No Slide Title · Mission: Guide our Clients to improve Overall Reliability and Lowering...

Reliability Engineer –What should be your role

By

IDCON INC.

September 2018

WWW.IDCON.COM©IDOCN INC for use by Maintrain

IDCON INC

2

Mission:

Guide our Clients to improve

Overall Reliability and Lowering

Manufacturing and Maintenance

Costs


Areas of Expertise

Public Seminars

In Plants/ Mills/ Mines

Reliability & Maintenance

for the Process Industry

▪ Advice

▪ Leadership & Organization

▪ Reliability Assessments

▪ Planning & Scheduling

▪ Shutdowns / Turnarounds

▪ Preventive Maintenance

▪ Operator Essential Care

▪ Root Cause Problem Elimination

▪ Spare Parts Management

▪ Technical Database

3

WWW.IDCON.COM©IDOCN INC for use by Maintrain 4

IDCON INC – International Presence


Recent Clients ExamplesWood, Building products

• Norbord, USA, Canada, Belgium, U.K.

• TAMKO ( 12 Plants)

• St. Gobain/ CertainTeed

• Georgia Pacific, OSB

• Weyerhaeuser

• Potlatch (ongoing)

• Huber Engineered Woods (Ongoing)

• Arauco (North Carolina)

Steel and metals

• Swedish Steel (SSAB), Sweden

• Reynolds Aluminum Foil, USA

• Nucor Steel

• ELG Utica Alloys (Ongoing)

Pharmaceutical

• Abbott, USA and Europe

• Jansen

• Bayer Crop Science

• Novo Nordisk (Ongoing)

• Genentech Roche 16 plants worldwide

Corporate

Mining• Kazakhmys, Kazakhstan ( 3 mines)

• US Silica, 12 plants/ mines, USA

• Arch Coal, 15 mines, USA

• Xstrata Copper, Canada

• Nyrstar, TN 3 mines

• Iluka, VA

• Yan Coal, NSW, Australia

• Sydvaranger, Norway

• African Minerals, Sierra Leone

• Eldorado Gold (Kisladag, Turkey)

• Goldcorp, Borden (Ongoing)

Food• Tyson Foods 30 of 300 plants

• Portales, NM, USA

• Glanbia Foods, USA

• Fonterra, NZ.

• ConAgra Foods, NC, USA

• Liguria Food, IA

• Foremost Farms corporate 5 plants

• Pepsi

• Rio Mare (Bolton Group)

• Ingredion North America 9 Plants (Ongoing)

• Rotella’s Bakery (Ongoing)

• Treetop (Ongoing)

Chemical• Akzo Nobel, TX, USA

• ICL Dead Sea Works, Israel (Ongoing)

• Kraton, USA, France(Ongoing)

• Scotts, OH, USA

• Agrium, Canada

• ICL, USA


Recent Client ExamplesOther

• Harley Davidson

• Boeing

• University of Miami

• University of Michigan

• Engineered Plastics

• Tacoma Water (ongoing)

• Birmingham Airport

• Petstar, Mexico

Oil and gas

• Calcasieu, LA

• Tesoro Refinery, CA, USA

• Marathon Oil, UK

• Colonial Pipe Line

• Syncrude, Canada

• Union Gas, Canada

• Delek Refining

• Union Gas Canada

Power Plants

• Nuclear Training Commission, Sweden

• Xcel Energy, MO, USA

• Grand Bahamas Power

• Minnesota Power

• Capital Power USA, Canada (12 plants)

• Swedish Nuclear Commission

Pulp and Paper

• Domtar corporate 13 mills (ongoing)

• Mondi Academy Corporate (Ongoing)

• Billerudkorsnäs 5 mills (Ongoing)

• Resolute Forest products (Ongoing)

• CMPC Tissue, S.A (all mills) (Ongoing)

• Catalyst Paper (Ongoing)

• Oji Paper, New Zealand (Ongoing)

• Atlantic Packaging

• CMPC Laja, Santa Fe, Pacifico

• Stora Enso, Gent, NL

• Kapstone, NC

• Georgia Pacific

• SCG, Thailand

• Tembec, USA, Canada and France (10 Mills)

• RockTenn (10 mills)

• Clearwater Paper Company

• Thilmany, WI, USA

• International Paper, USA (All Mills)

• PanPac, New Zealand

• Weyerhaeuser USA 5 Mills

• Aditya Birla, 3 mills

• Mondi, Syktyvkar, Russia


MAINTENANCE

PLANNING AND

SCHEDULING

DO

REACT

REPAIR

RETURN

REPEAT

TECHNICAL

DATABASE &

STORES

PRIORITIES,

CONDITION

MONITORING

PRODUCTION

PLAN

MARKET

CONTINUOUS

IMPROVEMENT

RCPE

RECORD

Prevention

+

Reliability Work Process

7


Equipment Reliability Moving from X to Y

8

Equ

ipm

ent R

elia

bili

ty

Time

X

Y

What Physically Needs Done To Existing Equipment To Go From X to Y?



