maintenance data support - for clients 1
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Data Management
ForIndustrial PlantMaintenance
EAM Services
Griha Software Technologies
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About Griha Software
Technologies Grihasoft is one of India's leading companies providing Data
Management Services to many global clients.
Grihasoft provide classification (UNSPSC, eCl@ss etc), item
master data cleansing, data enhancement and spend analysisetc which helps eProcurement/supply chain/materialmanagement (MM)
In the plant maintenance (PM) area we generate theequipment data, asset Management strategy, planning &
scheduling and Data management and mining to help clientsrealise the full potential of their EAM system
Grihasoft serve many global clients across US, UK, MiddleEast, South Africa and Australian markets.
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EAM Services
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Why Equipment fail?
Because the components fail
Why components fail?
Because they are designed to fail
Yes. Equipment have surfaces with relative motionand are built with wear components which will haveto fail after its design life.
Maintenance is all about realizing the designed lifeand changing the components in a planned mannerat the end of their design life before failure
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Maintenance function
Industrial plants have scores of machinery and theyhave to be serviced periodically to keep the plantrunning
In complex plants the equipment are seriallyconnected and every one of the equipment has tobe running to achieve production objectives
Frequent break downs will result in productionoutages and the plant will become uneconomical
The only purpose of the maintenance team is tokeep the plant running to meet the productionobjectives
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What is trouble shooting?
Every failure has to be fully understood and correctivemeasures taken to prevent repetitive failures
Trouble shooting is to pin point the exact reason for anyfailure
Correction is to eliminate the very reason for such failure If this is not done systematically we will end up in having
failures after failures in the plant To trouble shoot we need reliable data And the data analysis is the key to successful plant
maintenance And therefore accurate data availability is a must
The truth is that many plants have never been in a position tosay that they are current with their data.
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Current Scenario
Plants are faced with a growing backlog of un-posted work orders into their CMMS.
The requirements needed to keep the newlydeveloped database maintained with the latestsystem changes are frequently underestimated.
The timeliness and accuracy of this data is a criticalrequirement to the cost-justifying applications.
The application of the information technologyconcept of outsourcing can be an alternateapproach for plants trying to reduce datamaintenance costs, increase the reliability of theirdatabases, and accelerate the speed with whichdecisions can be made.
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The four types of support
Type 1 -First time collection and posting all relevant data forthe new EAM system to be operable from Day 1 including theasset management strategy build Green field projects
Type 2 - Migration from legacy system to a new system -
Reviewing the existing data, re-strategizing the assetmanagement approach and updating the data to reflect theplant as of today
Type 3 - Periodical review say every 5 to 10 years - of thetotal asset management strategy in the light of the pasthistory, current trends, technology, safety and environmental
needs Type 4 - Day to day up keep of the maintenance data to
keep the system data current a crucial step to ensure rightdecisions
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Type 1 -First time collection
and posting This is associated with new plants or plants getting into a
CMMS environment Asset Management Strategy build is an essential part of this
work
Strategy will include creating the asset register, rating thecriticality of each asset, building the maintenance strategy foreach piece of equipment, writing the equipment Maintenancetask lists, setting the frequency and scheduling them
Facilitating the system to provide all the necessary reports forperformance evaluation
All these ideally should be in place before commissioning theplant And will need a good team of well experienced maintenance
professional from the service provider driving the project
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Type 2 - Migration from
legacy system This is a requirement from all the operating plants Most of them migrating from a stand alone CMMS
to a PM module of an ERP like SAP, Oracle and
others Reviewing the strategy and re-working the
maintenance task list is an essential part of thisexercise
Building additional data for facilitating better
approaches like RCM and reliability analysis Data to include all the engineering changes done to
the plant in the past including physical verification
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Type 3 - Periodical review
Over the years the priorities in a plant is bound tochange due to revised production objectives, thepast performance, safety and environmental
realities and above all the need for continuousimprovement The review is based on the history available from
the CMMS data and can very well be carried outmostly offshore with some site visits
In house analysis may not be the right choice dueto lack of time for such work and further it may notbring out the real issues to the fore
The external agency will have no hesitation incalling a spade a spade.
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Type 4 - Day to day up keep
System with incomplete data is as good as no data Decisions are taken based on data from memories and can be
very wrong Expecting the technicians to enter the data after the days
work from his log has been a dream never realised fully If the log data is posted by an external agency the data would
not be lost and will be available for the decision making It will be an added feature if the external agency is capable of
identifying meaningful trends from the data for the ready useof the client Like flags
In complex systems right fist time is the mantra andrepetitive repairs have known to damage the integrity of theotherwise sound equipment
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Outsourcing is the solution
To address this ongoing problem,plants & utilities are evaluating the
possibility of outsourcing their datamaintenance and updating activities inorder to reduce their associated costs,
improve turnaround, and operate theirsystems with near 100 percentreliability.
