Harihar RCM Presentation for ARS_India_Narayan Rao

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    2011 ARS, India: Bangalore

    Track #, Session #Begins at X:XX AM, XXXday, October Xth

    Current Time:

    11:32 AM

    Fostering of RCM culture in

    Grasim, HariharPresenters Name and Affiliation

    1. Mr. Sudarshan.S.N (Manager,Spinning Process)

    2. Mr. Narayan Rao I K (Manager, Spinning Maint.)

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    Insert Name, Company Slide Number: 2Session #Track #Applied

    ReliabilitySymposium,

    India2011

    Agenda

    Introduction 5 min Selection of equipments for RCM 5 min

    Details of FMEA carried out 5 min

    Tasks listed after FMEA 10 min SOPs prepared after RCM 5 min

    Benefits after RCM 10 min

    Training imparted 5 min Summary 5 min

    Questions 10 min

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    Insert Name, Company Slide Number: 3Session #Track #Applied

    ReliabilitySymposium,

    India2011

    Introduction of our company

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    Insert Name, Company Slide Number: 4Session #Track #Applied

    ReliabilitySymposium,

    India2011

    Introduction of our company

    GRASIM: HARIHAR

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    ReliabilitySymposium,

    India2011

    Introduction of our company

    Flow Diagram of VSF Process

    Selected for RCM

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    Applied

    ReliabilitySymposium,

    India2011

    Selection of equipments

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    ReliabilitySymposium,

    India2011

    Trainingon RCM in HariharSelection of Equipments

    3 days training was conducted between 4thmay 2010

    6thMay 2010.

    6 different units from Aditya birla group participated in

    this training programme

    Cross functional teams (4 members) were formed in allunits

    First half day training was on introduction to RCM and

    rest of the days was spent in carrying out only FMEA

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    ReliabilitySymposium,

    India2011

    Selection of equipments

    After Training

    20 critical equipments were selected

    Criticality analysis of all the selected equipments are

    carried out

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    ReliabilitySymposium,

    India2011

    Selection of equipments

    Category Factor Option X1 - None

    2 - Low

    3 - Moderate X

    4 - High

    5 - Very High

    1 - None2 - Low X

    3 - Moderate

    4 - High

    5 - Very High

    1 - None

    2 - Low

    3 - Moderate X

    4 - Significant

    5 - Extreme

    1 - Not Possible

    2 - Very Unlikely

    3 - Unlikely

    4 - Likely X5 - Very Likely

    Criticality Analysis. Equipment 1 : Stretch Gear Box

    Safety = 12

    Potential for Personal Injury

    Severity of Personal Injury

    Health Hazards

    Fire / Explosion Event

    Possible

    1 - 10 Crores

    1 - 50 Lacs

    1 - Available in

    House X

    2 - 1 to 4 weeks

    3 - 1-3 Months4 - 3 to 6 Months

    5 - More than 6

    months

    Maintenance = 5

    Downtime Impact

    Repair Costs

    Spare Parts Availability

    1 - None

    2 - Near

    Equipment X

    3 - Local Area

    (Only Section)

    4 - Wider Area

    (Near-by Sec tions)

    5 - Whole

    Plant/Surrounding

    s

    1 - No X

    5 - Yes

    1 - None

    2 Minimal

    3 Moderate X

    4 - Significant

    5 - Extreme1 - No X

    5 - Yes

    Environmental = 7

    Spill/Release Haz. Material

    Pollution Control Device

    Env. Impact Potential

    Radiation Detection

    Criticality analysis

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    ReliabilitySymposium,

    India2011

    Selection of equipments

    1 - None X2 - Minimal (10-

    20% Loss)

    3 - Moderate (20-

    40% Loss)

    4 - Significant (40-

    60% Loss)

    5 - Extreme (Total

    loss)

    1 - No X

    5 - Yes

    1 - No X

    5 - Yes

    1 - No5 - Yes X

    1 - > 5 Years

    2 - 1-5 Years X

    3 - Once in a year

    4 - Once in 6

    Months

    5 - Once in Month

    Operations = 10

    Capacity Reduction Impact

    Regulatory Requirements

    Impact on Energy

    Consumption

    Impact on Scrap

    Failure Frequency Potential

    1 - None X

    2 - Minimal

    3 - Moderate

    4 - Significant

    5 - Extreme

    1 - No < 2 day

    delay X

    2 - 2 to 5 day

    delay

    3 - 5 to 15 day

    delay4 - 15 to 30 day

    delay

    5 - > 30 day delay

    1 - No X

    5 - Yes

    Overall Criticality = 37

    Quality Control = 3

    Quality Impact Potential

    Missed Delivery

    Customer Claim Possible?

