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EPRIGEN 3412 Hillview Avenue, Palo Alto, California 94304 PO Box
10416, Palo Alto, California 94303 USA800.313.3774 650.855.2121
[email protected] www.epri.com
Streamlined Reliability-CenteredMaintenance (SRCM)
Implementation Guidelines
TR-109795-V2
Final Report, December 1998
Project ManagerR. Pflasterer
Effective December 6, 2006, this report has been made publicly
available in
accordance withSection 734.3(b)(3) and published in accordance
withSection 734.7 of the U.S. ExportAdministration Regulations. As
a resultof this publication, this report is subject to only
copyrightprotection and doesnot require any license agreement from
EPRI. This notice supersedes theexport control restrictions and any
proprietary licensed material noticesembedded in thedocument prior
to publication.
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DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES
THIS REPORT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS
AN ACCOUNT OF WORKSPONSORED OR COSPONSORED BY EPRIGEN, INC. NEITHER
EPRIGEN, THE ELECTRIC POWERRESEARCH INSTITUTE, INC. (EPRI), ANY
COSPONSOR, THE ORGANIZATION(S) NAMED BELOW, NORANY PERSON ACTING ON
BEHALF OF ANY OF THEM:
(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR
IMPLIED, (I) WITHRESPECT TO THE USE OF ANY INFORMATION, APPARATUS,
METHOD, PROCESS, OR SIMILAR ITEMDISCLOSED IN THIS REPORT, INCLUDING
MERCHANTABILITY AND FITNESS FOR A PARTICULARPURPOSE, OR (II) THAT
SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY
OWNEDRIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III)
THAT THIS PACKAGE ISSUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE;
OR
(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY
WHATSOEVER (INCLUDINGANY CONSEQUENTIAL DAMAGES, EVEN IF EPRIGEN OR
ANY EPRIGEN REPRESENTATIVE HAS BEENADVISED OF THE POSSIBILITY OF
SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OFTHIS REPORT OR
ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR
ITEMDISCLOSED IN THIS REPORT.
ORGANIZATION(S) THAT PREPARED THIS REPORT
Erin Engineering & Research, Inc.
ORDERING INFORMATION
Requests for copies of this package should be directed to the
EPRI Distribution Center, 207 Coggins Drive, P.O.Box 23205,
Pleasant Hill, CA 94523, (925) 934-4212.
EPRI is a registered service mark of the Electric Power Research
Institute, Inc.
Copyright 1998 EPRIGEN, Inc. All rights reserved.
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iii
CITATIONS
This report was prepared by
Erin Engineering & Research, Inc.2033 N. Main Street, Suite
1000Walnut Creek, California 94596
Principal InvestigatorG. Toomey
This report describes research sponsored by EPRIGEN.
The report is a corporate document that should be cited in the
literature in thefollowing manner:
Streamlined Reliability-Centered Maintenance (SRCM)
Implementation Guidelines, EPRIGEN,Palo Alto, CA: 1998. Report
TR-109795-V2.
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REPORT SUMMARY
Following EPRIs philosophy of using and developing existing
technology where itmakes economic sense, EPRIGENs Plant Maintenance
Optimization Target hasadopted a reliability-centered maintenance
(RCM) process called streamlined RCM orSRCM that maintains and
improves all the basic steps of traditional RCM. SRCMprovides a
utility a cost-effective process to determine the optimum
maintenancestrategy for plant systems and equipment based on their
importance to businessobjectives.
BackgroundDeregulation and increasing competition have prompted
a drive to control operationand maintenance (O&M) programs
among electric utilities. For fossil-fired plants,controlling
O&M includes the transition from reactive maintenance to
apreventive/predictive maintenance strategy. To help its member
utilities make thetransition and become more competitive, EPRIGEN
has initiated development effortsunder the Plant Maintenance
Optimization Target (Target in 1998 and Target 75 in1999). These
efforts are intended to help utilities reduce production costs by
developingand demonstrating cost-effective maintenance methods.
This project is part of that
program.
ObjectivesTo develop an integrated program based on RCM
methodology that assists a utility incost-effectively developing
and maintaining an optimized maintenance program.
ApproachVolume One of this report, already published, described
the development status ofSRCM for fossil plants at the end of 1997.
For Volume Two of this report, the projectteam compiled guidelines
for the implementation of SRCM. The guidelines include anoutline of
the SRCM process, an account of current utility participation, and
adescription of SRCM project tools currently available or under
development. The teamalso analyzed the benefits of SRCM at three
utilities.
ResultsBy using SRCMs logical step-by-step approach to determine
the maintenance strategyfor plant/systems, utilities are able to
document the basis for the maintenance program,more effectively
manage change to the plant maintenance program, and focus
resources
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vi
on doing the right task at the right time on the right
equipment. This report describeshow all of the SRCM tools and
processes work together and provides information onthe status of
utility projects and tool development. Several tools have been
completed toenhance the performance and maintenance of SRCM
analysis. Both system level andcomponent level templates have been
developed to provide efficiency and consistency
in analysis. A Living Program module in the SRCM Workstation has
been developed toassist and automate the updating of the initial
SRCM analysis.
EPRI PerspectiveAs of the end of 1998, 22 utilities have
participated in the EPRI SRCM program. Someplants that have had
essentially no formal plant maintenance program are using SRCMto
create a program for the first time; other plants have used SRCM to
optimize theirexisting plant maintenance program. All utilities
anticipate a reduction in unscheduledbreakdown maintenance. Other
intangible benefits include improved communicationbetween key plant
staff concerning system functions, equipment failure causes,
and
their significance. Additionally, most utilities that have
applied SRCM have estimated apayback of less than one year.
TR-109795-V2
Interest CategoriesFossil Steam Plant Performance
OptimizationFossil Steam Plant O&M Cost Reduction
KeywordsMaintenance optimizationPerformancePredictive
maintenance
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CONTENTS
1 INTRODUCTION
.................................................................................................................
1-1
2 SRCM PROGRAM DESCRIPTION
.....................................................................................
2-1
2.1 Why SRCM?
................................................................................................................
2-1
2.2 The SRCM Process
.....................................................................................................
2-2
Data Collection and Plant History
Review.......................................................................
2-3
Identify Functional Failures
.............................................................................................
2-4
Critical
Analysis...............................................................................................................
2-4
FMEA
..............................................................................................................................
2-5
Non-Critical Analysis
.......................................................................................................