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CONCLUSION
By outsourcing data maintenance activities, plantsachieve a level of assurance that their datamaintenance requirements will be consistently metand that their internal resources can be directed tothe more pressing tasks of serving their customers
Data maintenance is one of the first and easiestfunctions plants can outsource. Compared to in-house solutions, they can expect their real costs todecline, and their information accuracy and
timeliness to increase. At the same time, they canre-deploy those in-house resources -- people,equipment, space and time -- to mission criticalactivities that will better benefit their top andbottom lines.
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What can we learn from
Maintenance History?
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Organized data can add to our understanding of ourasset performance
This is what GRIHA can do
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Maintenance Performance AnalysisDate Plant Equipment ID Location ID Equipment Description Maintenance
Type
Maintenance
Task List No.
Work Permit
No
Safety
Lockout No
Supervisor Technicians Work Start
Time
Work Done Work Complete
Time
Spares Used Tools Used Safety lockout
Closed
work permit
closed
Reason for failure - indicate
failure code
Remarks
S. No. Plant Equipment ID Location ID
Griha converts the maintenance history of each equipment to
this format If the data is fully available from either log books or
the work order details. From this format the following analysis
is possible
Equipment Description Maintenance
Type
Maintenance
Task List No.
Work Permit
No
Safety
Lockout No
Supervisor Technicians Work Start
Time
Work Done Work Complete
Time
Man Hours and
cost of labour
Spares Used and cost Total Cost of Maintenance Tools Used Safety lockout
Closed
work permit
closed
Remarks
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The history gives us cluesDate Plant Equipment ID Location ID Equipment Description Maintenance
Type
Maintenance
Task List No.
Work Permit
No
Safety
Lockout No
Supervisor Technicians Work Start
Time
Work Done Work Complete
Time
Spares Used Tools Used Safety lockout
Closed
work permit
closed
Reason for failure - indicate
failure code
Remarks
S. No. Plant Equipment ID Location ID
Searches of one particular ID can add to our understanding of the equipment behavior.Comparing similar equipment can give us insight into the problem area such as locationfaults, service faults, operational defects, lack of training and othersKPI Overall Equipment Effectiveness - OEE
There are particular locations which prove to be adding additional problems to the equipmentsuch as dusty locations, presence of acidic vapors, inherited construction faults, and manyothers
Plant-wise analysis can give comparative maintenance performance between plants.Repetitive failures of a particular type can indicate lack of trained personnel.Key Performance Indicators Plant Availability as %
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Maintenance TypeDate Plant Equipment ID Location ID Equipment Description Maintenance
Type
Maintenance
Task List No.
Work Permit
No
Safety
Lockout No
Supervisor Technicians Work Start
Time
Work Done Work Complete
Time
Spares Used Tools Used Safety lockout
Closed
work permit
closed
Reason for failure - indicate
failure code
Remarks
Equipment Description Equipment type Maintenance
Type
Equpt. Type code if not already available is added by GRIHA and failure analysis
type-wise can add valuable input to our trouble shooting capability, particularlywith regard to skill levels of the workmen , equipment selection criteria andothers
Maintenance type like Preventive, Breakdown, corrective, condition based etc., are clear
indicators of our maintenance work performance. The ratios of one with the others sayplenty on our ability to create an optimum Asset Management Strategy
KPI PM Effectiveness B/D Vs PM Ratio, Condition Monitoring Effectiveness
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Time to Repair
Repetitive failures under a supervisor or technician can indicate trainingneeds .Repetitive failures are sure indicators of poor reliability
D
at
e
Plant Equipment ID Location ID Equipment Description Maintenance
Type
Maintenance
Task List No.
Work Permit
No
Safety
Lockout No
Supervisor Technicians Work Start
Time
Work Done Work Complete
Time
Spares Used Tools Used Safety lockout
Closed
work permit
closed
Reason for failure - indicate
failure code
Remarks
Supervisor Technicians Work Start
Time
Work Done Work Complete
Time
Duration of work computed from start and completion time indicates thetime to repair. MTTR, Mean Time To Repair is an important performance
measure. This can lead to strategic decisions on improving repair facilitiesor adding RotablesThe average run time between failures is MTBF, a very important measureof the reliability of the equipment
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Cost of Maintenance
Man Hours
and cost of
labour
Spares Used and cost Total Cost of Maintenance Tools Used Safety lockout
Closed
work permit
closed
Remarks
Date Plant Equipment ID Location ID Equipment Description Maintenance
Type
Maintenance
Task List No.
