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Enteract 99
Jeffery P. Watkins
Strategic Project Manager
ENTERACT 99 Home
Objectives
Preventive Maintenance
Predictive Maintenance
BREAKDOWN
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
Run-to-Failure
Usage-Based PM
...
Spare Run-to-Failure
Re-design
Time-Based
On-Condition
Failure Finding
Test
Select Implement
Equipment Plan
Define Decide
Functions Prevention
Identify Failures
Assess
Effects
Determine
Root Causes
replace
10.0%
overhaul
15.0%
redesign
R-T-F 5.0%
25.0%
Overhaul CBM
6.3% 36.1%
Discard
0.6%
Redesign
5.4%
R-T-F
51.6%
Least Likely
Most Likely
70%
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
Watkins Beginning ENTERACT 99 Home
Maintenance Work Process :
Typical Distribution
TOTAL
100%
PLANNED UNPLANNED
30% 70%
TOTAL
70% 100% 30%
PLANNED UNPLANNED
30% 70%
10%
PdM/PM Corrective Corrective Breakdown
25% 5% 5% 65%
1.1 Fails to provide an adequate supply of sea water to cool the Yes
main condenser and auxiliary cooling water heat exchangers
Criticality Analysis
Functional Failure Component ID Failure Mode(s) Failure Effect(s) Critical? Remarks
Non-Critical Evaluation
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?
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
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
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.
XX Cooling tower inspection once Delete - Redundant task to the environmental inspection
a month
.. Is difficult
Sampler Pressure
Stack
Intake
Baghouse
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
RCM Workshops
Guidance for the introduction
Analysis of current machine problems
Project Management
Turnkey Project