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Make Life Easy

&
Innovative
Thru
RCM

© RMCPL All rights reserved

Vision
 To
improve reliability of critical plant and
machinery to improve upon Productivity,
Performance and Profitability.
Mission

 Formulate a Reliability Centered Maintenance plan

with clear strategy
 Would be able to have a firm grasp on application of
CBM techniques in improving reliability of a plant.
 Would be able to carry out deep analysis of failure
modes in order to improve upon the inherent
reliability of a plant
 WORK LIFE

ENVIRONMENT

COST & SAFETY

ENERGY
EFFICIENCY

MAINTENANCE
RELIABILITY
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RCM – some definitions

 Maintenance: Ensuring that physical assets continue to do what their users

want them to do.

 RCM: a process used to determine what must be done to ensure that any
physical asset continues to do what its users want it to do in its present
operating context.

 RCM helps people determine the best maintenance tasks in a cost

effective manner for managing the functions of physical assets – and for
managing the consequences of functional failures.
 RCM does not challenge the design of the equipment or system
Why RCM?

 IN ORDER TO SUCCESSFULLY COMPETE TODAY,

PLANT AVAILABILITY AND RELIABILITY MUST
BE MAINTAINED AT DESIRED LEVELS WHILE
OPERATING COSTS MUST BE KEPT AS LOW AS
REASONABLY ACHIEVABLE.

 A KEY ELEMENT IN THIS COST REDUCTION IS

CONTROLLING MAINTENANCE PRACTICES.
RCM - features

 Structured - Logical – nothing done without a reason

 Reduces intrusiveness and improves flexibility of maintenance teams
 Auditable -- Quantifiable results and benefits
 Induces higher skills (cognitive and physical) of technicians
 Living document
RCM – Benefits

 Choosing the appropriate maintenance strategies/tasks

 Formulating a structured maintenance plan and schedule
 Avoid/minimize consequence of a failure
 Reduction in maintenance tasks (25% to 50%)
 Reduction in number of failures (15% to 25%)
 Reduction in costs (25% to 50%)
 Improved quality of maintenance actions
 Maximizing Reliability, Availability, Safety
 Optimum use of maintenance resources
Main Benefits

1. PHASE-OUT COSTLY INTRUSIVE

INSPECTIONS
2. DEVELOP CBM PROGRAM TO
CONDITIONALLY DIRECT MAINTENANCE
ACTIVITIES.
3. DISCOVER “BAD ACTORS”
4. IDENTIFYING MORE COST-EFFECTIVE
TASKS
5. REFINE PRIORITIZATION Of Maintenance
Maintenance Strategies & Evolution

 On-Failure maintenance (OFM)

 Time Based Maintenance (TBM)
 Condition Based Maintenance (CBM)
 Detective Maintenance
 Design Out Maintenance (DOM)
 Opportunity Maintenance (OM)
On-Failure Maintenance

 Advantages:
 Can be effective where consequence of a failure is zero

 Disadvantages:
 Affects production (undesired downtime)
 Affects quality
 Large stand-by crew
 Large stock of spare parts
Time Based Maintenance

 Advantages:
 Can be applied to components purely subjected to time based wear (2%)
 And consequences of a failure is relatively low

 Disadvantages:
 Scheduled overhaul; however intensive; of complex equipment has little or no effect
on in-service reliability
 Increase in cost
 Lack of time
 Large stock of spare parts
 Large crew needed
Condition Based Maintenance
 Advantages:
 Maintenance can be done as needed
 Can be applied to random failures (minimum 68%)
 Applied where consequences of a failure ranges from Low to high
 Detects incipient and hidden failures in time
 Prevents secondary damage
 Maintenance can be planned in advance to fit production windows
 Resources can be optimized as per need and operating context
 Can be operator driven or system driven or IOT driven

 Disadvantages:
 High skill needed to implement and run a CBM system
 Multiple failures can happen at the same time stressing the maintenance system
 Condition Based Maintenance

Pump Vibration Measurement Non contact temperature measurement

Thermography of switch Yard Wear debris analysis (External) © RMCPL All rights reserved
 What is Trend Monitoring?
60
50
40

