SKF Group Slide 0 - Maintenance engineeringmaintenance-engineering.eu/downloads/public/04 - Gerald Rolfe.pdf · Executive Business Manager – Marine SKF Service Division 2010-09-28

October 8, 2010 © SKF Group Slide 0

Establishing a successful Condition Based Maintenance programme

Presented to IMarEST Conference 2010

Prepared by Gerald Rolfe

Executive Business Manager – Marine

SKF Service Division

2010-09-28


Brief introduction to SKF

41 172 employees 124 factories 56 227 MSEK turnoverin 130 countries 450 channels >10 % operating margin7 000 distributors in 29 countriesEnvironment: Global ISO 14001 certification, OHSAS 18001 certifcation

SKF 2009


SKF Group Vision

To equip the worldwith SKF knowledge


What is SKF knowledge?


Idea or concept

Design & manufacture

Install & commission

Operate & monitor

Maintain & repair

Restore & upgrade

OEMPerspective

End UserPerspective

Overall customer & business perspective

Transferableknowledge


SKF in the Marine Segment


SKF and the ship life cycle

Maintain andimprove

Operate and monitor

Build and install

Concept and design

Product delivery

October 8, 2010 © SKF Group Slide 9October 8, 2010 © SKF Group Slide 9

SKF Marine – Key capabilities & ValuesConcept and design

Product delivery

Build and install

Operate and monitor

Maintain & improve

• Design and engineering• Calculation, simulation and verification• Testing & validation

• 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)

• Maintenance tools and recommendations• Root Cause Failure Analysis• Validation and optimisation of design

Enable new reliable designs & minimise risk of machinery failures and warranty costs

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

Range of maintenance engineering and consulting services to boost asset uptime

End-

Use

rO

EM


SKF Marine – Key capabilities & Values


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 (SOX/NOX/CO2)

Maintenance efficiency– Reduced time required for maintenance– Reduced consumption of spares

A safer and more profitable End User business


Profit

Cost of Plant (CAPEX)

Time

Operating Cost

(OPEX)

Revenue

(Output)

Payback point

The basic business model

2010-10-08 ©SKF Slide 12 [Code] SKF [Organisation]

Cost & Revenue


Payback point

Downtime

Payback point

Additional cost to repair machinery

Loss of availability & revenue

Profit ?

Why should we use condition monitoring?

Cost of Plant (CAPEX)

Time

Cost & Revenue


Condition based maintenance


Condition Based Maintenance process

System set-up

Data collection

Maintenance strategy

Maintenance complexity

Bus

ines

s im

pact

1

23

4

Upgrade and improvement

Remote analysis

Correction

AEO


Reliability Issues (Design)

Pre-Defined Priorities

Maintenance Strategy Project Business Goals

Preventive Maintenance ( time based )Proactive Reliability Maintenance( includes Predictive Maint. )Operator Driven Reliability ( observation )Run to Failure ( reactive maintenance )Root Cause Failure Analysis

PM =PRM =

ODR =RTF =

RCFA =

Maintenance Strategy Plant Asset Management and

Maintenance Program (Living Program)

PM PRM ODR RTF

RC

FA

PRM/ODR Collection and Analysis

Information Integration and Decision

Work Order Generation CorrectiveMaintenance

Operators

Initiators

Planning

Rolling Schedule

Standard Job Plansand Procedures

Spare Parts Alignment

Work Execution

Post Maintenance Testing

Update Program

Work Identification

Work Control

WorkExecution

Asset Efficiency Optimisation (AEO) process


Client needs analysis - output

This provides an objective basis for the future improvement plan


Auxiliary machines:•Motors, Pumps, Fans•LO & HFO Purifiers, etc

Periodic data

• Inaccessible Machines:• Hazardous pumps & fans

Semi-Online

Condition monitoring strategy

Critical

Medium

Sudden onsetfailure

Gradualdegradation

Fina

ncia

l Ris

k

Time to machine failure

Examples:

Required Scan Rate FastSlowLow

High

Cos

t per

Poi

nt Critical Machines:• Turbochargers• IG FansOnline

Turbo machines:• Compressors• GeneratorsCritical Online


Citrix/Application ServerCitrix Server@ptitude Analyst Application SKF Transaction Server

Database ServerOracle 10g@ptitude Analyst Database

CBM Service ProviderCitrix ClientVPNTCT application

Internet

Direct connection available only to authorised SKF

users

Workstation onboardCitrix ClientVPNTCT application

-Citrix ClientVPNTCT application

SKF

Net

wor

k

Citrix/Application ServerCitrix Server@ptitude Analyst Application SKF Transaction Server

Database ServerOracle 10g@ptitude Analyst Database

SKF Data Hosting Centre

Citrix ClientVPNTCT application

Internet

Direct connection available only to authorised SKF

users

Workstation onboardVisualisation ClientTCT application

Remote Ship systems

Ship OperatorShore based personnel

-Citrix ClientVPNTCT application

SKF

Net

wor

k

An Internet CBM solution


Other Condition Monitoring techniques

Online monitoring:Oil Particle count - e.g. Gearbox wear & contamination

Process data analysis - to identify abnormal operating conditions

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 oil particle sensor


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


Key issues to be considered


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)



