Predictive maintenance as a means to increase the availability of positive displacement pumps at Ekurhuleni Base Metals

COPYRIGHT AND CITATION CONSIDERATIONS FOR THIS THESIS/ DISSERTATION o Attribution — You must give appropriate credit, provide a link to the license, and indicate if changes were made You may so in any reasonable manner, but not in any way that suggests the licensor endorses you or your use o NonCommercial — You may not use the material for commercial purposes o ShareAlike — If you remix, transform, or build upon the material, you must distribute your contributions under the same license as the original How to cite this thesis Surname, Initial(s) (2012) Title of the thesis or dissertation PhD (Chemistry)/ M.Sc (Physics)/ M.A (Philosophy)/M.Com (Finance) etc [Unpublished]: University of Johannesburg Retrieved from: I R O (Accessed: Date) ›Predictive maintenance as a means to increase the availability of positive displacement pumps at Ekurhuleni Base Metals A minor dissertation submitted in partial fulfilment of the requirements for the degree in MAGISTER OF PHILOSOPHIAE in ENGINEERING MANAGEMENT at the FACULTY OF ENGINEERING AND THE BUILT ENVIRONMENT of the UNIVERSITY of JOHANNESBURG MOTLALEPULA LAWRENCE KAU NOVEMBER 2016 SUPERVISOR: DR ARIE WESSELS CO-SUPERVISOR: PROF JAN-HARM PRETORIUS DECLARATION I, Motlalepula Lawrence Kau declare that this research is my own work, and it has never been submitted to any university worldwide for examination purposes This research is submitted to the University of Johannesburg in Gauteng, South Africa, for the Master’s degree in Engineering Management Signed ……………………………… Date …………………………… ii ACKNOWLEDGEMENTS I extend special thanks to my two study leaders, Dr Arie Wessels and Prof Jan-Harm Pretorius, for their advice and support during my research I would also like to thank Dr Michael Moolman, General Manager of Ekurhuleni Base Metals, and his team; my colleague Dr Surajit Bag, and Mr William Chabant, sales manager at Flowrox, for their support and guidance during my research I extend gratitude also to my grandparents in heaven, Richard and Lydia Kau, for encouraging me to further my studies My family, especially my daughter Reitumetse Kau has always encouraged and supported me throughout my master’s degree programme iii ABSTRACT Condition monitoring is a maintenance technique used to monitor parameters like vibration, overheating, overcurrent of the system or machinery at an early stage of failure; to forecast on the need for maintenance before a catastrophic failure; or to estimate system conditions It can be achieved through visual inspection or the use of a sophisticated intelligent diagnosis system Predictive maintenance helps the organisation to predict failure before a catastrophic failure It is a technique to help the user plan the job that needs to be done on the equipment to prevent an unexpected failure This technique is central to our research question This study investigated whether predictive maintenance is the best maintenance strategy to minimise maintenance costs In predictive maintenance, decisions are made based on the data collected through condition monitoring Condition monitoring has three steps: data acquisition, data processing and maintenance decision-making Condition monitoring helps to prevent equipment failure It also helps to avoid unplanned breakdowns and to optimise maintenance resources by planning maintenance or shutdown as required based on the data collected Peristaltic pumps, such as LPPT 65 (DN65), are commonly used for pumping slurry Ekurhuleni Base Metals uses it to pump slurry Due to several failures, the pumps are not operating at their peak efficiency point Before the implementation of predictive maintenance, the pumps did not receive regular maintenance In the past, the organisation did reactive maintenance, and maintenance costs were escalating Root Cause Failure Analysis (RCFA) helps to understand the root cause of equipment failure, and is commonly used to reduce costs, mean time to failure (MTTF) and mean down time (MDT) If implemented successfully, the organisation benefits significantly in terms of cost savings and/or total elimination of failure Organisations benefit considerably from implementing Reliability Centred