INT-21 IntelaTrac for Lubrication Routes

Transcription

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2 INT-21 IntelaTrac for Lubrication Routes By Jack Craighton 2013 Invensys Customer Conference Series October 16, 2013 / #SoftwareRevolution /InvensysVideos /Wonderware /Groups/ Wonderware IntelaTrac User Community 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are pr oprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

3 Objectives Understand how a Lubrication Program is part of an important preventive, predictive and proactive maintenance strategy Understand what it takes to implement a lubrication program Understand how IntelaTrac can help you manage and implement a lubrication program Slide 3

4 Outline For Building A Lubrication Program What is a Lubrication Program Program Management How a Lubrication Program Affects an Operating Plant Condition Monitoring Where Do You Start? Lubrication Training Standards Lubrication Equipment Document Slide 4 Storage & Handling Contamination Control Lubrication Management System (Under Development)

5 Defining a Lubrication Program A lubrication Program is a program designed to enhance the reliability of a facilities lubricated equipment to increase production time. A well run lubrication program will: Create a cultural change in how equipment is repaired, operated and maintained. Decrease reactive maintenance allowing for better planning, repairs and reduced maintenance cost. Reduce overtime cost. Reduce lubricant consumption cost. Reduce machinery downtime. Compliment other predictive methods for troubleshooting and diagnosis. Builds knowledge and reduces human error. Slide 5

6 How a Lubrication Program Affects an Operating Plant Slide 6

7 Maintenance Strategies $ Per HP / Per Year 5 ro ac tiv e P iv e e re di ct P nt iv re ve P R ea c tiv e 0 Hudachek, R. & Dodd, V The cost of Reactive Maintenance is three time as much as Proactive Maintenance. Slide 7

8 Lubrication Maintenance Strategy Example Compressor Lube System Turbine Oil Reactive Maintenance Change oil after a failure occurs. Preventive Maintenance Change oil on a time based schedule. Predictive Maintenance Test oil routinely and change based on condition. Proactive Maintenance Counteract system behaviors based on learning's. Recondition oil based on test results (i.e. filter, Top off) and only change oil when conditions predict. Install filtered breathers on reservoir to reduce particulate ingression. Routinely check & document oil levels and temperatures for changes. Routinely check & document filter differentials for changes. Filter new turbine oil during top offs and change outs to reduce particle contamination Store and handle the turbine oil properly to reduce contamination. Slide 8

9 P-F INTERVAL Time vs. Maintenance Strategies P P-F Interval F Equipment Performance - Risk of Failure Eliminate the potential failure before it occurs! Proactive Maintenance Predictive Maintenance Preventive Maintenance + Failure TIME (t) Slide 9

10 Lubrication Maintenance Strategies P P-F Interval F Equipment Performance Risk of Failure - + Failure TIME (t) Slide 10

11 Where Do You Start? Slide 11

12 Lubrication Front End Study A Lubrication FES provides direction or a road map as to where you are and where you want to go. A Lubrication FES will look at: Work & Data Management Base of Knowledge Industry Best Practices Storage & Handling Condition Monitoring Programs Contamination Control A complete FES can be built in IntelaTrac s Procedure Builder which later can be used to audit and report on the progress of your program. Slide 12

13 Lubrication Training Knowledge is what builds cultural change. Provides the know how to predict oncoming failures through: Routine Surveillance Oil Testing/Analysis Provides the understanding to building longevity into equipment through: Maintaining Oil Cleanliness Standards Using the Correct Lubricant New Equipment Design Provides the knowledge to reduce human error through: Reduced Cross Contamination Proper Installation Practices Improved Quality Control Measures Slide 13

14 IntelaTrac Rotating Equipment Fundamentals Course Lubrication Fundamentals and Devices The full potential of achieving machinery reliability is not realized without securing lubricant quality control. The modules offer training to operators that will guide them with surveillance techniques armed to catch and eliminate early failure mechanisms. Slide 14

15 Certification Certification is the ultimate goal to assure acceptable level of performance in the field and the laboratory. Society of Tribologists and Lubrication Engineers (CLS, OMA & CMFS) International Council for Machinery Lubrication (MLA, MLT & LLA) Provides independent objective proof of technical competency Slide 15

16 Lubrication Standards Lubrication Standards are the foundation blocks to maintaining an efficient and long running program. Lubrication Standards cover: Best Practice Guides Standard Operating Procedures Lubricant Selection Documentation Approved Vendor List and Contact Information IntelaTrac s SDK now allows for data to be pulled from document repositories like those used for SOP s and then converted to mobile procedures that can be completed digitally in the field. Slide 16

17 Lubricant Equipment Document The Lubricant Equipment Document is the first step in organizing the necessary data to begin a lubrication program. A Lubricant Equipment Document covers the documentation of the: Location of All Lubricated Equipment Number of Lubrication Points Type of Lubricant Used Method of Lubrication Lubricant Application Frequency IntelaTrac s release of 4.3 will now allow for assigning assets at runrun-time. This will allow Lube Technicians to build and maintain a Lubrication Equipment List easily using Asset Type Templates. Slide 17