    Criticality analysis

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    ReliabilitySymposium,

    India2011

    Selection of equipments

    Safety Maintenance Opearation Envirnomental Quality control Total

    1 Stretch Gear box 12 5 10 7 3 37

    2 Cutter Gear Box 12 4 10 6 5 37

    3 Godet gear box 8 3 5 5 4 25

    4 T Gear box 10 3 6 5 3 27

    5 Machine main Drive System 6 3 7 5 8 29

    6 Machine Pump Shaft drive system 6 3 5 6 3 23

    7 Eccentric shell assembly 11 4 7 3 5 30

    8 Fixed beam assembly 9 4 6 6 6 31

    9 Squeeze roller assembly 11 4 7 4 7 33

    10 Mat opener 11 4 7 5 5 32

    11 Aftertreatment main drive system 11 3 6 6 3 29

    12 Aft Soft Finish main drive system 7 3 6 5 4 25

    13 Alluminium conveyor assembly 9 4 8 4 3 28

    14 Spike Latice assembly 15 4 10 6 6 41

    15 Dryer Drum assembly 10 3 11 5 6 35

    16 Dryer Fan Assembly 10 3 7 4 5 29

    17 Bailing Press Full Press 12 3 9 4 6 34

    18 Bailing Press Half Press 11 4 9 5 5 34

    19 Dryer Nip roller assembly 9 4 6 4 4 27

    20 Dryer Intermediate conveyor assembly 10 4 9 4 6 33

    200 72 151 99 97 619Total

    Score

    EquipmentSI No

    Summary of criticality analysis

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    India2011

    Selection of equipments

    Four equipments having high scores

    Sl.

    No.Equipments Scores

    1Dryer Spike lattice

    assembly41

    2 Stretch gear box 37

    3 Dryer drum assembly 35

    4 Squeeze roller assembly 33

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    ReliabilitySymposium,

    India2011

    Selection of equipments

    Equipments selected for RCM

    Sl.

    No.Equipments Scores

    3Dryer Spike lattice

    assembly41

    4 Dryer drum assembly 35

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    ReliabilitySymposium,

    India2011

    FMEA of selected equipments

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    FMEA

    Along with 4 core team members another 8 membersteam were formed

    Training imparted to them

    All 12 members together carried out FMEA of

    selected equipments in presence of Reliasoft personnel

    from 14thto 16thJune of 2010.

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    ReliabilitySymposium,

    India2011

    FMEA

    Schematic sketch of Dryer

    Static

    Separator

    Baling

    Press

    1St Drive

    No. of drums: 12

    Drum Speed: 9 sec/rev.

    Temperature:

    1st Zone : 95 deg. C

    2nd Zone : 105 deg. C

    2nd Drive

    No. of drums: 8

    Drum Speed: 9 sec/rev.

    Temperature:

    3rd Zone :125 deg. C

    4th Zone : 100 deg. C

    3rd Drive

    No. of drums: 12

    Drum Speed: 9 sec/rev.

    Temperature:

    5th Zone : 120 deg. C

    6th Zone : 100 deg. C

    1St Intermediate

    opener:

    Speed: 330 rpm

    2nd Intermediate

    opener:

    Speed: 330 rpm

    Al. Conveyor Speed: 37 rpm

    Comber Speed : 160 rpm

    Spiked Lat. Speed : 55 rpm

    Al. Conveyor Spike lattice

    Comber

    Wet Rubbing

    Drum:

    Speed: 440 rpm

    Wet rubbing drum

    HP Steam line Header:

    Pressure: 15 Kg / cm2

    Temp. : 280 deg. C

    1st Zone steam inlet

    2nd Zone steam inlet

    3rd Zone steam inlet

    4th Zone steam inlet

    5th Zone steam inlet

    6th Zone steam inlet

    1st Int. Duct 2nd Int. Duct

    Baling Press:

