“Reliable Equipment Starts With
Reliable Attention”
Total Reliability Professionals
Technologies Division
Proposal for Pre...
Industries Serviced
Pulp & Paper
 Aluminum
 Food
 Plastics
 Pharmaceuticals
 Waste Water & Treatment
 Power & Energy...
Customer List
 TBD  TBD
“Reliable Equipment Starts With Reliable Attention”
Services Provided
 Vibration Analysis (Our Core Competency)
 Thermography
 Mechanical
 Electrical
 Ultrasonic Leak De...
Services Provided (cont.)
 Lubrication Services
 Program Setup
 Auditing
 Oil Analysis
“Reliable Equipment Starts With...
Future Endeavors
 Maintenance Program Audits
 TBD
“Reliable Equipment Starts With Reliable Attention”
Individuals Who Will Be Involved
 John Ciulla, Sr. Reliability Engineer
• Level III ASNT vibration analysis
• Level I in ...
Maintenance Strategies
 Run-to-Failure:  (A maintenance policy that allows a machine to run until it breaks down, at whi...
PdM vs. No PdM
“Reliable Equipment Starts With Reliable Attention”
Programs with PdM programs generally
have maintenance c...
Vibration Analysis
 Identifies defective
bearings and
gears, looseness, rubs
, misalignment, imbal
ance, etc.
 Cost of p...
Case History
“Reliable Equipment Starts With Reliable Attention”
• This bearing is on a large
washer roll at a pulp mill
•...
Thermography
“Reliable Equipment Starts With Reliable Attention”
• Thermography provides the quickest return on investment...
Case History
“Reliable Equipment Starts With Reliable Attention”
• The fuse from this disconnect was approaching 400 degre...
Ultrasound Leak Detection
“Reliable Equipment Starts With Reliable Attention”
 Air and gas leak detection
 Leaks occur a...
NDT – Visual Inspection
“Reliable Equipment Starts With Reliable Attention”
Most basic and common
inspection method.
Tools...
NDT – Penetrant
“Reliable Equipment Starts With Reliable Attention”
• A liquid with high surface wetting characteristics i...
NDT – Magnetic Particle
“Reliable Equipment Starts With Reliable Attention”
The part is magnetized. Finely milled iron par...
Magnetic Particle Case Histories
“Reliable Equipment Starts With Reliable Attention”
Power Loss Due to
Angular Misalignment
“Reliable Equipment Starts With Reliable Attention”
For example, a 500 HP ID Fan
th...
“Reliable Equipment Starts With Reliable Attention”
Equipment Set-Up
Obtaining information from machine components
is crit...
Reporting
“Reliable Equipment Starts With Reliable Attention”
Standard report includes machine sketch or image with
all ne...
Reporting – Asset Health
“Reliable Equipment Starts With Reliable Attention”
All reports include an asset health spreadshe...
Emergency Reporting
“Reliable Equipment Starts With Reliable Attention”
• Many times a report is needed immediately after ...
KPI’s for Measuring Success
“Reliable Equipment Starts With Reliable Attention”
 Cost savings analysis
 Emergency repair...
Cost Savings Analysis
“Reliable Equipment Starts With Reliable Attention”
“Reliable Equipment Starts With Reliable Attention”
Questions?
Upfront Costs & Reliability Engineer
Rate
 IPAD Vibration Analysis software
and hardware: $5,000
 Flir Thermography Gun:...
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TRP Presentation

  1. 1. “Reliable Equipment Starts With Reliable Attention” Total Reliability Professionals Technologies Division Proposal for Predictive Maint.
  2. 2. Industries Serviced Pulp & Paper  Aluminum  Food  Plastics  Pharmaceuticals  Waste Water & Treatment  Power & Energy  Mining  Steel “Reliable Equipment Starts With Reliable Attention”
  3. 3. Customer List  TBD  TBD “Reliable Equipment Starts With Reliable Attention”
  4. 4. Services Provided  Vibration Analysis (Our Core Competency)  Thermography  Mechanical  Electrical  Ultrasonic Leak Detection  Air & Gas Leaks  Steam Trap Testing “Reliable Equipment Starts With Reliable Attention”
  5. 5. Services Provided (cont.)  Lubrication Services  Program Setup  Auditing  Oil Analysis “Reliable Equipment Starts With Reliable Attention”
  6. 6. Future Endeavors  Maintenance Program Audits  TBD “Reliable Equipment Starts With Reliable Attention”
  7. 7. 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 “Reliable Equipment Starts With Reliable Attention”
  8. 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 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). “Reliable Equipment Starts With Reliable Attention” Which strategy are you currently employing?
  9. 9. PdM vs. No PdM “Reliable Equipment Starts With Reliable Attention” 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.
  10. 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. 11. Case History “Reliable Equipment Starts With Reliable Attention” • 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.
  12. 12. Thermography “Reliable Equipment Starts With Reliable Attention” • 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.
  13. 13. Case History “Reliable Equipment Starts With Reliable Attention” • 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.
  14. 14. Ultrasound Leak Detection “Reliable Equipment Starts With Reliable Attention”  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.
  15. 15. NDT – Visual Inspection “Reliable Equipment Starts With Reliable Attention” 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.
  16. 16. NDT – Penetrant “Reliable Equipment Starts With Reliable Attention” • 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.
  17. 17. NDT – Magnetic Particle “Reliable Equipment Starts With Reliable Attention” 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.
  18. 18. Magnetic Particle Case Histories “Reliable Equipment Starts With Reliable Attention”
  19. 19. Power Loss Due to Angular Misalignment “Reliable Equipment Starts With Reliable Attention” 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.
  20. 20. “Reliable Equipment Starts With Reliable Attention” 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
  21. 21. Reporting “Reliable Equipment Starts With Reliable Attention” 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
  22. 22. Reporting – Asset Health “Reliable Equipment Starts With Reliable Attention” 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
  23. 23. Emergency Reporting “Reliable Equipment Starts With Reliable Attention” • 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.
  24. 24. KPI’s for Measuring Success “Reliable Equipment Starts With Reliable Attention”  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)
  25. 25. Cost Savings Analysis “Reliable Equipment Starts With Reliable Attention”
  26. 26. “Reliable Equipment Starts With Reliable Attention” Questions?
  27. 27. 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.

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