2-5
PM Task Recommendations
...........................................................................................
2-6
Task Comparison
............................................................................................................
2-6
2.3 What Does It Take To Conduct SRCM?
......................................................................
2-7
2.4 Training and Analysis Support
.....................................................................................
2-9
3 UTILITY PROJECT STATUS
..............................................................................................
3-1
3.1 Current Utility Project Participation
..............................................................................
3-1
4 DESCRIPTION AND DEVELOPMENT STATUS OF SRCM PROGRAM
TOOLS............... 4-1
4.1 Overall SRCM Program
...............................................................................................
4-1
4.2 SRCM Process and Software Products
.......................................................................
4-3
4.2.1 SRCM
Workstation................................................................................................
4-3
PMO WORKSTATION DESCRIPTION
.......................................................................
4-3
4.2.2 System Templates
................................................................................................
4-4
4.2.3 Component Type
Templates.................................................................................
4-9
4.2.4 Industry
Data.......................................................................................................
4-10
4.3 SRCM Implementation and Living
Program...............................................................
4-11
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4.3.1 SRCM Implementation
........................................................................................
4-11
4.4 Living Programs Process and Software
.....................................................................
4-14
5 SRCM PROGRAM BENEFITS
............................................................................................
5-1
Case Study 1
......................................................................................................................
5-1Case Study 2
......................................................................................................................
5-2
Case Study 3
......................................................................................................................
5-2
A SYSTEM TEMPLATE
.........................................................................................................A-1
B COMPONENT TYPE TEMPLATES
....................................................................................B-1
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LIST OF FIGURES
Figure 1-1 EPRIs SRCM Program
........................................................................................
1-2
Figure 2-1 Classical RCM versus SRCM
...............................................................................
2-2
Figure 2-2 SRCM Process
.....................................................................................................
2-3
Figure 4-1 Integrated Maintenance Work Management Flow Chart
...................................... 4-2
Figure 4-2 Screen- selecting system template option
............................................................
4-6
Figure 4-3 Screen- selecting a specific system template
....................................................... 4-7
Figure 4-4 Screen - Electronic flowchart and review options for
system
templatemodification.....................................................................................................................
4-8
Figure 4-5 Screen - Maintenance Component Type Template
............................................ 4-10
Figure 4-6 Sample Implementation Template
......................................................................
4-13
Figure 4-7 Screen - Living Program
Options........................................................................
4-15
Figure 4-8 Screen - Living Program PM History
Review......................................................
4-16
Figure 4-9 Screen - Living Program PM Program Change
Recommendation Form ............ 4-17
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LIST OF TABLES
Table 2-1 SRCM Analysis Labor
Requirements.....................................................................
2-8
Table 2-2 Typical SRCM Project
Schedule............................................................................
2-9
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INTRODUCTION
As the electric power industry evolves into a non-regulated
industry, extreme pressuresare being placed on plant organizations
to reduce costs for competition whilemaintaining or enhancing plant
performance. Several utilities have gone through staffreductions as
a first line of action for cost reduction. This has prompted a
drive tocontrol the operation and maintenance (O&M) programs.
For the fossil fired plants inthe industry the controlling of the
O&M program includes the transition from reactivemaintenance as
the main stay to a preventive/predictive maintenance strategy.
Worldclass facilities know having the proper mix of maintenance is
key to cost-effective andenhanced maintenance. The Electric Power
Research Institute (EPRI) embarked on aprogram to assist member
utilities in making the transition and becoming
morecompetitive.
This project is part of EPRIGENs Plant Maintenance Optimization
development effortsunder Target 54 (1998), Plant Maintenance
Optimization, and Target 75 for 1999, whichis intended to help
utilities reduce the cost of production by developing
anddemonstrating cost-effective maintenance methods. Over the past
three years, severalutilities have embarked on the implementation
of SRCM at their various plants. These
utilities are at various stages of the program. As more
utilities participate in the EPRIprogram, process and product
refinements will evolve to provide enhanced tools todevelop and
maintain a RCM-based maintenance program.
A key element of EPRIs maintenance optimization program is the
use of reliability-centered maintenance (RCM) technology to guide a
utility in improving and optimizingtheir maintenance program.
Utilizing EPRIs philosophy to use and grow existingtechnology if it
makes economic sense the Plant Maintenance Optimization Target
hasadopted a RCM process called Streamlined RCM or SRCM. SRCM
allows a utility toanalyze down to the level required to make a
maintenance strategy decision while
maintaining all of the basic steps of traditional RCM.
Accompanying this process is:software, program management, system
and component templates, implementationsupport, training and living
program development. All of these integrated productsassist a
utility in cost-effectively optimizing and maintaining an optimized
maintenanceprogram. Figure 1 shows how these tools and support
provide EPRI members withcost-effective solutions when developing
or refining systems and equipment strategies.
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Utility Identifies needfor Improved
Maintenance Strategy
Identifies Systems/Equipment to
Review
Identifies SRCM as
Method of Evaluation
Conducts SRCM
Analysis by System
System Templates Component Type
Templates
Implementation
Support (what, when& why)
M & D CenterPDM Assessment
Implement Results
via CMMS, PDM,
etc.
PMO Workstation
Establish Process to
Update Maintenance
Program (Living
Program)
Industry SRCM Data
via EPRI Database
653
Figure 1-1EPRIs SRCM Program
Each utility and plant needs to decide on objectives and goals
when conducting aSRCM program. Usually utilities use SRCM as one
means to achieve competitiveproduction costs through maintenance
optimization. SRCM will optimize maintenanceby utilizing the
following principles:
Concentrate maintenance resources where they will do the most
good.
Eliminate unnecessary and ineffective maintenance tasks.
Devise the simplest and most cost-effective means of maintaining
equipment, ortesting for degradation focusing on predictive or
condition monitoring activitieswhen applicable.
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Develop a documented basis for the maintenance program.
Utilize plant maintenance and contractor experience when
determining PM tasksand frequencies.
In order to achieve the goal of an improved maintenance program
at a plant, it isnecessary to select systems that will meet the
specified goals of the program. Thesystems typically selected for
review are:
1. Main Steam
2. Fuel Handling
3. Circulating Water
4. Ash Handling
5. Sootblowing
6. Boiler Air and Gas
7. Feedwater Heater Drains/Extraction Steam
8. Coal Handling
9. Feedwater
10. Condensate
The criteria for selecting these systems is: overall importance
to plant operation, safety,reliability and historical maintenance
costs. Cost-effective maintenance is the programobjective.
