Optimising the Performance of Rotating Equipment

- A business case

Mahomed Chothia
Slide 1 [RS MFC] 2008-10-10 SKF SKF [MENA]

Manager, Reliability Systems SKF NV / SA, Brussels

Reliability improvement initiatives Machine Reliability Case Studies Lubrication Management

2008-10-10 SKF SKF [Organisation] Slide 2 [Code]

Asset Efficiency Optimization

Owning and operating Assets is one of the biggest cost items in a Production Enterprise Increasing Asset Efficiency is potentially one of the largest sources of profit Asset Management is much more than Maintenance Aim: Increased Lifetime Effectiveness & Return on Investment Focus on issues that impact machine performance and reliability
Slide 3 [RS MFC] 2008-10-10 SKF 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

Slide 4 [RS MFC] 2008-10-10 SKF SKF [MENA]

Reliability Focused Maintenance

Maximum Efficiency

Operator-Driven Reliability

Pro-Active Reliability Maintenance

Planning for a shift to an integrated proactive maintenance strategy starts with understanding where you are today in process for maintaining and managing capital assets. Use a mix of strategies

Predictive Maintenance Preventive Maintenance Reactive/Corrective Minimum Efficiency

<10% Reactive 25% to 35% Preventive 45% to 55% Predictive

Slide 5 [RS MFC] 2008-10-10 SKF SKF [MENA]

Who is responsible for Reliability?

Reduce emissions Reduce energy usage Assure compliance Avoid hazards Strategy Business cycles Shareholder value Budgets Compliance Reduce admin costs Cash flow-ROI

Safety/ Environment

Management

Finance

Engineering
Re-design current assets Coordinate maintenance needs Control projects Reduce capital outlay.

PLANT PERFORMANCE

Reliability
Increase asset efficiency Increase machine uptime Reliability systems

Operations
Increased production Production quality Comply w/ maintenance schedules Cost effective

Purchasing
Ensure product life cycle costs Increase service level Quality services Reduce inventory

Maintenance
Service response Perform precision work Maintain asset Control costs

Slide 6 [RS MFC] 2008-10-10 SKF SKF [MENA]

Cost of a Production Stop

INDUSTRY Steel Mill Paper Mill Power Plant (600 MW) Car Plant (Paint Shop) Petrochemical Cement Mill Food Processing
Slide 7 [RS MFC] 2008-10-10 SKF SKF [MENA]

COST
$10,000 / hour $10,000 / hour $15,000 / hour $100,000 / hour Millions of $ 1 stop = 3 to 4 days $1,000 / hour

Asset Efficiency and Machine Reliability

Bearings, seals and other machine components are an essential part of rotating equipment, their reliability is often critical to the plant equipment. The cost of these components are proportionally very small compared to the maintenance cost of replacement and potential lost production caused by premature failure.

Slide 8 [RS MFC] 2008-10-10 SKF SKF [MENA]

Typical Bearing Failures

Poor lubrication 36% Premature Fatigue 34%

Poor fitting 16%

Contamination 14%
Slide 9 [RS MFC] 2008-10-10 SKF SKF [MENA]

Bearing Failure Analysis

23280 CCK/C3 W33

Slide 10 [RS MFC] 2008-10-10 SKF SKF [MENA]

Predictive Maintenance Techniques - Typical

Condition Monitoring helps determine the deteriorating condition of a machine component, in advance of a breakdown. (Proactive Maintenance)
Typical machinery parameters measured, trended and analysed to detect imminent failure or onset of problems:

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]

Reliability Focused Maintenance

Various studies reveals some interesting statistics: Between 20% to 70% of maintenance currently undertaken is reactive in nature. Reactive maintenance is typically 10x more expensive than predictive maintenance [8]. The direct cost of repairs undertaken on a breakdown basis is typically three times the cost of planned repairs. Production outage time needed for completion of an emergency repair can be shown to be between three and five times that needed if the repair was carried out on a planned basis.
Slide 12 [RS MFC] 2008-10-10 SKF SKF [MENA]

Reliability Focused Maintenance

Slide 13 [RS MFC] 2008-10-10 SKF SKF [MENA]

Asset Efficiency Optimization

Survey results 55% is Reactive 31% Preventive 12% Predictive Proactive 2% as other Best Practice < 10 % 25 35% 45 55% 20%

Source: SMRP (Society of Maintenance & Reliability Professionals) survey.

