7. Individuals Who Will Be Involved
Johnnie Ciulla Jr. (President, TRP Services)
•
•
•
•
•
•
•
•
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
“Reliable Equipment Starts With Reliable Attention”
8. 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 timebased 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?
“Reliable Equipment Starts With Reliable Attention”
9. 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.
“Reliable Equipment Starts With Reliable Attention”
10. Vibration Analysis
Identifies defective
bearings and
gears, looseness, rubs
, misalignment, imbal
ance, etc.
Cost of program
startup is offset by
the results!
“Reliable Equipment Starts With Reliable Attention”
11. 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.
“Reliable Equipment Starts With Reliable Attention”
12. 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.
“Reliable Equipment Starts With Reliable Attention”
13. 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.
“Reliable Equipment Starts With Reliable Attention”
14. 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.
“Reliable Equipment Starts With Reliable Attention”
15. NDT – Visual Inspection
Most basic and common
inspection method.
Tools include fiberscope's,
borescopes, magnifying
glasses and mirrors.
Portable video inspection unit
with zoom allows inspection of
large tanks and vessels,
railroad tank cars, sewer lines.
Robotic crawlers permit
observation in hazardous or tight
areas, such as air ducts, reactors,
pipelines.
“Reliable Equipment Starts With Reliable Attention”
16. 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.
“Reliable Equipment Starts With Reliable Attention”
17. 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.
“Reliable Equipment Starts With Reliable Attention”
19. 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.
“Reliable Equipment Starts With Reliable Attention”
20. Equipment Set-Up
Obtaining 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
“Reliable Equipment Starts With Reliable Attention”
21. 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
“Reliable Equipment Starts With Reliable Attention”
22. 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.
“Reliable Equipment Starts With Reliable Attention”
23. 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)
“Reliable Equipment Starts With Reliable Attention”
