Maintenance Data Support - For Clients 1

7/31/2019 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


Time


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


Time


Time


Closed

work permit

closed


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


Time


Time


Closed

work permit

closed


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


Time


Time


Closed

work permit

closed


failure code

Remarks


Time


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


Time


Time


Closed

work permit

closed


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


failure code

Remarks

Date Plant Equipment ID Location ID Equipment Description Maintenance

Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No


Time


Time


Closed

work permit

closed


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


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




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


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




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


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)

Documents

Maintenance Data Support - For Clients 1