000 / hour
Bearings, seals and other machine components are an essential part of rotating equipment, their reliability is often critical to the plant equipment. The cost of these components are proportionally very small compared to the maintenance cost of replacement and potential lost production caused by premature failure.
Contamination 14%
Slide 9 [RS MFC] 2008-10-10 SKF SKF [MENA]
Machinery vibration Lube oil analysis including wear debris analysis Infrared thermography Ultrasonic testing Motor current analysis Alignment
Additional parameters such as flow rates, temperature, pressure, speed etc. can be monitored to detect problems. The techniques used depends on the criticality of the equipment.
Slide 11 [RS MFC] 2008-10-10 SKF SKF [MENA]
An effective maintenance program has many benefits. Return on investment: Reduction in maintenance costs: Elimination of breakdowns: Reduction in downtime: Increase in production:
Slide 15 [RS MFC] 2008-10-10 SKF SKF [MENA]
1 : 10 25 to 30 % 70 to 75 % 35 to 45% 20 to 25 %.
Stock Optimisation
Problem description MRO stock is a large part of the maintenance budget Approximately 15 to 25% Implemented solution Stores Audits and Recommendations Inventory management Stock optimization - (criticality, spares cost and availability) Storage, Handling, Obsolescence. Resulting benefits Reduced stock, better availability, correct items Savings generated Potential estimated - 100 000 Euro
Slide 16 [RS MFC] 2008-10-10 SKF SKF [MENA]
Slide 17 [Code]
Bearing Life Influence of load A 20% load increase reduces the calculated bearing life by half
L10h =
Slide 21 [Code]
review - shaft repair / machining tolerances - sealing arrangement - condition monitoring - lubrication selection
Electrical Motors
Typical failure modes: Bearings 40% Stator 30% Rotor 8% Others 22% mechanical
Misalignment Unbalance Soft foot Bearings Lubrication Overheating
SKF Reliability Maintenance Institute
Slide 23 [RS MFC] 2008-10-10 SKF SKF [MENA]
electrical
Poor power quality Insulation failure Excessive current
Centrifugal Pumps
Premature failures
Average cost of repair $6,000 / pump Given the number of pumps in operation the cost savings are substantial Typical failure are due to: Mechanical seal, bearing, lubrication Bearings - Angular Contact Ball Bearing, universal pairing Improved lubrication synthetic lubricant Sealing arrangement - mechanical seals, isolators
Slide 28 [RS MFC] 2008-10-10 SKF SKF [MENA]
Process Pump
BG =BECB P6 runout
Matched bearings are best suited for pumps. Usually fitted in a back-to-back arrangement (without the use of shims) SKF BECB bearings have the correct axial clearance after mounting.
Slide 29 [RS MFC] 2008-10-10 SKF SKF [MENA]
3 microns
Process Pump
API 610 standard for refinery service pumps specify bearings with machined brass cage eg.: 7218 BECBM B E CB M 40 degree contact angle High load carrying capacity Clearance class Brass cage
Exhaust Fan
Reliability improvement project
- design review and engineering - design of new components - shaft repair and impeller balancing - Installation and commissioning - lubrication selection
Lubrication: Oil circulation Sleeve bearings Operating temperature: 93 C Year installed: 1990 Mean Time Between Failure: 3 to 5 months
High impact on production ! Proposal to convert the plain bearings to Rolling Bearings.
Slide 33 [RS MFC] 2008-10-10 SKF SKF [MENA]
Exhaust Fan
Electric Motor
Customer Benefits Lower bearing temperature 60 C vs 90 C Reduced current drawn by motor (- 5 Amps) Simplified lubrication system - (oil circulation not required) Lower vibration levels Improved reliability
Slide 36 [RS MFC] 2008-10-10 SKF SKF [MENA]
Plain Bearing Failures .. Time to repair shaft / balancing Rebabbitting of bearings Installation / commissioning Failure of plain bearings New SKF solution
Plummer blocks
Slide 38 [RS MFC] 2008-10-10 SKF SKF [MENA]
Entry of water and contaminants Incorrect fits / geometric form tolerances of the housing seating Lubrication type and method
Paper Mill
Press Roll Section Reliability Improvement Project
Slide 41 [Code]
Total cost saving (improved reliability avoidance of breakdown) = 2.5 x 213,100 = Euro 532,750
Slide 43 [RS MFC] 2008-10-10 SKF SKF [MENA]
Lubrication Management
2008-10-10 SKF Slide 44 [Code] Slide 44 [RS MFC] SKF [Organisation] 2008-10-10 SKF SKF [MENA]
Lubrication Management
200%
150%
50%
0% 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Lubrication Management
Thank you