04 - Gerald Rolfe

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October 8, 2010 SKF Group Slide 0


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Establishing a successfulCondition Based Maintenance programme

Presented to IMarEST Conference 2010

Prepared by Gerald Rolfe

Executive Business Manager Marine

SKF Service Division

2010-09-28


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Brief introduction to SKF


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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


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SKF Group Vision

To equip the worldwith SKF knowledge


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What is SKF knowledge?


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Idea or concept

Design & manufacture

Install & commission

Operate & monitor

Maintain & repair

Restore & upgrade

OEMPerspective

End UserPerspective

Overall customer & business perspective

Transferableknowledge


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SKF in the Marine Segment


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SKF and the ship life cycle

Maintain andimprove

Operate and monitor

Build and install

Concept and design

Product delivery


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

SKF Marine Key capabilities & Values

Concept and design

Product delivery

Build and install

Operate andmonitor

Maintain & improve

Design and engineering Calculation, simulation and verificationTesting & 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 andsystems

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 machineryfailures and warranty costs

One-stop-shop for proven

world class products,available worldwide

Ensure optimised operationalperformance through best

practice installation services

Safer and more profitableoperations with increasedavailability and streamlined

classification agency surveys

Range of maintenanceengineering and consultingservices to boost asset

uptime

End-User

OEM


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SKF Marine Key capabilities & Values


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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


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Profit

Cost of Plant

(CAPEX)

Time

Operating

Cost

(OPEX)

Reve

nue

(Outp

ut)

Payback point

The basic business model

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

Cost &

Revenue


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Payback point

Downtime

Payback point

Additional cost to repairmachinery

Loss of availability & revenue

Profit ?

Why should we use condition monitoring?

Cost of Plant

(CAPEX)

Time

Cost &

Revenue


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Condition based maintenance


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Condition Based Maintenance process

System set-up

Data collection

Maintenancestrategy

Maintenance complexity

Bu

sinessimpact

1

23

4

Upgrade andimprovement

Remote analysis

Correction

AEO


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Reliabilit y Issues

(Design)

Pre-Defined Prioriti es

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 Analys is

PM =

PRM =

ODR =

RTF =

RCFA =

Maintenance

StrategyPlant Asset Management and

Maintenance Program (Living

Program)

PM PRM ODR RTF

RCFA

PRM/ODR Collection and Analysis

Information Integration and Decision

Work Order Generation CorrectiveMaintenance

Operators

Initiators

Planning

Rolling Schedule

Standard Job Plans

and Procedures

Spare Parts

Al ignment

Work Execution

Post Maintenance Testing

Update Program

Work

Identification

Work

Control

Work

Execution

Asset Efficiency Optimisation (AEO) process


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Client needs analysis - output

This provides an objective basis for the future improvement plan


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Auxiliary machines:

Motors, Pumps, FansLO & HFO Purif iers, etcPeriodic data

Inaccessible Machines:Hazardous pumps & fans

Semi-Online

Condition monitoring strategy

Critical

Medium

Sudden onset

failure

Gradual

degradation

Finan

cialRisk

Time to machine failure

Examples:

Required Scan Rate FastSlowLow

High

Costp

erPoint

Critical Machines:

TurbochargersIG FansOnline

Turbo machines:

Compressors

GeneratorsCritical Online

A I t t CBM l ti


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Citrix/Application Server

Citrix Server@ptitude Analyst ApplicationSKF Transaction Server

Database Server

Oracle 10g@ptitude Analyst Database

CBM Service Provider

Citrix ClientVPNTCT application

Internet

Direct connection

available only toauthorised SKF

users

Workstation onboard

Citrix Client

VPNTCT application

-


SKFNetwork

Citrix/Application Server

Citrix Server@ptitude Analyst ApplicationSKF Transaction Server

Database Server

Oracle 10g@ptitude Analyst Database

SKF Data Hosting Centre


Internet

Direct connection

available only toauthorised SKF

users

Workstation onboard

Visualisation ClientTCT application

RemoteShip systems

Ship Operator

Shore based personnel

-


SKFNetwork

An Internet CBM solution

Oth C diti M it i t h i


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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

A i hi diti


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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


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Key issues to be considered

Critical Success Factors


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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)



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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



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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