9

1. Repair known existing problems with the equipment

• Reactive

or

• Through: Prioritize - plan – schedule – repair

Remember: A Valid repair can never be avoided


Options to Deal with the Backlog

10

ExecuteSchedulePlanPrioritize



11

1. Repair known existing problems with the equipment

• Reactive

or

• Through: plan – schedule – repair (prioritize and work through backlog)

2. Also, need to find/ prevent unknown & future problems with equipment

• Find: Inspections (Condition Monitoring)

• Find/ Prevent: Root Cause Problem Elimination (RCPE)

• Prevent: Design

• Prevent: Install

• Prevent: Operate equipment correctly

• Prevent: Lubricate


Inspect & Prevent

12

ExecuteSchedulePlanPrioritize

Prevent

Inspect


Life Cycle Cost (LCC) – A Study from the Army

100%

50%

20%

5%

70%

85%

95%

80%

Decisions deciding future cost

Actual Cost

LCC

Phase

Design Project Assembly of Eq. Operation


Maintainability

14


Hydraulic motor shelf for belt tightening

15

Reference: Gemex belt tightening

Weir Minerals: Gällivare, Sweden


Maintainability


Prevention - Lubrication: Example Storage

17


Prevention - Lubrication: Example Storage

18


Poorly aligned Probably Well Aligned

Other Signs:

• Hot bearings

• Hot Couplings

• Vibrating Equipment

Installation - Alignment


A

Wear

Replace worn wheel unit $900.

6 hours down time

B

Replace worn wheel $270

2 hours down time

Installation Example

20


Set up a PM (on the run inspections and of line inspections)

A 125 HP, AC Motor Running 24/7


Example: Motor Inspection

On-The-Run

• Cleanliness (fins, plugged airflows, etc)

• Fan with strobe

• Temperatures with (IR Temperature - Max? 170F (75C)

• Vibration (feel or with Pen – Alarm 0.25 in/sec 6.35 mm/sec?)

• Hold down bolts

• Base

• Condition of Junction Box and wires

• Noise

Shutdown

• Winding test

CMS 100R

reference folder seminar/CMS100R.pdf


PM/ECCM Example Centrifugal Fan

CMS 142R Fan – Air Centrifugal

CMS129R Bearings

+ Temp. & vib. limit

CMS 137R Belt Drive

CMS 100R Motor AC

+ Amp. & Temp. & vib. limit


COMPONENT INSPECTION WHILE COMPONET OPERATES

Freq.* SHUTDOWN/ OFF-LINE INSPECTION Freq.*

Belt – Vbelt Drive

CMS 137R

General Condition, Noise and Vibration, sheave

condition, Belt position

1-4

weeks

No scheduled preventive maintenance (PM) tasks

necessary for shutdowns. All PM’s can be done while equipment is running.

Motor - AC

CMS 100R

Air intake, Detailed Cleaning, Water/ Humidity,

Temperature, Noise and vibration, Motor Base, Electrical, Greasing

Vibration analysis

Greasing of bearings (if not sealed)

1-4

weeks

2-3

weeks

For critical motors, it’s suggested to run a winding

test. A winding test can be done with a number of different tools, use the mill standard tool.

If there is a maintenance opportunity, do detailed

cleaning of unit, remove junction box cover and inspect connections. Follow required safety

procedures.

3-12

months

Bearing - Pillow Block

CMS 129R

Detailed Cleaning, Bolts, Noise, Vibration, &

Temperature, Seals, Set Screw and Lock Ring.

Comment: Horizontal vibration is sufficient when using a vibration pen.

1-4

weeks

Cleaning as needed

Fan - Centrifugal

CMS142R

Noise. Leaks. Vibration. Blades. Belts.

Bearings. Housing. Bolts. Base

3-8

weeks

No scheduled preventive maintenance (PM) tasks

necessary for shutdowns. All PM’s can be done while equipment is running.


Example: Measure Chain Wear 1.5-3%

25


Example Inspection

26

Inspection of

Carbon ring

Wear.

Reference IDCON CMS 124R


RCPE - Find Issues: Do You See a Problem?


Morning meeting: Motor tripped out causing production loss!

Maintenance Operations

Mechanical E / I

Electrical Instrumentation

WHO

Root Cause Problem Elimination – Typical?


Our Typical Thinking Process

31

With little

information…Then we look for more

information to support

our decision

We create an opinion

or a solution…

Opinion/

“The Solution”

We lock our thoughts

….because we told others our opinion

Defend your opinion!!!


What the THINKING PROCESS Should Look Like

More

Information

Possible

Causes

Possible

Solutions

Pick

Solutions

1. Collect Information

2. Develop & consider possible causes

3. Select most likely causes

4. Develop and consider possible solutions

5. Select solution

Most Likely

Causes


MAINTENANCE

PLANNING AND

SCHEDULING

DO

REACT

REPAIR

RETURN

REPEAT

TECHNICAL

DATABASE &

STORES

PRIORITIES,

CONDITION

MONITORING

PRODUCTION

PLAN

MARKET

CONTINUOUS

IMPROVEMENT

RCPE

RECORD

Prevention

+

Reliability Engineer - Focus

34

▪ Lubrication

▪ Design

▪ Installation

▪ Storage procedure

▪ Filtration

▪ Alignment, Balancing

▪ Operating Practices

▪ Fixed Time Maintenance

▪ Basic Inspection

▪ Predictive

▪ Investigation

▪ Corrective Actions

Questions

35

No Slide Title · Mission: Guide our Clients to improve Overall Reliability and Lowering...

Documents

Transcript of No Slide Title · Mission: Guide our Clients to improve Overall Reliability and Lowering...