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RCM

Where does it fit?

Enteract 99
Jeffery P. Watkins
Strategic Project Manager

ENTERACT 99 Home
Objectives

A quick look at PdM


a quick look at RCM
some reasons why it can pay off
does it fit your own organization??
a closer look at implementation

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Equipment: Heat exchanger
Failure mode: Periodic fouling
Cost: Production loss $5,000/hour

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Maintenance method: Wait for blockage, then clean
Result: 6 cleaning operations/year
16 hours/cleaning operation
Cost: $480,000/year

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Maintenance method: Clean every 4 weeks
Result: 13 cleaning operations/year
2 hours/cleaning operation
Cost: $130,000/year

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Maintenance method: Monitor differential pressure
Clean when above 50 psi
Result: 8 cleaning operations/year
2 hours/cleaning operation
Cost: $80,000/year

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Maintenance Costs

wait for blockage: $480k

clean every two weeks: $130k

monitor pressure changes: $80k

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Maintenance Methods
Breakdown Maintenance

Preventive Maintenance

Predictive Maintenance

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Strategies For Reliability

BREAKDOWN

CALENDAR BASED CONDITION BASED

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Problems?
How do you select maintenance tactic?
Real solution is combination of tactics.
Real savings of PdM program is minimizing all types of maintenance
not just preventing failures.
Boiler Feed Booster Pump at BG&E CP Crane plant would be
rebuilt every 5 years at a cost of $20,000.
Development of a true expert system
Existing systems based on personnel experience
Need structured approach and defined logic to development

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RCM is......

merely a tool to aid in improving cost effective


maintenance (others are TPM, CMMS...).

but one of the BEST tools you can use

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Who has used RCM?
Classical RCM
Nuclear Industry, Military, Aircraft
Streamline RCM
Developed by Erin Engineering under contract from EPRI.
Maintenance Optimization
Others (RCM Lite, etc.)

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Reliability Centered Maintenance

Concepts
1. Use an engineered approach to matching maintenance
tactics to failure modes
2. Tasks must be applicable to the failure mechanism and
effective at predicting, preventing or mitigating damaging
effects
3. Selection of cost-effective maintenance strategies meeting
operations and maintenance needs

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Goal / Method / Bias

Goal: Achieve design reliability at a reasonable cost by


taking the right actions and no more
Method: Matching of tactics to failure mechanism through
a structured logic
Bias: CBM is preferred tactic because it is usually non-
invasive and does not disrupt operation

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RCM employs all the standard
maintenance tactics:
Condition based preventive
Time based preventive
Usage based preventive
Time and usage discard
Run-to-failure
Failure finding test
Built-in redundancy
Redesign

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Maintenance Tactics...

Run-to-Failure
Usage-Based PM
...
Spare Run-to-Failure

Re-design
Time-Based
On-Condition
Failure Finding
Test

.Depend on the Failure Mechanism


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RCM approach
Combine Criticality and Failure Mode Effects Analysis
with RCM decision logic
Criticality Analysis used to select best equipment and
systems for analysis
FMEA used to identify the failure modes that RCM will
target
RCM decision logic selects the best maintenance tactics
Use as a feed-in to your CMMS and PdM system

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The RCM Process

Select Implement
Equipment Plan

Define Decide
Functions Prevention
Identify Failures
Assess
Effects

Determine
Root Causes

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Does RCM Pay?

1. Do the RIGHT maintenance

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RCM Tactics will vary widely...

Pulp Mill BENCHMARK


on-condition
35.0%
test
10.0%

replace
10.0%
overhaul
15.0%
redesign
R-T-F 5.0%
25.0%

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Maintenance Task Distribution
Hydraulic System for Haul Truck in a coal mine

Overhaul CBM
6.3% 36.1%
Discard
0.6%
Redesign
5.4%

R-T-F
51.6%

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Does RCM Pay?

