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Maximizing Your Assets Life Through Reliability
James Decker, PE, CRL
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Asset Management helps to answer the five fundamental questions of Infrastructure Management
1. What assets do we own?
2. What is their condition?
3. How should we manage them?
4. What is best timing for investments?
5. How much money do we need?
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Asset Management Definition
Effective Asset Management is:
An integrated set of processes to minimize the life-cycle costs of
owning, operating and maintaining assets, at an acceptable level
of risk, while continuously delivering established levels of service
Managing Public Infrastructure Assets to
Minimize Costs and Maximize
Performance
AMSA, AMWA, AWWA, WEF
Implementing Asset Management – A Practical Guide
AMWA, NACWA, WEF
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Asset Management is a Balancing Act…
RISK
Service Levels
Low Costs
Minimize the lifecycle costs of owning, operating and
maintaining infrastructure assets,
at an acceptable level of risk,
while continuously delivering established levels of service.
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Planning, Engineering and O&M Groups must work together to minimize lifecycle costs
Le
ve
l o
f S
erv
ice
Time
Unacceptable performance
Acceptable performance
Marginal performance
Re
ha
b Service Life
Useful Life
Re
pa
ir
Re
plac
e
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Disposal
Acquisition, Construction, & Installation
Operation and Maintenance
Dispose Operate/
Maintain
Planning and Design
90 -95% of Asset Life
The Asset Lifecycle
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Managing Assets Throughout Their Life Cycle
Planning & Design
Acquisition, Construction, & Installation
Operation & Maintenance
Disposal
Rule of thumb #1 – 65% of Life Cycle Cost is set during design / specification
Rule of thumb #2 – The O&M costs usually account for the largest component of total life cycle costs (between 2x to 20x the acquisition/construction cost).
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Our Job as Reliability Professionals
•Reduce overall asset operational risk using the resources provided to us.
•Therefore, a proper measurement of our job performance would be Total Risk Reduced / Total Resources Invested
Investment
Risk
To improve…..we can either reduce more risk, or reduce resource investment…..or better yet, do both!!!
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5 Basic Functions of Maintenance
Increase asset performance/reliability to reduce operational costs and liabilities (risk)
Dedicate maintenance resources based on liabilities of equipment operation, or in other words, based on asset risk (includes operational, safety, environment & financial)
Increase the efficiency and effectiveness of maintenance performance to reduce planned costs and liabilities
Increase the efficiency and effectiveness of maintenance performance to reduce unplanned costs and liabilities
Document data and information to be used for improving the performance of the maintenance and reliability program
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Maintenance Basics
Asset
Condition
Overhaul / Repair
User Defined Failure
Asset wears over time
Extended useful life through overhauls / maintenance
Avg O&M Costs over time
O&M Costs
Required Performance
Initial Useful Life
$$
Time
Repair Downtime
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Asset
Condition
Avg O&M Costs over time
O&M Costs
Goal #5 is to determine when it makes sense to replace rather than overhaul / repair
$$
Goal #1 is to extend the interval between failures/ overhauls (MTBF) thru effective O&M practices, (doing the right maintenance right / Operating correctly)
Goal #4 is to extend the full life of the asset to as long as practical thru effective maintenance
Goal #2 is to address poor condition in advance of functional failure and/or catastrophic damage
Goal #3 is to minimize the downtime & costs by increasing efficiency in the work process, effective logistics, etc. (reduce MTTR)
Time
Maintenance Basics
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F “Worst New” High infant mortality then random failure
B “Bathtub Curve” - High infant mortality, then a low level of random failure, then a wear out zone
A “Traditional View” Random Failure then a wear out zone
C “Slow Aging” - Steady increase in the probability of failure
D “Best New” - Sharp increase in the probability of failure then random failure
E “Constant Random Failure” Random - No age related failure pattern
Equipment Failure Patterns
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F “Worst New” High infant mortality then random failure
B “Bathtub Curve” - High infant mortality, then a low level of random failure, then a wear out zone
A “Traditional View” Random Failure then a wear out zone
C “Slow Aging” - Steady increase in the probability of failure
D “Best New” - Sharp increase in the probability of failure then random failure
E “Constant Random Failure” Random - No age related failure pattern
2 %
4 %
5 %
7 %
14 %
68 %
DOD RCM 1978
3 %
17 %
3 %
6 %
42 %
29 %
USN MSP 1982
2 %
10 %
17 %
9 %
56 %
6 %
SUBMEPP 2001
Study Average – Only 21% of all components exhibit an aging to failure rate relationship.