    Capsule Bales

    No. of wires : 6

    Bale Weight: 235 Kgs

    Mat opener

    Achordis

    Blower

    Fine

    opener

    1st zone 2nd zone 3rd zone 4th zone 5th zone 6th zone

    Flash

    pot

    v

    To desulf bath circ. tank

    To wash

    water tank

    Condensate tank

    SilencerDryer

    condensate

    bypass line

    Hpmv1

    Zv1 Zv2 Zv3 Zv4 Zv5 Zv6

    Zva4

    Zva5

    Zva6

    St1

    St2

    St3

    St4

    St5

    St6

    Fp1

    Fp2

    Sc1

    Spike lattice Drum assembly

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    Applied

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    FMEA System Hierarchy

    Dryer Assembly

    is broke down

    into its sub-

    systems and

    assemblies

    Dryer Drums FMEAis done with these

    sub-assemblies

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    Applied

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    FMEA

    Failure Modes

    Function

    Effect

    Causes

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    Applied

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    FMEA

    Task Selection Logic

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    Applied

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    FMEA

    Maintenance Task Selection

    The logic is applied for all the identified

    causes task were defined Currently practiced maintenance as well

    as new tasks were proposed where everpossible as per the logic

    For Currently practiced tasks the departments are assigned

    responsibility.

    For Proposed (New) Tasks One individual of the department is

    assigned responsibility.

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    Applied

    ReliabilitySymposium,

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    FMEAFMEA of Dryer drum assembly

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    FMEA

    FMEA of Dryer spike lattice conveyor

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    Tasks listed after FMEA

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    Insert Name, Company Slide Number: 25Session #Track #Applied

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    Tasks listed after RCM

    For Dryer drum Assembly

    - Current Task : 20- Proposed Task :13

    For Spike Lattice Assembly

    - Current Task : 15

    - Proposed Task :8

    Tasks listed

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    Insert Name, Company Slide Number: 26Session #Track #Applied

    ReliabilitySymposium,

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    Status of proposed task (Drum assembly)

    Sl.

    No

    Task description Status Target date

    1 Establish specific SOP for worm

    gear box

    Completed -

    2 Inspect & ensure the static balance

    of the dryer drums with ExternalVendor

    Completed in 8 drums

    in Dryer # 2 during lastpreventive

    Mar. 11

    3 RCM of After treatment section To be taken up Mar.11

    4 Ensure adherence to the

    established SOP use visuals near

    the equipment etc.

    Sticker received & to be

    fixed

    10thMar. 11

    5 Time based replacement of the

    damper seal

    Started for 8 drums. Mar.11

    6 Review the current SOP and ensure

    its compliance for damper seal

    Reviewed -

    7 Establish specific SOP for worm

    gear box

    Completed -

    Tasks listed

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    Status of proposed task (Drum assembly)

    Tasks listed

    Sl.

    No

    Task description Status Target date

    8 Time based replacement of the

    moving ring bearing

    Completed in 8 drums 31stMar. 11

    9 Tack welding of washer to the fanframes where ever applicable Completed -

    10 Check the temperature near bearing

    points if its >60 C lubricate the gear

    box

    Being practiced. -

    11 Oil lubricated gear box with higher

    series bearings is proposed

    Gear box received. Will

    be replaced during next

    available stoppage.

    31stMar. 11

    12 Replace the worn out fan pulley

    during preventive

    Being practiced. 8 no.

    replaced during last

    preventive

    -

    13 Review the moving ring bearing SOP Reviewed -

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    Status of proposed task (Spike lattice assembly)

    Tasks listed

    Sl.

    No

    Task description Status Target date

    1 Sealing of the Spk. lattice motor

    junction box

    Material is on order 10thMar. 11

    2 Tighten the bolts using torque wrench at

    60 lb inches

    Being practiced

    3 To follow the revised SOP regarding the

    quality of chain

    Reviewed

    4 Appropriate anti vibration pads to be

    provided for zone drive gear box

    motors.

    Material received. To be

    installed.

