TRP Presentation

“Reliable Equipment Starts With Reliable Attention”

Total Reliability Professionals Technologies

DivisionProposal for Predictive Maint.

Industries ServicedPulp & Paper Aluminum Food Plastics Pharmaceuticals Waste Water & Treatment Power & Energy Mining Steel


Customer List TBD TBD


Services Provided Vibration Analysis (Our Core Competency)

Thermography Mechanical Electrical

Ultrasonic Leak Detection Air & Gas Leaks Steam Trap Testing


Services Provided (cont.)

Lubrication Services Program Setup Auditing Oil Analysis


Future Endeavors

Maintenance Program Audits TBD


Individuals Who Will Be Involved

John Ciulla, Sr. Reliability Engineer• Level III ASNT vibration analysis• Level I in thermography• Level I in ultrasound• Background in Total Reliability Practices• Masters Degree in Mechanical Engineering• Six Sigma Green & Black Belt• 10 years experience in reliability field• Vibration Analysis Committee member of ASNT


Maintenance Strategies Run-to-Failure: (A maintenance policy that allows a machine to run until it breaks down, at

which point reactive maintenance may be performed). Preventive Maintenance (PM) (Care and servicing by personnel for the purpose of

maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects).

Predictive Maintenance: (PdM) (Techniques help determine the condition of in-service equipment in order to predict when maintenance should be performed. This approach offers cost savings over routine or time-based preventive maintenance, because tasks are performed only when warranted. The main value of Predicted Maintenance is to allow convenient scheduling of corrective maintenance, and to prevent unexpected equipment failures).

Reliability-based /centered Maintenance: (RCM) (Reliability centered maintenance is an engineering framework that enables the definition of a complete maintenance regime. It regards maintenance as the means to maintain the functions a user may require of machinery in a defined operating context. Successful implementation of RCM will lead to increase in cost effectiveness, machine uptime, and a greater understanding of the level of risk that the organization is managing).

Total Productive Maintenance: (TPM) (TPM is a management process developed for improving productivity by making processes more reliable and less wasteful.TPM is an extension of TQM(Total Quality Management). The objective of TPM is to maintain the plant or equipment in good condition without interfering with the daily process. To achieve this objective, preventive and predictive maintenance is required. By following the philosophy of TPM we can minimize the unexpected failure of the equipment).


Which strategy are you currently employing?

http://en.wikipedia.org/wiki/Preventive_maintenance

PdM vs. No PdM


Programs with PdM programs generally have maintenance costs that run below their budgets.

Programs without PdM programs generally have maintenance costs that contain peaks and valleys. The peaks can exceed budget constraints when catastrophic failures occur.

Vibration Analysis Identifies defective

bearings and gears, looseness, rubs, misalignment, imbalance, etc.

Cost of program startup is offset by the results!


Case History


• This bearing is on a large washer roll at a pulp mill

• Inner race frequencies were detected (top spectrum)

• The bearing was reported and the maintenance department replaced it during a short outage

• A new baseline was acquired after the bearing was replaced (bottom spectrum)

• If this bearing were to fail online, total production dollars lost would be estimated at $25,000-$40,000.

Thermography


• Thermography provides the quickest return on investment of all the predictive technologies.

• Can be used for electrical and mechanical inspections.• Useful for roof and insulation leaks.

Case History


• The fuse from this disconnect was approaching 400 degrees.• The case was reported but the fuse had blown before maintenance

could schedule repairs.• Image of the fuse after it had blown is shown on the right.

Ultrasound Leak Detection


Air and gas leak detection Leaks occur at high frequencies that can be detected in

the ultrasonic range.

Generated reports will include approximate savings upon repair.

Steam trap inspection

Ultrasound can be used to detect steam traps that are stuck open or closed.

Generated reports will include approximate savings upon repair.

NDT – Visual Inspection


Most basic and common inspection method.

Tools include fiberscope's, borescopes, magnifying glasses and mirrors.

Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines.

Portable video inspection unit with zoom allows inspection of

large tanks and vessels, railroad tank cars, sewer lines.

NDT – Penetrant


• A liquid with high surface wetting characteristics is applied to the surface of the part and allowed time to seep into surface breaking defects.

• The excess liquid is removed from the surface of the part. • A developer (powder) is applied to pull the trapped

penetrant out of the defect and spread it on the surface where it can be seen.

• Visual inspection is the final step in the process. The penetrant used is often loaded with a fluorescent dye and the inspection is done under UV light to increase test sensitivity.

NDT – Magnetic Particle


The part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen. These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over the discontinuity. This indication can be visually detected under proper lighting conditions.

Magnetic Particle Case Histories


Power Loss Due to Angular

Misalignment


For example, a 500 HP ID Fan that is operating 24/7 (or 8760 hours) at a misaligned condition of 10 mils at a cost of $0.11 per kilowatt would have an effective power loss of $3,595.00 per year

500HP x 7.19 = 3,595

Aligning the shaft to 0.50 mils would result in a power loss of $180.00 per year. This results in a savings of $3,415.00 per year.


Equipment Set-UpObtaining information from machine components is critical in the accurate diagnosis of a machine. Important information includes:• Speed• Bearing numbers• Number of vanes/blades• Gear tooth counts• Machine configuration• Load• Sheave sizes• Belt lengths

Reporting


Standard report includes machine sketch or image with all necessary information included:• Survey Date• Machine ID• Machine Area• Severity Code• Findings• Recommendations

Reports can be altered to meet our customer’s needs

Reporting – Asset Health


All reports include an asset health spreadsheet that contains information on every asset that is analyzed in the plant. It includes:• Color codes based on severity• Percentage of assets in alarm• Machine ID’s and area• Machines that were not in operation during

the survey• Overall plant vibration (in the case of a

vibration survey)

Reports can be altered to meet our customers’ needs

Emergency Reporting


• Many times a report is needed immediately after a machine has been analyzed.

• TRP Reliability Engineers carry field service reports for these occasions.

• They provide the maintenance department with a report for those crucial meetings where timely decisions need to be made.

KPI’s for Measuring Success


Cost savings analysis Emergency repairs as % of scheduled

repairs Planned and scheduled work completion Maintenance overtime as % of overall

time PM hours completed on time as % of

scheduled PM hours (Refer back to benchmark data)

Cost Savings Analysis



Questions?

Upfront Costs & Reliability Engineer Rate

IPAD Vibration Analysis software and hardware: $5,000

Flir Thermography Gun: $1,500

Laptop: $1,000

Total Investment: $7,500.00

Reliability Engineer Rate: $135hr plus Travel expenses.

60/40% split: 138hrs billable / 3.5 weeks to recoup total investment cost of $7,500.

Business

TRP Presentation