A real, but difficult to document, benefit is that the SRCM
process involves andimproves communication between the key plant
staff functions (operations,maintenance and tech support in
traditional organizations, and Production andSupport Teams in more
recent organizations) concerning system functions, equipmentfailure
causes and their significance. The need for and benefits of,
participation by keyplant staff in the SRCM process can not be
over-emphasized.
Volume One of this report, published in early 1998, described
the developmentprogram status of SRCM for fossil plants at the end
of 1997.
This report provides the latest status of utility program
development, current status ofSRCM process tools and software as
well as some documented benefits from the
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program. Integration of other EPRI programs, such as predictive
maintenance activitiesand the interfaces and plant processes
affected by the SRCM programs, are becomingclear. Several utilities
have embarked on multi-plant projects which have caused
thedevelopment of several new tools to provide efficiency and
consistency.
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SRCM PROGRAM DESCRIPTION
2.1 Why SRCM?
EPRIs experience with RCM methodology began in 1983 with trial
applications withnuclear power plant systems. These applications
were a direct transfer of existingmethodology from the commercial
airline industry. Since then, numerous utilities haveapplied RCM
principles to their nuclear plants. In 1991, EPRI responded to
utility
concern that classical RCM requires too many resources to
perform an analysis on anaverage system. As a result, EPRI embarked
upon a major project to investigatepossible methods of lowering the
cost to perform an RCM analysis while maintainingthe technical
integrity of the process and results. One approach that resulted
from thisproject was the SRCM process. The SRCM process was
validated against classical RCMby applying both methods
independently on the same plant system. This comparisonfound
essentially identical PM recommendations with only minor
differences driven bythe two analysts different knowledge of the
plant and equipment involved. Athorough knowledge of basic RCM
methodology is necessary to ensure accurate resultswhen performing
SRCM. Figure 2-2 shows a comparison of the two methods.
Given the success of SRCM in the nuclear sector of the power
industry, EPRIs fossilgroup funded several pilot SRCM applications
at fossil plant systems. The pilotprojects confirmed the cost
effective applicability of SRCM to fossil units. Over the pastthree
years, the EPRI-sponsored SRCM process has been applied or is in
progressapplying SRCM to over 400 systems at 22 utilities. These
successful SRCM applications,together with the high level of
utility acceptance, has prompted EPRI to develop severaladditional
tools and enhancements of a commercial RCM software tool
specificallydesigned to support the SRCM process. This commercial
tool known as the PMOWorkstation, developed by ERIN Engineering and
Research, Inc., has been used tosupport the EPRI projects and is
now available to members. The software
enhancements, funded by EPRI, consist of system and component
task selectiontemplates as well as a living program module.
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Identify Ke y
Import ant Function s
Pe rf orm Critical
Analysis
Perform Non-Critical
Analysis
Non-Critical
Evaluation
Non-Critical
Task Selection
Task Comparison Task Comparison
Im ple me nta tion Im ple me nta tion
RC M SRCM
System/SubsystemPartitioning
Functional Failure
Analysis (FFA )
Failure Mo des and
Effects An alysis (FM EA)
Critical TaskSelection
Figure 2-1Classical RCM versus SRCM
2.2 The SRCM Process
The SRCM produced PM plan must support an individual units
mission (base load orload following, etc.) to assure the unit
performance in compliance with its intended useor mission. Thus, a
units mission provides the basis for determining
componentcritically and subsequent PM task selection.
The following describes the PMO process and Figure 2-3
illustrates the steps of theprocess.
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Data
Collection
Identify Key
Important Functions
Perform Non-Critical
Analysis
Compare SRC M R esults
W ith Existin g
M aintenance Program
Perform Critical
Analysis
Implement
Changes
Review Plant H istory
and Co nduct P lant
Reviews and Interviews
Establish Living
Program
Figure 2-2SRCM Process
Data Collection and Plant History Review
The same system data is required to perform this streamlined
analysis as is needed fora standard RCM analysis. In order to
facilitate this streamlined analysis process and
maximize the associated cost benefit, the analyst should perform
a detailed review ofall the pertinent system information including
corrective maintenance and existing PMand surveillance programs
prior to starting the main analysis process steps.
Documentation or data required to support this analysis are:
System Description
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System Drawings (P&IDs, electrical schematics, logic
diagrams, etc.)
Component Listing (electronic)
Component Corrective Maintenance History (3-5 yrs. if
available)
Existing Preventive Maintenance and Surveillance program (PM and
PdM tasks,operator rounds, etc.)
Commitments/Requirements for existing PM/Surveillance tasks
Information not readily available from the above sources is
obtained by interview ofknowledgeable plant people.
Identify Functional Failures
The identification of system functional failures is performed in
the same manner as instandard RCM. This process varies from
standard RCM by focusing the analysisresources on the 'important'
functional failures. The analyst identifies all applicablefunctions
for the system and then sorts the functions into two groups with
appropriatejustification: (1) Important functions and (2)
Non-important functions. The criteria fordetermining whether a
function is important can be modified by the organizationperforming
the analysis. Generally, any function that directly affects plant
safety,environmental limits, or power production is considered
important. Non-importantfunctions typically include such items as
local indication or secondary systemfunctions. Components that
support important functions will be evaluated in the
Critical Analysis module. The remaining system components that
support non-important functions may still be analyzed in the
Non-critical Analysis module.
One way to provide additional benefit in analysis effort is to
limit identified functions toonly those that are important for
plant operation and safety. This can be done by firstcharacterizing
the functions in fairly general terms and only using resources to
identify thefunctions that are important. This avoids wasting time
identifying functions that are notgoing to be analyzed in the
Critical Analysis module, while the remaining systemcomponents get
analyzed through the Non-Critical Analysis module.
Critical Analysis
Following the standard RCM analysis methodology, the
determination that a systemcomponent is 'critical' places heavy
emphasis on the overall plant effect caused by aspecific failure
mode of the component. However, in this streamlined process, only
thefunctions that are identified as 'important' are evaluated with
a streamlined FailureModes and Effects Analysis (FMEA) to determine
critical equipment. In this
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streamlined process, the standard FMEA and LTA have been
combined into onerecord. The following discusses the FMEA portion
of the component record and theLTA process is described in the PM
task recommendation section:
FMEA
In standard RCM analysis, the analyst typically has an
individual FMEA record foreach dominant failure mode and the
resultant local, system, and plant effects. Thisdocumentation
provides direct linkage of the Functional Failure Analysis
(FFA),specific component failure mode, and the local, system, and
plant effects for eachseparate component-failure mode combination
to determine component criticality.However, in the SRCM process,
the analyst identifies every component that supportsthe functional
failure and lists only the most significant failure modes for
eachcomponent, along with the most dominant plant effects for the
failure modes, all in onecomponent record. The analyst determines
the component criticality based on the
various failure mode/plant effect combinations and the
cumulative significance of thecomponents failure of the specific
function.
