Operations, Maintenance, and Commissioning

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1 | www.femp.energy.gov/training eere.energy.gov Building 54, Pearl Harbor Naval Facilities Engineering Command, Hawaii

www.femp.energy.gov/training

Operations,

Maintenance,

and

Commissioning

2 | www.femp.energy.gov/training eere.energy.gov

FEMP First Thursday Seminars

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.

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3 | www.femp.energy.gov/training eere.energy.gov Building 54, Pearl Harbor Naval Facilities Engineering Command, Hawaii

www.femp.energy.gov/training

Operations,

Maintenance,

and

Commissioning

Ray Pugh

Operations and Maintenance Pacific Northwest National

Laboratory

Commissioning?

Is It Part of Your O&M?

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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.

Commissioning

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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

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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

Defining

Operations & Maintenance

Modern Definition:

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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

Importance of

Operations & Maintenance

• Northwest industries survey

• Potential energy savings of between 5 - 7 thousand MWh per year could

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O&M Potential

DOE Case Study

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 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

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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

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

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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!!!!

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

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Measuring The Quality

of your O&M Program

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Effective Operations & Maintenance

Program Management: OMETA

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23 | www.femp.energy.gov/training eere.energy.gov Operations Maintenance Engineering Support Training Administration

OMETA

Operations

• Organizational structure

• Interface defined and understood • Plant evolutions and testing

authorized and controlled • Use of approved procedures

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Maintenance

• Work priority system • Work documentation

• Maintenance program implemented

Engineering Support

• Sufficient staff and resources • Adequate design and modification • Interface with Operations and

Maintenance personnel • Data collected and trended • Configuration control

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Training

• Staff and resources are sufficient • Training mated with job

• Evaluation

• Initial and continuing training needs met

Administration

• Program • Work Control

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A Good O&M Program Has An

Integrated OMETA

Operations Maintenance Engineering Support Training Administration 30 | www.femp.energy.gov/training eere.energy.gov

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Maintenance Program

Maintenance Programs

• Component Life-cycle

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The Component Life Cycle

Nominal Life Cycle

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Life Cycle

New Component

Design technical bases:

• Temperature • Pressure • Clearances • Vibration New Component Design Basis Operations Design Basis Degradation Preventative Maintenance Surveillance Repair Refurbish Schedule End of Life Condition Common Replacement

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

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Life Cycle

Preventive Maintenance

Surveillance

• Standard PM approach used – Keep up with routine

preventive maintenance – Measure degradation-prone

areas

Repair/Refurbish Schedule

• Brings component performance back to a more acceptable level

New Component Design Basis Operations Design Basis Degradation Preventative Maintenance Surveillance Repair Refurbish Schedule End of Life Condition Common Replacement 38 | www.femp.energy.gov/training eere.energy.gov

Life Cycle

End-Of-Life Condition

• No longer cost effective

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BREAK

Ab Ream

Department of Energy

Federal Energy Management Program

Abbreviated Component

Life-Cycle

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Why Things Go Wrong

Premature failure Improper maintenance Unaccounted for stressors

Off-Design Operation Incorrect application

Maintenance Practices

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Maintenance Practices – A Closer Look

• Reactive maintenance (corrective) • Preventive maintenance (PM) • Predictive maintenance (PDM)

• Reliability centered maintenance (RCM)

Reactive Maintenance

• “Run it till it breaks”

• The exclusive maintenance mode up until the

last decade

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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 46 | www.femp.energy.gov/training 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:

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Ideal Reactive Maintenance

• Ideal Maintenance Program

– Best Practice or top quartile plants:

• <10% Reactive • 25-35% Preventive • 45-55% Predictive • Balance Proactive

Reactive Maintenance

Advantages

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Reactive Maintenance - Disadvantages

• Unplanned downtime • Labor $

• Repair or replacement $

• Secondary equipment damage $

• Inefficient use of staff resources

Preventative Maintenance

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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

Preventative Maintenance

• Useful against age related modes of failure

– Wear

– Fatigue

– Corrosion

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Preventative Maintenance Advantages

• Cost effective

• Flexibility allows for the adjustment of

maintenance periodicity

• Increased component life-cycle • Energy savings

• Reduced equipment or process failures

Preventative Maintenance Disadvantages

• Catastrophic failures still likely to occur • Labor intensive

• Performance of unneeded maintenance • Incidental damage to components through

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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

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

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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

Predictive Maintenance

Measurements that detect the onset of a degradation mechanism thereby allowing casual stressors to be

eliminated or controlled prior to any

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Predictive Maintenance

• Measuring component stress levels

before they can cause a problem

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

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Predictive Maintenance - Disadvantages

• Increased investment in diagnostic equipment • Increased investment in training of staff

• Savings potentials not readily • seen by management

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

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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

Reliability Centered Maintenance

• Comprised of three major tasks:

1. Careful analysis of failure modes and effects 2. Identify effective maintenance tasks or

mitigation strategies

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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

Reliability Centered Maintenance –

Advantages, cont.

• Able to focus maintenance activities on

critical components

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Reliability Centered Maintenance -

Disadvantages

• Can have significant startup costs – Manpower

– Equipment – Training

Reliability Centered Maintenance

• Represents the Premier Maintenance Program • The underlying principles can be integrated into

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PNNL Maintenance Program

Utilizing one-line system diagrams to generate equipment list

Comp Type System Acronym Identifier Main Component Sub- 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 3150

Define Component Related Failures

POTENTIAL FAILURE PNL BL21, Room 3150

E MODE

Failure Cause Failure Rate

Failed to close

when it should 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) 4. Failure of trip units 5 (.0027 per yr) (1:370) Failed while

opening 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)

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Effect Severity of Effect on R&D Operations Ranking

Safety related without warning

Inoperable due to degradation to safety of personnel or facility 10 Safety related

with warning

Inoperable due to challenge to safety of personnel or facility 9 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

performance

4 Minor Operable with minor degradation to equipment performance 3 Very Minor Operable with minimal interference 2

None Not affected 1

Prioritize Component List

Probability of Failure Component Failures/Years Ranking

Very high: failure almost inevitable >1 in 2 10

1 in 3 9

High: Repeated failures 1 in 8 8

1 in 20 7

Moderate: Occasional failure 1 in 80 6

1 in 400 5

1 in 2000 4

Low: Relatively few failures 1 in 15,000 3

1 in 150,000 2

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Prioritize Component List

Detection Likelihood of Detection by Current Maintenance Practices

Ranking

Absolute Uncertainty

Maintenance cannot detect potential failure cause and subsequent failure mode

10 Very Remote Very remote change maintenance will detect

potential failure cause and subsequent failure

9 Remote Remote chance maintenance will detect potential

failure cause and subsequent failure

8 Very Low Very low chance maintenance will detect potential

failure cause and subsequent failure mode

7

Low Low chance maintenance will detect potential

failure cause and subsequent failure mode

6

Priority

• Risk Priority Number

• Severity x Failure Rate x Detection Probability =

RPN

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Why Change?

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:

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What Does Reactive Maintenance Cost?

• Extra Inventory

• Downtime

• Energy

• Overtime

• Equipment Failure

Operations and Maintenance

• Start program development early • Recognize the program entities

(OMETA)

• Evaluate needs

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Resources to Get Your Started

FEMP Website on O&M

http://www1.eere.energy.gov/femp/program/operations_maintenance.html

FEMP O&M Best Practices Guide

http://www1.eere.energy.gov/femp/pdfs/omguide_complete.pdf

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.