14209 29th Street East, Ste 105 - Sumner, WA 98390
Tel: (253) 942-9000 - FAX (253) 942-9009
Email Address: ops@impactengineering.com
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Total Reliability Management (TRM) - The Bottom Line Estimated annual cost saving for an A.B.S. certified steam plant taking part in a Total Reliability Management program: |
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| Part I | Condition Monitoring - Deferred Maintenance | ||||||||||
| Total Number of Machines in Program | 75 | ||||||||||
| Deferred Maintenance (15% per year) | 11 | ||||||||||
| Assume 20% Mandatory Inspection Required without Condition Monitoring | |||||||||||
| Average Cost to Disassemble/Inspect/Re-Assemble | $ 4,000 | ||||||||||
| Annual Savings | $ 44,000 | ||||||||||
| Part II | Failure Prevention - Catastrophic | ||||||||||
| Standard Failures per Year (without TRM Program) | 5 | ||||||||||
| Average Cost per Failure | $ 8,000 | ||||||||||
| Failures Prevented with TRM Program | 4 | ||||||||||
| Annual Savings | $ 32,000 | ||||||||||
| Assumes Preventive Maintenance Program already in place | |||||||||||
| Part III | Schedule Reliability - Uptime | ||||||||||
| Daily Operational costs (enter real costs) | $ 50,000 | ||||||||||
| Additional days gained per year by successful | 1 | ||||||||||
| TRM implementation (Annual basis) | |||||||||||
| Annual Savings | $ 50,000 | ||||||||||
| Part IV | Estimated Total Annual Savings Total Annual Savings | $ 126,000 | |||||||||
| Typical Costs Associated with Inspections/Rebuild: | |||||||||||
| Mn. Coffin Feed Pump: new bearings, rings - same rotor | $ 20,000 | ||||||||||
| Mn. Circulator: new impeller, rings, bearings. | $ 12,000 | ||||||||||
| Mn. Condensate Pump: new impeller, rings, bearings | $ 7,500 | ||||||||||
| F.O. Service Pump: New Bearings Only | $ 3,500 | ||||||||||
| Turbogenerator: Inspect, Lift Cover, no major work | $ 12,000 | ||||||||||
| Mn. Turbine (HP or LP): Inspect, lift cover, no major work | $ 40,000 | ||||||||||
| Typical S.W. Cooling Service Pump: Open, inspect, new impeller, rings, bearings | $ 10,000 | ||||||||||
| Note: New construction surveys have proven to be extremely valuable due to detection of problems that | |||||||||||
| can be identified and corrected prior to resulting wear / damage. This work can and should be billed to the | |||||||||||
| initial guarantee budgets and ultimately cost the customer no maintenance dollars and actually create an | |||||||||||
| immediate return from this Predictive Maintenance effort. | |||||||||||
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14209 29th Street East, Ste 105 - Sumner, WA 98390 Tel: (253) 942-9000 - FAX (253) 942-9009 Email Address: ops@impactengineering.com |