If a component is determined to be critical, the next step is to
identify appropriatecauses for the potential failure modes to allow
the analyst to identify applicable andeffective maintenance tasks
for the failure modes and causes that are consideredimportant to
identify or eliminate. If a component is determined to be
non-critical, it isevaluated further in the non-critical analysis.
Task selection for critical components isdiscussed in detail
later.
As with standard RCM, it is important and beneficial to receive
engineering andoperations review and input into the critical
evaluation of the systems components.
Non-Critical Analysis
The non-critical evaluation applies a different set of criteria
which places moreemphasis on equipment level economic
considerations for the components that weredetermined to be
non-critical in the critical analysis or components that support
non-important functions. These new criteria will evaluate the
benefit of maintainingexisting PM tasks or identifying new PM tasks
rather than allowing the component torun to failure to help provide
a basis for a complete PM program. The criteria used forthe
non-critical evaluation can be modified to meet plant specific
requirements. If thecomponent does not meet any of the non-critical
criteria, then the determination ismade to allow this component to
run-to-failure and perform corrective maintenancewhen required. If
there is a 'yes' response to one of the non-critical evaluation
criteria,an appropriate PM task recommendation is made. The
identification of appropriatePM task for non-critical equipment
will be described in more detail below.
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A Maintenance Engineer reviews of the non-critical evaluation
are important to ensurea well documented evaluation. This should be
performed in conjunction with thereview of the critical evaluation
to maximize the efficiency of the process. Dependingupon the task
developed for the non-critical evaluation, it may also be desired
to havethe responsible Operations personnel available to provide
input on some of the
maintenance related criteria in the non-critical evaluation.
PM Task Recommendations
Once a component has been determined to be critical, or
non-critical but not allowed torun-to-failure, the next step is to
recommend applicable and effective preventivemaintenance tasks
based on the component's importance. Selecting the type of task
tobe performed and the frequency of the task can be accomplished in
several manners.
The approach will utilize preventive maintenance templates as
much as possible (see
Section 4.2.3). SRCM projects use generic templates that combine
EPRIs current in-house templates with capabilities and maintenance
philosophies of the plant. Becausethe maintenance templates do not
identify specific component failure modes or links toany specific
plant effect, careful consideration must be exercised to ensure
that theanalyst selects preventive maintenance tasks that will
prevent specific dominant failuremodes and causes to ensure they
are adequately addressed by the preventivemaintenance programs.
These failure modes and causes can be incorporated fromspecific
facility experience or generic industry experience on similar
equipment.
For critical equipment, the analyst selects failure causes
associated with the dominantfailure modes and effects that are
desired to address through the preventivemaintenance program. The
analyst then identifies the applicable and effectivepreventive
maintenance tasks that are recommended to address the failure mode
andcause combinations (failure mechanisms) of concern. A similar
step is performed fornon-critical equipment that has been
identified as requiring a PM task except no failurecauses need to
be identified.
Another method available to determine the appropriate preventive
maintenance tasksfor each component is the standard RCM Logic Tree
Analysis (LTA). This method canalso be used for any component type
that does not have a maintenance template.
Task Comparison
After the SRCM PM recommendations have been identified, the
final step in the processis to reconcile these recommendations with
the existing PM program. The existing PMprogram should consist of
every task performed on a component that has the ability toidentify
or prevent potential component failures and adverse effects (e.g.
PreventiveMaintenance tasks, surveillance tasks, lubrication,
condition monitoring, etc.). This
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report becomes the basis for the actions required to implement
the finalrecommendations after approval from the appropriate
station personnel. Appendix Acontains an example of SRCM work
products.
2.3 What Does It Take To Conduct SRCM?
Performance of SRCM on any plant system entails a coordinated
effort between plantpersonnel and the analyst. The plant personnel
involved include craft, engineering,operations personnel, as well
as those directly responsible for the project (Core Team).In order
to obtain the most thorough and accurate information about the
system underanalysis, the analyst must solicit input from these
various organizations. For this tohappen, the project lead/manager
must coordinate schedules such that, for the mostfavorable impact
on the project, the personnel most knowledgeable are available
foranalysis reviews (Criticality, Task selection and Task
Comparison) and Maintenanceinterviews. This can, at times, be a
substantial investment of manpower into the SRCM
analysis, therefore, it is vital that the reviews and interviews
be conducted efficiently,without sacrificing quality for speed.
Typically, the Core Team make-up consists of personnel from
engineering, operations,planning and maintenance (including
supervisors, foremen and craft personnel). Thesepersonnel are
empowered to make decisions and implement changes in themaintenance
program (change existing PM tasks, add new tasks, purchase
PdMtechnology/equipment, etc.). The Core Team will also know which
personnel areexpert on a particular system, and will ensure that
these experts are available toparticipate in the analysis. Most
often, the analyst will perform the analysis with
predetermined steps identified as review points. Usually, these
points are theCriticality Analysis, Task Selection and Task
Comparison. The reviews are usuallyconducted by the analyst with
the Core Team and any other personnel as appropriate.Quite often,
the Criticality Analysis is reviewed by the analyst with only
arepresentative from Operations. This is acceptable, as Criticality
is a functionaldetermination based on the effects of failure on the
operation of the plant. However,the criticality review and
determination should involve all members of the Core Team,as this
will ensure that all members of the group understand the reasoning
behind acomponents criticality. Task Selection and Task Comparison,
however, require fullCore Team participation in the reviews.
As part of the Task Selection process, it is necessary for the
analyst to conductinterviews with the system experts to identify
problems, design deficiencies, ineffectivemaintenance tasks and
practices, as well as suggestions for improvement of themaintenance
performed. These experts are usually senior craft personnel or
foremen/supervisors from the mechanical, electrical and
instrumentation disciplines, operationsand engineering. The
interviews are conducted individually or collectively, dependingon
availability and the goal is to collect information to determine
equipment
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performance and make recommendations as to what maintenance
should beperformed.