30
20
10

0
Life Units

CM depends on the trending of parameters which

are indicators of the condition of key equipment
failure modes © RMCPL All rights reserved
Warning

Alarm

Detection of Defects

Cause finding through

correlation

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© RMCPL All rights reserved
Design Out Maintenance (DOM)

 Advantages:
 Can be applied to prevent repeat failures
 Minimizes or eliminates failure rate
 Generally applied where consequences of a failure is high
 Maintenance can be minimized
 Minimum resources needed to maintain assets

 Disadvantages:
 High skill needed
 Time
 EXISTING STRATEGIES
OFM
no control on failures

TBM
Preventing age related failures
(2% to 5%)
CBM
Detects random failures(>68%)

RCM
prevents consequences of failures

#POWEROFSEE © Dibyendu De
Basic Steps to RCM
On-Failure Condition Based
Fix it when it fails Maintain based upon known condition

Fixed Time Maintenance Plan

Maintain based upon Design Out
calendar or running time Identify & design out root cause of failure

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7 Questions….

1. WHAT ARE THE FUNCTIONS AND RELATED

PERFORMANCE STANDARDS OF THE ASSET IN
ITS CURRENT OPERATING CONTEXT?
2. WHAT ARE THE POSSIBLE WAYS IN WHICH THE
ASSET MAY FAIL TO PERFORM ITS REQUIRED
FUNCTIONS?
3. WHAT ARE THE CAUSES OF EACH FUNCTIONAL
FAILURE OR FAILURE MODE?
4. WHAT ARE THE EVENTS THAT FOLLOW EACH
FAILURE?
7 Questions…

5. WHAT IS THE SIGNIFICANCE OF

EACH FAILURE?
6. WHAT MEASURES CAN BE TAKEN
TO PREVENT FAILURE?
7. WHAT MIGHT BE THE CORRECTIVE
MEASURES THAT MAY BE TAKEN
IF THERE IS NO APPROPRIATE
PREVENTIVE STEP?
The RCM Process Application
 DURING EQUIPMENT DESIGN AND
DEVELOPMENT PHASE, WHEN IT IS USED TO
DEVELOP MAINTENANCE PLAN.

 DURING EQUIPMENT/PRODUCT OPERATION

AND DEPLOYMENT, THESE PLANS ARE THEN
MODIFIED BASED ON FIELD EXPERIENCE.
2 criteria
 PARTS THAT ARE NOT CRITICAL TO
SAFETY –preventive maintenance tasks should
be chosen that will decrease the ownership life
ownership life cycle cost (LCC).
 PARTS THAT ARE CRITICAL TO SAFETY –
maintenance tasks should be chosen that will
that will help prevent reliability or safety from
safety from drooping to an unacceptable level,
unacceptable level, or will help reduce the
the ownership life cycle cost (LCC).
Heart of the thing

 INCIPIENT & HIDDEN FAILURES ARE DETECTED

AND CORRECTED – APPLICATION OF CBM
TECHNIQUES
 PROBABILITY OF FAILURE IS REDUCED –
APPLICATION OF DESIGN OUT MAINTENANCE
(DOM)
 SYSTEMIC ROOT CAUSE FAILURE ANALYSIS
(SRCFA)
 REDUCE OWNERSHIP OF LIFE CYCLE COST
Analysis & design of systems
 FOCUS ON CRITICAL EQUIPMENT WITH
DOCUMENTED FAILURE MODES. (Maintenance
Records)
 STRATEGY EMPHASIZING CONDITION-BASED
TASKS.
 IDENTIFYING ACTIONS THAT HELP PRECLUDE
COSTLY UNPLANNED CORRECTIVE
MAINTENANCE.
 IDENTIFYING AND REMOVING UNNECESSARY
ROUTINE PM TASKS. (Review of Equipment
Maintenance - REM)
The 7 step process
STEP 1:
DETERMINE EQUIPMENT/PARTS WITH HIGHEST
MAINTENANCE PRIORITY. OBTAIN APPROPRIATE
FAILURE DATA, WHICH MAY BE OBTAINED FROM – A)
A) EQUIPMENT HISTORY B) WORK ORDERS

STEP 2:
DETERMINE CONTEXTUAL FAILURE MODES

STEP 3:
PERFORM SYSTEMIC ROOT CAUSE ANALYSIS – FTA,
FTA, FMECA, SRCFA TECHNIQUES
 Reliability Centered Maintenance
review
• NOTICE • ENGAGE

CHANGES PATTERN
? S?