1. Do the RIGHT maintenance


2. Not too much maintenance

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Chemical Plant

Aromatics unit - furnace sootblowers


Quarterly overhauls: needed 2 mechanics full time, cost
$400k/yr. (labor, materials, parts, equipment)
With RCM: semi-annual CBM performance checks: 1
mechanic, 1/4 time, cost savings $300k/yr.

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Does RCM Pay?

1. Do the RIGHT maintenance


2. Not too much maintenance
3. Achieve Plant Design Capacity

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Chemical Plant

PVC plant expansion: RCM used first time.

Initial Planned capacity 50 % of original plant design


capacity

Achieved 75 % of original plant design capacity

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Does RCM Pay?

1. Do the RIGHT maintenance


2. Not too much maintenance
3. Achieve Plant Design Capacity
4. Significant Cost Savings

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Aircraft:

DC8 - 339 items included in scheduled monthly overhaul


747 - 7 items - annual savings $200,000 per plane

DC8 Lifetime heavy inspections required 4,000,000 m/h


747 - 66,000 - annual savings $10 million per plane

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Does RCM Pay?

1. Do the RIGHT maintenance


2. Not too much maintenance
3. Achieve Plant Design Capacity
4. Significant Cost Savings
5. Increase Uptime and Reduce Overtime

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Polymer Fiber Plant

85% Uptime 98% Uptime

17% Mtce Overtime 5% O/T

Net Dollar benefit $96M over 10 years

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Probability of failure

Least Likely

Most Likely

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The Best Maintenance is.......
no maintenance??????

70%

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Post-Maintenance Failures
Number of Forced Outages
2,000
56%
1,000

0
wk

mo

mo
wk

wk

wk

mo
>3
<1

1-2

2-3

3-4

1-2

2-3
Time Following Planned Shutdown
Thermal Power Plants
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Maintenance Work Process :
Typical Distribution

TOTAL
100%

PLANNED UNPLANNED
30% 70%

PdM/PM Corrective Corrective Breakdown


25% 5% 5% 65%

Emergency Non Emergency


25% 40%

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Maintenance Work Process :
Benchmark Distribution

TOTAL
70% 100% 30%

PLANNED UNPLANNED
30% 70%
10%
PdM/PM Corrective Corrective Breakdown
25% 5% 5% 65%

Emergency Non Emergency


45% 25% 25% 40%
20%
1% 9%

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RCM is not the only way to go..

...will not predict quantitative results such as increases in


reliability, decreases in downtime or cost of alternative
maintenance tactics

these require a different analysis

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Is this your operating environment?

Capital intensive business


Production output increases are necessary to stay
competitive
Production is dependent upon a small number of machines
(bottlenecks)
Breakdowns of equipment are seriously affecting output
Maintenance is Mission Critical

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To adopt RCM...

You must be prepared to change the way you think about


and do maintenance
You must have at least one skilled frustration- proof RCM
engineer/practitioner
You must be prepared to invest time
And you must not be wedded to the quick fix

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Selecting Equipment
Could be the entire plant?
Could be limited systems?
Circulating water, Condensate, Boiler, Feedwater,
Instrument & Plant Air, Turbine Generator Support, Waste
Water Treatment, Fly Ash/Bottom Ash, Fuel Handling, Fuel
Delivery, Precipators
Could be single machine/system?
Tissue Converter

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EXAMPLE SYSTEM STUDY
***Circulating Water***
Functional Failure Analysis (FFA)
ID Functional Failure Analyzed? Remarks

1.1 Fails to provide an adequate supply of sea water to cool the Yes
main condenser and auxiliary cooling water heat exchangers

2.1 Fails to provide means to adequately clean the condenser yes


tubes and auxiliary cooling water heat exchangers tubes

3.1 Fails to provide proper indication and/or control of system Yes


parameters

Criticality Analysis
Functional Failure Component ID Failure Mode(s) Failure Effect(s) Critical? Remarks

1.1 CT-401 Cooling tower 401 Cooling tower


loss Reduction in plant Yes
(includes tower, flumes and of or degraded heat efficiency results in
basin) transfer capability possible reduced power
operation
CWIP Pumps circ water Motor driven pump Loss of redundancy No Intake pumps are
intake pumps 1 & 2 fails to run (includes redundant; only
degraded operation); one is required
fails to start per unit

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EXAMPLE SYSTEM STUDY
***Circulating Water***
Critical Task Selection
C om ponent R ecom m ended T a sk F req. R esp. R ecom m ended B a ses
ID T ype D iscip.