Table 2-1 lists the typical man-hour requirements for performing
an SRCM systemanalysis.
Table 2-1SRCM Analysis Labor Requirements
ACTIVITY HOURS
Analyst Resource/Core Team
Data Collection 24 8
Critical Analysis and Task Selection 80 20
Non-Critical Evaluation and Task Selection 16 8
Analysis Reviews 16 16
Task Comparison and Review 24 12
Implementation -- 20-200 (1)
Totals 152 76-256 (1)
(1) The number of hours required for implementation is
utility-specific and driven by a variety of factors,including the
scope of changes to the PM program, purchase and installation of
new PDM equipment,training in the use, upkeep and interpretation of
PDM data, interface between the SRCM software and the
utilitys maintenance management software, etc. Some systems may
require as little as 20 hours.
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Table 2-2Typical SRCM Project Schedule
Note: 2 systems/per phase
The key to success for multi-system SRCM projects of this nature
is to allow acontinuous flow of analysis and recommendations that
can be reasonably implemented.The timeline below depicts the
overall project schedule for a typical 10 system project.
The timeline above shows the process used to complete 2 systems
per phase. Note thatphase 1 is longer due to OJT training. Also
note this is a nominal timeline, the actualschedule for a specific
phase may be shorter or longer depending on the system sizes,data
collection, and availability of plant staff.
During each phase, the EPRI contractor conducts several meetings
on-site. Typically,there are 3 one-week long meetings. The first is
at the beginning of the phase to finishthe task comparison of the
previous phase of systems and collect the data for the nextphase of
systems. The second meeting is to review the FMEA portion of the
analysis
along with potential task selection. The final meeting is to
complete task selection andcomparison.
2.4 Training and Analysis Support
A Typical 10 system project provides detailed SRCM training at
multiple levels. TheCore Team members receive extensive training.
Others will have training
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commensurate with their level of participation. Training for
Core Team members isprovided at the plant and is performed in a
workshop environment in which utilitypersonnel would obtain actual
experience performing SRCM analyses on a simplifiedsystem. The
workshop includes:
System function and functional failure determination
Equipment failure mode and effects analysis (FMEA) and
criticality determination
Component task selection
Implementation
Living program development
Effect based analysis (criticality checklist)
This training is conducted over one (1) day and provides
employees a firmunderstanding of RCM/SRCM concepts.
The primary training method used is on-the-job (OJT) training.
Training is held duringsite visits for reviews and interviews of
the system studies. This OJT will provide CoreTeam members required
knowledge for implementing results and supporting theremaining
phases of system studies.
To complement the training of core team members, it is important
for plant staff tohave an understanding of the SRCM process. While
at the plant site, EPRI provides a 1-2 hour training session to as
many plant staff members as desired. The presentationmaterial are
left with the utility to continue training by core team members for
futureneeds.
The following minimal support options are available and are not
intended asequivalent to full service support. Even though the PMO
Workstation is free of chargeto Target 54(98)/(Target 75 in 99)
members, EPRI requires a member to at least havethe minimal
training.
1. Software provided without enhancements for immediate use (PMO
Workstation,
Version 4.0) with one week of training consisting of 1 days on
SRCM process, plus day on workstation, plus 1 day of facilitation,
and 1 day of off-site paper reviewof final product. Note: if
personnel to do system study received SRCM training viaEPRI SRCM
workshop, then the option changes to 2 days of facilitation
supportinstead of 1 day. It is intended that the plant actually
perform and SRCM analysis(as time permits) on a unit system during
the week of training.
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2. Facilitation support consisting of 3 one-week hands-on
training on-site at one plant.
3. Pilot project where utility personnel conduct 1 to 2 systems
analysis in parallel withan ERIN analyst performing analysis on 1
to 2 different systems.
4. Pilot project where ERIN conducts 3-5 system studies with
utility training.
5. Total unit project where ERIN conducts 10 system studies.
6. All plants/units analysis conducted by ERIN - cost subject to
number ofunits/plants and similarity of units.
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UTILITY PROJECT STATUS
3.1 Current Utility Project Participation
Over the past 3 years since the EPRI initiation of the SRCM
program, numerous utilitieshave participated in the program. The
participation ranges from attending an EPRIsponsored SRCM workshop
to full plant analysis and implementation support. Thefollowing
table lists the utilities that have started an SRCM program. Note
some
utilities are working at multiple plants.
Utility Single or MultipleSites
Type of Participation Status
PG&E single analysis work finished
FPC single analysis & implementation finished
OG&E multiple analysis finished
PECO single analysis finished
PSE&G single analysis in progress
Union Electric single analysis finished
DECO multiple facilitation training finished
C&SW single facilitation & analysis finishedHL&P
multiple analysis & implementation in progress
Penn Power single facilitation training finished
Georgia Power multiple facilitation training in progress
Mid-American single analysis finished
First Energy multiple analysis & facilitation finished
Associated Electric single facilitation finished
Hoosier Energy single facilitation finished
Salt River Project multiple analysis in progress
Kentucky Utilities single analysis in progress
New Century single facilitation finished
PS of New Mexico single analysis finished
PEPCO single facilitation in progressTucson Electric single
analysis in progress
BG&E single facilitation in progress
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Given the fact that the SRCM methodology was a proven process
and the early projectsat FPC and PG&E validated that the
process worked at a fossil plant, EPRI hascontinued the project for
many reasons. The major focus at this time is to improve theprocess
by developing more cost efficient tools and processes such as
templates and theliving program module, gain useful experience data
such as task selection informationand implementation practices and
to further integrate the process into other focusessuch as
predictive maintenance and maintenance management processes.
It should be pointed out that not all of these projects have
been fully successful. Projectsuccess limitations, however, are
mostly driven by either insufficient upper and mid-management level
support including sustained, long-term support and a lack
ofequipment and/or resources to fully utilize the results of the
SRCM analysis. Thus, themore successful utilities are the ones who
dedicate the necessary resources for not onlythe initial project
results but also the living program and sustain management
supportuntil the process and results become the way to do
business.
