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Maintenance and inspection adapted to equipment criticality – essential for competitiveness

Jens Gunnars, InspectaOla Jonsson, Holmen Iggesund

SPCI Convention 2013

Content

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1. Expectations and problems for maintenance

2. Opportunities by implementation of maintenance & inspectionadapted to equipment criticality and condition

3. Work process model for optimization of proactive activities

4. Challenges in the execution of the different steps

5. Conclusions

Content

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1. Expectations and problems for maintenance

2. Opportunities by implementation of maintenance & inspectionadapted to equipment criticality and condition

3. Work process model for optimization of proactive activities

4. Challenges in the execution of the different steps

5. Conclusions

Typical challenges and expectations on maintenance & inspection

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• Reduce the number of failures and stops

• Provide fast repairs, of high quality

• Shorter and fewer planned stops

• Improve safety

• Efficient prioritization and use of personnel

• Keep the team motivated

Some common problems for proactive maintenance & inspection

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• Not having resources or desire for continuous improvement ‒ Sitting back satisfied with procedures and technology that were

up to date 15 years ago

• Lack of time for development of proactive maintenance work‒ Urgent problems, or large rebuild projects , distracting focus to

the more long-term preventive maintenance work

• Reduction of personnel for cost savings and survival in downturns ‒ All resources required for the corrective work, no time for

preventive work

• Number of tasks overwhelming by time ‒ Due to new systems, new equipment and suppliers added ‒ Lack of time for re-evaluation of the plan for maintenance tasks

Content

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1. Expectations and problems for maintenance

2. Opportunities by implementation of maintenance & inspectionadapted to equipment criticality and condition

3. Work process model for optimization of proactive activities

4. Challenges in the execution of the different steps

5. Conclusions

Opportunities by adapting maintenance to equipment criticality

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• Planned, proactive maintenance & inspection activities has the purpose to detect damage and replace parts before they fail and cause production stop.

• Analysis of the criticality of each equipment with respect to their importance forq productionq safety

can be used as a mean to obtain an efficient plan for the proactive activities

• Proactive monitoring, inspection and prediction of the condition of the equipment can be focused to objects of high criticality.

• A common work process and concepts can be used for all maintenance groups (Pulp and Paper), for the planning of proactive maintenance, monitoring, inspections and tests.

• This provides a structured process for the prioritizationof proactive work, with the overall aim to

‒ Reduce the number of failures and stops‒ Focusing resources for early detection of damage

in high impact objects

Opportunities by adapting maintenance to equipment criticality

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Content

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1. Expectations and problems for maintenance

2. Opportunities by implementation of maintenance & inspectionadapted to equipment criticality and condition

3. Work process model for optimization of proactive activities

4. Challenges in the execution of the different steps

5. Conclusions

Requirements on a work process for optimization of Preventive Maintenance & Inspection

• Systematic work method for going through the systems and also for breakdown to components

• Practical work process− Simplified and adapted to local needs− Re-use of work per object types − Involvement of the personnel for knowledge and commitment

• Using risk and reliability principles

• Use industry experience − Failure modes, damage causes, statistics, good practices for diagnostics, ...

• Complementing preventive actions − Monitoring, inspection and tests for condition diagnostics and prognostics− Regular replacements − Prepared repair work

• Efficient connection to maintenance system (from input data to work orders)

General work process model for optimization of proactive activities– some important steps

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Operating conditions, functionality,

item data, history, spare parts

Predictable

Yes No

Cost efficient

FMEA - Damage mechanisms & Causes- Failure patterns, subcomponents- Possible mitigation strategies- Templates per object type

No

Yes

Feedback for continuous improvement

Scheduling

Run to failureEvaluation of preventive

approaches- Condition monitoring and prognosis- Periodic inspection- Periodic tests- Residual life assessment- Periodic replacement

Criticality Analysis

Monitor condition / performance

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Analysis of equipment criticality with respect to production – Evaluation of equipment utilization (A, P, Q) and safety (S)

