Total Reliability Professionals
www.trp-services.com

Proposal for Predictive Maint.
“Reliable Equipment Starts With
Relia...
Industries Serviced










Aluminum
Pulp & Paper
Food
Plastics
Pharmaceuticals
Waste Water & Treatment
Power &...
Customer List


TBD



TBD

“Reliable Equipment Starts With Reliable Attention”
Services Provided


Vibration Analysis (Our Core Competency)



Thermography



Mechanical
Electrical

Ultrasonic Leak...
Services Provided (cont.)


Lubrication Services





Program Setup
Auditing
Oil Analysis

“Reliable Equipment Starts ...
Future Endeavors

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Maintenance Program Audits
TBD

“Reliable Equipment Starts With Reliable Attention”
Individuals Who Will Be Involved
Johnnie Ciulla Jr. (President, TRP Services)


•
•
•
•
•

•
•
•

Level III ASNT vibratio...
Maintenance Strategies








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Run-to-Failure:  (A maintenance policy that allows a machine to run until it breaks...
PdM vs. No PdM
Programs with PdM programs generally
have maintenance costs that run below
their budgets.

Programs without...
Vibration Analysis




Identifies defective
bearings and
gears, looseness, rubs
, misalignment, imbal
ance, etc.
Cost of...
Case History
• This bearing is on a large
washer roll at a pulp mill
• Inner race frequencies were
detected (top spectrum)...
Thermography

• Thermography provides the quickest return on investment of all the predictive
technologies.
• Can be used ...
Case History

• The fuse from this disconnect was approaching 400 degrees.
• The case was reported but the fuse had blown ...
Ultrasound Leak Detection
 Air and gas leak detection
 Leaks occur at high frequencies that can be detected in the
ultra...
NDT – Visual Inspection
Most basic and common
inspection method.
Tools include fiberscope's,
borescopes, magnifying
glasse...
NDT – Penetrant

• A liquid with high surface wetting characteristics is applied to
the surface of the part and allowed ti...
NDT – Magnetic Particle
The part is magnetized. Finely milled iron particles coated with a dye
pigment are then applied to...
Magnetic Particle Case Histories

“Reliable Equipment Starts With Reliable Attention”
Power Loss Due to
Angular Misalignment
For example, a 500 HP ID Fan
that is operating 24/7 (or 8760
hours) at a misaligned...
Equipment Set-Up
Obtaining information from machine components
is critical in the accurate diagnosis of a machine.
Importa...
Reporting
Standard report includes machine sketch or image with
all necessary information included:
• Survey Date
• Machin...
Emergency Reporting
• Many times a report is needed immediately after a
machine has been analyzed.
• TRP Reliability Engin...
KPI’s for Measuring Success






Cost savings analysis
Emergency repairs as % of scheduled repairs
Planned and sched...
Cost Savings Analysis

“Reliable Equipment Starts With Reliable Attention”
Questions?

“Reliable Equipment Starts With Reliable Attention”
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Trp reliability presentation 2

  1. 1. Total Reliability Professionals www.trp-services.com Proposal for Predictive Maint. “Reliable Equipment Starts With Reliable Attention”
  2. 2. Industries Serviced          Aluminum Pulp & Paper 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 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. 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. 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. 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 • 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. 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. 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. 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. 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. 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. 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”
  18. 18. Magnetic Particle Case Histories “Reliable Equipment Starts With Reliable Attention”
  19. 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. 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. 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. 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. 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”
  24. 24. Cost Savings Analysis “Reliable Equipment Starts With Reliable Attention”
  25. 25. Questions? “Reliable Equipment Starts With Reliable Attention”

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