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DESCRIPTION AND DEVELOPMENT STATUS OFSRCM PROGRAM TOOLS
4.1 Overall SRCM Program
A SRCM program requires as previously mentioned, commitment by
all levels ofmangement as well as dedicated resources. It also
requires several infrastructureprocesses and programs to fully
utilize and effectively achieve the maximum resultsfrom the
program. Key maintenance management programs that should be in
placeare: planning and scheduling; root cause failure analysis
(RCFA); computerizedmaintenance management system (CMMS); operator
rounds/logs; engineeringperformance testing; predictive maintenance
(PdM); post maintenance testing (PMT);and condition monitoring
(CM). All of these programs are required to some level
ofimplementation to truly obtain maximum volume from the SRCM
results. Integrationof the SRCM results in how the plant performs
the work should happen to effect andmaintain the bases and
decisions made during the initial SRCM analyses. Figure
4-1demonstrates how the various maintenance management processes
could be organized
with SRCM program requirements including to the initial analyses
and living program.
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INTEGRATED MAINTENANCE WORK MANAGEMENT FLOW CHART
RCM ENGCondition
Data Analysis& Proactive
W/O generation
Data Inputs( s in Ops, PdM, etc.)
RCM ENGMaintenance
Program
Change Control
MonthlyOperatingStatistics
RCM Monthly Reports
SRCM Analyses
Perform PostMaintenance Test
RCM Condition Monitoring& Perf. Test Program
(Predictive Maintenance)W/O to RCM Engineer
File Reports
PM Program & Oil Samples
(Preventive Maintenance)CMMS Generates PM Work
Sheets (No W/Os) & AsFound/As Left Close Out With
PM Feedback Rating
RCM Scheduled Overhaulor NDE Inspection
(Proactive Maintenance)Planned CMMS Work Order.Record As
Found/As Left
Operating Crew
Supervisor Generates & CloseOut CMMS W/O Document
As Found/As LeftInitiate RCA
RCM Engineer
Coordinate RCA Studies forimmediate issues
Admin. Staff DocumentsResults in CMMS
32498
Maintenance Planner
Close Out W/OEnter As Found/As Left Info
Schedule Post Maintenance Test
Maintenance
Planned, W/O Defines WorkDocument As Found/As Left
Assist RCA Process
Maintenance Planner
Plan and Schedule CMMSW/O Attach As Found/As LeftForm, Initiate
RCA Process for
CM W/O
Do
R
RCM Surveillence Program
Data Logger InitiatesRounds and Records Data(No W/Os)
OperatorsLog BookOn Line DASand PIN DataTrends & Flags
Operating Crew
Performed RequiredCorrective Maintenance or
Generate W/O Request
C
IsWork
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The intent of this discussion is to show an example model of how
SRCM is to beintegrated into the daily processing of maintenance
activities. Each box on the figurerequires certain data inputs and
outputs, roles and responsibilities, procedures andactions. EPRI is
working on several of these boxes and particularly relevant to
SRCM,several tools, processes and databases are developed or in the
process of beingdeveloped to assist in achieving maximum
effectiveness. There are products thatsupport the initial SRCM
analysis and implementation efforts, products for theupdating and
maintenance of the living programs and initial databases for
industrymaintenance practices. The following sections describe work
to date and thedevelopment status of each product.
4.2 SRCM Process and Software Products
There have been three major areas of focus to date in improving
and enhancing the
execution of performing an initial SRCM analysis on a plant
system. The three areasare SRCM workstation, system templates and
component type templates. An emergingfourth area is compiling
industry data on maintenance practices. This area is focusedon
providing a member with readily available information on industry
practice ofapplying various maintenance strategies (i.e. task
content and frequency) and taskinstruction data.
4.2.1 SRCM Workstation
The SRCM program at EPRI includes the use of ERINs PMO
Workstation. Through a
cross license, EPRI has obtained a no-cost to member license for
the installation and useof the PMO Workstation at a members
plants.
PMO WORKSTATION DESCRIPTION
The Plant Maintenance Optimizer (PMO) Workstation Version 4.0 is
an MS-Windowsrelational database management software package for
the PC that uses ACCESS filestructures. The PMO Workstation
provides an on-line data entry, storage, retrieval,and report
generating capability. The principle PMO tools are: Functional
FailureAnalysis (FFA), Criticality Analysis, Non-Critical
Evaluation, Critical and Non-CriticalTask Selection, PM Task
Comparison, and Implementation Tracking. Lookup files areused to
store common information such as component descriptions, failure
modes,failure causes and effects, and the current maintenance
program for the system(s) beinganalyzed.
The PMO Workstation is designed to be used efficiently with
simple manipulations of amouse, thus minimizing keystrokes. PMO has
extensive built-in reports which may bemodified by the user through
a separate report generation software package. Reports
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are printed using standard MS-Windows fonts and may be viewed in
their entiretyprior to printing through the PMO View Report window.
In addition, reports may befiltered to isolate any portion of the
database.
The PMO Workstation is completely self-contained and requires no
additional database
software. To assist with setting up new system analyses, certain
data files may beimported by the user by using flat files in ASCII
comma-delimited format. This dataincludes System Component Lists,
Current Maintenance Program data, and CorrectiveMaintenance History
data, if desired. Additionally, many of the lookup files are
pre-loaded with standard data based on the EPRI work to date for
fossil generation. Thesefiles consist of codes and corresponding
descriptions that are used to simplify the dataentry in many PMO
modules. The lookup databases including Component Types,Failure
Effects, Failure Causes, Task Bases, Recommended PM Tasks, and
PMORecommendation Justifications were developed by ERIN Engineering
to provide a setof commonly used choices for these fields and to
provide a foundation for developing
plant-specific lookup databases for PMO Workstation users. NOTE:
As with PMOWorkstation databases in general, the contents of any
lookup files may be customizedby the user at any time.
The EPRI project related enhancements to the PMO Workstation are
the system andcomponent type templates and the living program
module. All software will be year2000 ready.
4.2.2 System Templates
The task for system templates involves the development and
automation of SRCManalysis templates by system (e.g. boiler
feedwater, circulating water, etc.) usingpreviously performed
system studies for the bases. These system templates will
bearranged by various types (e.g. circulating water - Type A is no
redundant pumps,Type B - redundant pumps) allowing the user to
select the type that most closelyreflects the users system. The
generic system templates will be electronically availablethrough
the PMO workstation and once selected, electronic guidance via
analysischecklists/questionnaires, etc. will be used to guide the
user in the conversion of thegeneric study to plant specific.
Currently, there are generic system templates for 3systems analyzed
with automated guidance. Additionally, as more systems areanalyzed
via EPRIs SRCM program, the use and expansion of available
system
templates can occur.
