3.05 Maintenance Delivery

A practical and efficient condition based maintenance (CBM) program is built of two fundamental elements-one for rotating and dynamic assets in the adopted term of a (PdM) or Predictive Maintenance program and one for static assets known as Risk Based Inspection (RBI) program. This presentation will highlight these NSPI asset management programs for monitoring the state and reporting condition based (CBM) deficiencies on our physical assets. The discussion will review the development, management, integration and day-to-day application of our PdM/RBI programs including tools and techniques for VA, IR, MCA, HEP/FAC inspections and more. Participants will also discuss the general journey to condition monitoring for equipment over the thermal fleet. NSPI consciously chose innovative vendors, technologies and techniques. The audience will learn what challenges it faced internally and externally. The differences between how the CBM programs are integrated into our business today as opposed to piecemeal prior to AM program implementation starting in 2012.

Vibration condition monitoring programs play an important role in an organization's rotating equipment reliability and maintenance strategy.  While organizations may be in different stages of establishing their program, there are some common things to implement in order to get the greatest benefit from any program.  This workshop focusses on starting your program off on the right foot.  The workshop will use case histories to outline reasonable expectations, current vibration technology, and specific vibration standards for various industries.In addition to starting off on the right foot the success of a vibration condition monitoring program will depend on maintaining momentum.  This workshop will finish by addressing areas within the participants program where they can focus on improving the long term reliability of their assets instead of simply finding failures.

Vibration measurement has come of age in the last 20 years.  While the practice of continuous on-line monitoring of critical machines in the oil, gas, and petrochemical industries has been commonplace for several decades, it is only recently that companies who had been using intermittent data collection techniques are now embracing continuous monitoring.  This session will discuss that the new horizon for continuous monitoring is mobile equipment; draglines, shovels, bucket-wheel excavators, stacker-reclaimers, heavy haul trucks, are all equally important to production and just as critical as a gas compressor.  Participants will learn that, unlike stationary machinery, monitoring mobile equipment brings substantial challenges that must be addressed to ensure accurate, repeatable, and reliable data acquisition.  Rapid speed and load variations are just one element of the application.  The logistics of sensor mounting, cabling, network communications, and general serviceability bring unique complications to the task of monitoring these machines.  Ron will discuss these obstacles and present new solutions that have the potential to bring significant reliability improvements to large mobile equipment.

James Gunn, one of PEMAC’s 2015 Capstone Project Winners in the Business Process category, presents his Maintenance Management Professional Capstone Project: Proactive Process Development, during this lunch and learn webcast. The Capstone is the final project course of the Maintenance Management Professional program. Serving as an introduction to Lake Utopia Paper’s operation, this MMP capstone project dives into the reactive maintenance practices of a corrugating medium paper mill, and examines tactics to develop a proactive maintenance culture.  Acting as a proof of concept, this project narrows its scope to focus on the pumps and rolls around the paper machine.  With a core focus on developing proactive tactics, the project is expanded to also provide analysis of inventory optimization and workforce management practices to drive cost initiatives and engagement.  Even as a proof of concept, the application provides a structure that is able to be deployed to all areas of the facility.  The payback period for this project is less than one year, provides a Year 5 net present value in excess of $1.7M, and an internal rate of return of 170%.James Gunn has been involved in maintenance and engineering for the last 12 years, working as a Professional Engineer in a variety of fields, including aerospace, automotive, food & beverage, and pulp & paper. Starting his MMP education while working with JD Irving’s Lake Utopia Paper operation as a Mechanical Maintenance Team Lead, James is now the Director of Maintenance and Engineering for JD Irving’s Irving Consumer Products division.

In 2012, Calgary Water launched a comprehensive program (Secondary Water Supply Facilities Rehabilitation Program) which included assessing the condition of 18 pump stations. The result of this program ranked Shaganappi Pump Station as the most critical based on the condition of the equipment, the relatively large population and number of critical institutions it services. Listen to this webcast and learn how this Calgary Water effectively implemented a condition-based maintenance strategy for this pump station, and how you can utilize some of the learnings in your own environment to minimize and control risk, and create an effective infrastructure. 

How can we be sure that our efforts to correct deficiencies are going to derive value for our organization? Do we fully understand that our area of focus is the right one? In this webcast we discuss how we often deal with symptoms and not the specific problem. We identify the tools that will help point us in the right direction and figure out how we can develop them. We examine the standard approaches to arriving at the root cause, discuss some that don't work, and identify systemic causes that seem to provide the best results. Learn how to understand the links in front of you when it comes to solving your problem.

Nova Scotia Power owns, operates and maintains the majority of its power production. This is in the form of thermal steam units, combustion turbines, hydro, tidal, wind and biomass. The age and complexity of the power production facilities and equipment ranges from 90 years in some hydro stations, 40 years in some steam turbines, 40 for many combustion turbines  and as new as 3 months old in our wind turbines. Like any business, the stakeholders expect cost efficient and reliable electricity supply. Technical people expect to understand the risks, operators and maintainers expect safe and trustworthy equipment.  A need to run leaner and more profitably is a challenge that a strong asset management program can support. This presentation will highlight NSPI's approach to building an asset management program in our power generation fleet. We consciously chose innovative technologies and techniques to get results and avoid the pitfalls when following the process "by the book". Finally participants will discuss what we learned along the way and will discuss how to improve as we move forward in the never ending journey of asset management.

Today, leaders of organizations are stretched to do more with less. They are asked to cover more areas with fewer resources, with less time and smaller budgets. Given these constraints, how can we continue to drive improvement and achieve success? We must focus tactically to drive improvement and eliminate issues that impact our ability to perform. In this session participants will see how focused improvement efforts can provide significant bottom line impacts and be sustained after the project. Learn how chronic and persistent reliability issues can be solved using a targeted Process Performance OptimizationSM (PPO) approach that integrates best practices in change management, lean and asset management. In order to effectively drive PPO, organizations should focus on this four-step approach along with weaving in an appropriate level of change management to sustain the gains.

In 2011, Cameco's Port Hope conversion facility embarked on a journey towards reliability excellence.  In doing so it attempted to adopt many best practices only to find out that not all practices could work right away, or as designed, or even at all.  Lessons learned covering a number of areas such as materials management, work management, and plant performance measurement will be shared and discussed.

The evolution of Preventive Maintenance (PM) is based on analyzing equipment operating conditions, its criticality to production and maintenance cost. In this case study, participants will see the journey starts with setting safe PM schedule and parts stock to sustain production. Then root causes of failures are analysed, and plans for improvement are launched. Learn how plans-in-action should be supported by motivating everyone to the expected achievement. Ahmed will share that implementation is not the end of journey - it is where we need to evaluate whether we landed on the right solution from all aspects. He will also show that sometimes, touch ups are needed. Participants will see the real journey of RajhiSteel, started with a greenfield mini mill 8 years ago. See real examples of doing more than PM in the harsh environment of steel melting Electric Arc Furnace (EAF) and its specific equipment as Water Cooled Cables (WCC).