Data Management For Industrial Plant Maintenance

EAM Services
Griha Software Technologies
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About Griha Software Technologies

Grihasoft is one of India's leading companies providing Data Management Services to many global clients. Grihasoft provide classification (UNSPSC, eCl@ss etc), item master data cleansing, data enhancement and spend analysis etc which helps eProcurement/supply chain/material management (MM) In the plant maintenance (PM) area we generate the equipment data, asset Management strategy, planning & scheduling and Data management and mining to help clients realise the full potential of their EAM system Grihasoft serve many global clients across US, UK, Middle East, South Africa and Australian markets.
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EAM Services

Why Equipment fail?

Because the components fail Why components fail? Because they are designed to fail Yes. Equipment have surfaces with relative motion and are built with wear components which will have to fail after its design life. Maintenance is all about realizing the designed life and changing the components in a planned manner at the end of their design life before failure
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Maintenance function

Industrial plants have scores of machinery and they have to be serviced periodically to keep the plant running In complex plants the equipment are serially connected and every one of the equipment has to be running to achieve production objectives Frequent break downs will result in production outages and the plant will become uneconomical The only purpose of the maintenance team is to keep the plant running to meet the production objectives

What is trouble shooting?

Every failure has to be fully understood and corrective measures taken to prevent repetitive failures Trouble shooting is to pin point the exact reason for any failure Correction is to eliminate the very reason for such failure If this is not done systematically we will end up in having failures after failures in the plant To trouble shoot we need reliable data And the data analysis is the key to successful plant maintenance And therefore accurate data availability is a must

The truth is that many plants have never been in a position to say that they are current with their data.
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Current Scenario

Plants are faced with a growing backlog of unposted work orders into their CMMS. The requirements needed to keep the newly developed database maintained with the latest system changes are frequently underestimated. The timeliness and accuracy of this data is a critical requirement to the cost-justifying applications. The application of the information technology concept of outsourcing can be an alternate approach for plants trying to reduce data maintenance costs, increase the reliability of their databases, and accelerate the speed with which decisions can be made.
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The four types of support

Type 1 -First time collection and posting all relevant data for the new EAM system to be operable from Day 1 including the asset management strategy build Green field projects Type 2 - Migration from legacy system to a new system Reviewing the existing data, re-strategizing the asset management approach and updating the data to reflect the plant as of today Type 3 - Periodical review say every 5 to 10 years - of the total asset management strategy in the light of the past history, current trends, technology, safety and environmental needs Type 4 - Day to day up keep of the maintenance data to keep the system data current a crucial step to ensure right decisions

Type 1 -First time collection and posting

This is associated with new plants or plants getting into a CMMS environment Asset Management Strategy build is an essential part of this work Strategy will include creating the asset register, rating the criticality of each asset, building the maintenance strategy for each piece of equipment, writing the equipment Maintenance task lists, setting the frequency and scheduling them Facilitating the system to provide all the necessary reports for performance evaluation
All these ideally should be in place before commissioning the plant And will need a good team of well experienced maintenance professional from the service provider driving the project

Type 2 - Migration from legacy system

This is a requirement from all the operating plants Most of them migrating from a stand alone CMMS to a PM module of an ERP like SAP, Oracle and others Reviewing the strategy and re-working the maintenance task list is an essential part of this exercise Building additional data for facilitating better approaches like RCM and reliability analysis Data to include all the engineering changes done to the plant in the past including physical verification
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Type 3 - Periodical review

Over the years the priorities in a plant is bound to change due to revised production objectives, the past performance, safety and environmental realities and above all the need for continuous improvement The review is based on the history available from the CMMS data and can very well be carried out mostly offshore with some site visits In house analysis may not be the right choice due to lack of time for such work and further it may not bring out the real issues to the fore The external agency will have no hesitation in calling a spade a spade.
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Type 4 - Day to day up keep

System with incomplete data is as good as no data Decisions are taken based on data from memories and can be very wrong Expecting the technicians to enter the data after the days work from his log has been a dream never realised fully If the log data is posted by an external agency the data would not be lost and will be available for the decision making It will be an added feature if the external agency is capable of identifying meaningful trends from the data for the ready use of the client Like flags In complex systems right fist time is the mantra and repetitive repairs have known to damage the integrity of the otherwise sound equipment

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Outsourcing is the solution

To address this ongoing problem, plants & utilities are evaluating the possibility of outsourcing their data maintenance and updating activities in order to reduce their associated costs, improve turnaround, and operate their systems with near 100 percent reliability.
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CONCLUSION

By outsourcing data maintenance activities, plants achieve a level of assurance that their data maintenance requirements will be consistently met and that their internal resources can be directed to the more pressing tasks of serving their customers Data maintenance is one of the first and easiest functions plants can outsource. Compared to inhouse solutions, they can expect their real costs to decline, and their information accuracy and timeliness to increase. At the same time, they can re-deploy those in-house resources -- people, equipment, space and time -- to mission critical activities that will better benefit their top and bottom lines.
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What can we learn from Maintenance History?

