CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla ....
Transcript of CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla ....
![Page 1: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/1.jpg)
GROWTH INNOVATION SOLUTIONS SUCCESS
1
Reliability Centered Maintenance to Minimize Integrity Failure
CCPS Asia regional PSM Meeting
Bhavesh Shukla
![Page 2: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/2.jpg)
Agenda
•Failure Case study
•Types of Maintenance
•Risk Based Maintenance Strategy
•Process Steps
•Exercise
2
![Page 3: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/3.jpg)
Coupling with
Torque Limiting Slip (TLS) Plate (Clutch)
3
Reactor agitator failure
![Page 4: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/4.jpg)
Cost Analysis:
i. Additional cost to Business due to failure =1.3 Million
ii. Cost to prevent failure=$10000
Causal Factor:
i. Aging equipment
ii. Lack of predictive maintenance
iii. torque limiting setting was set too low during gear box replacement
which caused pre-mature clutch top limiter slipping which
generated heat and caused the high speed coupling to fail
Preventive Action:
i. Temperature monitoring of Gearboxes and motor
ii. Vibration check and analysis program
iii. Lubrication test and analysis program
4
Agitator Failure
![Page 5: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/5.jpg)
Types of Maintenance
5
•Repair
Run to failure
•Preventive Maintenance
Time based
•Predictive Maintenance Condition based
![Page 6: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/6.jpg)
•Repair – run to failure is Suitable only for
Non critical
Inconsequential
Unlikely to fail
Redundant
6
Repair
![Page 7: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/7.jpg)
Repair
• Repair of unexpected break-downs cost more than money
• run to failure, is suitable for small items which are non critical,
inconsequential, unlikely to fail and redundant.
• For critical equipments and parts, it is not an option.
7
![Page 8: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/8.jpg)
Repair
8
![Page 9: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/9.jpg)
Preventive Maintenance
9
•Preventive maintenance is time base
Maintenance. We change parts or service
equipment before it fail and some time
before it need to be.
![Page 10: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/10.jpg)
Preventive Maintenance
10
![Page 11: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/11.jpg)
Preventive Maintenance
11
![Page 12: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/12.jpg)
Preventive Maintenance
12
![Page 13: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/13.jpg)
Predictive Maintenance
13
• Is based on predictive testing, monitoring and inspection.
• It is suitable for critical equipment which has
random failure
not subject to wear
PM induced failure
![Page 14: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/14.jpg)
Predictive Maintenance
14
![Page 15: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/15.jpg)
Predictive Maintenance
15
![Page 16: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/16.jpg)
Predictive Maintenance
16
![Page 17: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/17.jpg)
17
Condition Based Maintenance
![Page 18: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/18.jpg)
Reliability Centered Maintenance
• Reliability Centered Maintenance (RCM) is a maintenance
strategy that is implemented to optimize the maintenance program
of a company or facility using cost-effective maintenance
techniques.
• There are four principles that are critical for an RCM program.
The primary objective is to preserve system function
Identify failure modes that can affect the system function
Prioritize the failure modes
Select applicable and effective tasks to control the failure modes
18
![Page 19: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/19.jpg)
RCM Process Steps
19
Operational Risk Number
System Risk Number
Asset Risk Number
Failure Probability Factor
Maintenance Priority Number
Safety Issues, Regulatory Compliance,
Product Quality Issues, Process Throughput,
Operational Cost
In series and will stop the system (24 hr lost)
, Important (8 hr lost) ,Can be Bypassed,
Little effect to system, No effect to system
Reactive Maintenance Performed…
Daily, Weekly, Monthly, Quarterly, Annually
![Page 20: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/20.jpg)
System Risk Ranking Process
Area SF RC QF PT OC SRN
PROCESS SYSTEM NAME
Safety
Failures
Regulatory
Compliance
Quality
Failures
Process
Throughput
Operational
Cost
System
Risk Number
Reactor
(1-10) (1-10) (1-10) (1-10) (1-10) 1-10
Agitator TLS plate 8 2 10 10 10 8
Cooling control valve 6 8 9 8 5 7.35
Heating Control valve 5 6 6 8 8 6.71
Cooling insulation 3 2 3 4 3 3.07
20
![Page 21: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/21.jpg)
21
Maintenance Priority Ranking Process
Risk Number ORN FPF
10 24 Hours Lost Daily
8 8 Hours Lost Weekly
6 2 Hours Lost Monthly
4 <1 Hour Lost Quarterly
2 No Lost Annually
PROCESS SYSTEM NAME
System
Risk
Number
Operational
Risk
Number
Asset
Risk
Number
Failure
Probability
Factor
Maintenance
Priority Number
#1-10 (1-10) # 1-100 (1-10) # 1-1000
Reactor SRN ORN ARN FPF MPN
Agitator TLS Plate 8 10 80 3 240
Cooling control valve 7.35 4 29.40 2 59
Heating Control valve 6.71 3 20.13 5 101
Cooling insulation 3.07 2 6.14 1 6
![Page 22: CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla . Agenda •Failure Case study ... Torque Limiting Slip (TLS) Plate (Clutch) 3 Reactor](https://reader031.fdocuments.us/reader031/viewer/2022040203/5ea60b93ef82f86ca2514efb/html5/thumbnails/22.jpg)
Maintenance Strategy
22
Maintenance Priority Index to determine which type of maintenance is
most effective.
• Repair- run to failure
• Preventive Maintenance
• Predictive Maintenance