MINIMA
L INTERACTI
CHANG ONS?
ES
• EXCHAN • MULL
GE

#POWEROFSEE © Dibyendu De
 Process Reliability

1 2 3 4

0.99 x 0.99 x 0.99 x 0.99

= 0.96 ≈ 96%

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Equipment diagram

Pump Gear Box Motor

A B C

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Determining Criticality
Period selected = 2 yr/1yr/6m (Tp)
# Equipment Frequency Downtime (total) F x DT Rank
# (F) Hrs (DT)
1 Xxxx 20 50 1000 2
2 Yyyy 5 500 2500 1
3 Zzzz 10 40 400 3

From this we also obtain:

MTBF = Tp/F

MTTR = DT/F

Steady State Reliability R = MTBF/(MTBF + MTTR) and other maintenance

parameters

Risk
Critical equipment for Power plant

1. MAIN STEAM AND WATER

2. FUEL HANDLING
3. CIRCULATING WATER
4. ASH HANDLING
5. SOOTBLOWING
Critical equipment for Power plant….

6. BOILER GAS AND AIR

7. FEEDWATER HEATER
DRAINS/EXTRACTION STEAM
8. COAL HANDLING
9. FEEDWATER
10. CONDENSATE
 Analysis of Maintenance Records permits an effective strategy to be chosen
Failure
Characteristics
Failure Probability
Graph

Condition
Monitoring
Mean Time Before
Failure

Strategy in order
of preference

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The 7 step process
STEP 1:
DETERMINE EQUIPMENT/PARTS WITH HIGHEST
MAINTENANCE PRIORITY. OBTAIN APPROPRIATE
FAILURE DATA, WHICH MAY BE OBTAINED FROM – A)
A) EQUIPMENT HISTORY B) WORK ORDERS

STEP 2:
DETERMINE CONTEXTUAL FAILURE MODES

STEP 3:
PERFORM SYSTEMIC ROOT CAUSE ANALYSIS – FTA,
FTA, FMECA, SRCFA TECHNIQUES
Critical Equipment: Vertical Roller Coal Mill
Sub-assembly: Main Gear Box
Performance Standard: To provide constant torque to Mill table

Failure MTBF Failure Warning Root Cause Consequence Risk

Mode Pattern Effect Rating
Bearing 2 yrs Random Increased Bush Wear of Full Load loss 1
cracked noise output shaft ->
(anti-friction) Lateral shift of
input shaft
De Diagram: S^S -> E -> Failure Mode
7 step process…..
STEP 5:
CLASSIFY MAINTENANCE REQUIREMENT –

CBM, DOM, TBM, OFM, LABOUR, SPARES,

INSTRUMENTS, SOFTWARE, ETC.

STEP 6:
IMPLEMENT RCM DECISIONS. CHECK
EFFECTIVENESS.
Critical Equipment: Vertical Roller Coal Mill
Sub-assembly: Main Gear Box
Performance Standard: To provide constant torque to Mill
table

Maintenance Action Strategy Frequency Responsibility Remarks

1. Measure CBM 1M MID Use low frequency
displacement (H) sensor
on Input shaft
2. Change Bush
material DOM One Time Engineering Within 3 m
3. Change lubricant
specification DOM One Time Engineering Within 3 m;
4. Drill hole on Servomesh EE
bearing cover 320
DOM One Time Engineering To let out debris;
else enter bearing
On-Failure Condition Based
Fix it when it fails Maintain based upon known condition

Fixed Time Maintenance Plan

Maintain based upon Design Out
calendar or running time Identify & design out root cause of failure

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RCM Maintenance Plan Distribution