Organized data can add to our understanding of our asset performance

This is what GRIHA can do

Maintenance Performance Analysis

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

S. No.

Plant

Equipment ID

Location ID

Equipment Description

Maintenance Maintenance Work Permit Safety Type Task List No. No Lockout No

Supervisor

Technicians

Work Start Time

Work Done

Work Complete Time

Man Hours and cost of labour

Spares Used and cost

Total Cost of Maintenance

Tools Used

Safety lockout Closed

work permit closed

Remarks

Griha converts the maintenance history of each equipment to this format If the data is fully available from either log books or the work order details. From this format the following analysis is possible

The history gives us clues

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

S. No.

Plant

Equipment ID

Location ID

Plant-wise analysis can give comparative maintenance performance between plants. Repetitive failures of a particular type can indicate lack of trained personnel. Key Performance Indicators Plant Availability as % Searches of one particular ID can add to our understanding of the equipment behavior. Comparing similar equipment can give us insight into the problem area such as location faults, service faults, operational defects, lack of training and others KPI Overall Equipment Effectiveness - OEE

There are particular locations which prove to be adding additional problems to the equipment such as dusty locations, presence of acidic vapors, inherited construction faults, and many others

Maintenance Type
Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

Equipment Description

Equipment type

Maintenance Type

Equpt. Type code if not already available is added by GRIHA and failure analysis type-wise can add valuable input to our trouble shooting capability, particularly with regard to skill levels of the workmen , equipment selection criteria and others

Maintenance type like Preventive, Breakdown, corrective, condition based etc., are clear indicators of our maintenance work performance. The ratios of one with the others say plenty on our ability to create an optimum Asset Management Strategy KPI PM Effectiveness B/D Vs PM Ratio, Condition Monitoring Effectiveness

Time to Repair
D at e Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

Supervisor

Technicians

Work Start Time

Work Done

Work Complete Time

Repetitive failures under a supervisor or technician can indicate training needs .Repetitive failures are sure indicators of poor reliability Duration of work computed from start and completion time indicates the time to repair. MTTR, Mean Time To Repair is an important performance measure. This can lead to strategic decisions on improving repair facilities or adding Rotables The average run time between failures is MTBF, a very important measure of the reliability of the equipment

Cost of Maintenance
Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

Man Hours and cost of labour

Spares Used and cost

Total Cost of Maintenance

Tools Used

Safety lockout work permit Closed closed

Remarks

Key input to determine the crew size and reduce the Mean Time To Repair MTTR Cost of labor is key to the economics of asset management Forms a significant part of the total cost of maintenance
Cost of Spares used is another significant factor for the total cost of maintenance Repetitive consumption of a particular component can trigger investigations on component life/ procurement source/maintenance requirements THE Most Important criteria for assessing cost effectiveness of maintenance Will play a major part in the Total Life Cycle Costing of the asset KPI Cost Maintenance Vs Budget Vs Replacement Cost of Equipment

Failure Analysis is key to successful asset management

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

work permit closed

Reason for failure - indicate failure code

Remarks

The single most important data for analysis. MAINTENANCE IS NOT COMPLETE UNLESS WE KNOW WHY AN EQUIPMENT FAILED AND TAKE CORRECTIVE MEASURES TO AVOID RECURRENCE GRIHA uses standard failure codes

Reliability Case Study

Suggest Hyperlinking

Typical Log Book Extract

Log Book Extract of a typical thermal power plant - Equipment - 07-J-101A,B and C - Boiler feed pumps - 70 Hp 3000 Rpm Multistage 07-J-101A - PM done - Task list No: 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observe 07-J-101B - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observed OK 07-J-101C - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observed OK 07-J-101A - Oil Analysis report received - Copper particles from cage seen confirmed in oil - raised work order to change oil again - changed oil - oil again sent for lab analysis David/28-9-2004 - 2 Hrs - 1 Technician 07-J-101 A,B,C -Vibration analysis Task List No 119 carried out on A and C and changed over C to B and took readings on B - B and C velocity readings are normal within limit in the "SLIGHTLY ROUGH" region and A had moved from slightly rough to"ROUGH" regi

07-J-101A pump taken for maintenance - isolated - decoupled - bearings inspected - radial movement at the bearing was high indicating radial bearing wear - Oil found contaminated with copper particles again - Work Order generated for corrective maintenanc 07-J-101A - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observed OK 07-J-101B - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observed OK 07-J-101C - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observed OK 07-J-101 A,B,C -Vibration analysis Task List 119 carried out on A and B and changed over B to C and took readings on C - Readings on all three pumps were normal with velocity readings showing "SLIGHTLY ROUGH" range at the bearings- However Pump A indicate 07-J-101A - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observed OK 07-J-101B - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observed OK 07-J-101C - PM done - Task list 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observed OK 07-J-101 A,B,C -Vibration analysis Task List 119 carried out on A and B and changed over B to C and took readings on C - Readings on B and C pumps were normal with velocity readings showing "SLIGHTLY ROUGH" range at the bearings- However Pump A had moved