365 days

Planned outages

Unplanned stops

Used capacity

Quality yield

A

P

Q

• The utilization of a process plant may be measured using the concept Overall Equipment Effectiveness, OEE = A x P x Q, where the indexes are

(A) Availability - percentage of scheduled time available for production (uptime)(P) Performance - percentage use of the designed production speed/capacity (Q) Quality - percentage of production with good quality

• In addition a performance index for safety and environment should be used (S)

• The criticality of each equipment with respect to the production and safety is assessed by use of the indexes A, P, Q, S

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Condition monitoring and prognosticsContinuous or periodic diagnostics

Different types of methods for condition monitoring:• Periodic walkdowns; general physical inspection of equipment

• Process parameters; reduced performance, cycles, limits

• Vibration monitoring; measurement and analysis, spectrum, balancing

• Non Destructive Evaluation; visual inspection, thermography, acoustics, ultrasonic, radiography, magnetic, eddy current, replica, …

• Oil and particle analysis • Analysis of corrosion environment• Mechanical measurements; alignment, tolerances• …

The condition result is used for prognostics based on:- Physical models for the damage/failure evolution, or- Data driven approaches/statistical relations

Content

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1. Expectations and problems for maintenance

2. Opportunities by implementation of maintenance & inspectionadapted to equipment criticality and condition

3. Work process model for optimization of proactive activities

4. Challenges in the execution of the different steps

5. Conclusions

Summary of ongoing Iggesund project for development of PM

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§ Common project for all maintenance groups at the mill

§ Started with development of work concept

‒ Utilizing proven methods as much as possible

§ Criticality analysis

‒ Analysis of all systems in the mill is accomplished

§ Detailed work ongoing for critical equipment (red line)

Maintenance work load

Maintenance work

Business as usual… Unplanned stops under control by corrective maintenance, but resources could be better used…

Implementation of adapted PM. Tough period. Temporary peak in work load.

Reduced numbers of failures and unplanned stops. Increased degree of planning of PM work. Increased focus to critical equipment, decreased focus to other.

Higher reliability by reduced number of failures and stops.Decrease in maintenance costs.

1 2 3 Time

Budget

Adaptation of Preventive Maintenance to the equipment criticality – Temporary tough peak during implementation

Start of development for

PM adaption

Challenges in the execution

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• Documentation and basic data − Hugh work to secure complete electronic

documentation

• Functional descriptions for the equipment− Descriptions of specific requirements for our process− Connections to other parts of the process

• Compilation of historical data − Good event classification is very valuable− Reporting discipline will become evident

• Use of templates for different object types − Provides large time savings

Challenges in the execution

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• Criticality analysis − Use of own model based on OEE and HSE− Classification is easy if background information is

complete

• Classification of subsystems and parts − Efforts to identify the weakest links, in order to find

the right methods for condition assessment, or rebuild

• Assessment of alternative preventive actions − Cost-benefit assessment used

• Scheduling and instructions − Packaging of task when PM planning is performed

for several objects − Instructions so that no tasks are dependent on

individual persons

Content

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1. Expectations and problems for maintenance

2. Opportunities by implementation of maintenance & inspectionadapted to equipment criticality and condition

3. Work process model for optimization of proactive activities

4. Challenges in the execution of the different steps

5. Conclusions

Conclusions

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• Implementation of adapted preventive maintenance & inspection in relation to the equipment criticality and condition is important for‒ focusing resources to high impact proactive activities‒ reducing unplanned stops

• Some challenges to be aware of at implementation ‒ Support and patience from the top management is necessary.

It is typically a 2-3 years project. Basic education recommended. ‒ Important to establish well thought-out work systematics ‒ Training of personnel, also for acceptance of the methodology to

increasing the desire for change ‒ During the first implementation period the peak in work load is

substantial

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Thank you!

Questions?