18 Lubricant Equipment Document IntelaTrac s Dynamic Procedure Builder can dynamically export data to an excel spread sheet using an integration tag. It can also import and add Extended Properties to assets from an Excel spread sheet. This allows for the saving of lubricant properties directly to an individual piece of equipment. Slide 18

19 Program Management A program management system is needed to track and schedule lubrication preventive, predictive and proactive maintenance tasks. A good program management system should be able to: Give instruction down to a single Lube Point Import/Export Data to and from third party systems (IntelaTrac SDK) Be PC-based with Networking Capabilities Be Relatively Easy to Use Incorporate the use of a Mobile Handheld Devices Identify Lubrication Points in the Field Interface with CMMS (IntelaTrac Extension) Slide 19

20 Program Management - WOE Mobile Work Orders for Execution Material Reservations Attached Documents Measurement Points (As Found As Left Conditions) Material Returns Exceptions and Exclusions Planned Preventive Maintenance Work Orders for Execution Work Order for Scoping Material Reservations Attached Documents Measurement Points (As Found As Left Conditions) Material Returns Corrective Orders Work Notifications Asset Hierarchy Reference Data for WON Component Lists (BOM) Asset Types Work Order Types Work Order Status Planner Groups Work Centers Fault Codes Exception and Exclusion Codes SAP Master Data Attached Documents *grouped by asset and document type Document Repository Junot Middleware Based Architecture Web Service Based Architecture Mobile Work Order Notifications Slide 20

21 Storage & Handling The Storage and handling of new lubricants is often the most overlooked Proactive Maintenance practice in industrial plants. Good storage and handling practices will: Reduce the practice of overstocking lubricants Reduce the need for costly emergency deliveries Reduce the possibility of using outdated lubricants (shelf life) Decrease contamination levels due to moisture and airborne contaminants Reduce the possibility of cross contamination Increase equipment reliability! Slide 21

22 Storage & Handling Packaged Lubricants: Small packaged items should be stored in a dedicated cabinet. Properly labeled using a Color Coding System to reduce cross contamination. Drums should be stored in a lubricant facility in such a way that reduces the ingression of external contamination. Bulk lubricants should be: Protected from; air borne contamination, extreme temperatures, humid conditions, chemical fumes and ultra violet rays. Segregated Labeled Color & Lubricant Code Slide 22

23 Storage & Handling Drums & Dispensing Tools should be stored in a lubricant facility in such a way that reduces the ingression of external contamination. Drums & Dispensing Tools need be segregated and labeled based on a Color Coding System to reduce cross contamination. Slide 23

24 Storage & Handling A facility used for the storage and dispensing of lubricants should be: Lube Shed Separate from other plant materials and liquids. Safely accessible to Lube Technicians Free of airborne particulates, wet/humid conditions and chemical fumes. Climate controlled. Equipped with containment to avoid environmental spills. Slide 24 Lube Rooms

25 Storage & Handling Storage Locations IntelaTrac can easily be used for performing house keeping and structural audits that can be performed by your lubricant vendor or Lube Technician. Reports can be sent to management personnel responsible for enforcing compliance. IntelaTrac can be used to maintain inventory in your lubrication facility. Lubricant vendors, Technicians or Operators can perform routine rounds that account for needed supplies. A low supply can generate an ed report to a vendor or person responsible for reordering supplies. Slide 25 Lube Rooms

26 Condition Monitoring The condition monitoring of lubricants is a means by which to transition your facility from reactive to predictive and proactive. It will provide the data necessary for the early detection of failures and the ability to counteract potential failures before they occur. Some of the tools that can be used to achieve this are: Predictive and Proactive Tools: Oil Analysis Shock Pulse Monitoring Temperatures Routine Surveillance Slide 26

27 Condition Monitoring Oil Analysis Oil is the life blood of rotating equipment. In turn, it should be monitored to maintain equipment health. This is done through oil analysis. There are three primary areas of testing related to oil analyses. Oil Chemistry Machinery Wear Oil Cleanliness = IntelaTrac can integrate with your LIMS interface to pull oil analysis data into a mobile device to trigger proactive maintenance Tasks at the point of inception. If oil samples are being analyzed within a plant, IntelaTrac s LIMS integration will assist in dynamically creating, scheduling and processing routine oil samples. Slide 27

28 Condition Monitoring Shock Pulse The Pruftechnik Vibtool: Trend potential changes in oil film thickness Detect bearing failures Slide 28

29 Condition Monitoring Temperature Trending the temperature of a lubricant Trending the Temperature of a Surface in Contact with a Lubricant Slide 29

30 Condition Monitoring Surveillance Routine Surveillance Monitoring Oil Levels Checking for abnormal conditions (i.e. Leaks, Vibrations, Noises Checking the condition of lubricant devices (i.e. Greasers, Oilers, BS&W bulbs) Slide 30

31 Condition Monitoring Results Lubricant Integrity is understanding the limitation of a specific lubricant and operating equipment within those parameters. CLEAN Set oil cleanliness standards for each lubrication point. COOL Set high and low temperature limits for each piece of equipment. DRY Drain free water and report emulsified oil immediately. It is easy to monitor and report. It takes effort to react and correct. It is reaction that builds reliability. By reacting to the Predictive you predict the reactive! Slide 31