The three systems are listed below:
1. Electric Distribution
2. Service Water
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3. Feedwater
Each system type consists of variations in system configuration.
The types are bysystem and allow the user to select a system type
closest to his to begin his ownanalysis. Once a type has been
selected, the Workstation generates the appropriate
copy of the data to allow change for specific aspects of
analysis. The workstationprompts the user to review the template
for appropriate changes of minor configurationdifferences,
operational and maintenance use/strategies, specific history
differences,and equipment identification. Once the analyst has
completed his review, a specificsystem study is ready for
implementation. Appendix A contains an example of asystem
template.
The following screens illustrate the system template software
features. Figure 4-2shows the tool bar option of selecting system
templates to initiate a system analysis.Figure 4-3 shows how to
select a system to begin the process of converting the
closesttemplate to an actual system study. Figure 4-4 illustrates
how the software provideselectronic flowchart guidance for the
conversion process. For each step of an SRCManalysis (i.e. FFA,
criticality analysis, non-critical evaluation and task selection),
theanalyst can review the template data and modify the data based
on his actual systemthat is being analyzed.
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Figure 4-2Screen- selecting system template option
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Figure 4-3Screen- selecting a specific system template
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Figure 4-4 Screen - Electronic flowchart and review options for
system template modification
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4.2.3 Component Type Templates
The second kind of template developed is the component type
maintenance templates.These templates consist of maintenance
strategies for various component types. These
templates are based on system studies previously analyzed via
the SRCM program.The templates will be expanded as more information
becomes available, particularly bymake and model or new component
types. The templates are specific to fossil unitexperience and
include component types unique to fossil such as pulverizers,
fuelhandling, scrubbers, etc. The templates are automated and
provide user customizationof templates based on user criteria such
as technology capabilities and level ofconservatism desired in
their maintenance program.
The workstation accommodates an unlimited number of component
templates allowingexpansion. The templates support the task
selection activity for critical and non-criticalequipment. The
templates look similar to Figure 4-5 and the following is a list
ofcurrently available component type templates. These templates are
provided inAppendix B.
1. Relief Valves 17. Vertical Pumps
2. Heat Exchangers 18. Switchgear
3. AOVs 19. Compressors
4. Switches (various) 20. Fans
5. Electronic Controllers 21. Oil-Cooled Transformers
6. 480v Circuit Breakers 22. Coal Feeders
7. AC Motor 23. Igniters
8. Pulverizers 24. Car Dumper
9. Boiler 25. Scales
10. Sootblowers 26. Coal Belts
11. Relays (various) 27. Electrical Precipitator
12. SOVs 28. High Voltage Breakers
13. Check Valves 29. 480v Switchgear
14. Turbines 30. Instrument Loops
15. 120v Dist. Panels 31. Horizontal Pumps16. MOVs 32. Boiler
Controls
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Figure 4-5Screen - Maintenance Component Type Template
4.2.4 Industry Data
The PMO Workstation has built into it fields that will allow the
development ofindustry data and general task instructions suitable
for use in a CMMS. The industrydata will consist of a compilation
by component type and task type the frequencies atwhich plants are
performing these tasks. This data does not reflect the
optimumfrequency necessarily between reliability and cost but
provides some indication of what
the norm might be. To illustrate, assume that a plant is
currently performing clean,inspect and lubricate tasks of their
480v motors at two years. The database in the PMOWorkstation will
show the frequencies of the current data set is performing the
sametask on similar equipment. This will be shown as below:
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480v Motor Clean, Inspect and Lubricate
FREQUENCY
All 480v motors (500 motors total) 10% of population @ 1 yr, 60%
@ 3 yrs, 30% @ 5 yrs
480v motors (ash system) (100 total) 40% @ 6 months, 20% @ 1 yr,
40% @ 2 yrs
480v motors (lube oil) (70 total) 50% @ 2 yrs, 50% @ 0 yrs
This illustration will show how the data can be used to
potentially change thefrequency of 2 years in general application
to 3 years. Granted there is no informationas to whether there is
equivalent reliability (i.e. no impact between 2 years vs. 3
years)but at least the basis would be there to say that 60% of the
population performs the taskat 3 years.
The level of detail for each component type/task combination
will be contingent on theprojects (e.g. system studies) of the SRCM
program. A separate initiative to developthis data further as well
as reliability data could expand and enhance this source.
4.3 SRCM Implementation and Living Program
4.3.1 SRCM Implementation
The results from an SRCM analysis include the addition of new PM
tasks or thedeletion, modification, or retention of existing tasks.
For the tasks to be retained, noeffort is required for
implementation other than ensuring the tasks are packaged
andplanned appropriately. For new tasks, determining whether it is
for a criticalcomponent or not and the type of PM task (e.g.,
condition monitoring, operator rounds,PdM, time-directed, or
testing task) is necessary to understand the importance andeffort
required for implementation. In fact, these recommendations tend to
be the mosttime consuming, particularly when the recommendation is
for a new PdM activity. Formodification or deletion of current
tasks, the activity is merely updating the taskfrequency or
deleting the task from the CMMS. Task information contained in
theCMMS may include specific direction to the maintenance crafts on
what maintenance
actions are required as well as what maintenance history
information is needed.Emphasis is placed on what actions are
required not on how to perform the actions.
Full implementation is achieved when an executable PM program is
contained withinthe CMMS or other appropriate programs such as
operator rounds, test procedures, etc.using the SRCM analyses as
its bases. This will in-turn require updating the SRCM
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analyses when changes of the maintenance program are required.
The living programis designed to manage the change to the SRCM
analyses.
The ongoing work under EPRI and utility funded SRCM projects
providesrecommendations for continued maintenance program
improvements. One such
improvement opportunity has been identified which allows a
utility to ensure adequateand optimum implementation of the SRCM
analysis. As part of the current SRCMprojects, EPRI is gathering
the task instructions developed during the projects.
As mentioned earlier, the PMO Workstation will have a structure
to hold a generic taskinstruction for each component type/task
combination. Figure 4-6 below is an exampleof a generic
implementation task instruction. These instructions will be linked
to thework plan button of the component type templates shown in
Figure 4-5.
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Description and Develo
PUG M ILL DISCH CNVR
Recommendation: PERFORM CLEAN, INSPECT & LUBRICATE.