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



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


CBM - Marine customer gap analysis


CBM - Marine customer gap analysis


Demonstrating value


Effective CBM contract management

Fleet Average Overdues Since start of SKF Contract

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

01/01

/07 01

/02/07

01/03

/07 01

/04/07

01-05

-0701

-06-07

01-08

-0701

-09-07

01-10

-0701

-11-07

01-12

-0701

-01-08

01-02

-0801

-03-08

01-04

-0801

-05-08

01-06

-0801

-07-08

01-08

-0801

-09-08

01-10

-0801

-11-08

01-12

-0801

-01-09

01-02

-0901

-03-09

01-04

-0901

-07-09

Reduction in Overdue data – To improve Assurance

Effective CM system support tracking – To ensure data integrity

Critical Machine Datasheets

-To improve

Knowledge of the Assets & accuracy of

Analysis

Support Case Trends

0

5

10

15

20

25

30

35

40

45

50

1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 73 77 81 85 89 93 97 101 105 109 113 117 121 125 129 133 137 141 145 149 153 157 161 165 169 173 177 181Week Number

Num

ber o

f Cas

es

Open Cases New Cases Closed Cases


Satisfactory machines = Improved Fleet Assurance


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


Benefit reporting – Marine Fleet CBMTotal Benefits per Class

Total= $855,260

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000

Class

Per Vessel

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

Bird Border C_LPG P's Trader Tree E's and Virtues

Loch Rannoch

Gem

Total Benefits per VesselTotal= $855,260

$0

$5,000

$10,000

$15,000

$20,000

$25,000

$30,000

$35,000

Bird Border C_LPG P's Trader Tree E's and Virtues

Loch Rannoch

Gem

Cost Benefit Vessel Class

Total Average per vessel Average per machine per vessel

P's $120,410 $30,103 $284 Bird $289,890 $24,158 $244

Tree $102,890 $12,861 $153 Loch Rannoch $19,300 $19,300 $145 Gem $12,480 $12,480 $139

Trader $68,320 $17,080 $132 C_LPG $41,670 $10,418 $104 E's and Vir tues $192,000 $8,727 $95 Border $8,300 $2,767 $54

Total $855,260 $14,496 $148

SKF cost-benefit model (CM event) adapted to large scale reporting

Class 1Class 2Class 3Class 4Class 5Class 6Class 7Class 8Class 9

C1 C2 C3 C4 C5 C6 C7 C8 C9


So how does vibration analysis actually work then?


How does Vibration Analysis actually work?

Bearing Outer Ring defect

A proven technique: Especially good for steady-state conditions

Key issues: Data Quality: Variable machine speeds & loadsReliability: Operating environmentEase of use: Remote monitoring


Vibration facts of life…Static vs. Dynamic Data

Am

plitude

Time

Each machine component generates its own

characteristic “Vibration Signature”

Bearing

coupling

Gear

meshGenerator

Rotor Hub

Σ

Amplitude

Frequency & Range

FFT Processing

Dynamic data(Spectra)

4 kb of data

2 bytes of data

Static Value(RMS)


What can we see with Vibration Analysis?

What Defects can be identified?

• Misalignment & Unbalance

• Looseness & clearances

• Gear defects - lube, wear, damage

• Bearing defects - lube, wear, damage

• Process faults – Temp, Pressure, etc

• And many more…

What Parameters can we monitor?

• Component defect frequencies

• Trends (Vel, Accel, Freq. Band, gE)Normal level

Increasing

Unacceptable

Normal FFT spectra

Defect FFT spectra


Marine CM technology

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

Portable hardware:• Suitable for ATEX and non-ATEX use• Test signal generator (1st route point)• >200-off Quick Connect Studs & Glue• Effective calibration cycle (12-24 months)


Fixed sensors for inaccessible & hazardous areas

Cargo pump room

Engine room

Pump room

Vac pumps

Ballastpumpstbd

Ballastpumpport

Cargopumpport

Cargopumpstbd

Cargopumpcentre

Main junction

box

Exhaust fan

Exhaust fan

Switch box

Fixed sensors Multi-core cables

SAFETY BARRIER

S


Online condition monitoring

Machinesignals

Convert signal

Processing of data & FFT’s

Signals, FFT dataand Trends

Analysis ofTrends & FFT

ACC

Machine Multilog IMXSensors CM Database @ptitude Software

Signal processing & data capture

Data storage (1,5Mb/Machine/day)

Data management & analysis

• Shaft speed (rpm)

• Vibration

• Steering angle

• Oil particles, Water, Temp

• Oil Pressure (gravity tanks)


Remote database access for different users

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

WebServer

Database Server& Virtualisation

Application Server(@ptitude)

SKF Remote Monitoring CentreLive access (e.g. Citrix)

Ship operator/manager


Application-specific condition monitoring

Turbocharger

SKF Turbocharger monitorSpeedswitch

Accelerometers with separate

charge amplifiers

DigitalControlSystem

Machine Condition

Transmitters

Onboard PC

Vibration levels& Alarm relays

T/C Efficiency & Performance:T/C compressor intake temperatureT/C compressor air flowTemperature before T/C turbineT/C turbine gas flowCharging air pressureBarometric pressureExhaust gas pressure before T/C turbine

T/C Condition:Vibration levelsEngine speedT/C speedSea state

Status/conditionAlarm

4-20 mAmp

OP

C

SKF remote monitoring

Inte

rnet

(C

itrix

/VP

N)

Sat

ellit

e/G

PR

S,

etc.

.

Status reportsWork orders

Alarmsetc.

Condition dataNotes/commentsetc.

PC with application installed to automatically store and transfer data to

SKF

Monitoring centre with T/C reliability

database, efficiency formulas, reporting tools and formats

etc.

Example: Turbocharger monitoring

BNC connection for Portable MicrologFFT


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


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


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


Documents

SKF Group Slide 0 - Maintenance engineeringmaintenance-engineering.eu/downloads/public/04 - Gerald Rolfe.pdf · Executive Business Manager – Marine SKF Service Division 2010-09-28