Plan

30

DOM

5
TBM CBM
68

OFM CBM TBM DOM

 Just Restore Restore with
(Plan) Improvements
(Innovate)

Threshold

Risk
Life Lost

Additional Life

Time N

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 1/100 RI:cREATIvITY

1/40 RCM:RISK

1/20 CBM:STEM

1/10 TPM:PEOPLE

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Failure Modes: Verb + Noun

# Noun Verb # Noun Verb

1 Bearing Seized 11 Switch Open
2 Bearing Worn 12 Circuit Open
3 Shaft Cracked 13 Valve Sticking
4 Seal Worn 14 Lubricant Foaming
5 Motor Burnt 15 Lubricant Heated
6 Contact Short-circuited 16 Tubes Clogged
7 Coil Burnt 17 Rotor Bowed
8 Gear Worn 18 Filter Jammed
9 Hinge Bent 19 Oil Contaminated
10 Packing Leaked 20 Contact Pitted
MTBF

 Mean Time Between Failures =

Time period of observation/#of failures

Usually a two years of observation period is ideal.

With lack of information a 6 months period is just enough
With no information Dynamic analysis is employed to ascertain
failure modes.
 Early Random Failure Wear Out
Failure
Rate

Time

Typical “Bathtub” Curve 30%

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 Possible

05% 05%
> 2hr Big Wear
Problem

Medium 25% Early 25%

< 2 hr
Problem

< 30m 70% 70%

Small Random
Problem

2 Pyramids (Nature of Problems) © RMCPL All rights reserved

Failure Patterns – contd..

 Random (68 to 80% cases)  CBM is the default

 Time based (2 to 5% cases)  TBM is the default
 Early (> 10%)  DOM is the default
 Hidden (5%)  CBM/DOM is the default
 Complex  Combination of strategies needed
Warning Effect (e.g.)

 Vibration
 Noise
 Loss of performance
 Quality
 Overheating
 Leakage
 Corrosion
 Etc.
Actions are taken by considering both effect and causes
Failure Cause(s): FRECTLS (e.g.)
# Basic Cause Manifestations # Basic Cause Manifestations
1 F Unbalance 2 R Selective Transfer
Force/ Misalignment Reactive Chemical reaction
Inertia Looseness Material
Acceleration Moisture
Decelration Restrictions
Impact 3 E Dust
Torsion Environment Humidity/Dryness
Bending/Bow Ambient Temp

Crack/Open EM interference
Heat transfer
Fatigue (low)
Vibration
Fatigue (high)
Nox/Ozone
Flow
Human
Flow turbulence
Pressure
Foundation
Failure Cause(s): FRECTLS (e.g.)

# Basic Cause Manifestations # Basic Cause Manifestations

4 C Small Changes Thermal shocks
Chaos Periodic attractor Variations
& Resonance Entropy
Complexity Point attractor Heat band
Oscillating Radiation
Big changes Convection
Non-Equilibrium Conduction
Non-Linearity 6 L Incompatible
Feedback loop Lubrication Additive loss
5 T High & Viscosity
Temperature Low Wear Moisture
Transition Temperature
Failure Cause(s): FRECTLS (e.g.)
# Basic Cause Manifestations # Basic Cause Manifestations
L Wear 7 S Structure/Soil
Lubrication Adhesive Structure Speed
& Abrasive (2 body) Speeds Surface rough
Wear Abrasive (3 body) Surfaces Sync
(contd) Erosion Space/Shape
Catastrophic Symmetry/Asym
Pitting Softness/Sticky
Spalling Surface interfaces
Flaking Shocks/Impact
Brinelling Sound/Noise
Fluting Substance
Fretting Shorting
Corrosion (8) Separation
Stress Corrosion System design
Consequences and Ranking
Priority Reliability/Capability Efficiency Environment Safety Employee Worklife
1 Full Load loss Non-compliance Asset required to Protect employee
protect life
life/property
2 Major derating 40% or Imminent
more violation
3 Significant derating 20% Heat rate effect
or more significant
4 0% derating but possible Prevents Redundant safety Employee Safe
generation loss due to effective system work
extended asset failure management environment
5 Possible loss of generation due to Heat rate effect Supports training
to failure of redundant equipment moderate needs

