Simple Predictive and Preventive Maintenance: Your Roadmap to - - PowerPoint PPT Presentation

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Simple Predictive and Preventive Maintenance: Your Roadmap to - - PowerPoint PPT Presentation

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Simple Predictive and Preventive Maintenance: Your Roadmap to Machine Wellness by Dale Nicholson, PE, CMRP,CRL Reliability Engineer, Tate & Lyle Digital Tools for Manufacturing November 20, 2019 Plant Reliability Dale C. Nicholson,

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“Digital Tools for Manufacturing” November 20, 2019

Simple Predictive and Preventive Maintenance: Your Roadmap to Machine Wellness by Dale Nicholson, PE, CMRP,CRL Reliability Engineer, Tate & Lyle

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Plant Reliability

Dale C. Nicholson, PE, CMRP, CRL November 20, 2019

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Proactive vs. Reactive

Proactive: That motor has a bearing defect, let’s stage a spare and dedicate a crew to swap it out during the next planned outage. Reactive: That motor stopped running and we’re not making product. Hurry and get it fixed NOW!

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When Do You Change Your Tires?

When they’re new? That would obviously be a waste of money. When they have no treads left? They are still functional, and may have many miles left in them. However, the loss of traction may leave you or your loved ones stranded, with a wrecked vehicle, or worse yet, injured. Do you run them right down to the wires, getting every last penny out of them? Do you assume that they will blow out at a convenient time and place? Or do you consider that risk unacceptable?

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At the Doctor’s

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What, exactly, is your point?

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Oil Storage & Handling

Esco 3D Bullseye, $30

  • Filtration
  • Clean, enclosed, dedicated containers
  • Label containers and reservoirs
  • Sight glasses
  • Desiccant breathers
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Oil Analysis (OA)

  • In-house oil lab: $100,000
  • Oil sample (external lab): $30
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SLIDE 9

Engineering Flowchart

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SLIDE 10

Ultrasound Energy (UE)

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SLIDE 11

Air Leaks

Cost of air leaks, 100 PSI system pressure, $.07 per KWH

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Leak Diameter Annual Cost

1/64" $ 49 1/32" $ 196 1/16" $ 785 1/8" $ 3,143 1/4" $ 12,572 3/8" $ 28,288 1/2" $ 50,169 5/8" $ 78,456 3/4" $ 112,909 7/8" $ 153,770 1" $ 200,795

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SLIDE 12

Bearing Examples

Bearing A

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Grease added to motor bearing

Bearing B

Tool for airborne & contact UE: $3,000

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Infrared (IR)

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Infrared (IR)

  • FLIR One $200
  • FLIR C2 $450
  • FLIR E6 $2,000
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Strobe

  • Couplings
  • Belts
  • Should have 2% - 4% slip
  • Rolls
  • Shafts
  • Anything else that moves

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https://empoweringpumps.com/a-coupling-inspection/

$600

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Vibration Analysis (VA)

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Motion Amplification Video (MAV)

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Motor Circuit/Electric Signal Analysis (MCA)/(ESA)

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Predictive Tools

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But Wait, There’s More!

  • Look at assets regularly
  • Check for:
  • Loose bolts
  • Oil leaks
  • Plugged cooling vents
  • Odd noises or smells
  • Jog equipment monthly

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PF Curve

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Bearing Failure

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http://www.me.metu.edu.tr/courses/me5 60/Wear.htm

  • Bearing surface spalling – a common failure mode
  • Fatigue cracking, caused by compression/tension cycles.
  • Microscopic cracks form below the metal surface.
  • Eventually they grow to the point where the surface flakes off.
  • Once spalling starts, it is likely that there are many other cracks around the

ball path surfaces.

  • It will continue until the bearing is thrashed.
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SLIDE 23 wikipedia.org

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http://www.me.metu.edu.tr/courses/ me560/Wear.htm

Asphalt Steel

Bearing Failure

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PF Curve

Lubrication & precision maintenance (laser alignment) extend the green line – the time before failure is initiated.

