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Reduce Steam Trap Failures at Chambers Works GB/BB Name: Cyndi Kouba Mentor/MBB : Andrew Degraff. Team Members - PowerPoint PPT Presentation
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Reduce Steam Trap Failures at Chambers Works
GB/BB Name: Cyndi KoubaMentor/MBB: Andrew Degraff
Team Members
Michael Crowley(Site Energy Lead), (Charlie) Flanigan (Aramids-maintenance), Ben Snyder (Aramids-ATO),
Michael Scruggs (Central Maintenance Mechanic), Rick Ragsdale (Fluor), Joyce Finkle (PC), Denis P
Humphreys (Fluoroproducts), Jack Hemmert, Charlie Brown
04/20/23
2
Steam trap failures are nothing new
Steam trap programs are nothing new
WHAT makes this program
have such a huge impact and
How is it sustainable
HOW we went about finding a solution
What do you have learn from this
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3
Six Sigma Methodology was KEY to success
Savings: $1MM annualized in only 6 months!
04/20/23
4Define: Project CTQ’s
Customer: Chambers Works site
Voice Of Customer (VOC) data:
• Wasting energy
• High variable cost due to steam losses.
• Use full service maintenance contractor for this work
• Need sustainable process
• Take into account other work streams
• Safety
Create a sustainable steam trap program
that reduces steam loss and lowers failure rate.
04/20/23
5Define: Project Charter
Problem Statement:
• 2007 Survey showed 14% Failure Rate.
Project Goal:
• Reduce steam trap failures from 14% to 4.2%
• Steam loss (lbs/hr) from 15203lb/hr to less than 3000 lb/hr
Expected Benefit:
• Net variable cost savings of $450,000 (based on achieving goal)
Process Owner: Chambers Works Maintenance Unit Manager
Process Sponsor: Chambers Works Site Manager
Actual savings ~$1MM annualized in only 6 months!
04/20/23
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Analyze • Mapped existing process
• Generated process X’s
• What is needed for a successful program
• Gained alignment
• Issues
• Potential Solutions
Energy Team Decides to do
Survey
Does Management
fund?
Contact Sarco to Schedule
Contact Sarco for quote
Sarco Surveys entire site
Report sent to Site Energy Lead from
Sarco
Energy Team Reviews Results
Individual areas take list back
Fix Traps?Work Order writtenWork Order placed in Que with other
WO’s
WO order Completed
Trap Fixed
Analyze
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Low Medium High
Controllable
Installed incorrectly
Wrong trap for the application
Steam Leaks are identified and reported
Steam Leaks associated with trap line identified and fixed
Ultrasonic equipment used
Insulation removed and reinstalled
Setting routes for survey
*Traps being labelled
Operational definitions well defined
Survey Database used
*Good Trap Location Detail
Metrics Reporting System
System for Tracking traps fixed
Partially ControllableTurnover in repair team
Access to the Trap for repair
Resources to Fix traps
Training of surveyor/Turnover
High Failure rate Identification
System for Fixing traps
Lockout procedures
Uncontrollable Paying for the system
Analyze: Impact Control Matrix
Focus efforts on key items for success
04/20/23
10Improve: Proposed Solution Summary
• Have a steam trap team
• Surveyor
• Repair mechanics
• Work Order to do survey created automatically within SAP
• Survey performed and work orders created
• Surveyor/Team Leader coordinates repair work
• Use backlog of work to justify number of mechanics
• Prioritize work for mechanics
• Repair Mechanics work across the site
• SAP Work Order history updated for individual traps
• Surveyor updates excel spreadsheet with repair history
• Monthly reports sent to area and site management
04/20/23
11Piloted Solution Key Learnings
• SAP Cumbersome and slows repair process
• Use SAP to generate survey timing
• Fundamental issues with SAP that cannot be addressed with this project
• Use excel to track repairs and do repairs
• Crew charges to same functional locations WO that surveyor uses
• Some areas need dedicated trap work
• One crew member dedicated to a critical area
• All members can work across site for trap repairs and other significant work
04/20/23
12Sustained Solution
Microsoft PowerPoint Presentation
ReportsSurvey Log Sheet
Microsoft Excel Worksheet
04/20/23
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Sustained Solution: Control Plan• Control Plan is KEY to sustainability of work
• Control Plan identifies who, what and when for critical steps
Department/ Individual
What must be controll
ed?
Y,X,or other?
Require-ments (specs)
Ongoing Control
Mechanisms
Measurement Plan Response Plan
Technique
Frequency
Who Measur
es?Action
Timing
Owner
Steam Trap Team Leader/Surveyor
Steam Traps Failure
Y 3-5%
Survey and repair failed traps, flag repeat failures
Ultrasonic Inspection
At least 2 times per year
Steam Trap Surveyor
Submit reports to area management, energy team, and reliability engineers for each area
every month
Steam Trap Team Leader
Control Plan
• Process Owner agrees to control plan
• Control Plan is evergreen
04/20/23
14Key Learnings to Share
• Multi-functional team to brainstrom X’s
• No one person understands all the issues and problems
• Communications raise awareness and highlight savings
• Management needs justification to continue funding efforts
• Dedicated crew needed to survey and make repairs happen
• Doing repairs is more effective when it is a full time job versus 25% of a job
• Support from key leadership is critical
• When industry standard is met, work is not over
• Will have continued failures that must be found and repaired routinely
• If site team is not fully utilized, leverage them with smaller sites nearby
• Leveraging is not straight forward
• Each site needs to examine why steam trap repairs are a problem
• Other site had different X’s – eliminate welding to reduce manpower required to repair
04/20/23
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