Work Permit
No
Safety
Lockout No
Supervisor Technicians Work Start
Time
Work Done Work Complete
Time
Spares Used Tools Used Safety lockout
Closed
work permit
closed
Reason for failure - indicate
failure code
Remarks
Key input to determine the crew size and reduce the Mean Time To Repair MTTRCost of labor is key to the economics of asset managementForms a significant part of the total cost of maintenance
Cost of Spares used is another significant factor for the total cost of maintenance
Repetitive consumption of a particular component can trigger investigations oncomponent life/ procurement source/maintenance requirements
THE Most Important criteria for assessing cost effectiveness of maintenanceWill play a major part in the Total Life Cycle Costing of the assetKPI Cost Maintenance Vs Budget Vs Replacement Cost of Equipment
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Failure Analysis is key to successful
asset management
work permit
closed
Reason for failure - indicate
failure code
Remarks
Date Plant Equipment ID Location ID Equipment Description Maintenance
Type
Maintenance
Task List No.
Work Permit
No
Safety
Lockout No
Supervisor Technicians Work Start
Time
Work Done Work Complete
Time
Spares Used Tools Used Safety lockout
Closed
work permit
closed
Reason for failure - indicate
failure code
Remarks
The single most important data for analysis.MAINTENANCE IS NOT COMPLETE UNLESS WE KNOW
WHY AN EQUIPMENT FAILED AND TAKE CORRECTIVEMEASURES TO AVOID RECURRENCE
GRIHA uses standard failure codes
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Reliability Case Study
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Typical Log Book ExtractLog Book Extract of a typical thermal power plant - Equipment - 07-J-101A,B and C - Boiler feed pumps - 70 Hp 3000 Rpm Multistage
07-J-101A - PM done - Task list No: 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump check ed for free rotation, for axial movement and
radial movement - found ok - inboard and outboard bearing oil drained and observe
07-J-101B - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and
radial movement - found ok - inboard and outboard bearing oil drained and observed OK
07-J-101C - PM done - Task li st 121 - Isolated pump, decoupled pump from motor, Checked coupl ing for wear - OK , Pump checked for free rotation, for axial movement and
radial movement - found ok - inboard and outboard bearing oil drained and observed OK
07-J-101A - Oil Analysis report received - Copper particles from cage seen confirmed in oil - raised work order to change oil again - changed oil - oil again sent for lab analysis -
David/28-9-2004 - 2 Hrs - 1 Technician
07-J-101 A,B,C -Vibration analysis Task List No 119 c arried out on A and C and changed over C to B and took readings on B - B and C velocity readings are normal within limit in
the "SLIGHTLY ROUGH" region and A had moved from slightly rough to"ROUGH" regi
07-J-101A pump taken for maintenance - isolated - decoupled - bearings inspected - radial movement at the bearing was high indicating radial bearing wear - Oil found
contaminated with c opper particles again - Work Order generated for corrective maintenanc
07-J-101A - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and
radial movement - found ok - inboard and outboard bearing oil drained and observed OK
07-J-101B - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and
radial movement - found ok - inboard and outboard bearing oil drained and observed OK
07-J-101C - PM done - Task li st 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and
radial movement - found ok - inboard and outboard bearing oil drained and observed OK
07-J-101 A,B,C -Vibration analysis Task List 119 carried out on A and B and changed over B t o C and took readings on C - Readings on all three pumps were normal with velocityreadings showing "SLIGHTLY ROUGH" range at the bearings- However Pump A indicate
07-J-101A - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and
radial movement - found ok - inboard and outboard bearing oil drained and observed OK
07-J-101B - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and
radial movement - found ok - inboard and outboard bearing oil drained and observed OK
07-J-101C - PM done - Task li st 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and
radial movement - found ok - inboard and outboard bearing oil drained and observed OK
07-J-101 A,B,C -Vibration analysis Task List 119 carried out on A and B and changed over B to C and took readings on C - Readings on B and C pumps were normal with
velocity readings showing "SLIGHTLY ROUGH" range at the bearings- However Pump A had moved
07T-J-101A - Vibration Analysis carried out on the Pump A - Vibration readings were around the same level as that of 20-5-2005 - However the bearing oil had fine copper particles
and maintenance stopped the pump and changed the oil - The repeat of the bea
07-J-101A - PM done - Task list No: 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump check ed for free rotation, for axial movement andradial movement - found ok - inboard and outboard bearing oil drained and observe
Suggest Hyperlinking
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Pump 101 A History07-J-101A Pump
History Date Supervisor Type of Work Task List No. Work Done Man Hours Spares Used21/9/2004
From 0800
Hrs to 1600
Hrs
David PM 121 Isolated pump, decoupled pump from
motor, Checked coupling for wear - OK ,
Pump checked for free rotation, for axial
movement and radial movement - found ok -
inboard and outboard bearing oil drained
and observed - Found shiny brass like
metal particles
16 MHrs
2
Technicians
for 8 Hrs -
Micheal and
Mathew
Lube Oil No. 13632
Coupling Grease No.