Maintenance Reliability Asset Management

Slide 14 [RS MFC] 2008-10-10 SKF SKF [MENA]

Reliability advantages are well known

World Class Average life of electric motors Mean time between repairs for pumps Average machine vibration levels (mm/s) > 15 yrs > 6 yrs < 2 to 5 Average < 10 yrs < 3 yrs >5

An effective maintenance program has many benefits. Return on investment: Reduction in maintenance costs: Elimination of breakdowns: Reduction in downtime: Increase in production:
Slide 15 [RS MFC] 2008-10-10 SKF 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]

Rotating Equipment Reliability

Machine Improvements
Design review aimed at evaluating applications, then recommending and implementing design improvements to extend machine life.
Root Cause Failure Analysis Application analysis Mechanical Design Machine Upgrade Technology Upgrades
Slide 18 [RS MFC] 2008-10-10 SKF SKF [MENA]

Bearing Life Influence of load A 20% load increase reduces the calculated bearing life by half
L10h =

1,000,000 x (C/P) (60 x n)

Slide 19 [RS MFC] 2008-10-10 SKF SKF [MENA]

Sealed Spherical Roller Bearings

Regreasing bearings used to present serious problems. Heat of the casting process caused the bearing grease to melt and blend with the cooling water. Grease used: 16 tons/yr. By installing sealed spherical roller bearings, which do not need to be regreased, the problems have been reduced substantially.
Slide 20 [RS MFC] 2008-10-10 SKF SKF [MENA]

Caster Bearings in Steel Mill

Savings (grease): Euro 60,000

* Other savings not considered

Machine Reliability Improvements Case Studies

2008-10-10 SKF SKF [Organisation]

Slide 21 [Code]

Electrical Motor Reliability

- design

review - shaft repair / machining tolerances - sealing arrangement - condition monitoring - lubrication selection

Slide 22 [RS MFC] 2008-10-10 SKF 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

Electrical Motors Lubrication Program

Refinery Middle East Conversion from pure mist lubrication to grease lubrication. High Voltage Motors Motor population: about 100 60% converted to grease. Savings / Benefits Elimination of oil mist system and associated maintenance Simplified lubrication procedures Improved environment / health
SKF Reliability Maintenance Institute
Slide 24 [RS MFC] 2008-10-10 SKF SKF [MENA]

Reliability Improvement in Large Electrical Motors

Motor in Steel Mill Reference case: SIEMENS
Common to use sleeve / plain (hydrodynamic) bearings. Can be expensive if it includes; extra oil pressure systems for low or reversing speeds. Oil Circulation required to control temperature. Rolling Bearing offer an advantage compared to sleeve bearings. Initial Cost savings 30%. + Lower life cycle cost
Flanged Bearing Unit
SKF Reliability Maintenance Institute
Slide 25 [RS MFC] 2008-10-10 SKF SKF [MENA]

Electric Motor - Machine Reliability

Flue Gas Recirculation Fan Motor
A European company, faced high maintenance and material costs due to electrical current damage to critical electric motors. Standard ball bearings lasted about 6 months To reduce costs and to achieve reliable operation INSOCOAT bearings were used. Since 1995 there have been no bearing failures. Financial outcome Initial investment Total savings
Slide 26 [RS MFC] 2008-10-10 SKF SKF [MENA]

5,000 Euro 250,000 Euro

Centrifugal Pump Reliability

Slide 27 [RS MFC] 2008-10-10 SKF 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

Matched bearings are best suited for pumps. Usually fitted in a back-to-back arrangement (without the use of shims) SKF BECB bearings have the correct axial clearance after mounting.
Slide 29 [RS MFC] 2008-10-10 SKF 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 40 degree contact angle High load carrying capacity Clearance class Brass cage

Correct choice of shaft and housing fits is essential for reliability

Slide 30 [RS MFC] 2008-10-10 SKF SKF [MENA]

Case study Centrifugal Pump

Reverse Osmosis Plant
Application: Horizontal centrifugal pump (6 off) Speed: 3600 rpm Power: 75 kW Oil bath lubrication (ISO VG 68) - oil pick-up ring Problem: Premature failures: 3to 4 months Investigation revealed the following: Incorrect bearings Incorrect fit on shaft Lubricant supply to the bearings
Slide 31 [RS MFC] 2008-10-10 SKF 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

Slide 32 [RS MFC] 2008-10-10 SKF SKF [MENA]

Exhaust Fan case study

Cooler Scrubber Exhaust Fan
Power: Speed: 320 kW 890 rpm

Lubrication: Oil circulation Sleeve bearings Operating temperature: 93 C Year installed: 1990 Mean Time Between Failure: 3 to 5 months

High impact on production ! Proposal to convert the plain bearings to Rolling Bearings.
Slide 33 [RS MFC] 2008-10-10 SKF SKF [MENA]

Exhaust Fan

Electric Motor

Slide 34 [RS MFC] 2008-10-10 SKF SKF [MENA]

Exhaust Fan - failure

Damage to sleeve bearing

Slide 35 [RS MFC] 2008-10-10 SKF SKF [MENA]

Damage to shaft and thrust collar

Exhaust Fan Solution

Customized solution using CARB and SRB + SONL Housing

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]

Exhaust Fan - Savings (Estimated)

Energy savings: Lubrication: Maintenance / Labour: Lost Production: Cost of shaft repair: $ 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 *

Plain Bearing Failures .. Time to repair shaft / balancing Rebabbitting of bearings Installation / commissioning Failure of plain bearings New SKF solution

first fan commissioned mid Feb 2005

SAVINGS: > $ 360,000 /yr

Second fan commissioned end Sep 2006
2008-10-10 SKF SKF [Organisation] Slide 37 [Code]

