Operations, Maintenance, and Commissioning

Transcription

1 Operations, Maintenance, and Commissioning Building 54, Pearl Harbor Naval Facilities Engineering Command, Hawaii eere.energy.gov Objectives Upon completion of this seminar, you will be able to: 1. give an up-to-date definition of operations and maintenance today. 2. explain the relationship of O&M and commissioning. 3. discuss the benefits of a well run O&M program. 4. explain some of the common barriers to O&M and how to overcome those barriers. 5. list 5 performance measures for an effective O&M program. 6. explain O.M.E.T.A. in terms of an complete O&M program. 7. explain lifecycle implications in O&M from new component design to replacement. 8. discuss the benefits of each of these types of maintenance: reactive, preventative, predictive, and reliability centered. 9. locate resources to support you in O&M. 2 eere.energy.gov 1

2 Operations, Maintenance, and Commissioning Ray Pugh Operations and Maintenance Pacific Northwest National Laboratory Building 54, Pearl Harbor Naval Facilities Engineering Command, Hawaii eere.energy.gov Commissioning? Is It Part of Your O&M? 4 eere.energy.gov 2

3 What is Commissioning? Process of verifying (typically new construction) that all subsystems, i.e., HVAC, Electrical, Fire Safety, etc., perform in accordance with design expectations. 5 eere.energy.gov Commissioning If the building subsystem s performance/ operation meets or exceeds design criteria, a key question is, For how long? 6 eere.energy.gov 3

4 Commissioning A well designed and supported O&M program is critical to: Maintaining system performance Extending equipment/component operational life Cost avoidance Equipment replacement Maintaining system efficiency 7 eere.energy.gov What is O&M? 8 eere.energy.gov 4

5 Operations & Maintenance Classic Definition: The processes related to the performance of routine, preventative, predictive, scheduled, unscheduled and emergency maintenance. Includes operational factors such as scheduling procedures work/systems control 9 eere.energy.gov Defining Operations & Maintenance Modern Definition: The coordinated integration of the operations, maintenance, engineering support, training, and administrative areas (OMETA) of any process in order to maintain and/or increase the efficiency, reliability, and safety of the process eere.energy.gov 5

6 Northwest Survey Findings: History of Neglect Operating equipment in manual override Incorrectly adjusted equipment Inoperative equipment Steam, air, water leaks Faulty control systems Damaged HVAC equipment 11 eere.energy.gov Importance of Operations & Maintenance Northwest industries survey Potential energy savings of between 5-7 thousand MWh per year could be achieved by improving O&M practices. O&M energy savings of 5-20% common Low-cost, no-cost savings prevalent 12 eere.energy.gov 6

7 DOE Forrestal Building No steam metering or active O&M Performed system audit to correct deficiencies Annual steam savings of $250,000 (leaks and traps) O&M Potential DOE Case Study 13 eere.energy.gov O&M First Benefits Reduce energy consumption Reduce unscheduled equipment repair and/or replacement Reduced capital costs for replacing equipment which prematurely fails Ensure other energy conservation technologies achieve their expected cost savings Improved staff morale 14 eere.energy.gov 7

8 Barriers to an O&M First Philosophy Limited staff Lack of training Inadequate diagnostic equipment Missing technical documentation Budget Inadequate building/equipment metering Lack of management commitment Poor morale 15 eere.energy.gov Barriers to Selling O&M to Management You must address each and every concern The program will not succeed Costs are too much Too technical/i ll have less control Limited understanding of technologies No confidence No personal benefit Human resource problems 16 eere.energy.gov 8

9 Overcoming the Barriers to Selling O&M to Management Understand the decision makers Understand the competition Speak the language of decision makers Economics: Return on investment NPV?? Life Cycle Costs Help them reach their goals EDUCATE!!!! 17 eere.energy.gov Overcoming the Barriers to Selling O&M to Management Getting the program off the ground: Start small Select troubled equipment Pick situations which will provide immediate, positive results Keep accurate records Time and costs Maintenance cost savings Maintenance cost avoidance Blow your own horn 18 eere.energy.gov 9

10 Measuring The Quality of your O&M Program 19 eere.energy.gov O&M Performance Indicators O&M Metrics: Work orders generated/closed out Backlog of corrective maintenance Backlog of preventive maintenance Safety record 20 eere.energy.gov 10

