Optimising the Performance of

Rotating Equipment
- A business case

Mahomed Chothia

Manager, Reliability Systems

SKF NV / SA, Brussels
Slide 1 [RS MFC]
2008-10-10 SKF

SKF [MENA]

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.

Predictive Maintenance

Use a mix of strategies

Preventive Maintenance
Reactive/Corrective
Minimum Efficiency

Slide 5 [RS MFC]

2008-10-10 SKF

SKF [MENA]

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

Who is responsible for Reliability?

Reduce emissions
Reduce energy usage
Assure compliance
Avoid hazards

Safety/
Environment

Engineering

Strategy
Business cycles
Shareholder value

Management

Finance

PLANT
PERFORMANCE

Re-design current assets

Coordinate maintenance needs
Control projects
Reduce capital outlay.

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

Slide 6 [RS MFC]

2008-10-10 SKF

SKF [MENA]

Budgets
Compliance
Reduce admin costs
Cash flow-ROI

Reliability
Increase asset efficiency
Increase machine uptime
Reliability systems

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

Maintenance
Service response
Perform precision work
Maintain asset
Control costs

Cost of a Production Stop

INDUSTRY

COST

Steel Mill

$10,000 / hour

Paper Mill

$10,000 / hour

Power Plant (600 MW)

$15,000 / hour

Car Plant (Paint Shop)

$100,000 / hour

Petrochemical
Cement Mill
Food Processing
Slide 7 [RS MFC]
2008-10-10 SKF

SKF [MENA]

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

Best Practice

55% is Reactive
31% Preventive
12% Predictive
Proactive
2% as other

< 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

Average life of electric motors

> 15 yrs

< 10 yrs

Mean time between repairs for pumps

> 6 yrs

< 3 yrs

Average machine vibration levels (mm/s)

< 2 to 5

>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
p

L10h =

Slide 19 [RS MFC]

2008-10-10 SKF

SKF [MENA]

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

Sealed Spherical Roller Bearings

Regreasing bearings used to
present serious problems.

Caster Bearings in Steel Mill

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]

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:

320 kW

Speed:

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

Plain Bearing Failures ..

Time to repair shaft / balancing
Rebabbitting of bearings
Installation / commissioning

4 days
1 day
1-2 days

Failure of plain bearings

New SKF solution

3 5 months
> 33 months *

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

Slide 39 [RS MFC]

2008-10-10 SKF

SKF [MENA]

Equipment:

Rolling Mill - Stands 1 and 2

Bearing
Designation

SKF 24148 CC/C2.W33

OEM Bearing
Designation

SKF 24148 CC/C2.W33/235220

Lubrication:

Grease EP2

Environment:

High operating temperature.

High humidity

Service Life:

Few months

PROBLEM
DESCRIPTION

Low MTBF of the bearings.

Cracking of the outer ring (some)
Premature flaking.

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

Slide 44 [Code]
Slide2008-10-10
44 [RS MFC]SKF
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

Slide 45 [RS MFC]

2008-10-10 SKF

SKF [MENA]

Corrective Actions
Contamination free systems
Training in lubrication
Cleaner work areas
Use of oil filtration / breathers
Redesign the sealing arrangement

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
Maximum of 200 ppm

250%

1 ppm = 1 mg / kg
200%

New lubricant guideline

25 ppm at 20 C

150%

Based on 100% Life at 100ppm water

Rated Bearing
Life
100%

50%

0%
500

1000

1500

2000

Water in Oil (ppm)

Slide 50 [RS MFC]

2008-10-10 SKF

SKF [MENA]

2500

3000

3500

4000

4500

5000

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