Sequence Ins truc tions Com bo rewCo tManH Materials
MaterialsDe
10 Verify lockout/tagout MECH 20.00
20 Visually inspec t components MECH 0.00
30 Clean all com ponents MECH 0.00
40 Check belt scrapper for excess ive wear MECH 0.00
41 Check tip of sc rapper for excessive wear MECH 0.00
50 Check belt wear MECH 0.00 81-1947 Belt Conv. #3
51 Look for grooves, exposed cords, rips , holes, MECH 0.00
and exces sive wear
60 Check Troughing Idler MECH 0.00 80-8513 Troughing Idler
35 deg.
61 Check for cleanliness , lubrication, and rusty holes MECH
0.0070 Check Return Idlers MECH 0.00 80-11053 Return Idlers
80 Check for cleanliness , lubrication, and rusty holes MECH
0.00
90 Sound gear box ; Listen for grinding, c linking, and MECH
0.00
vibration s ounds
100 Make minor adjustments and repairs MECH 0.00
Figure 4-6Sample Implementation Template
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4.4 Living Programs Process and Software
As shown in Figure 4-1, the SRCM analyses become the basis for
the maintenanceprogram. Because this bases needs to be maintained
to be current and reflect actual
practices and activities, a living program is needed that is
integral to the workmanagement process.
EPRI has two products that can be used or customized to assist a
utility in starting aliving program. The first is a procedure that
provides guidance on updating the SRCManalyses given various data
inputs such as CM and PM history, design and operationalchanges,
industry experience, etc. The procedure also provides an
exampleadministrative control and roles and responsibilities
requirements. This example isbased on a single individual at a
unit/plant that is authorized to update the SRCManalyses and
ultimately authorizes changes to the maintenance program. Any
plant
personnel can request a change but only this living program or
RCM coordinator canactually make the changes. Forms are provided
for requesting and documenting theprocess and decisions.
The second product is a living program (LP) module that is part
of the PMOWorkstation. The LP module will provide electronic
guidance and decision retentionfor updating the SRCM analysis.
Guidance is provided for PM and CM history, newPdM technology
application, design changes, industry experience, operating
procedurechanges, equipment replacement and vendor recommendations.
This electronicguidance steps the reviewer through a series of
operations and directs them to theappropriate part of the analysis
for update. Electronic request forms and tracking is
provided. Historical records of all requests and changes will be
kept for futurereference.
The LP module is currently ready for beta testing. A test plan
has been developed foruse by a participating utility. As part of
the beta test, an interface with the specifictesters CMMS will be
developed to allow efficient transport of available CMMS data.
The following screens show the software features of the living
program module.Figure 4-7 shows the various data input options
under the LP menu. Figure 4-8 is anexample of the electronic
guidance provided in the software. Certain fields will be
loaded with CMMS data such as work order number,
as-found/as-left data, etc. Eachmenu option in Figure 4-7 has this
level of guidance specific to the data to be reviewed.Figure 4-9 is
the PM Recommendation form that can be used to track a
maintenanceprogram change from any requester either electronically
or hard copy.
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Figure 4-7
Screen - Living Program Options
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Figure 4-8Screen - Living Program PM History Review
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Figure 4-9Screen - Living Program PM Program Change
Recommendation Form
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SRCM PROGRAM BENEFITS
The benefits from applying SRCM at the various plants has
included both qualitativeand quantitative benefits. Not all
utilities track costs to perform an effectivequantitative analyses,
thus there is a small set of information relative to quantifying
thecost benefit, however, in all cases that have calculated cost
benefit, a less than one yearpayback was seen.
The following provides some examples of where the savings have
been calculated:
Florida Power Corp. - Crystal River Units 4 & 5 (11 systems
applied to two units)Total Annual Savings: $343,962Estimated
Payback on Investment: < 1 year
Mid American Energy - Council Bluffs (10 systems)Estimated
Payback on Investment: < 1 year
Centerior - 11 units (135 systems)Estimated Payback on
Investment: < 1 year
Qualitatively several areas are affected by the analysis. The
analysis has providedinsights and direction for work management,
design changes, operational philosophy,enhanced condition
monitoring and other non-maintenance task activities. Thefollowing
are examples from various projects:
Case Study 1
Plant - 2 Unit Coal Fired Power Plant
System - Fuel Handling (Pulverizers)
Component - Coal Pulverizers
Existing PM Program - 6 month overhaul, monthly lube oil
analysis, quarterly vibrationmonitoring.
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RCM Recommendation - take advantage of current lube oil and
vibration analysis todetermine component health. During next
overhaul make the upgrade to the stronger,more expensive, wear
components that were available from the vendor.
Results - using the existing condition monitoring/predictive
maintenance tools, the
good operating history and the improved wear components that
will be added, theoverhauls were extended from 6 months to
annually.
Cost Savings - the total cost savings including the additional
cost of the more expensivewear components was
$50,000/year/unit.
Case Study 2
Union Electric - Rush Island Unit 1Boiler Draft and Pulverized
Fuel Systems
For all of the large motors in both systems (and for all systems
to be subsequentlyanalyzed), the time based intrusive motor
overhauls will be phased out in favor ofelectrical diagnostic
testing using various testing including motor current
waveformsignature analysis and oil analysis.
For the Induced Draft Fan Lube Oil Skid, a recommendation was
made andapproved to re-evaluate the control scheme. A re-design may
be required to ensurea standby lube oil pump auto start, a low lube
oil pressure fan trip and alarms.
Case Study 3
Mid American Energy Co. - Council Bluffs Energy Center Unit
3
Ten Systems
In the Boiler Steam and Water System, more frequent leak
monitoring wasrecommended for high energy steam valves. Also, a
program will be initiated forhigh energy traps.
In the Boiler Air and Gas System, a shift to condition
monitoring with vibration and
lube oil analyses and NDE to extend frequency of overhauls and
intrusiveinspections on the Fans and Motors has been recommended
and approved.
A reliability problem with the Circulating Water Recycle Pump
was identified andaddressed with performance testing and an
evaluation into pump monitoringdesign changes.
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In the Fuel Handling System, an increased reliance on vibration
monitoring andlube oil analysis has been recommended for the
Conveyors, Crushes, and Feeders(and their motors and gearboxes), as
well as simple tasks performed by the CoalHandlers to monitor
equipment operation during daily walkdowns.
Increased condition monitoring will enable the plant to
comfortably extend theMain Turbine overhaul to seven years. (Input
was solicited from GE by CBEC onmonitoring techniques and
diagnostics.)
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