07T-J-101A - Vibration Analysis carried out on the Pump A - Vibration readings were around the same level as that of 20-5-2005 - However the bearing oil had fine copper particles and maintenance stopped the pump and changed the oil - The repeat of the bea

07-J-101A - PM done - Task list No: 121 - Isolated pump, decoupled pump from motor, Checked coupling for wear - OK , Pump checked for free rotation, for axial movement and radial movement - found ok - inboard and outboard bearing oil drained and observe

Pump 101 A History

07-J-101A Pump History
Date Supervisor 21/9/2004 David From 0800 Hrs to 1600 Hrs Type of Work PM Task List No. Work Done Man Hours 121 Isolated pump, decoupled pump from 16 MHrs motor, Checked coupling for wear - OK , 2 Pump checked for free rotation, for axial Technicians movement and radial movement - found ok - for 8 Hrs inboard and outboard bearing oil drained Micheal and and observed - Found shiny brass like Mathew metal particles Spares Used Lube Oil No. 13632 Coupling Grease No. 34 Standard Technician Tool Box 28/09//2004 David Corrective Lube 89 Oil Analysis report received - Copper particles from cage seen confirmed in oil raised work order to change oil again changed oil - oil again sent for lab analysis 1 Technician 30 Minutes lube iol No 13632

25/10/2004 David

Condition Monitoring

CM 12

Vibration analysis Task List No 119 carried CM out on A and C and changed over C to B Tecnician and took readings on B - B and C velocity readings are normal within limit in the "SLIGHTLY ROUGH" region and A had moved from slightly rough to"ROUGH" region at the outboa

IRD 880 Vibration Analyses

26/10/2004 David

Corrective Maintenance

TL126

pump taken for maintenance - isolated decoupled - bearings inspected - radial movement at the bearing was high indicating radial bearing wear - Oil found contaminated with copper particles again Work Order generated for corrective maintenance - Task l

32 M Hrs Radial Bearing Part 2 No 34567 Technicians Lube Oil No. 13632 Coupling Grease No. 34 Standard Technician Tool Box

A typical reliability analysis

Reliability Analysis from the data available Time Between Failure = 300 Hrs for 07-J-101A while B&C are running normal Bearing life is about 300 Hours. It is very low. Expected life of antifriction bearings is as per the chart along side. A well selected industrial pump bearing should achieve 40000 Hrs of life provided, it is selected properly, stored properly, fitted properly, lubricated properly and loaded as per design
Basic Rated Life of Bearings: The basic rated life is defined as the number of revolutions that ninety percent of a group of identical bearings would be expected to achieve. It is determined via the life required of the bearing. Typical life requirements for various machine categories are listed below. Machine Usage Type Life Required of Bearings (Hours) household appliances intermittent use 300 - 3000 hand tools, construction equipment short period use 3000 - 8000 lifts, cranes high reliability for short periods 8000 - 12000 8h/day gears, motors full day partial use 10000 - 25000 8h/day machine tools, fans full day full use 20000 - 30000

Continuous use 40000 - 50000 Hrs

Considering that the other pumps are running normal, we have to suspect one of the operating conditions of pump A Pump A is putting undue load on the bearing There are two indications from the data available 1. The 6X frequency is indicating some cavitation conditions on this pump. This is possible if the number of vanes in the impeller are six Considering the pump A alone is failing it could be restrictions on suction flow to pump Check suction side of the pump for flow restrictions 2. The pump is getting misaligned and requires correction. It is suspected that the piping could be pulling the pump especially when the lines are hot. Part the flanges at suction and discharge to ascertain pipe pull. Correct by adequately adjusting the pipe supports 3. Ensure that the bearing has been sourced from autherised suppliers

Prequalification Docs
PREQUALIFICATION QUESTIONNAIRE
CONTENTS Bidder is requested to complete the following questionnaire and submit within its tender document:
1. COMPANY & FINANCIAL DETAILS 2. ADDRESSES & CONTACTS 3. FACILITY DETAILS 4. QUALITY 5. HEALTH, SAFETY & ENVIRONMENT 6. TRACK RECORD 7. CURRENT & PROJECTED WORKLOAD 8. LIST OF MAJOR CLIENTS 9. SUBCONTRACTED SERVICES 10. ASSOCIATION WITH EQUIPMENT MANUFACTURERS

Attachments
ATTACHMENTS (scanned copies to be inserted in these Attachments) Attachment 1 Management Organisation Chart Attachment 2 Audited Financial Statements Attachment 3 Facility Location Map Attachment 4 CVs of Key Personnel Attachment 5 Quality Certification, System Details, Organisation and Key Personnel CVs Attachment 6 HSE Management System Details, Organisation and Key Personnel CVs (including any attachments requested in Section 5 of this Questionnaire) Attachment 7 Commercial Registration & Certification for Trading in Qatar + Tax Certificate Attachment 8 Company Profile & Brochure Attachment 9 Additional Information (if required)