Maintenance (RCM) It aims to identify routine maintenance that preserves the system in such a way that costs are acceptable If preventive maintenance costs are higher than those of operational losses and repair, maintenance will not be beneficial, unless it relates to regulatory, safety or environmental requirements iv Total Productive Maintenance (TPM) is a known method to improve and enhance an organisation’s productivity The main objective of TPM is to improve Original Equipment Effectiveness (OEE) v TABLE OF CONTENTS DECLARATION ii ACKNOWLEDGEMENTS iii ABSTRACT iv LIST OF FIGURES ix LIST OT TABLES xi ACRONYMS xii CHAPTER INTRODUCTION 1.1 Dissertation Outline 1.2 Background of Ekurhuleni Base Metals 1.2.1 Plant decommissioning and dismantling of plant equipment 1.2.2 Reprocessing of old Zincor residue 1.2.3 Treatment of contaminated water 1.2.4 Reclamation of gold tailings 1.2.5 Removal of miscellaneous waste and clean up of surrounding areas 1.3 Environmental Impact 1.4 Applicable Legislation 1.5 Problem Statement 1.5.1 Breakdown of failures 1.5.2 Current maintenance strategy at EBM 1.6 Research Objectives 1.7 Research Questions 1.8 Research Methods 1.9 Chapter Summary CHAPTER LITERATURE REVIEW 2.1 Introduction 2.2 Peristaltic Pumps 11 2.2.1 Basic operation of peristaltic pump 11 2.2.2 Types of peristaltic pumps 11 2.2.3 Factors that influence pump availability 16 2.2.4 Bathtub curve 16 2.2.5 Maintenance strategies 17 2.2.6 RCM and FMECA 18 2.2.7 Predictive maintenance 20 2.2.8 Preventive maintenance 21 2.2.9 Root Cause Failure Analysis 22 2.2.10Fault tree analysis 22 2.2.11FRACAS 23 2.2.12Total productive maintenance 25 2.2.13Condition monitoring techniques 28 2.2.14Vibration analysis 28 vi C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an 2.2.15Oil analysis 29 2.2.16Noise analysis 29 2.2.17Visual inspection 30 2.2.18Temperature monitoring 30 2.3 Conclusion 31 CHAPTER RESEARCH METHOD 32 3.1 Introduction 32 3.2 Research Method 32 3.3 Survey 32 3.4 Questionnaire design 32 3.5 Documentary Sources 33 3.6 Justification of Research Method 33 3.7 Study Matrix 34 3.8 Data Collection 35 3.9 Data Analysis and Data Interpretation 35 3.10 Conclusion 35 CHAPTER RESULTS AND FINDINGS OF THE RESEARCH INTERVIEWS AND FIELD DATA 36 4.1 Introduction 36 4.2 Response to Questionnaires 36 4.3 Discussion and Graphs 36 4.3.1 Maintenance personnel 36 4.3.2 Maintenance superintendent 45 4.3.3 Procurement manager 46 4.3.4 Control room operators 46 4.3.5 Production manager 47 4.3.6 Sales manager from Flowrox 48 4.4 Field Data and Results 49 4.5 Classification of Failures 49 4.6 Total Downtime and Maintenance 50 4.7 Total Downtime Failures 50 4.8 Predictive Maintenance Implementation 51 4.8.1 Methods used in electric motor condition monitoring 51 4.9 Stator Current Analysis 53 4.9.1 Stator 54 4.9.2 Bearing 55 4.9.3 Rotor 56 4.10 Results of Predictive Maintenance 56 4.11 Conclusion 58 CHAPTER RESEARCH DISCUSSION RESULTS 59 5.1 Introduction 59 5.2 Research Question No 1: Will predictive maintenance increase the availability of positive displacement pumps? 59 5.3 Research Question No 2: What are the parameters that must be controlled and monitored in predictive maintenance? 61 Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn vii C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an 5.3.1 Pump installation 64 5.3 Benefits of Predictive Maintenance 65 5.4 Conclusion 66 CHAPTER CONCLUSION 67 6.1 Conclusion to the Research questions 67 6.1.1 Does predictive maintenance increase the availability of positive displacement pumps? ………………………………………………………………………………….67 6.1.2 What are the parameters that must be controlled and monitored in predictive maintenance? 