CH HGRS Maintenance

7/21/2019 CH HGRS Maintenance

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Welcome to Maintenance

Maintenance

Introduction to Cement and Concrete

HGRS / CTS / MER

August 24, 2006

Eric Laancette


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August 2006Hocim Grou! Su!!ort Introduction to Cement Concrete " Aggregates

#$%ecti&es 'or Toda(

Enhance understanding of:

T)e *e( success 'actors in t)e Maintenance

+rocess

T)e im!act o' Maintenance on Manu'acturing

+er'ormance


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Agenda

Introduction to maintenance

Ins!ections

+anning

o$ e-ecution

Summar( " concusion


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.)at are e doing

Maintenance Team at Hocim Grou! Su!!ort

To $e t)e tec)nica e-!ertise turnta$e 'or maintenance int)e Hocim Grou!

Su!!ort t)e !ants / com!anies in t)eir goas o' o!timi1ing

o&era asset e''ecti&eness

M+Rs

Maintenance Assessment

MAC Im!ementation and Sustaina$iit(

Training in Maintenance

Re&ie o' 3uait( and esign o' E5ui!ment

Condition Monitoring Root Cause aiure Ana(sis


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.)o are e

Hans 7urger

Monia 7en1oni

Tan%a Meier

Andreas Steinmann

Arturo de a Te%era

anie Reiser

Eric Laancette

Eric Lan1

Hans 78rtsc)i

Hoa 9an Le

Ignacio :a1

;icoae 7ara

Ren< 7ur*)ater

Risto Sc)mid

Rodo'o Tigao

Ste'an e*en

T)omas R)einegger

T)omas Stut1

=a&ier Andries


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e'inition o' Maintenance

To maintain and restore the desired

condition

To define and assess the actual

condition

> of technical assets.

?E5ui!ment " Com!onents,7uidings, S!are +arts@@@


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E&oution o' Maintenance in Industr(

Break downmaintenance

Fix it when itbreaks

State of the artLubrication

Inspections

Conditionmonitoring

Root CauseFailure nal!sis

Failure histor! ofparts ande"uipment

#re$enti$emaintenance

Relationshipbetween failureprobabilit! andage

S!stem forplanning andcontrolling

#lanned

maintenance

Inter$entionsbased oncondition

%esign forreliabilit!

Risk ssessment

Conditionbased

maintenance


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.ea* +oint Eimination

7rea*dons eiminated$( remo&a o' causes

Causes o' $rea*dons do not

)a&e to $e continuous(

re!aired eimination o' ea*!oints

#!timum

Re5uirement

Re5uirement

Increased A&aia$iit(

Reduce Maintenance Cost

Reduce B o' sto!s / MT7 Re5uirement


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&aintenance

BRE

'%()*

&I*+E**

CE

#lanned&aintenance

#re$enti$e&aintenance

Correcti$e&aintenance

Reliabilit! nal!sis

Condition&onitoring Repair

&odi,ficationSe

r$ic

e

Repl

ace

Lubrica

te-calib

rate

-cle

an-etc

.

Repla

cem

ents

-weld-

etc

.

)alk,B

!In

spectio

n

/ib

ratio

nnal!

sis

(il

nal!

sis

)ear

&easurements

*on,%

estructi$e

+esting

&oto

rC

urrent

nal!

sis

+h

erm

ograph

!

Spec

ific

&easuremen

ts

Reliabilit!0

&aintainab

ili!

impro$em

ents-weak

point

optimi1ation-et

c.

2ctionstorestoreanitem

to

astateinwhichitcanpe

rform

itsre"uiredfunction2

#areto nal!sis Root Cause Failure nal!sis

Condition $ased

Maintenance


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.)( do Ma%or E5ui!ment 7rea*dons #ccur

esign and manu'acturing o' e5ui!ment

Inade5uate 5uait( o' e5ui!ment

#!erating imits Im!ro!er o!eration

Maintenance

;ot ade5uate( maintained E-ceeded ser&ice i'e

House*ee!ing


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Ma%or $rea*dons can $e a&oided ?/D

7( correctinge5ui!ment %esign

7( detecting de'ects during

t)e manufacturing!)ase 3uait( Contro o' E5ui!ment

?3CE


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Ma%or $rea*dons can $e a&oided ?2/D

7( correct (peration!rocedures


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7( esta$is)ing an a!!ro!riate &aintenancestrateg(

+ime to Failure+ime to Failure

22Cr

itical3

Cr

itical3

22Essential3

Essential3

22Fre"uent3

Fre"uent3

CostofL

ost#roduction

CostofL

ost#roduction

4radual %egradation4radual %egradationSudden FailureSudden Failure

(n,line(n,lineSur$eillanceSur$eillance

S!stemsS!stems)alk,round)alk,round

%ata Collectors%ata Collectors

and nal!1ersand nal!1ers

)alk, round)alk, round

Inspection routinesInspection routines

Mont)sMont)s .ee*s.ee*s a(sa(s HoursHours MinutesMinutes SecondsSecondsearsears

555555

5555

55

)alk b!