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CBM - Marine customer gap analysis

CBM Marine customer gap analysis


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CBM - Marine customer gap analysis


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Demonstrating value

Effective CBM contract management


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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

01-05-07

01-06-07

01-08-07

01-09-07

01-10-07

01-11-07

01-12-07

01-01-08

01-02-08

01-03-08

01-04-08

01-05-08

01-06-08

01-07-08

01-08-08

01-09-08

01-10-08

01-11-08

01-12-08

01-01-09

01-02-09

01-03-09

01-04-09

01-07-09

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 Tr ends

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 97 101 105 109 113 117 121 125 129 133 137 141 145 149 153 157 161 165 169 173 177 181

Week Num ber

NumberofCases

Open Cases New Cases Closed Cases

Satisfactory machines = Improved Fleet Assuranc


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Satisfactory machines Improved Fleet Assuranc

Cost-Benefit reporting


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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 CBM


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Benefit reporting Marine Fleet CBM

Total 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 $12,480Per 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 TreeE's and

Virtues

Loch

RannochGem

Total Benefits per Vessel

Total= $855,260

$0

$5,000

$10,000

$15,000

$20,000

$25,000

$30,000

$35,000

Bird Border C_LPG P's Trader TreeE's and Loch

Gem

Cost BenefitVessel Class

Total Average per vessel Average permachine per vessel

P's $120,410 $30,103 $284

Bird $289,890 $24,158 $244

Tree $102,890 $12,861 $153Loch 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 Virtues $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 report ing

Class 1

Class 2

Class 3Class 4

Class 5

Class 6

Class 7

Class 8

Class 9

C1 C2 C3 C4 C5 C6 C7 C8 C9


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So how does vibration analysisactually work then?

How does Vibration Analysis actually work?


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y y

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


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Static vs. Dynamic Data

Amplitude

Time

Each machine component

generates its own

characteristic Vibration

Signature

Bearing

coupling

Gear

meshGenerator

Rotor Hub

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?


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y

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


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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 & hazardousareas


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areas

Cargo pump room

Engine room

Pumproom

Vacpumps

Ballastpumpstbd

Ballastpumpport

Cargopumpport

Cargopumpstbd

Cargopumpcentre

Mainjunction

box

Exhaustfan

Exhaustfan

Switch box

Fixedsensors Multi-core cables

SAFETY

BARRIER

S

Online condition monitoring


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Machine

signalsConvert

signal

Processing of

data & FFTsSignals, FFT data

and Trends

Analysis of

Trends & 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


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SKF CM Engineer

System conf iguration

Database management

Machine data & history

Analysis & Reporting

Contract management

Ship operator

Fleet/Class status

Ship status

Machine trend

Machine history

Web

Server

Database Server& Virtualisation

Application Server(@ptitude)

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

Ship operator/manager

Application-specific condition monitoring


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Turbocharger

SKF Turbocharger monitor

Speedswitch

Accelerometers with separate

chargeamplifiers

DigitalControlSystem

MachineCondition

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 levels

Engine speedT/C speedSea state

Status/condition

Alarm

4-20 mAmp

O

PC

SKF remote monitoring

Internet

(Citrix/VPN)

Satellite/GPRS,

etc..

Status reportsWork orders

Alarmsetc.

Condition dataNotes/commentsetc.

PC with applicationinstalled to automaticallystore and transfer data to

SKF

Monitoring centrewith T/C reliability

database, efficiencyformulas, reportingtools and formats

etc.

Example: Turbocharger monitoring

BNC connection forPortable MicrologFFT

Benefits of CBM - Gearbox problem


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Acceleration trend shows an increaseSpectrum identif ies IMS/LSS gear mesh frequency

with sidebands.

Recommendation: Inspect & replace gears

Root Causes: Lubrication, Alignment, Excess loads

Benefits of CBM - Coupling problem


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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 prof ile.

Recommendation: Inspect the coupling

(damaged)

Root causes: Excess misalignment, Shock

loads

Benefits of CBM Motor bearing problem


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Increase in Enveloped Acceleration (gE)

trend. Spectra shows bearing outer race

frequency with harmonics.

Recommendation: Change the bearing

Root Cause: Electrical damage, poorinsulation


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04 - Gerald Rolfe

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