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Protectingg youryAssets Return of Investmentand Boosting Performance viaReliability Centered MaintenanceCustomer Pre-Sales Consulting ServicesKittiwake Hellas S.A.January 2011 – R02.00instrumentation & controlenvironmental controlnaval engineeringmarine ip communications

What Maintenance Strategy?On-Sight MaintenanceReactive MaintenanceProactive MaintenanceR li bilit CenteredReliabilityC td MaintenanceM i tPredictive MaintenancePreventive MaintenanceMaintenance Preventioninstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

Why Advance Furtherour Maintenance Strategy? PProtect or even iincrease theh return on iinvestments bby iimprovingiassets performance Increase assets lifetime; non compromising performance Decrease expenses Increase predictability on financial performance Reduce downtime duration and frequency Increase customers and shareholders satisfaction Build company culture and corporate quality IncreaseIcompetitivenesstitiinstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

Gain over Total Cost of Ownership115%OpexCapex% vs CorrectiveMedium to LargeSize VesselTCO % vvs "corrective" maint. strgy110%Capex and OOpex105%100%TCO is the “Total Cost ofOwnership” of the asset.95%i.e. the Capex and the Opexover the asset lifetime90%Reactiveinstrumentation & controlenvironmental controlCorrectivePreventivenaval engineeringPredictivemarine ip communications

Gain over Total Cost of Ownership102%OpexCapex% vs CorrectiveVery Large100%Size Vessel98%TCO % vvs "corrective"" maint. strgy96%Capex and Opex94%92%90%88%TCO is the “Total Cost ofOwnership” of the asset.86%84%i.e. the Capex and the Opexover the asset lifetime82%80%Reactiveinstrumentation & controlenvironmental controlCorrectivePreventivenaval engineeringPredictivemarine ip communications

Reducing maintenance costs Cost is not a stand-alone variable It forms an inseparable part of a trilogyRiskPerformanceCostinstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

Preventive Maintenance PPreventivei MMaintenancei(PM) iis theh ffoundationd i off theh entireimaintenance philosophy. PM keyy success contributors are:PM DataPM Data EquipmentSelectedManagementSponsorshipSuccessfulPM programSufficient Detailsin PMinstrumentation & controlRegulationsgComplianceRegularlygyUpdated PMsenvironmental controlWorkforceMaintenanceSkillsnaval engineeringmarine ip communications

Predictive Maintenance PredictivePdi ti maintenancei tiis ththe monitoringit i off equipmentit operatingti conditionsditito detect any signs of wear that is leading to a failure of a component.The goal of the predictive maintenance program is to track the componentwear with a methodology that insures that any impending failure isdetected at its early stages based on key indicators.Within the equipment operating dynamics, we may find the key indicatorsto use:––––––UltrasonicVibration analysisOil analysisLubricant conditionWear particlesetc.instrumentation & controlenvironmental controlnaval engineeringmarine ip communications

Reliability Centered Maintenance Reliability Centered Maintenance (RCM) is an evolutionary approach toequipment reliability. It focusesfon theth optimizationti i ti off theth preventiveti andd predictivedi timaintenance programs to:– increase equipment efficiencyefficiency, as: Uptime Performance Quality– while, minimizing the related maintenance costsinstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

Reliability Centered Maintenance Any RCM process shallAh ll ensure ththatt allll off ththe seven questionstiare answeredd satisfactorilyti f t iland in the sequence shown below:1.What are the functions and associated desired standards of performance of the asset in its presentoperating context (functions)?2.In what ways can it fail to fulfill its functions (functional failures)?3.What causes each functional failure (failure modes)?44.What happens when each failure occurs (failure effects)?5.In what way does each failure matter (failure consequences)?6.What should be done to predict or prevent each functional failure (proactive tasks and task intervals)?77.What should be done if a suitable proactive task cannot be found (default actions)? To answer each of the previous questions “satisfactorily”, the information shall be gathered, andthe decisions shall be made. All information and decisions shall be documented in a way which makes the information and thedecisions fully available and acceptable to the owner of the assetSource: SAE JA1011 "Evaluation Criteria for Reliability-Centered Maintenance (RCM) Processes referencing Message Specificationinstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

Source: USA GAOO FAA RCM Maintenancce ProcessRCM Decision Logicg Treeinstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

