October 8, 2010 SKF Group Slide 0

Transcription

1 October 8, 2010 SKF Group Slide 0

2 Establishing a successful Condition Based Maintenance programme Presented to IMarEST Conference 2010 Prepared by Gerald Rolfe Executive Business Manager Marine SKF Service Division

3 Brief introduction to SKF October 8, 2010 SKF Group Slide 2

4 SKF employees 124 factories MSEK turnover in 130 countries 450 channels >10 % operating margin distributors in 29 countries Environment: Global ISO certification, OHSAS certifcation

5 SKF Group Vision To equip the world with SKF knowledge October 8, 2010 SKF Group Slide 4

6 What is SKF knowledge? October 8, 2010 SKF Group Slide 5

7 Overall customer & business perspective Idea or concept OEM Perspective End User Perspective Design & manufacture Install & commission Operate & monitor Maintain & repair Transferable knowledge Restore & upgrade October 8, 2010 SKF Group Slide 6

8 SKF in the Marine Segment October 8, 2010 SKF Group Slide 7

9 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

10 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 End-User OEM Product delivery Build and install Operate and monitor Quality SKF products Efficient global distribution network Wide portfolio (five platforms) 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) One-stop-shop for proven world class products, available worldwide Ensure optimised operational performance through best practice installation services Safer and more profitable operations with increased availability and streamlined classification agency surveys Maintain & improve Maintenance tools and recommendations Root Cause Failure Analysis Validation and optimisation of design Range of maintenance engineering and consulting services to boost asset uptime October 8, 2010 SKF Group Slide 9

11 SKF Marine Key capabilities & Values October 8, 2010 SKF Group Slide 10

12 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 (SO X /NO X /CO 2 ) 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

13 The basic business model Cost & Revenue Profit Payback point Operating Cost (OPEX) Revenue (Output) Cost of Plant (CAPEX) Time SKF Slide 12 [Code] SKF [Organisation] October 8, 2010 SKF Group Slide 12

14 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

15 Condition based maintenance October 8, 2010 SKF Group Slide 14

16 Condition Based Maintenance process Maintenance strategy System set-up Business impact Maintenance complexity AEO Data collection Upgrade and improvement Remote analysis Correction October 8, 2010 SKF Group Slide 15

17 Asset Efficiency Optimisation (AEO) process Maintenance Strategy Project Business Goals Maintenance Strategy Reliability Issues (Design) Pre-Defined Priorities Plant Asset Management and Maintenance Program (Living Program) PM PRM ODR RTF RCFA 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 Work Identification PRM/ODR Collection and Analysis Information Integration and Decision Work Order Generation Corrective Maintenance Operator s Initiators Work Control Standard Job Plans and Procedures Planning Rolling Schedule Spare Parts Alignment Work Execution Work Execution Post Maintenance Testing Update Program October 8, 2010 SKF Group Slide 16

18 Client needs analysis - output This provides an objective basis for the future improvement plan October 8, 2010 SKF Group Slide 17

19 Condition monitoring strategy Examples: Critical High Critical Online Turbo machines: Compressors Generators Medium Financial Risk Cost per Point Low Slow Gradual degradation Online Semi-Online Periodic data Required Scan Rate Time to machine failure Inaccessible Machines: Hazardous pumps & fans Auxiliary machines: Motors, Pumps, Fans LO & HFO Purifiers, etc Fast Sudden onset failure Critical Machines: Turbochargers IG Fans October 8, 2010 SKF Group Slide 18

20 An Internet CBM solution Internet Remote Ship systems CBM Service Provider SKF Network Citrix Client VPN TCT application Direct connection available only to authorised SKF users Citrix/Application Server Citrix Analyst Application SKF Transaction Server Database Server Oracle Analyst Database Ship Operator Shore based personnel - Citrix Client VPN TCT application Workstation onboard Workstation onboard Citrix Client VPN Visualisation Client TCT TCT application application SKF Data Hosting Centre October 8, 2010 SKF Group Slide 19

21 Other Condition Monitoring techniques Periodic monitoring: Oil & Grease - for Oil condition (e.g.transformer), Component wear Thermographic - for Temperature checks & Electrical system faults Ultrasonic - for Air leaks, Steam leaks, NDT, etc Online monitoring: Oil Particle count - e.g. Gearbox wear & contamination Process data analysis - to identify abnormal operating conditions Online oil particle sensor October 8, 2010 SKF Group Slide 20

22 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

23 Key issues to be considered October 8, 2010 SKF Group Slide 22

24 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

25 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

26 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

27 CBM - Marine customer gap analysis October 8, 2010 SKF Group Slide 26

28 CBM - Marine customer gap analysis October 8, 2010 SKF Group Slide 27

29 Demonstrating value October 8, 2010 SKF Group Slide 28

30 Effective CBM contract management Effective CM system support tracking To ensure data integrity Support Case Trends Open Cases New Cases Closed Cases Number of Cases Week Number 30.00% 25.00% 20.00% 15.00% 10.00% Reduction in Overdue data To improve Assurance Fleet Average Overdues Since start of SKF Contract Critical Machine Datasheets - To improve Knowledge of the Assets & accuracy of Analysis 5.00% 0.00% 01/01/07 01/02/07 01/03/07 01/04/ October 8, 2010 SKF Group Slide 29