C T -4 01 C oo ling T ow er 40 1 (inclu de s to we r, flum e s an d basin)


M C T C oo ling T ow er
F a ilure M o de (s) L oss o f o r de grad ed h ea t tra nsfe r cap ab ility;
F a ilure C a use(s) F o ulin g; dirt accu m ulation ; sub com p on ent fa ilure; corrosion
In spe ct coo ling to we r for sign s of corrosion , erro sio n, stru ctura l 2M MECH
da m ag e, com p on en t da m ag e an d g en era l to w er con dition ,
rep air/rep la ce co m pon en ts a s ne cessary, re cord in spe ctio n re su lts to
de te rm ine if fre qu en cy ca n be extend ed (2m )
O p en m ud valves fo r 1 we ek e very 6 m on ths. 6M OPS

Non-Critical Evaluation

Component Component Type Failure Modes Non-Critical Evaluation Criteria Critical?

CWIP-Motors
circ EMO Motor Fails to run (includes High repair/replacement No
water intake pumps 1 & 2 degraded operation); cost?; Causes failure of
motors (including fails to start another significant
breakers) component?
CWIP-Pumps
circ MPM Motor driven Fails to run (includes High repair/replacement No
water intake pumps 1 & 2 pump degraded operation); cost?; Causes failure of
fails to start another significant
component?

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EXAMPLE SYSTEM STUDY
***Circulating Water***
Non-Critical Task Selection

Component Recommended Task Freq. Resp. Discip. Critical?


ID Type
CWIP-Pumps circ water intake pumps 1 & 2
MPM Motor driven pump
Evaluation Criteria High repair/replacement cost?;
Causes failure of another significant component?
Inspect Coupling (24M) 24M MECH No

Perform vibration signature analysis (just prior to outage) to utilize 24M VIB GROUP No
condition information to direct maintenance needs (24M)
Perform pump inspection prior to outage to determine required 24M TECH No
maintenance (24M) SERVICES

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EXAMPLE SYSTEM STUDY
***Circulating Water***
Task Comparison

Component Current Maintenance Program PMO Recommendations?

CWIP-Pumps OP-10A Weekly equipment tests Retain - task does not address a critical component failure mode identified
and equipment auto start testing - in the PMO analysis, but provides additional assurance of functionality.
once a week

XX Vibration Monitoring Modify - Change frequency to 6 months to further optimize task interval

Add - Inspect coupling every 24 months

Add - Perform thermographic inspection every 12 months

CT-401 496001 Normal outage activities Retain - task does not address a critical component failure mode identified
in the PMO analysis, but provides additional assurance of functionality.

Add - Open mud valves for one week every 6 months


XX Cooling tower inspection once Delete - Redundant task to the environmental inspection
a month

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Implementing RCM

.. Is difficult

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Ten Steps to Effective RCM
1. Select equipment for review

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The Dust Collector

Sampler Pressure

Stack
Intake
Baghouse

Motor Fan Temperature

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Ten Steps to Effective RCM

1. Select equipment for review


2. Define functions

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Identify Functions

PRIMARY - remove dust from intake gas.


SECONDARY - measure dust level in stack gas and
adjust flow to keep within limits.
PROTECTIVE - being capable of automatically shutting
down system as a result of high temperature or differential
pressure.

