Rotating Equipment
- A business case
Mahomed Chothia
SKF [MENA]
Slide 2 [Code]
SKF [MENA]
Reliability / Maintenance
The purchase price of rotating equipment
represents only about 10 to 25 % of its total
cost of ownership,
. while energy, maintenance and operating
costs represent 75 to 90 %.
Source:
Lee Culbertson, Royal Purple Ltd., "Justify Lubricant Upgrades with
Energy Savings". Machinery Lubrication Magazine. July 2001
SKF [MENA]
Operator-Driven Reliability
Predictive Maintenance
SKF [MENA]
<10% Reactive
25% to 35% Preventive
45% to 55% Predictive
Safety/
Environment
Engineering
Strategy
Business cycles
Shareholder value
Management
Finance
PLANT
PERFORMANCE
Operations
Increased production
Production quality
Comply w/ maintenance
schedules
Cost effective
SKF [MENA]
Budgets
Compliance
Reduce admin costs
Cash flow-ROI
Reliability
Increase asset efficiency
Increase machine uptime
Reliability systems
Purchasing
Ensure product life cycle costs
Increase service level
Quality services
Reduce inventory
Maintenance
Service response
Perform precision work
Maintain asset
Control costs
COST
Steel Mill
$10,000 / hour
Paper Mill
$10,000 / hour
$15,000 / hour
$100,000 / hour
Petrochemical
Cement Mill
Food Processing
Slide 7 [RS MFC]
2008-10-10 SKF
SKF [MENA]
Millions of $
1 stop = 3 to 4 days
$1,000 / hour
SKF [MENA]
Contamination 14%
Slide 9 [RS MFC]
2008-10-10 SKF
SKF [MENA]
SKF [MENA]
Machinery vibration
Lube oil analysis including wear debris analysis
Infrared thermography
Ultrasonic testing
Motor current analysis
Alignment
Additional parameters such as flow rates, temperature,
pressure, speed etc. can be monitored to detect problems.
The techniques used depends on the criticality of the
equipment.
Slide 11 [RS MFC]
2008-10-10 SKF
SKF [MENA]
SKF [MENA]
SKF [MENA]
Best Practice
55% is Reactive
31% Preventive
12% Predictive
Proactive
2% as other
< 10 %
25 35%
45 55%
20%
Maintenance
Reliability
Asset Management
Slide 14 [RS MFC]
2008-10-10 SKF
SKF [MENA]
Average
> 15 yrs
< 10 yrs
> 6 yrs
< 3 yrs
< 2 to 5
>5
SKF [MENA]
1 : 10
25 to 30 %
70 to 75 %
35 to 45%
20 to 25 %.
Stock Optimisation
Problem description
MRO stock is a large part of the maintenance budget
Approximately 15 to 25%
Implemented solution
Stores Audits and Recommendations
Inventory management
Stock optimization
- (criticality, spares cost and availability)
Storage, Handling, Obsolescence.
Resulting benefits
Reduced stock, better availability, correct items
Savings generated
Potential estimated - 100 000 Euro
Slide 16 [RS MFC]
2008-10-10 SKF
SKF [MENA]
Bearing Technology
Machine Reliability
2008-10-10 SKF
SKF [Organisation]
Slide 17 [Code]
SKF [MENA]
L10h =
SKF [MENA]
1,000,000 x (C/P)
(60 x n)
SKF [MENA]
2008-10-10 SKF
SKF [Organisation]
Slide 21 [Code]
review
- shaft repair / machining tolerances
- sealing arrangement
- condition monitoring
- lubrication selection
SKF [MENA]
Electrical Motors
Typical failure modes:
Bearings 40%
Stator
30%
Rotor
8%
Others
22%
mechanical
Misalignment
Unbalance
Soft foot
Bearings
Lubrication
Overheating
SKF Reliability Maintenance Institute
Slide 23 [RS MFC]
2008-10-10 SKF
SKF [MENA]
electrical
Poor power quality
Insulation failure
Excessive current
2008-10-10 SKF
SKF [MENA]
2008-10-10 SKF
SKF [MENA]
SKF [MENA]
5,000 Euro
250,000 Euro
SKF [MENA]
Centrifugal Pumps
Premature failures
Average cost of repair $6,000 / pump
Given the number of pumps in operation
the cost savings are substantial
Typical failure are due to:
Mechanical seal, bearing, lubrication
Bearings
- Angular Contact Ball Bearing, universal pairing
Improved lubrication synthetic lubricant
Sealing arrangement - mechanical seals, isolators
Slide 28 [RS MFC]
2008-10-10 SKF
SKF [MENA]
Process Pump
BG =BECB
P6 runout
SKF [MENA]
3 microns
Process Pump
API 610 standard for refinery service
pumps specify bearings with machined
brass cage
eg.: 7218 BECBM
B
E
CB
M
SKF [MENA]
SKF [MENA]
Exhaust Fan
Reliability improvement project
- design review and engineering
- design of new components
- shaft repair and impeller balancing
- Installation and commissioning
- lubrication selection
SKF [MENA]
320 kW
Speed:
890 rpm
SKF [MENA]
Exhaust Fan
Electric
Motor
SKF [MENA]
Damage to sleeve
bearing
Slide 35 [RS MFC]
2008-10-10 SKF
SKF [MENA]
Customer Benefits
Lower bearing temperature 60 C vs 90 C
Reduced current drawn by motor (- 5 Amps)
Simplified lubrication system
- (oil circulation not required)
Lower vibration levels
Improved reliability
Slide 36 [RS MFC]
2008-10-10 SKF
SKF [MENA]
$ 3,000 / fan / yr
$ 2,500 / year
$ 3,400 / failure
$ 40,500 / day
$ 15,000
4 days
1 day
1-2 days
3 5 months
> 33 months *
Slide 37 [Code]
Plummer blocks
Slide 38 [RS MFC]
2008-10-10 SKF
SKF [MENA]
SKF [MENA]
Equipment:
Bearing
Designation
OEM Bearing
Designation
Lubrication:
Grease EP2
Environment:
Service Life:
Few months
PROBLEM
DESCRIPTION
SKF [MENA]
Paper Mill
Press Roll Section
Reliability Improvement Project
2008-10-10 SKF
SKF [Organisation]
Slide 41 [Code]
SKF [MENA]
SKF [MENA]
Lubrication Management
Slide 44 [Code]
Slide2008-10-10
44 [RS MFC]SKF
SKF [Organisation]
2008-10-10 SKF
SKF [MENA]
SKF [MENA]
Corrective Actions
Contamination free systems
Training in lubrication
Cleaner work areas
Use of oil filtration / breathers
Redesign the sealing arrangement
SKF [MENA]
Lubrication Management
SKF [MENA]
SKF [MENA]
Water concentration in a
stationary bearing
Deep-seated rust during
stand-still conditions
SKF [MENA]
250%
1 ppm = 1 mg / kg
200%
150%
Rated Bearing
Life
100%
50%
0%
500
1000
1500
2000
SKF [MENA]
2500
3000
3500
4000
4500
5000
SKF [MENA]
Lubrication Management
SKF [MENA]
SKF [MENA]
Slide 54 [Code]
Thank you