31 Satisfactory machines = Improved Fleet Assurance October 8, 2010 SKF Group Slide 30

32 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

33 Benefit reporting Marine Fleet CBM $350,000 Total Benefits per Class Total= $855,260 Class Per Vessel $300,000 $250,000 $200,000 $150,000 $100,000 $50,000 $0 E's and Loch Bird Border C_LPG P's Trader Tree Virtues Rannoch Gem C1 C2 C3 C4 C5 C6 C7 C8 C9 Class $289,890 $8,300 $41,670 $120,410 $68,320 $102,890 $192,000 $19,300 $12,480 Per Vessel $24,158 $2,767 $10,418 $30,103 $17,080 $12,861 $8,727 $19,300 $12,480 SKF cost-benefit model (CM event) adapted to large scale reporting Cost Benefit Total Average per vessel Average per Vessel Class Total Benefits per Vessel machine per vessel Total= $855,260 P's $120,410 $30,103 $284 Class 1 Bird $289,890 $24,158 $244 $35,000 Class 2 Class $30,000 3 Class 4 Class 5 Tree $102,890 $12,861 $153 Loch Rannoch $19,300 $19,300 $145 $25,000 Gem $12,480 $12,480 $139 Class $20,000 6 Trader $68,320 $17,080 $132 Class 7 $15,000 Class 8 Class 9 C_LPG $41,670 $10,418 $104 E's and Virtues $192,000 $8,727 $95 Border $10,000 $8,300 $2,767 $54 Total $855,260 $14,496 $148 $5,000 October 8, 2010 SKF Group Slide 32$0 Bird Border C_LPG P's Trader Tree E's and Loch Gem

34 So how does vibration analysis actually work then? October 8, 2010 SKF Group Slide 33

35 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

36 Vibration facts of life Static vs. Dynamic Data Gear Generator Bearing mesh Each machine component generates its own characteristic Vibration Signature Amplitude Dynamic data (Spectra) 4 kb of data Frequency & Range coupling Rotor Hub FFT Processing Σ Amplitude Time Static Value (RMS) 2 bytes of data October 8, 2010 SKF Group Slide 35

37 What can we see with Vibration Analysis? What Parameters can we monitor? Component defect frequencies Trends (Vel, Accel, Freq. Band, ge) What Defects can be identified? Misalignment & Unbalance Normal level Unacceptable Increasing Looseness & clearances Gear defects - lube, wear, damage Bearing defects - lube, wear, damage Process faults Temp, Pressure, etc And many more Normal FFT spectra Defect FFT spectra October 8, 2010 SKF Group Slide 36

38 Marine CM technology Portable hardware: Suitable for ATEX and non-atex use Test signal generator (1 st 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

39 Fixed sensors for inaccessible & hazardous areas Fixed sensors Cargo pump room Multi-core cables Pump room Exhaust fan Vac pumps Exhaust fan Ballast pump stbd Engine room Cargo pump stbd Cargo pump centre Main junction box SAFETY BARRIER S Switch box Cargo pump port Ballast pump port October 8, 2010 SKF Group Slide 38

40 Online condition monitoring Signal processing & data capture Data storage (1,5Mb/Machine/day) Data management & analysis Machine signals Convert signal Processing of data & FFT s Signals, FFT data and Trends Analysis of Trends & FFT ACC Shaft speed (rpm) Vibration Steering angle Oil particles, Water, Temp Oil Pressure (gravity tanks) Machine Sensors Multilog IMX CM Software October 8, 2010 SKF Group Slide 39

41 Remote database access for different users SKF Remote Monitoring Centre Live access (e.g. Citrix) Application Server Database Server & Virtualisation Web Server Ship operator/manager SKF CM Engineer System configuration Database management Machine data & history Analysis & Reporting Contract management Ship operator Fleet/Class status Ship status Machine trend Machine history October 8, 2010 SKF Group Slide 40

42 Application-specific condition monitoring SKF Turbocharger monitor Example: Turbocharger monitoring Machine Condition Transmitters Speed switch BNC connection for Portable Microlog FFT 4-20 mamp Vibration levels & Alarm relays Status/condition Alarm Onboard PC Digital Control System 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 Turbocharger Accelerometer s with separate charge amplifiers PC with application installed to automatically store and transfer data to SKF Status reports Work orders Alarms etc. Internet (Citrix/VPN) Satellite/GPRS, 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

43 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

44 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

45 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

46 October 8, 2010 SKF Group Slide 45