32 Contamination Control Contamination control is the ultimate goal of the entire lubrication program. By eliminating sources of contamination you remove potential failure mechanisms. Therefore, you are being proactive. Once contamination has reached our equipment either through poor design, improper handling or just simply wear, there are means of controlling the contamination. Some of these methods are: Inline filtration for forced fed systems Oil changes (frequency depends on equipment) Kidney loop filtration through the use of filter carts or permanently mounted filter skids. Purge systems (nitrogen sweep or oil mist) operational if equipped High velocity flushing Slide 32

33 Contamination Control Purification units require monitoring when connected to a machine and maintenance to maintain their readiness. Required PM s and ad-hoc surveillance rounds are now much easier to apply with IntelaTrac 4.3. Slide 33

34 Lubrication Management System Note: System currently under development Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are pr oprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

35 Lubrication Management System Slide 35

36 Step 1 Prioritize Activities The flow of work will start with the LMS having the ability to prioritize specific lubrication activities along with their assigned assets. The prioritization process is to remain dynamic having the ability to update automatically based on completed activities and conditional based findings. Priorities will be based on but not limited to the following criteria: Slide 36 Equipment Criticality Calendar/Run Based Timing since last activity Criticality of Activity Overdue Task Priority Progression

37 Step 2 - Create A Round Once activities are prioritized the LMS will need to have the ability to sort through these activities and group them into a proposed PM round based on but not limited to the following criteria: Slide 37 Operating/Permit Area Lube Type Activity Type Required Tools Required Materials Craft Capable of Completing the Work Man Hours per Activity Proper Activity Status

38 Step 3 - Assign Work Order After a round is created, the LMS will require the ability to call on the CMMS for an assigned Work Order number and attach that number to the title of the round. At this point it will simply be a request awaiting approval and scheduling. Data recorded to the CMMS Work Order from the round will be based on site specific requirements. An example of such data will be: Slide 38 Craft Man Hours Required Materials Tools Summary of Activities

39 Step 4 Approve & Schedule It will be the duty of Planner/Scheduler to approve and schedule all lubrication PM s initiated from LMS. This approval process will be determined by the available manpower for a given time frame. Slide 39

40 Step 4 Cont. Operator Prep During the prioritization process some planned PM activities can be thwarted by equipment operating Status. This creates further difficulties in completing planned activities. While this problem cannot be totally eliminated due to plant operational conditions, operation awareness can assist in equipment status preparation ahead of time. This can be completed with synergies between operational rounds and planned PM activities. This in turn assist with better time management and wrench time. Slide 40

41 Step 4 Cont. Additional Manpower If additional manpower becomes available during a specified work period, additional PM work orders can be generated by reverting back to Steps 2 & 3. The dynamic ability of the priority process will allow for the most up to date PM activities to be available. Activities that don t get scheduled will be reprioritized for future work plans. Slide 41

42 Step 5 PM Completion The approval and scheduling of a work order will allow the round to be released to the Mobile device for completion. The round will be assigned to the proper craft within a specific permit area. The craft assigned the round will then carry out the activities in the designated time frame. Note: Some user application data will be dynamic within an activity depending on when an activity is completed (E.g. Grease quantities will vary based on the amount of days since the last applied amount) Calculations on the mobile device will be required in order to adjust application data for these activities. Slide 42

43 Step 6 Incomplete Activities Activities will be carried out in the field as time permits. There are many factors that can effect activity completion negatively that are out of the control of the technician. These incomplete activities will need to be identified in the LMS and reprioritized for future work plans. Slide 43

44 Step 7 Completed Activities Completed activities are to be updated in the LMS and CMMS as they are completed. Data recorded to the CMMS will be based on site specific requirements. An example of such data will be: Slide 44 Summary of Activities Completed Start Time Completion Time Materials Consumed

45 Step 8 Conditional Findings Conditional findings will be generated from routine PM activities from time to time. These findings will either be directly related to the PM activity or non-pm related. The following work flow is to occur based on the type of condition: PM related findings will need to be captured in the LMS along with its predefined proactive activity. Some of these activities will be added to the prioritization process for completion at a later time or completed at the point of inception. Non-PM related findings will be sent directly to the CMMS system in the form of a Work Request. Slide 45

46 Work Flow Complete The flow of work will end where it started by capturing field data from routine and conditional based activities. The data produced from these activities will be fed back into the prioritization process at variable rates depending on the activity itself. The results of the data can produce additional PM activities that will be scheduled based on the criticality. Slide 46

47 Lubrication Resources Slide 47

48 Lubrication Front End Study John Craighton - CLS & OMA I Certified Jack.Craighton@Invensys.com Mobile: Slide 48

49 Lubrication Training & Certification Resources Society of Tribologist & Lubrication Engineers for CLS & OMA Certifications Noria for ICML Certifications MLA & MLT IntelaTrac s Operator Rotating Equipment Training Contact your Invensys/Wonderware Sales Representative Slide 49

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