34
Standard Technician
Tool Box
28/09//2004 David Corrective Lube 89 Oil Analysis report received - Copper
particles from cage seen confirmed in oil -
raised work order to change oil again -
changed oil - oil again sent for lab analysis
1
Technician
30 Minutes
lube iol No 13632
25 /10/2004 David Cond it ion Moni toring CM 12 Vibrat ion ana lys is Task List No 119 carried
out on A and C and changed over C to B
and took readings on B - B and C velocity
readings are normal within limit in the
"SLIGHTLY ROUGH" region and A had
moved from slightly rough to"ROUGH"
region at the outboa
CM
Tecnician
IRD 880 Vibration
Analyses
26/10/2004 David Corrective
Maintenance
TL126 pump taken for maintenance - isolated -
decoupled - bearings inspected - radial
movement at the bearing was high
indicating radial bearing wear - Oil found
contaminated with copper particles again -
Work Order generated for corrective
maintenance - Task l
32 M Hrs
2
Technicians
Radial Bearing Part
No 34567
Lube Oil No. 13632
Coupling Grease No.
34
Standard Technician
Tool Box
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A typical reliability analysisReliability Analysis from the data available
Time Between Failure = 300 Hrs for 07-J-101A while B&C are running normal
Bearing life is about 300 Hours. It is very low. Expected life of antifriction
bearings is as per the chart along side. A well selected industrial pump bearing
should achieve 40000 Hrs of life provided, it is selected properly, storedproperly, fitted properly, lubricated properly and loaded as per design
Basic Rated Life of Bearings:
The basic rated life is defined as the number of revolutions that ninety percent of a group of
identical bearings would be expected to achieve. It is determined via the life required of the
bearing. Typical life requirements for various machine categories are listed below.
Machine Usage Type Life Required of Bearings (Hours)
household appliances intermittent use 300 - 3000
hand tools, construction equipment short period use 3000 - 8000
lifts, cranes high reliability for short periods 8000 - 12000
8h/day gears, motors full day partial use 10000 - 25000
8h/day machine tools, fans full day full use 20000 - 30000
Continuous use 40000 - 50000 HrsConsidering that the other pumps are running normal, we have to suspect one of the operating conditions of
pump A
Pump A is putting undue load on the bearing
There are two indications from the data available1. The 6X frequency is indicating some cavitation conditions on this pump. This is possible if the number of vanes
in the impeller are six
Considering the pump A alone is failing it could be restrictions on suction flow to pump
Check suction side of the pump for flow restrictions
2. The pump is getting misaligned and requires correction. It is suspected that the piping could be pulling the
pump especially when the lines are hot. Part the flanges at suction and discharge to ascertain pipe pull. Correct
by adequately adjusting the pipe supports
3. Ensure that the bearing has been sourced from autherised suppliers
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Prequalification DocsPREQUALIFICATION QUESTIONNAIRE
CONTENTS
Bidder is requested to complete the following questionnaire and submit within its tenderdocument:1. COMPANY & FINANCIAL DETAILS2. ADDRESSES & CONTACTS3. FACILITY DETAILS4. QUALITY5. HEALTH, SAFETY & ENVIRONMENT
6. TRACK RECORD7. CURRENT & PROJECTED WORKLOAD8. LIST OF MAJOR CLIENTS9. SUBCONTRACTED SERVICES10. ASSOCIATION WITH EQUIPMENT MANUFACTURERS
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Attachments
ATTACHMENTS (scanned copies to be inserted in these Attachments)Attachment 1 Management Organisation ChartAttachment 2 Audited Financial StatementsAttachment 3 Facility Location MapAttachment 4 CVs of Key PersonnelAttachment 5 Quality Certification, System Details, Organisation and Key Personnel CVsAttachment 6 HSE Management System Details, Organisation and Key Personnel CVs (including any
attachments requested in Section 5 of this Questionnaire)Attachment 7 Commercial Registration & Certification for Trading in Qatar + Tax CertificateAttachment 8 Company Profile & BrochureAttachment 9 Additional Information (if required)