(ff line

(n line

Ma%or $rea*dons can $e a&oided ?D/D


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#$%ecti&e

Eiminate or reduce ris* o' ma%or $rea*dons

6ualit!

Control ofE"uipment

Condition

&onitoring

#re,operation (peration

F%esign Re$iew

F)orkshop Inspections

FInstallation andCommissioningSuper$ision

FBaseline %etermination


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7asis .)at does 3CE mean

3CE means 3uait( Contro o' E5ui!ment and is a

3uait( assurance !rocess a!!ied during t)e design,

manu'acturing, instaation and commissioning o' critica

com!onents / e5ui!ment

6CE


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.)( is 3CE ;ecessar(

o (ou ant to sto! (our *in

)en t)e mar*et is rea(

$ooming

Ha&e (ou got t)e time 'or t)is

re!air i' (our sios are em!t(


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Common +ro$ems ?3CE

4GHD2H

6H4HCCH

without

small

medium

large

discarded

+otal number inspections: 789

Le$el ofcomplaint

ision dateI

3CEStatistics 3uait( Le&e 200D


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#!eration Condition Monitoring

.)at is Condition Monitoring

etermine t)e condition o' t)e e5ui!ment t)roug)ins!ections at a gi&en 're5uenc(

Identi'( and ana(1e de&iations 'rom re5uired e&es Initiate actions to correct t)e situation

C&


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/isual

Smell

udio

+ouch

.a*$( ins!ections


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.a*$( ins!ections


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&isalignment

nbalance

Looseness

Lubrication

#''ine ins!ections


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#''ine Ins!ections ?E-am!e I an

7rea*don,

Maintenance

emergenc(


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FMotor MonitoringMotor Monitoring

FReducer MonitoringReducer Monitoring

FRotation measurementRotation measurement

FMotor Current (out of PLC System)Motor Current (out of PLC System)

FTemperature (out of PLC System)Temperature (out of PLC System)

FDifferential pressure (out of PLC System)Differential pressure (out of PLC System)

&onitoring concept

#nine Monitoring


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#nine Monitoring ?E-am!e Gear Cou!ing


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Jin ontime Causes

T)e 'ooing is a t(!ica $rea*don o' t)e dontime

causes 'or a *in

re5uenc( o' s)ut2do/ns Causes o' s)ut2do/ns

K0H 7ric* ining 'aiures

0H Mec)anica 'aiures

6H Eectrica 'aiures

4H #t)ers


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Radia e'ormation and its E''ect


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#nLine Ins!ections Jin S)e Tem!eratures


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Learn *e( success 'actors 'or e''ecti&e

MaintenancePlanning

to ensure a consistent de'inition and understanding

o' acti&ities to o!timi1e dontime and a&aia$iit( o'e5ui!ment

to ensure on time a&aia$iit( o' resources and!re!aration o' or* to a&oid contingencies causing

additiona maintenance e-!enses

#$%ecti&e


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Maintenance +anning

;ob Execution

+anned

S)utdons

T)ree e&es

o' !anning

&aintenance#lanning

Condition &onitoring

.or* #rder S(stem

Management S(stem


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T)e Maintenance Management S(stem

D

2

Budget

%ail!plan

SIC

nnual&aint. #lan

7< weekplan

)eekl!plan

)=(

*otification

%ail!Report

&onthl!Report

)eekl!Report

%ail!meeting

%ail!meeting

)eekl!

#lanningmeeting

&onthl!#rod. plan

Re!ort and

ata Ana(sisE-ecution+anorecast

%%%%

&onthl!

Re$iewmeeting


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Master Sc)edue / .ee*( / ai( +anning

.ee*( +an

ai( +an

MaintenanceMaster

Sc)edue

+ersonneMaterias

Toos

+rocedures

+roduction !an

ai( .or*

.)en to sto!