11 Effective Operations & Maintenance Program Management: OMETA 21 eere.energy.gov O.M.E.T.A O - Operations M - Maintenance E - Engineering T - Training A - Administration 22 eere.energy.gov 11

12 Engineering Support Maintenance Training Operations Administration OMETA 23 eere.energy.gov Operations Organizational structure Interface defined and understood Plant evolutions and testing authorized and controlled Use of approved procedures Operating conditions effectively monitored 24 eere.energy.gov 12

13 Maintenance Work priority system Work documentation Maintenance program implemented 25 eere.energy.gov Engineering Support Sufficient staff and resources Adequate design and modification Interface with Operations and Maintenance personnel Data collected and trended Configuration control 26 eere.energy.gov 13

14 Training Staff and resources are sufficient Training mated with job Evaluation Initial and continuing training needs met 27 eere.energy.gov Administration Program Work Control Configuration control 28 eere.energy.gov 14

15 A Good O&M Program Has An Integrated OMETA Maintenance Operations Engineering Support Training Administration 29 eere.energy.gov Weak Link in OMETA = O&M Less Effective 30 eere.energy.gov 15

16 Maintenance Program 31 eere.energy.gov Maintenance Programs Component Life-cycle Maintenance Programs and Practices 32 eere.energy.gov 16

17 The Component Life Cycle Nominal Life Cycle 33 eere.energy.gov Life Cycle New Component Common Replacement Design Basis Operations End of Life Condition Design Basis Degradation Repair Refurbish Schedule Preventative Maintenance/ Surveillance 34 eere.energy.gov 17

18 Life Cycle New Component Design technical bases: Temperature Pressure Common Replacement New Component Design Basis Operations Clearances Vibration End of Life Condition Design Basis Degradation Repair Refurbish Schedule Preventative Maintenance Surveillance 35 eere.energy.gov Life Cycle Design Basis Operation Operate and maintain the component as the designer intended (technical manual) Design Basis Degradation Component is expected to degrade at some known controlled rate Common Replacement End of Life Condition Repair Refurbish Schedule New Component Design Basis Operations Preventative Maintenance Surveillance Design Basis Degradation 36 eere.energy.gov 18

19 Life Cycle Preventive Maintenance Surveillance New Component Standard PM approach used Keep up with routine preventive maintenance Common Replacement Design Basis Operations Measure degradation-prone areas End of Life Condition Design Basis Degradation Repair/Refurbish Schedule Brings component performance back to a more acceptable level Repair Refurbish Schedule Preventative Maintenance Surveillance 37 eere.energy.gov Life Cycle End-Of-Life Condition No longer cost effective to refurbish component Common Replacement New Component Design Basis Operations Component Replacement A new component selected and purchased End of Life Condition Design Basis Degradation Repair Refurbish Schedule Preventative Maintenance Surveillance 38 eere.energy.gov 19

20 BREAK Ab Ream Department of Energy Federal Energy Management Program 39 eere.energy.gov Abbreviated Component Life-Cycle What Happens When Things Go Wrong What Happens When Things Go Wrong 40 eere.energy.gov 20

21 Why Things Go Wrong Incorrect application Off-Design Operation Unaccounted for stressors Improper maintenance Premature failure 41 eere.energy.gov Maintenance Practices The aggregate of direct and supporting actions that detect, preclude or mitigate the degradation of a system or component functionality, or restore that function to an acceptable level of performance following failure eere.energy.gov 21

22 Maintenance Practices A Closer Look Reactive maintenance (corrective) Preventive maintenance (PM) Predictive maintenance (PDM) Reliability centered maintenance (RCM) 43 eere.energy.gov Run it till it breaks Reactive Maintenance The exclusive maintenance mode up until the last decade Continues to be the predominate method of maintenance 44 eere.energy.gov 22

23 Reactive Maintenance A benchmark study in 1988 >55% Reactive <30% Preventive <10% Predictive A CSI published study in 1992 Approximately 50% Reactive 25% Preventive 15% Predictive 10% Proactive 45 eere.energy.gov Reactive Maintenance 1997 benchmark study: > 50% Reactive 25-30% Preventive < 25% Predictive and/or Proactive Winter 2000 Society for Maintenance and Reliability Professionals newsletter: > 55% Reactive 31% Preventive 12% Predictive 2% Other 46 eere.energy.gov 23