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Nowlan & Heap

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Nowlan & Heap

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Preventive Maintenance (PM)

  • Wear and failure modes: What can go wrong?
  • Use PdM technologies and running inspections to watch for those

defects/potential failures

  • Establish PM procedures to address remaining wear & failure modes
  • E.g. use gauges to check belts & sheaves
  • Check maintenance manual for additional PM items
  • Wear components
  • Clearance settings/adjustments

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Saves

Prevented an unnecessary 330 gallon oil change Saved $2700 in unnecessary expenditure A capital project is underway to upgrade the motor and reducer. It was assumed that we should change the oil at the same time, but the oil analysis history showed that the oil is in perfect condition. Delaminated coupling was found and replaced Prevented 100k BPD unplanned grind loss for 2-3 hours, prevented coupling from flying apart and possibly injuring someone. Vibration analysis detected a problem with the pump assembly. Visual inspection with a strobe showed the delaminated elastomeric coupling. Pellet mill lube rate optimized Annual food grade grease consumption reduced by 135 kegs, or $48,000. I collaboration with the pellet mill OEM, lubrication frequency was reduced from 30 minutes to 120 minutes Call out on motor bearing failing Was able to change out when planning allowed Motor in board bearing had been failing for several months. Noticed a increase in inboard bearing DB.Was able to change it out when the process allowed. Motor bearing failure Was able to plan replacement when process allowed This motor was not on a monthly route for data collection. Had noticed that the motor was making a lot of noise. Ultrasound was showing impacting , and vibration backed up the decision to change it out. Motor is now on a monthly route. Mounting bolts loose Was able to have repaired the day after w/o was written The large foot bolts to the gear bow was loose, causing the gear box to move with each rotation of the shaft. Was caught during a quarterly lube route. Found that the mixerbox shaft was moving back and forth. Was able to incroporate into the next days shutdown While running a route, found that the mixerbox shaft was moving. Was able to have a initial repair on a next day shutdowm. Second shutdown was was incorporated, to replace a bearing that has failed. Used VA to find improperly installed belt drive Prevented an unnecessary centrifuge bowl change An analysis of the vibration data showed that the problem was in the motor/belt drive area of the machine. Motion Amp. Video was used to illustrate the problem and prevent the unnecessary bowl change. PdM2 callout on inboard motor bearing defect Able to plan for proper shutdown to replace before bearing failed, causing rotor to contacct windings Callout ot by Ultrasound and Vibration data. Able to plan changeout before failure. Pdm2 callout on inboard motor bearing
  • defect. Also replaced the gear box due to IB
seal failure Was able to run the other alternating screws to repair to affected motor. Was able to repair/ replace before it failed . Failure of screw, expecially on the end can cause bridging in fines bin. Strong PdM2 callout on IB motor bearing failure. Able to plan changeout during a shutdown. Regular monthly route had it start to showup on Ultrasound . Pdm1, Motor IB bearing Able to change out before motor fails Regular routes, and inspections. Was able to find during walk through PdM3, Pump OB bearing Able to run on backup pump, and change out. While running a route, was able to detect Pump bearing making noise . Pulled further data to double check. Motor bearings, heat, possible rotor bar problems 2 hour grind cut to 50% UE, vibe, & IR detected bearing & possible rotor bar problems PdM1, internal vibration Able to run on backup pump, and change out. Had been watching closely. Evan H reported it has started vibrating. Pulled vibration data, showing possible out of balance rotor? Used motion amplification before changing out Motor. call out of pump coupling Had to cut grind to replace While running the third floor grease route found a coupling going out. Was able to use a strobe light and see the coupling had large chunks out of it and had cross hatch cracks in the element. Was able to replace it before the coupling failed and possible plugged germ line. Evan H found the motor making noise while
  • n a walk through