High Speed Fans

For high speed applications Fan Unit Housing Assembly improves reliability

Plummer blocks
Slide 38 [RS MFC] 2008-10-10 SKF SKF [MENA]

Ready to mount unit

Bearing Failure Analysis Steel Mill

Equipment: Bearing Designation OEM Bearing Designation Lubrication: Environment: Service Life: PROBLEM DESCRIPTION Rolling Mill - Stands 1 and 2 SKF 24148 CC/C2.W33 SKF 24148 CC/C2.W33/235220 Grease EP2 High operating temperature. High humidity Few months Low MTBF of the bearings. Cracking of the outer ring (some) Premature flaking.

Slide 39 [RS MFC] 2008-10-10 SKF SKF [MENA]

Bearing Failure Analysis

Root Cause Failure Analysis

Entry of water and contaminants Incorrect fits / geometric form tolerances of the housing seating Lubrication type and method

Savings: EURO 250,000 Elimination of premature failures

Slide 40 [RS MFC] 2008-10-10 SKF SKF [MENA]

Paper Mill
Press Roll Section Reliability Improvement Project

2008-10-10 SKF SKF [Organisation]

Slide 41 [Code]

Paper Mill (Egypt),

Press Roll Upgrade Project
Customer requirements: Improve reliability of the press section. Increase speed of the machine and production. Solution: Improved design of the housing / bearing assembly 10 housings, oil circulation system, sealing arrangement. Root cause failure analysis Optimized housing design (stiffness) Improved sealing arrangement Oil circulating system Customer benefits: Improvements to the machine performance Financial savings uptime, increased MTBF
Slide 42 [RS MFC] 2008-10-10 SKF SKF [MENA]

23280 CCK/C3 W33

Paper Mill - Press Roll Upgrade Project

Before - Premature bearing failures each 8 months. After implementation of the improved solution Bearing life was extended to more than 20 months. Time required to change the bearing: 36 hours The manpower cost: Euro 2,500 Production: 9 tons/ hour. Price of one ton of paper: EURO 650 Financial calculation - Cost Savings 1- Number of tons lost due to 1 break down = 9 x 36 = 324 tones 2- Cost of production lost = 324 x 650 = Euro 210,600 3- Total cost of one break down = 210,600 + 2500 = 213,100 4- No. of break downs avoided = 20/8 = 2.5

Total cost saving (improved reliability avoidance of breakdown) = 2.5 x 213,100 = Euro 532,750
Slide 43 [RS MFC] 2008-10-10 SKF SKF [MENA]

Lubrication Management

2008-10-10 SKF Slide 44 [Code] Slide 44 [RS MFC] SKF [Organisation] 2008-10-10 SKF SKF [MENA]

Best Practice in Lubrication Management

Lubrication Management - Why?
Contamination reduces machine reliability and causes bearing / component failures
Reasons Contaminated environment Contaminated lubricants Ineffective seals Component wear
Corrective Actions Contamination free systems Training in lubrication Cleaner work areas Use of oil filtration / breathers Redesign the sealing arrangement

Slide 45 [RS MFC] 2008-10-10 SKF SKF [MENA]

Poor Storage - Not Best Practice

Slide 46 [RS MFC] 2008-10-10 SKF SKF [MENA]

Lubrication Management

Contamination in new oil

Contaminants cause wear to components in machinery

Slide 47 [RS MFC] 2008-10-10 SKF SKF [MENA]

Failed Bearing - Lubricant Analysis

Fresh: Brown colour Used: Yellow colour

Water in the lubricant

Slide 48 [RS MFC] 2008-10-10 SKF SKF [MENA]

Lubrication Water Content

Water concentration in a stationary bearing Deep-seated rust during stand-still conditions

Slide 49 [RS MFC] 2008-10-10 SKF SKF [MENA]

Lubrication Water Content

Effect on bearing life
250%

Maximum of 200 ppm 1 ppm = 1 mg / kg

200%

New lubricant guideline 25 ppm at 20 C

150%

Rated Bearing Life 100%

Based on 100% Life at 100ppm water

50%

0% 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Water in Oil (ppm)

Slide 50 [RS MFC] 2008-10-10 SKF SKF [MENA]

Best Practices, Lube Bay Management

Slide 51 [RS MFC] 2008-10-10 SKF SKF [MENA]

Lubrication Management

Slide 52 [RS MFC] 2008-10-10 SKF SKF [MENA]

Best Practices, Transfer Containers

Oil Safe Lubrication System
Protect Lubricants from Contamination Reduce Machinery Downtime Minimize Spills & Accidents 10 Colors to Code Lubricant Grades

Slide 53 [RS MFC] 2008-10-10 SKF SKF [MENA]

Reliability improvement initiatives Machine Reliability Case Studies Lubrication Management

2008-10-10 SKF SKF [Organisation] Slide 54 [Code]

Thank you