    15thMar.11

    5 Review the existing SOP of spike lattice

    assembly regarding correct torque of

    bolts tightening

    Reviewed

    6 Review the SOP regarding chain

    tightening method

    Reviewed -

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    Status of proposed task (Spike lattice assembly)

    Tasks listed

    Sl.

    No

    Task description Status Target date

    7 Increase the bolt shank length by 0.5 mm to

    ensure enough clearance

    Completed -

    8 Stress re leaving to be done after

    fabrication of spikes over latches

    Correspondence is done

    to the party. Awaiting forhis reply.

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    SOPs prepared after RCM

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    SOPs preparedFor drum assembly

    DRYER DRUM INSTALLATION

    Sub: Assembly of Dryer Drum as per Drg No.: 3-H-DRY-200/30

    Check list for Dryer drum assembly

    Sl.No.

    Description Min(mm)

    Max(mm)

    Allow

    1 Drum perforated hole size 9.98 10.02

    2 Drum perforated hole pitch 10.0 10.02

    3 Drum perforated sheet thickness 2.98 3.02

    4 Drum Diameter 1398 1402 1400

    5 Drum Length 1602 1605 1600

    6 Damper & Drum clearance 10 10.1

    7 Drum throughness 0.001 0.001

    8 Drum shaft coupling clearance 2.5 3.0

    9 Moving Ring and fixed ring clearance 2.8 3

    10 Drum side cover straightness 90o

    6. Damper & Drum Clearance:

    How to measure Damper & Drum Clearance?

    Place 10 mm key bar at bottom & side portion of the drum damper. Adjust the damper arm downwards such that it just touches the damper. Then tighten the arm. Remove the key bar kept at bottom & side.

    7. Drum Throughness

    How to measure the Drum throughness?

    Fix the assemble Drum over the stand. Then rotate it manually with side touching to the dial gauge. Take the Dial gauge reading

    Note down the reading Adjust the moving ring & coupling fixing bolt to get the zero reading in dialgauge through out the circumference.

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    SOPs prepared

    Assembly of Dryer Drum at site:

    Electrically isolate the equipment. Obtain the hot & cold work safety permit. Remove the Fan assembly. Mark the Dryer panel doors. Remove all side doors. Position the gear box jack & drum jack to its position. Remove the universal joint & gear box. Dismantle the coupling & shaft. Lead the Dryer Drum outside with chain block.Sl.

    No.

    Description Min Max Allow

    1 Clearance between dryer drum coupling &side panel

    65 68

    2 Clearance between drum coupling & gearbox coupling

    2.5 3

    3 Clearance between moving ring & fixed ring 3 3.5

    How to measure the clearance between drum coupling & drum frame?

    By depth gauge measure the coupling face distance end frame face. Maintain it for 70mmHow to maintain for 70mm?

    If the distance is less than 70mm, then slight hammer the drum shaft by 10lbhammer.

    If the distance is more than 70mm, then the puller over back side of the shaft. Then tighten the screw of the puller & drum shaft assembly to maintain thedistance of 70mm.

    Clearance between Gear Box Coupling & Drum Coupling is 3mm.

    How to measure the clearance?

    Insert the feeler gauge between couplings. And measure the thickness of the feeler gauge.

    For drum assembly

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    SOPs preparedFor Spike lattice assembly

    Assembly of Spike Lattice Conveyor Drive & Driven ShaftsSub: Ref Drg No 2/H/DRY/210/10

    Ref Drg No 1/H/DRY/210/27

    Ref Drg No 2/H/DRY/210/19

    Check list before assembly of spike lattice conveyor

    Sl.No.

    Description Min(mm)

    Max(mm)

    Allow

    1 Chain roller dia. 30 30.012 Chain pitch 40.0 40.013 Roller dia. clearance 1 1.0014 Chain connecting plate thickness 4.62 4.655 Connecting link hole PCD 28.8 28.96 No. Of links - - 1107 No. of teeth in drive and driven sprockets 24 24

    8 Sprocket pitch 40 409 Centre distance between the sprockets 1589 1589.210 Drive shaft dia. 55 55.0211 Driven shaft dia. 45 45.0212 Key way dimension 14x5x12513 Idler sprocket teeth 1214 Latch width 50 50.0215 Latch thickness 2 2.0116 Latch pin PCD 30 30.0117 Latch pin angle 10o 10.1o18 Latch fixing hole PCD 1618 161819 Thoroughness of the shaft 0.00 0.001

    SUB: Chain Roller Dia : Min 30mm, Max 30.01mm

    Once chain recd at assembly shop, proper checking of conveyor chain will bedone. Any deviation in dimension will be noted and cross verified , whether is itis in acceptable condition. If found deviation is above the acceptable limit,same will be rejected.