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.or* #rder S(stem

T)e .or* #rder is t)e &e)ice o' !anning

Rootcauseana(sis

E-ecutionCondition#J

Create;oti'ication

Create a.or*#rder

+ant)e#rder

#rderCon'irmation

Sc)edue

t)e #rder

nacce!ta$econdition


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+anned S)utdons

Shutdown

It is a +ant e&ent ;#T a Maintenance e&entNN

&R'E+

E6I#&E*+

#E(#LE

T) S i Hi ) M * t d


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ocus on reducing e-ecution time 'or acti&ities Ensure 5uait( o' or*

7aance o' cost &s duration o' t)e s)utdon is re5uired #!!ortunit( cost 'or ost !roduction

A&aia$iit( and Reia$iit( o' e5ui!ment is critica

Hig) mar*et demand

T)e Scenarios Hig) Mar*et emand

T) S i L M * t d


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ocus on Cost reduction Im!ro&e on a$or !roducti&it( and 5uait( o' or* #!timi1e t)ird !art( ser&ices #!timi1e i'e o' s!ares )ig)er ris* &s )ig)er cost

Time is ess critica

Lo mar*et demand

T)e Scenarios Lo Mar*et emand

+ d S) td +


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+anned S)utdon +rocess

A continuous c(ce

%efinitionA'terActionRe&ie/ Meas

urestoim!ro&e

Condition&onitoring

#reparation

+rogress Re&ie

#lanningnal!sis

C(ceTimeCom!ression

Execution

+anning meetings

Acti&esu

!er&is

ion

#$% ti


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#$%ecti&e

Learn *e( success 'actors 'or e''ecti&e

J b Executi n

to ensure or* is done

it) t)e rig)t 5uait( in order to not )a&ing to

re!eat it it)in t)e aocated time in order to o!timi1e

t)e e5ui!ment dontime

t)is )as a direct im!act on e5ui!menta&aia$iit( and maintenance e-!enses

T)e Im!ortance o' o$ E-ecution


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T)e Im!ortance o' o$ E-ecution

T)e num$er o' o!!ortunities to do maintenance on t)e

e5ui!ment is imited

It is t)e time to im!ro&e t)e condition o' t)e e5ui!ment

It is t)e most e-!ensi&e !)ase in maintenance in terms

o' time and mone(

It is )ere t)e 5uait( o' or* must $e em!)asi1ed

T)e +re re5uisite to o$ E-ecution


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T)e +rere5uisite to o$ E-ecution

Condition Monitoring is t)e starting !)ase to %o$

e-ecution and aos to !re!are actions

T)e !anning !)ase is t)e de'inition and !re!aration o'

actions to ensure a&aia$iit( o' resources

T)e *e( !oints to good %o$ e-ecution


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T)e *e( !oints to good %o$ e-ecution

S!are !arts

Toos Measurement e5ui!ment

Com!etent !eo!e

.or* #rders / +rocedures S)ort Inter&a Contro / E-ecution 'oo u!

Historica re!ort / Jnoedge s)aring

S)ort Inter&a Contro / E-ecution oo !


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S)ort Inter&a Contro aos>

To monitor and contro osses &ersus a !anned target

on a 're5uent $asis $( identi'(ing !ro$ems )ic) can

$e corrected in a time( manner

To c)ec* t)e or* status

To moti&ate !eo!e



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oo u! o' or* on a 're5uent $asis

Re&ie meetings it) com!arison o' !an &s@ actua andresc)eduing according(

Acti&e su!er&ision su!!orting and moti&ating or*ers

#nt)e%o$training, so&ing !ro$ems and gi&ing ad&ice

Concusions 'rom t)ese Maintenance a(s


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T)e 'irst o$%ecti&e as

En)ance understanding o' the ke! successfactors in the &aintenance #rocess

Condition Monitoring the basis to perform the right >ob?

+anning a compulsor! process to be prepared?

o$ E-ecution follow up to >ob execution is mandator!?



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T)e second o$%ecti&e as

En)ance understanding o' the impact of&aintenance on &anufacturing #erformance


&aintenance #roduction

$ailabilit!-Reliabilit! and&aintenance

Spending

C#E@

#rocess#arameters

%uration ofShutdowns

#lanning

6ualit! of )ork;ob Execution

&a>or 0 &inorBreakdowns

Condition &onitoring

de"uateE"uipment

&aterials=FR

(peration

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CH HGRS Maintenance