Maintenance StrategiesanddEEarlyl FFailureilDDetectiont tiOn-Condition Maintenance Using P-F Interval or Failure Detection Threshold (FDT)On-condition maintenance relies on the capability to detect failures before they happen so that preventive maintenance can be initiated. Many failuremodes exhibit signs of warning as they are about to occuroccur. IfIf, during an inspectioninspection, maintenance personnel can find evidence that the equipment isapproaching the end of its life, then it may be possible to delay the failure, prevent it from happening or replace the equipment at the earliest conveniencerather then allowing the failure to occur and possibly cause severe consequences.P-F curves and P-F IntervalsA common curve that illustrates the behavior of equipment as it approaches failure is the P-F curve. The curve shows that as a failure starts manifesting,th equipmenttheitddeterioratest i t tto ththe pointi t att whichhi h it can possiblyibl bbe ddetectedt t d (P)(P). If ththe ffailureiliis nott ddetectedt t d andd mitigated,iti t d it continuestiuntiltil a "h"hard"d" ffailureiloccurs (F). The time range between P and F, commonly called the P-F interval, is the window of opportunity during which an inspection can possibly detectthe imminent failure and address it. P-F intervals can be measured in any unit associated with the exposure to the stress (running time, cycles, miles, etc).For example, if the P-F Interval is 200 days and the item will fail at 1000 days, the approaching failure begins to be detectable at 800 days.Equipment CondiitionFailure initiatedUltrasonic detectionVibrationVibti ddetectiont tiOil Analysis DetectedAudible NoiseHot to TouchMechanically LooseAncillary DamagePREDICTIVEPREVENTIVERUN TO FAILURECatastrophic FailureTimeinstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

Oil Qualityy Analysisyan Early Warning to Equipment Failure Oil analysisl i fifindingsdiare an earlyl warningi tto equipmentit ffailure,ilandd ffurthermorethprofilefil ththe wearroot causes. To this direction oil analysis should cover the following dimensions:–Solid particle counts –Viscosity –Associated with the remaining useful life of the lubricantFerrous and Non-Ferrous metal level indication –Preferably maintained below the saturation point to avoid additive damage and system corrosionTotal Acid Number (TAN) or in the case of diesel engines, Total Base Number (TBN) –Associated with determining either fluid dilution, incorrect lubricant or as an indicator of the lubricant’s remaining usefullifeMoisture –associated with the root cause of system wear and additive depletionAssociated with the amount of wear metals in the lubricantTemperature Associated with lubricant damage, or incorrect system specification such as alignment problemsinstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

OOn-LineMoonitoringOil Quality Monitoring StrategySample aandOn-SitteAnalysisLinerSCANLinerSCANSample andnd-to-LabSenANALEXAlertANALEXAlertReactive - Correctiveinstrumentation & controlPreventiveenvironmental controlPredictivenaval engineeringmarine ip communications

Next Generation Monitoring Today On-Line Sensors– Data Aggregation– HMI displays and SCADA monitors On-ShipOn-Shore Visibility and Alarm Escalation– On-ship controllers and data aggregation on central operations system (computer)On-Ship Visual Monitoring– What is measured whereCommunication and synchronization with corporate H/QIntegration to the Enterprise Asset Management System–Integration to corporate EAM;based on Asset Management PASS 55 standard (BSI PASS 55:2008)instrumentation & controlenvironmental controlnaval engineeringmarine ip communications

The CompletepPictureOn-ShoreShipping Co.HeadquartersVessel #1VesselCommunicationsGatewayFleet MgrandSuperintendentsVessel rsinstrumentation & controlMCMSSystemenvironmental controlSensorsnaval engineeringmarine ip communications

Kittiwake Hellas yyour end-to-end ppartnerin advancing your PM programme maturity level AAssisti you ini Oil anddLLubricantsbiLLabb analysisl i withi h root causediagnosis Provide yyou with all equipmentq pand trainingg requiredqto insure highgquality Water, Oil, and Lubricants in-depth analysis on-board Upgrade your engines with on-line sensors, for continuousmonitoring of WaterWater, OilOil, and Lubricants Enhance your monitoring quality with supervisory computer-basedvisual workstations on-ship Connect corporate H/Q with IP Satellite communications, enablingintegration to corporate ERP system, Enterprise AssetManagement subsysteminstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

The Kittiwake Sensors Suiteinstrumentation & controlenvironmental controlnaval engineeringmarine ip communications

Kittiwake SensorsLinerSCAN(3/8” BSP)The world’sworld s first real-time alarm system for engine liner wearwear.LinerSCAN marks a new era in asset protection, providingearly warning against critical damage whilst providingOilsightinformation needed to save on lube oil costscosts.glassOil inOil outLinerSCAN measures the amount of iron in cylinder lubricant by amethod known as magnetometry, where a sample is tested in amagnetic field. Utilising a novel shielding method the system exploitsa fundamental physical effect namely the change inductance due tothe presence of a magnetic material.Analyzing the scavenging air space drain oil from each cylinder for iron (Fe) hasbeen proven to give operators an indication of relative changes of cylinder linerwear. At very early stages, the sensors reported the onset of severe wear andother enginegpproblems such as cat fines in the fuel.The system will also highlight periods where the engine is subjected to increased Levelstress levels and indicate changes in iron levels caused by imbedding processes Sensorand increases in wear caused by routine inspection.instrumentation & controlenvironmental controlnaval engineeringAir input(1/2” BSP10Bar max)FerrousMaterialSensormarine ip communications