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    SOPs preparedFor Spike lattice assembly

    SUB: Chain Pitch ; Min 40 mm , Max 40.01mmChain pitch will be checked through out the length. Any deviation in dimensionwill be noted and cross verified , whether is it is in acceptable condition. If

    found deviation is above the acceptable limit, same will be rejected.

    SUB: Roller Dia clearance Min : 1mm max : 1.001 mm

    Chain roller dia will be checked through out the length. Any deviation indimension will be noted and cross verified , whether is it is in acceptablecondition. If found deviation is above the acceptable limit, same will berejected.

    SUB: Chain connecting plate thickness Min : 4.62mm, Max :4.65mmChain connecting plate thickness will be checked through out the length. Anydeviation in dimension will be noted and cross verified , whether is it is inacceptable condition. If found deviation is above the acceptable limit, same willbe rejected.

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    SOPs preparedFor Spike lattice assembly

    SUB: Chain connecting link hole PCD , Min 28.8mm, Max 28.9mm

    Chain connecting link PCD will be checked through out the length. Any

    deviation in dimension will be noted and cross verified , whether is it is inacceptable condition. If found deviation is above the acceptable limit, same willbe rejected.

    SUB: Through ness of the Drive and Driven shaft, Min : 0.00mm, max :0.01mm

    Through ness of the shaft will be checked between center in test bench/Lathemachine. If found zero reading in dial gauge, while rotation then job will beremoved. If the readings above the acceptable limit , then bend will beremoved and once again readings will be taken, This exercise ill be continued illwe get the readings well within acceptable condition

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    Benefits after RCM

    B fit

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    Insert Name, Company Slide Number: 37Session #Track #Applied

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    0.5

    0

    0.9

    2

    0.54

    0.79

    0.18

    0.00

    0.20

    0.40

    0.60

    0.80

    1.00

    FY-10 FY-11 Apr'11 May'11 Jun'11

    Year and month

    DryerDowntim

    e%

    Trend of Mechanical Breakdown in Fibre Dryer

    Benefits

    Better

    RCM Implemented from Jun-10

    B fit

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    Insert Name, Company Slide Number: 38Session #Track #Applied

    ReliabilitySymposium,

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    723.5

    0 726

    .50

    711.79

    732.9

    4

    709.9

    4

    705.00

    710.00

    715.00

    720.00

    725.00

    730.00

    735.00

    FY-10 FY-11 Apr'11 May'11 Jun'11

    Year and month

    Uptimehou

    rs

    Dryer uptime

    Benefits

    Better

    RCM Implemented from Jun-10

    B fit

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    Insert Name, Company Slide Number: 39Session #Track #AppliedReliabilitySymposium,

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    6

    65

    552

    720.0

    0

    558.00

    720.0

    0

    500.00

    540.00

    580.00

    620.00

    660.00

    700.00

    740.00

    FY-10 FY-11 Apr'11 May'11 Jun'11

    Year and month

    Hrs,

    Dryer MTBF (Due drum assembly)

    Benefits

    Better

    RCM Implemented from Jun-10

    B fit

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    Insert Name, Company Slide Number: 40Session #Track #AppliedReliabilitySymposium,

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    730

    720

    720.0

    0

    744.0

    0

    720.0

    0

    700.00

    710.00

    720.00

    730.00

    740.00

    750.00

    FY-10 FY-11 Apr'11 May'11 Jun'11

    Year and month

    Hrs,

    Dryer MTBF (Due spike lattice)

    Benefits

    Better

    RCM Implemented from Jun-10

    B fit

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    0.6

    7

    1.2

    3

    0.50

    1.00

    1.50

    FY-10 (Before RCM) FY-11 & upto date(After RCM)

    Year and month

    Hrs,

    Dryer MTTR (Due drum assembly)