Equipment Failure Patterns
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Pipe Failure Modes
©Water Services Association of Australia
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Pipe Failure Modes
©Water Services Association of Australia
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Pipe Failure Modes
©Water Services Association of Australia
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Preventive
Reactive
Rel
iab
ility
& A
vaila
bili
ty
Maintenance Cost
Data ~ Condition Based
Analysis ~ Reliability Based
Predictive
Proactive
Time Based
Breakdown
Evolution To Best Practice
Identifying & Quantifying Risk
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Asset Management is a Balancing Act…
RISK
Service Levels
Low Costs
Minimize the lifecycle costs of owning, operating and
maintaining infrastructure assets,
at an acceptable level of risk,
while continuously delivering established levels of service.
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To effectively implement a “Reliability Based” maintenance program, it is essential to
identify and quantify the operational risk within our asset population.
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Risk is quantified by the classic equation
Risk = (Consequence x Probability)
How severe are the
consequences of asset
failure?
How likely is it for
the asset to fail?
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Understanding the risk of asset failure provides…
The basis for investing in condition assessments
The basis for optimizing O&M
The basis for prioritizing R&R capital investments
A uniform and rigorous methodology that results in defensible decisions
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2 Basic Options For Identifying Risk
Proactively – What could happen
Risk Ranking, RCM, FMEA – to anticipate where risk is highest and to implement actions that will minimize, prevent or mitigate anticipated failures.
Risk = Consequence x Probability
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1. Health & Safety (public and organization)
• Potential loss of life
• Multiple illness or injury
• Single illness or injury
2. Environmental
• Major impact (Permit violation, EPA, regulatory fine, etc.)
• Minor impact (Internal documentation only)
3. Costs (Maintenance or Operations)
• Greater than $50k
• Between $25k and $50k
• Less than $25k
4. Impact on Operations
• Long term high
• Short term high
• Low
5. Impact on Services to Customer
• Complete loss - long term
• Complete loss – short term
• Partial loss - long term
• Partial loss – short term
Risk Ranking of Assets
X Probability of Failure
The difficult piece
Consequence x Probability
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2 Basic Options For Identifying Risk
Historically – What has happened
Historical Failure Analysis – to use failure reporting information to understand where it’s been demonstrated that risk is highest, and to implement actions that will minimize, prevent or mitigate that risk.
Notice the repeated concentration of reactive labor hours against the same assets year after year
Risk = Consequence x Probability
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Pareto Principle
• Pareto was right! A large percentage of the problems (equipment failures) are associated with only a very small percentage of the assets
• Although commonly known as the 80-20 rule, in industrial settings it’s closer to 80 – 5 (80% of problems are associated with only 5% of assets)
• And then within those 5% of assets, it’s only a small percentage of failure modes that cause a majority of the downtime
• Effective work documentation and failure reporting will allow easy targeting of the small percentage of failure modes that we need to be concerned with and actively go after
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Water Treatment 4.1%
What percentage of your asset population consumes 80% of your resources?
Identifying Risk - Historically
Condition Based Maintenance
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Asset Management is a Balancing Act…
RISK
Service Levels
Low Costs
Minimize the lifecycle costs of owning, operating and
maintaining infrastructure assets,
at an acceptable level of risk,
while continuously delivering established levels of service.
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Because of the work done in the 1970’s establishing that most equipment failures are
random in nature, condition based maintenance was born into industry…….
Maximo Training - EAM Benefits
…..because if you don’t know when a failure is coming (random), the only option is to
monitor a parameter of that equipment that will provide advanced warning of the
impending failure.
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Point where impending failure is detected is Potential Failure (P)
Vibration 1 to 9 months
P1
Oil Analysis 1 to 6 months
P2
Thermography 3-12 weeks
P3
P – F Interval
Heat by touch 1-5 days
P5
Audible noise 1-4 weeks
P4 Life at the Bottom
•Plan on the fly •Expedite Parts •Parts Not Available •Extended Outages •Hurry & Fix It Fast •No Time To Analyze Failure •High Impact on Operations •Rework
Point where asset stops doing what its users want it to do is Failure (F)
Smoke 0 days
P6
Condition Based Maintenance
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Point where impending failure is detected is Potential Failure (P)
P – F Interval
Heat by touch 1-5 days
P5
Audible noise 1-4 weeks
P4 Life at the Top
•Time to Plan & Schedule •Parts Can Be Ordered •Less Parts On Site •Less Costly Repairs •Less Impact On Operations •Time & Data To Analyze Failure •Less Rework
Point where asset stops doing what its users want it to do is Failure (F)
Smoke 0 days
P6
Vibration 1 to 9 months
P1
Oil Analysis 1 to 6 months
P2
Thermography 3-12 weeks
P3
Condition Based Maintenance
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PM is 29% Less Costly Than RTF
PdM is 42% Less Costly Than PM
PCM is 43% Less Costly Than PdM
RTF – Run To Failure PM – Preventive Maintenance PdM – Predictive Maintenance PCM – Precision Centered Maintenance
Cost of Reliability Programs
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CBM Techniques (Short List)
•Performance Monitoring
•Vibration Monitoring
•Oil Analysis
•Thermography
•Ultrasonic Detection
•Motor Static Testing
•Motor Dynamic Testing
•Human Senses (look, listen, smell, touch)
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What Technique To Use?