6 Loss of assets causes loss of auto Detracts from Protects equipment

function to multiple equipment or improvement goals from damage
or system

7 Loss of asset causes significant Heat rate effect minimal Provides employee
operational inconvenience comfort

8 Loss of asset precludes normal

system or equipment operation

9 No effect No effect No effect No effect No effect

Maintenance Tasks are guided by

 Nature of Failure Mode, Pattern, Warning

Effect, Cause(s) and Consequence
 Frequency of a CBM task = MTBF/5
 Task takes care to avoid the
consequences
 Task takes care to detect incipient defects
 Task takes care to increase the MTBF
 Task takes care to reduce the MTTR
 Application of Monitoring Techniques
Equipment Causes of Failure Techniques Comments
Fan Out of balance Overall acceleration Simple application using
Misalignment Spike energy windowed spectra to trend
Bearing damage measurement deterioration in specific
Aerodynamic Overall vibration faults.
forces Vibration analysis
Belt problems Flow measurement Equipment performance is
Motor current monitored by measuring
measurement process parameters

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Basic Steps to RCM
7 step process….

STEP 7:
BASE SUSTAINING ENGINEERING ON REAL-LIFE
LIFE EXPERIENCE DATA – LIVING RCM
 2% Unpredictable

30%
Plan Make Life easy
&
Innovative

68%
Improvements

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# Audit Parameters Previous After 1year After 2years

1 No. of breakdowns per 57 19 3

year
2 % of breakdown hours 25 12 5

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 effects of

Reliability Centered Maintenance

ON CEMENT PLANT
# Audit Parameters Previous After 1 Year After 2 Years
1 No. of Breakdowns /Year 57 19 3
2 % of Breakdown Hours 25 12 5

Effect of ACM
60
57
50

40

30
25
20 19
10 12
5
3
0
Previous After 1 Year After 2 Years
No of BreakDowns/Year % of BreakDown Hours

#POWEROFSEE © Dibyendu De
 No. of Breakdowns (Avg/Month)
30

20
Number

10

0
1st Year 2nd Year 3rd Year 4th Year

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 Reliability vs. Cost
25
40

30

20
20

10

0
15
1 2 3 4 5 6 7 8 9 10 11 12

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RCM – broad steps - Implementation

 Equipment survey to establish time and costs

 Prioritise and plan the project
 Set up Study Team
 Carry out study
 Produce reports and schedules
 Monitor results, failure modes, schedules and tune the program
RCM – Outcome of the Study

 Facilitated sessions between –

 RCM Facilitator
 Stakeholders of an area/equipment
 Study Group produces the reports in form of a structured plan
 Reports are turned into actionable maintenance schedules and
recommendations.
 Produce reports and schedules
 Monitor results, failure modes, schedules and tune the program
summary

 CONCENTRATE MAINTENANCE RESOURCES WHERE THEY

WILL DO THE MOST GOOD.
 ELIMINATE UNNECESSARY AND INEFFECTIVE
MAINTENANCE.
 DEVISE THE SIMPLEST AND MOST COST-EFFECTIVE MEANS
OF MAINTAINING EQUIPMENT, OR TESTING FOR
DEGRADATION
 FOCUS PM TASKS ON PREDICTIVE OR CONDITION
MONITORING ACTIVITIES WHERE APPLICABLE. DEVELOP
A DOCUMENTED BASIS AND HISTORY FOR THE
MAINTENANCE PROGRAM.
 MAXIMIZE PLANT EMPLOYEE AND ANALYST EXPERIENCE
WHEN DETERMINING EQUIPMENT TASKS WITH
 ingredients
Reilability Centered Maintenance
PEOPLE

LEADERS

#POWEROFSEE © Dibyendu De
Once done the company
gains permanent on-
going benefits.
Prof. Tim Henry, Manchester University, U.K

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 Contact
Dibyendu De
dde337@gmail.com
+91 7044627404 / 9836466678

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