    Benefits

    Better

    RCM Implemented from Jun-10

    B fit

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    Insert Name, Company Slide Number: 42Session #Track #AppliedReliabilitySymposium,

    India2011

    0.4

    5

    0.5

    7

    0.40

    0.45

    0.50

    0.55

    0.60

    FY-10 (Before RCM) FY-11 & upto date(After RCM)

    Year and month

    Hrs,

    Dryer MTTR (Due spike lattice)

    Benefits

    Better

    RCM Implemented from Jun-10

    B fit

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    Insert Name, Company Slide Number: 43Session #Track #AppliedReliabilitySymposium,

    India2011

    44

    95

    72 70

    46

    0.00

    10.00

    20.00

    30.00

    40.00

    50.00

    60.00

    70.00

    80.00

    90.00

    100.00

    FY-10 FY-11 Apr'11 May'11 Jun'11

    Year and month

    Bales/month

    Benefits

    Better

    Fiber accumulation due dryer stoppage

    RCM Implemented from Jun-10

    B fit

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    Insert Name, Company Slide Number: 44Session #Track #AppliedReliabilitySymposium,

    India2011

    78.1

    2

    62.0

    0

    86.19 86

    .97 87.33

    50.00

    60.00

    70.00

    80.00

    90.00

    100.00

    FY-10 FY-11 Apr'11 May'11 Jun'11

    Year and month

    %o

    fbales

    % of bales having moisture between 10-12%

    Benefits

    Better

    RCM Implemented from Jun-10

    B fit

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    Insert Name, Company Slide Number: 45Session #Track #AppliedReliabilitySymposium,

    India2011

    0.9

    6

    1.0

    0

    0.96

    0.98

    0.95

    0.90

    0.92

    0.94

    0.96

    0.98

    1.00

    1.02

    FY-10 FY-11 Apr'11 May'11 Jun'11

    Year and date

    T/TF

    HP steam consumption, T/TF

    Benefits

    Better

    RCM Implemented from Jun-10

    B fit

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    Insert Name, Company Slide Number: 46Session #Track #AppliedReliabilitySymposium,

    India2011

    3

    7

    2

    3

    1

    0

    2

    4

    6

    8

    10

    FY-10 FY-11 Apr'11 May'11 Jun'11

    Year and month

    No.s

    /month

    Dryer stoppage incidences due fiber jamming (due process)

    Benefits

    Better

    RCM Implemented from Jun-10

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    Insert Name, Company Slide Number: 47Session #Track #AppliedReliabilitySymposium,

    India2011

    Training imparted

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    Insert Name, Company Slide Number: 48Session #Track #AppliedReliabilitySymposium,

    India2011

    Training imparted

    Sl.

    No.Department

    Equipment

    selectedStatus Completion date

    1 Viscose TRPTasks

    generatedNov-11

    2 Recovery MSFETasks

    generatedNov-11

    3 CS2/H2SO4 FurnaceTasks

    generatedNov-11

    Grasilene division

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    Insert Name, Company Slide Number: 49Session #Track #AppliedReliabilitySymposium,

    India2011

    Training imparted

    Sl.

    No.Department

    Equipment

    selectedStatus Completion date

    1 Chipper house Faulgum chipper

    Tasks

    generated Nov-11

    2 Pulp mill Vacuum filter

    Tasks

    generated Nov-11

    Pulp division

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    Insert Name, Company Slide Number: 50Session #Track #AppliedReliabilitySymposium,

    India2011

    Summary

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    Insert Name, Company Slide Number: 51Session #Track #AppliedReliabilitySymposium,

    India2011

    Summary

    1. After training on RCM, two equipments were selected for RCM

    after carrying out criticality analysis of 20 critical equipments.

    2. FMEA of selected equipments were carried out in presence of

    Reliasoft personal.

    3. Tasks were listed out.

    4. Pictorial SOPs prepared after RCM.

    5. Benefits after RCM are summarized.

    6. Trainings are given to other departments/divisions regarding

    RCM.

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    Insert Name, Company Slide Number: 52Session #Track #AppliedReliabilitySymposium,

    India2011

    Questions please

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    edReliabilitySymposium,

    India2011

    Thank You