67 6.2 Conclusion and Research Objectives 67 6.3 Recommendations 68 6.4 Future Research 69 REFERENCES 70 APPENDIX 1: QUESTIONNAIRES………………………………………………………76 APPENDIX 2: MAINTENANCE AND DOWNTIME BEFORE PREDICTIVE MAINTENANCE APPLIED 95 APPENDIX 3: PUMP FAILURE RATES 97 Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn viii C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an LIST OF FIGURES Figure 1: 11kW Peristaltic Pump on Site, LPPT 65 (DN65) Figure 2: Pump Performance as per OEM Figure 3: The Structure of Pump LCC Figure 4: Schematic of Peristaltic Pump Flow Figure 5: Main Components of LPP65T (DN65) Figure 6: Types of drive units for positive displacement pump Figure 7: Pump Performance Curve Figure 8: Bathtub Curve Figure 9: Overview of different maintenance types Figure 10: Components of RCM Figure 11: Different approaches of condition monitoring Figure 12: Fishbone Diagram Figure13: Fault Tree Analysis Figure 14: Closed Loop Corrective Action Process Figure 15: Typical FRACAS Process Figure 16: Eight-Pillar Approach to TPM Figure 17: The OEE formulation and the six losses Figure 18: Computerised Maintenance Management System Figure 19: Condition Monitoring System Design Figure 20: Slurry Pump Vibration Analysis Figure 21: Statistics Related to Motor Failure Figure 22: Time plot of a stator current measurement Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn ix C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an How keep record of your spares? File External Server Do you have budget for spares Yes No Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 87 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an Questionnaire sent to EBM Control Room Operator Dear Respondent, I am currently a student at University of Johannesburg studying towards a Master’s Degree in Engineering Management You are kindly requested to take part in a survey questionnaire in order to improve the availability and reliability of displacement pumps on site This study is also aimed at reducing downtime, maintenance costs and maximising plant availability You are assured that information you provide will be treated confidentially and only be used for academic purpose only The survey questionnaire will take +/- 15 minutes of your time Any queries can be directed to my supervisor: Dr ArieWessels Email:ariewessels@gmail.com Tel: 011 70402520 Thank you for your contribution towards this research questionnaire Kind Regards, Lawrence Kau Email: Lawrence.kau@webmail.co.za Candidate: Master’s in Engineering Management Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 88 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an What kinds of breakdowns are experiencing from LPP65 Larox pump? Electrical Mechanical How you notify the artisans about the breakdown during the day and after hours? Breakdown/Maintenance request booklet Telephone Radio How you record the breakdown during your shift? Record book Shift report book No recording Do artisans any maintenance on Larox pumps? Yes No No idea Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 89 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an Questionnaire sent to EBM Production Manager Dear Respondent, I am currently a student at University of Johannesburg studying towards a Master’s Degree in Engineering Management You are kindly requested to take part in a survey questionnaire in order to improve the availability and reliability of displacement pumps on site This study is also aimed at reducing downtime, maintenance costs and maximising plant availability You are assured that information you provide will be treated confidentially and only be used for academic purpose only The survey questionnaire will take +/- 15 minutes of your time Any queries can be directed to my supervisor: Dr ArieWessels Email:ariewessels@gmail.com Tel: 011 70402520 Thank you for your contribution towards this research questionnaire Kind Regards, Lawrence Kau Email: Lawrence.kau@webmail.co.za Candidate: Master’s in Engineering Management Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 90 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an Do you always meet your monthly targets? Yes No How shift you have per day? One Two Three How often is maintenance done on Larox pumps? Weekly Monthly Quarterly None How you communicate with the Maintenance Superintendent where there are breakdowns in the plant? Telephone Radio Meetings Maintenance/Breakdown request booklet Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 91 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an Questionnaire sent to EBM Sales Manager FromFlowrox Dear Respondent, I am currently a student at University of Johannesburg studying towards a Master’s Degree in Engineering Management You are kindly requested to take part in asurvey questionnaires in order to improve the availability and