•Depends on failure mode trying to detect.
•Depends on techniques available.
•Depends on P-F interval technique will provide.
•Depends on “bang for the buck”. Some techniques will monitor several failure modes at the same time.
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Technique #1- Performance Monitoring Performance Monitoring - evaluation of an asset’s operating parameters (e.g. pressure, temp, flow, speed) through trend analysis or set point thresholds that will allow forecasting asset failure.
Pump Performance
Flow Rate
Hea
d
New Pump
Meets Reqt's
Needs Repair
January
February
March
April
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Vibration Monitoring - periodic or continuous measurement of a machine’s vibration amplitude and/or signature in an effort to detect machinery problems and/or to alarm or shut down the machine at a predetermined vibration value.
Technique #2 - Vibration Monitoring
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Technique #3 - Oil Analysis
Oil Analysis - periodic sampling and analysis of various properties and materials in lubricating oil, insulating oil, fuel oil, or hydraulic fluid to determine the condition of the oil or the condition of the machine.
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Technique #4 - Thermography
Thermography - an electronically produced image representative of thermal patterns on a surface.
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Technique #5 - Ultrasonic Detection
Ultrasonic Detection - Using specialized equipment to detect sound with a frequency greater than 20,000 Hz, approximately the upper limit of human hearing (ultrasound).
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Technique #6 - Electrical Insulation Testing
Electrical Insulation Testing - Applying a controlled voltage to an insulated wire conductor system and measuring the current “leakage” to determine the condition of the insulation.
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Technique #7 - Motor Current Signature Analysis
Motor Current Signature Analysis (MCSA) - Using the induction motor electric power supply signature to identify electrical and mechanical equipment problems.
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Condition Assessment for Water Pipes
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Phase 1 Techniques
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Phase 2 Techniques
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Phase 3 Techniques
Reliability Methods for Asset Management
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Maintenance Analysis Methods to Consider
Inc
re
as
ing
As
se
t (
Sy
st
em
) C
om
ple
xit
y
Inc
re
as
ing
Re
so
ur
ce
In
ve
st
me
nt
Method Focus Application Pros Cons RCM Function Highly critical and
complex assets Promotes reliability of the essential aspects
of the asset
Most effective for analyzing complex assets and minimizing maintenance efforts
Process can be used as a template for similar assets
Requires participation of individuals who thoroughly understand the function the asset serves within its process context
Time and resource intensive
FMEA Equipment Mid to highly critical assets with moderate complexity
Structured and repeatable approach that is relatively easy to learn
Can be performed by a single individual who is familiar with the equipment type
Process can be used as a template for similar assets
Potential to add unnecessary maintenance activities for mitigating failures
Human errors may not be captured
Less effective in sharing knowledge among staff as compared with RCM
MTA Maintenance Tasks
Improving or optimizing existing PM program tasks
Faster than either RCM or FMEA if just being used to optimize a PM program
Can be used with FMEA to optimize PM program to address all failure modes
Can be performed by a single individual who is familiar with the equipment type
If just used to analyze existing PM program, there is a possibility to miss failure modes
Doesn't share knowledge as effectively as RCM
PMO Program Optimizing heavily-loaded PM programs
Provides rapid returns in the form of improved PM tasks and / or reduced PM labor hours
Analyzes all PM activities defined in the “program”, not just on critical assets
Addresses PM scheduling and coordination issues
Relies heavily on expertise and experience of PMO analyst
Not a failure mode level analysis
Effort is focused more on improving use of PM labor resources as opposed to mitigating risk
DE Problem For resolving evident and high impact problems
Addresses existing problems
Results are realized in near-term which maintains momentum
Empowers staff to identify and implement solutions which increases acceptance of the process
Only deals with historical problems, not on potential failures that have yet to occur
Concentrates on specific problems making it difficult to leverage the effort across a population of assets
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Uptime Elements Identify Critical Success Factors for Organizations to Consider
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Uptime Elements Identify Critical Success Factors for Organizations to Consider
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Uptime Elements Identify Critical Success Factors for Organizations to Consider
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Uptime Elements Identify Critical Success Factors for Organizations to Consider
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Uptime Elements Identify Critical Success Factors for Organizations to Consider
Thank You!
Questions?
Maximizing Your Assets Life Through Reliability James Decker, PE, CRL
614-825-6777