24 Ideal Reactive Maintenance Ideal Maintenance Program Best Practice or top quartile plants: <10% Reactive 25-35% Preventive 45-55% Predictive Balance Proactive 47 eere.energy.gov Reactive Maintenance Advantages Low costs Less staff 48 eere.energy.gov 24

25 Reactive Maintenance - Disadvantages Unplanned downtime Labor $ Repair or replacement $ Secondary equipment damage $ Inefficient use of staff resources 49 eere.energy.gov Preventative Maintenance Actions that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level eere.energy.gov 25

26 Preventative Maintenance Maintenance activities are based on specific time intervals (sometimes referred to as Periodic Maintenance ) Calendar days Run time Parts produced Includes routine tasks such as: Changing oil Replacing filters Greasing bearings Instrument calibration 51 eere.energy.gov Preventative Maintenance Useful against age related modes of failure Wear Fatigue Corrosion Analogous to an automobile schedule of maintenance eere.energy.gov 26

27 Preventative Maintenance Advantages Cost effective Flexibility allows for the adjustment of maintenance periodicity Increased component life-cycle Energy savings Reduced equipment or process failures 53 eere.energy.gov Preventative Maintenance Disadvantages Catastrophic failures still likely to occur Labor intensive Performance of unneeded maintenance Incidental damage to components through poor maintenance practices 54 eere.energy.gov 27

28 How to Build a Preventative Maintenance Program Master equipment list Prioritize components based on importance to process Assign components into logical groupings Determine the type and number of maintenance activities required Assess the size of maintenance staff Identify tasks that may be performed by operations maintenance personnel 55 eere.energy.gov How to Build a Preventative Maintenance Program Determine the periodicity Manufacturer technical manuals Machinery history Root cause analysis findings - Why did it fail? Utilize good engineering judgment Prepare and implement a maintenance schedule Daily Weekly Quarterly Annually 56 eere.energy.gov 28

29 How to Build a Preventative Maintenance Program Prepare a schedule of maintenance activities to be performed during outages If possible, incorporate schedule into a computer-based management system more accurate ease in report generating ease in updating Provide a method to monitor program performance 57 eere.energy.gov Predictive Maintenance Measurements that detect the onset of a degradation mechanism thereby allowing casual stressors to be eliminated or controlled prior to any significant component degradation eere.energy.gov 29

30 Predictive Maintenance Measuring component stress levels before they can cause a problem 59 eere.energy.gov Predictive Maintenance - Advantages Increased component operational life/availability Allows for preemptive corrective actions Decrease in equipment or process downtime Decrease in costs for parts and labor Improved worker and environmental safety Improved worker morale Energy Savings 60 eere.energy.gov 30

31 Predictive Maintenance - Disadvantages Increased investment in diagnostic equipment Increased investment in training of staff Savings potentials not readily seen by management 61 eere.energy.gov Reliability Centered Maintenance Plan is based upon reliability criteria with priority given to the most critical components. Determine what types of failures are likely to occur. Focuses on preventing failures whose consequences are likely to be serious. Emphasizes the use of predictive maintenance practices. Includes aspects of reactive and preventive maintenance concepts eere.energy.gov 31

32 Reliability Centered Maintenance Pioneered by the U.S. Airline Industry and is the standard for airlines today Adopted by many Nuclear Power Plants Being introduced into Fossil Power Plants 63 eere.energy.gov Reliability Centered Maintenance Comprised of three major tasks: 1. Careful analysis of failure modes and effects 2. Identify effective maintenance tasks or mitigation strategies 3. Integration into the existing maintenance program 64 eere.energy.gov 32

33 Reliability Centered Maintenance - Advantages Can be the most efficient maintenance program Lower costs by eliminating unnecessary maintenance or overhauls Minimize frequency of overhauls Reduced chance of sudden equipment failure 65 eere.energy.gov Reliability Centered Maintenance Advantages, cont. Able to focus maintenance activities on critical components Increased component reliability Incorporates root cause analysis 66 eere.energy.gov 33