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Ten Steps to Effective RCM
1. Select equipment for review
2. Define functions
3. Define performance standards

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Define Performance Standards

PRIMARY- removes all particles greater than 97 microns


- removes 95% of all particles greater than 65
microns
SECONDARY - measures dust levels to within+/- 10
microns
does automatic measure every 30 seconds
automatically adjusts flow to 5500 cu ft/min +/- 15%

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Ten Steps to Effective RCM
1. Select equipment for review
2. Define functions
3. Define performance standards
4. Define how it can fail (Functional Failures and Effects
Analysis)

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Failures can be classified as:

1. TOTAL FUNCTIONAL FAILURE -fails to remove any


dust.
2. PARTIAL FUNCTIONAL FAILURE -fails to remove
dust to meet performance and environmental standards.
3. SPURIOUS FUNCTIONAL FAILURE -shuts down
when dust level in intake surges above design capacity..

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Ten Steps to Effective RCM
1. Select equipment for review
2. Define functions
3. Define performance standards
4. Identify Functional Failures
5. Determine Failure Modes

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Determine Failure Modes

Failure modes are the things that actually go wrong:


For the Total Functional Failure: Fails to remove any
dust
The following are the Failure Modes:
Fan motor stops - Fan Belt breaks - Fan bearings seize -
Filter bags torn - Intake blocked - Filter bags full, bypass
opens

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Ten Steps to Effective RCM
1. Select equipment for review
2. Define functions
3. Define performance standards
4. Identify Functional Failures
5. Determine Failure Modes
6. Assess Root Causes

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Assess Root Causes

Fan Motor Stops because:


1. Overload due to Material Surge
2. Faulty breaker
3. Too much Vibration due to poor alignment
Fan Belt Breaks because
1. Wear due to poor alignment
2. Wear due to incorrect belt selection
3. Wear due to abrasive pulley
4. Old age

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Ten Steps to Effective RCM
1. Select equipment for review
2. Define functions
3. Define performance standards
4. Identify Functional Failures
5. Determine Failure Modes
6. Assess Root Causes
7. Assess Effects and Consequences

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Assess Effects and Consequences

Fan motor stops----


air handling ceases
have half hour to resolve before baghouse has to be shut
down
production will continue with dust back-up in baghouse
replacement motor has capacity to catch up
no safety issue
replacement time is 20 minutes if new pump is on stand-by

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Ten Steps to Effective RCM
1. Select equipment for review
2. Define functions
3. Define performance standards
4. Identify Functional Failures
5. Determine Failure Modes
6. Assess Root Causes
7. Assess Effects and Consequences
8. Select Best Maintenance Tactics

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Select Maintenance Tactics

Fan motor stops - run to failure


Fan Belt breaks - periodic inspection + vibration
analysis
Fan bearings seize - regular lubrication +
vibration analysis
Filter bags torn - performance monitor
Intake blocked - performance monitor
Filter bags full, bypass opens - performance monitor

Watkins Beginning ENTERACT 99 Home


Ten Steps to Effective RCM
1. Select equipment for review
2. Define functions
3. Define performance standards
4. Identify Functional Failures
5. Determine Failure Modes
6. Assess Root Causes
7. Assess Effects and Consequences
8. Select Best Maintenance Tactics
9. Implement the Program

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Implement the Program
Translate maintenance tactic into regular maintenance
task:
"Fan Belt breaks.... periodic inspection + vibration
analysis"
1. set-up PM task - description of job, including
recording of measurements - frequency and schedule
- who does the work - materials and tools - vibration
equipment to be used
2. enter into CMMS

Watkins Beginning ENTERACT 99 Home


Ten Steps to Effective RCM
1. Select equipment for review
2. Define functions
3. Define performance standards
4. Identify Functional Failures
5. Determine Failure Modes
6. Assess Root Causes
7. Assess Effects and Consequences
8. Select Best Maintenance Tactics
9. Implement the Program
10. Analyze the results

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Analyze the Results

Pull out the results of the jobs and measure the frequency
of failure
Calculate the Savings
Monitor the readings on belt wear, vibration etc
Evaluate the trends
Improve performance
Set the analysis up as a PM work order

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How can we help?

RCM Workshops
Guidance for the introduction
Analysis of current machine problems
Project Management
Turnkey Project

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