reliability of displacement pumps on site This study is also aimed at reducing downtime, maintenance costs and maximising plant availability You are assured that information you provide will be treated confidentially and only be used for academic purpose only The survey questionnaire will take +/- 15 minutes of your time Any queries can be directed to my supervisor: Dr ArieWessels Email:ariewessels@gmail.com Tel: 011 70402520 Thank you for your contribution towards this research questionnaire Kind Regards, Lawrence Kau Email: Lawrence.kau@webmail.co.za Candidate: Master’s in Engineering Management Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 92 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an Where you get spares? Locally Internationally How you update your stock level? External Server Filing How you deliver spares to customers to customers after hours? Standby personnel No deliveries after hours How long you take to deliver spares to customers? 30 minutes 45 minutes One hour What is maximum flow rate of the pump you supplies to EBM? 20m3/h 40m3/h Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 93 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an What is the model of the pump you have supplied to EBM? LPP25 LPP65 What is the lifespan of the pump you have supplied to EBM? 5-10 years 10-20 years 20-30 years How you customer satisfaction of your customers? Regular visits every week Regular visits every month By customer complaints What is minimum qualification of your Sales Person/Engineer? ND Engineering: Mechanical / Electrical BSc Engineering: Mechanical/Electrical Matric (Grade 12) with Mathematics and Physical Science Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 94 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an APPENDIX 2: MAINTENANCE AND DOWNTIME BEFORE PREDICTIVE MAINTENANCE APPLIED Costs of repairs and downtime Failure Cost of Classification failure in Downtime Year1 Year Year rands A R41.2K 9.5 B R30.0K 4.5 2 C R15.6K 2 Calculation of downtime A>Time for diagnostic + logistic spare part +net repair +commissioning = (2+3+1+3.5) =9.5 B>Time for diagnostic + installation of spare + commissioning = (0.5+1.5+2.5) = 4.5 C> Dismantling + rework on piping + installation of spare = (2+4+2) =8 Total Downtime Costs due to Failures For example, total costs for year are calculated as follows: Costs of failure A + Costs of failure B + Costs of failure C = (41.2X 3) + (30.0 X 2) + (15.6 X 1) = 123.6 + 6.0 + 15.6 Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 95 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an = R145.2K Downtime Costs in Rand Downtime in Hours Classification Year Year Year Year Year Year A R123.6K R206.2K R247.4K 28,5 47,5 57 B R60.0K R30.0K 60.0K 4,5 C R15.6 R31.3K 31.3K 16 16 Total R145.2K R267.5K R338.8K 45,5 68 82 Failure Total downtime due to failures For example total downtime for year is calculated as follows: Costs of failure A + Costs of failure B + Costs of failure C = (9.5 X 3) + (4.5 X 2) + (8 X 1) = 28.5 + + = 45 Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 96 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an APPENDIX 3: PUMP FAILURE RATES Frequency of Pump Failures Pump Location Year Year Year Pump Purification Plant Pump Residue 3 Treatment Plant Calculation of Failure Rate Failure rate per year = 1/ frequency of pump failure, e.g Year = 1/3 is equal to 0.33 Pump Year Year Year Pump 0.33 0.2 0.16 Pump 0.33 0.33 0.25 Failure Rate of Each Pump Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 97 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an Frequency of Pump Failures Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 98 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 99 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn 100 C.33.44.55.54.78.65.5.43.22.2.4 22.Tai lieu Luan 66.55.77.99 van Luan an.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.C.33.44.55.54.78.655.43.22.2.4.55.22 Do an.Tai lieu Luan van Luan an Do an.Tai lieu Luan van Luan an Do an Stt.010.Mssv.BKD002ac.email.ninhd 77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77.77.99.44.45.67.22.55.77.C.37.99.44.45.67.22.55.77t@edu.gmail.com.vn.bkc19134.hmu.edu.vn.Stt.010.Mssv.BKD002ac.email.ninhddtt@edu.gmail.com.vn.bkc19134.hmu.edu.vn