34 Reliability Centered Maintenance - Disadvantages Can have significant startup costs Manpower Equipment Training 67 eere.energy.gov Reliability Centered Maintenance Represents the Premier Maintenance Program The underlying principles can be integrated into any maintenance program 68 eere.energy.gov 34

35 PNNL Maintenance Program Utilizing one-line system diagrams to generate equipment list Comp Type System Acronym Identifier Main Sub- Component Component Location CB E E-CB-EAL1 EAL1 0 PNL EAL150A Incoming CB P E E-P-EAL1 EAL1 PNL EAL1, By Room 109 in hallway P E E-P-EBH21 EBH21 PNL EBL21, Room 3150 P E E-P-EBL21 EBL21 PNL EBL21, Room eere.energy.gov Define Component Related Failures POTENTIAL FAILURE PNL BL21, Room 3150 E MODE Failed to close when it should Failure Cause Failure Rate 1. Mechanical binding 5 (.0027 per yr) (1:370) 2. Contact degradation (pitting, corrosion, dirt) 5 (.0027 per yr) (1:370) 3. Misalignment/adjustment 5 (.0027 per yr) (1:370) Failed while opening 4. Failure of trip units 5 (.0027 per yr) (1:370) 1. Mechanical binding 1:833 (.0012 per yr) 2. Contact degradation (pitting, corrosion, dirt) 1:833 (.0012 per yr) 3. Misalignment/adjustment 1:833 (.0012 per yr) 4. Failure of trip units 1:833 (.0012 per yr) 70 eere.energy.gov 35

36 Prioritize Component List Effect Severity of Effect on R&D Operations Ranking Safety related Inoperable due to degradation to safety of personnel or facility 10 without warning Safety related Inoperable due to challenge to safety of personnel or facility 9 with warning Very High Inoperable with destructive failure without compromising safety 8 High Inoperable with major damage 7 Moderate Inoperable with minor damage 6 Low Restricted due to degradation to safety of personnel or facility 5 Very Low Operable with significant degradation to equipment 4 performance Minor Operable with minor degradation to equipment performance 3 Very Minor Operable with minimal interference 2 None Not affected eere.energy.gov Prioritize Component List Probability of Failure Component Failures/Years Ranking Very high: failure almost inevitable >1 in in 3 9 High: Repeated failures 1 in in 20 7 Moderate: Occasional failure 1 in in in Low: Relatively few failures 1 in 15, in 150,000 2 Remote: Failure is unlikely 1 in 1,500, eere.energy.gov 36

37 Prioritize Component List Detection Absolute Uncertainty Very Remote Remote Very Low Low Likelihood of Detection by Current Maintenance Practices Maintenance cannot detect potential failure cause and subsequent failure mode Very remote change maintenance will detect potential failure cause and subsequent failure Remote chance maintenance will detect potential failure cause and subsequent failure Very low chance maintenance will detect potential failure cause and subsequent failure mode Low chance maintenance will detect potential failure cause and subsequent failure mode Ranking eere.energy.gov Risk Priority Number Priority Severity x Failure Rate x Detection Probability = RPN Maintenance Practices Adjusted and focused at high RPN component and failure modes 74 eere.energy.gov 37

38 Why Change? 75 eere.energy.gov Program Cost Savings 15 to 60% of traps in a plant can be expected to blow through Approximate annual cost (based on $3/1000 lb and a 100 psig system) ¼ orifice - $7,800 ½ orifice - $30,000 Assume plant with 100 traps (1/4) and 20% failure: 20x $7800 = $156, eere.energy.gov 38

39 What Does Reactive Maintenance Cost? Extra Inventory Downtime Energy Overtime Equipment Failure 77 eere.energy.gov Operations and Maintenance Start program development early Recognize the program entities (OMETA) Evaluate needs (Reactive, Preventive, Predictive) Document program results 78 eere.energy.gov 39

40 Resources to Get Your Started FEMP Website on O&M FEMP O&M Best Practices Guide eere.energy.gov Operations, Maintenance, and Commissioning Seminar Evaluation and the Open Book Quiz Almost done... The link below will take you to the brief open-book Quiz and Evaluation. Earn a Certificate of Completion for your records! eere.energy.gov 40