Was able to plan a shutdown to replace Evan h reported the possible noise to the Ultrasound tech. Was able to go and trouble shoot the motor Vibration Data indicated impeller issues. Loss of this pump reduces gring to 80K. Repairs were made under controlled circumstances. Catastrophic loss would have caused considerable down time for repairs. The impeller was worn and had caused damage to the pump, volute, and piing. PdM3, motor bearings Able to plan change out during a shutdown. While running monthly route, found the motor was making more noise. After looking at the data it shown a large change in DB. Pdm3 , IB motor bearing. Outer race defect Changed over and ran #2 hammermill during a reduced grind. Shows that motor has been in use before SAP. 1999? High levels of vibration were present, even after the recent repairs. Loss of this pump reduces gring to 80K. Repairs were made under controlled circumstances. Catastrophic loss would have caused considerable down time for repairs. Further investigation indicated severe damage to the motor base/foundation. Modifications to the base improved vibration levels considerably. Ultrasound data shows a large change in IB motor bearing. Was able to change out at anytime due to we wear only running 3 Pellet mills While running a monthly route, pulled data on motor. Found it was considerally
  • louder. Motor was Hot to the touch, 260 Deg .
Strong PdM2, spindle bearings Was able to shut down before failure and replace when manpower allowed Was told the centi was making noise. UE indicated spindle bearing, OB. Vibration backed up Large piece of urethane missing from coupling, guard damaged Prevented 2-hour 50% grind cut Caught during vibration data collection gearbox leaking oil profusely changed before catastrophic failure, these are csds found during lubrication routes UE and vib data indicated fan bearings were failing prevented unplanned work and loss of aspiration of wetmill found during lubrication routes,backed up by UE data and vib data motor and coupling noisy visibly out of alignment prevented unplanned outage of fiber system found during lubrication routes tail bearing on fire grease burned out of it prevent un planned loss of grind if this fails while we r running wet feed on gr system found during lubrication routes Reliability team identified 8 PdM 2&3s in the millhouse on pump couplings by using strobe technology. Prevented unplanned grind reductions (even one zero grind). Vibration data indicated possible misalignment. Failed coupling could have caused mill and feed conveyor to plug leading to Pellet building outage; loose feed or possbily wet feed. Coupling was checked with the use of a strobe light and was found at near complete
  • failure. Coupling was replaced and equipment was found to be in a state of severe
misalignment. Ultrasound indicated motor OB damage Was able to change out during planned shutdown Motor was added to Feed house route. It was found that the OB motor bearing was failing Vibration and ultrasound indicated IB motor bearing issues, and rotor bars pass frequency. Changed out during shutdown Ultrasound and Vibration showed that the IB motor bearing was in state of failure. Vibraton data also was showing a rotor bar pass frequency . Ultrasound indicated impacting in the IB motor area/IB gearbow area. Motor was pulled, it was found that the gearbox bearing was bad Gearbox was replaced due to the IB gearbox bearing was missing several rolling
  • elements. The drive motor was also changed out at the same time.
Visual inspection showed drive belt nearing failure Able to get belt replaced on scheduled shutdown. Replaced sheaves and belt (aligned and tensioned); extisting sheaves were not aligned properly. Made temporary modifications to seal guard from contamination (possible root cause) as a trial; belt has a history of repeat failures. Asked to inspect vibration issue. Avoided unplanned equipment downtime/failure. Vibration analysis detected a problem with the blower assembly. Visual inspection with a strobe showed the delaminated elastomeric coupling. Routine vibration route data detected coupling issue. Avoided unplanned equipment downtime/failure. Vibration analysis detected a problem with the pump assembly. Visual inspection with a strobe showed the delaminated elastomeric coupling. Routine vibration route data detected coupling issue. Avoided unplanned equipment downtime/failure. Vibration analysis detected a problem with the pump assembly. Visual inspection with a strobe showed the delaminated elastomeric coupling. Vibration data indicated fan imbalance. Fan cools water that aids in the evaporation of steep water. Fan taken down and blades replaced before possible failure. Fan experienced increase in vibration amplitudes. Avoided unplanned equipment downtime/failure. Resonant conditions due to increased fan speeds were suspected and confirmed. (see Save Report) Vibration data indicated looseness in bearings. Avoided unplanned equipment downtime/failure. Recurring issues with looseness in these bearing. Both were fixed slip on style; replaced with taper adjust style (one fixed/one floating). IR scan detected bad pump IB bearing. Pump seal noted to be leaking as well. Avoided unplanned equipment downtime/failure and GMP issues. This is a backup pump that does not run very often. IR tech became aware it was in service and went to inspect. IR scan detected misaligment at pump coupling. Able to schedule alignment on a planned outage. Misaligment is a potential cause for premature machinery compenent failures (bearings, couplings, seals). IR scans of elastomeric couplings allow us to detect and rectify. IR scan detected misaligment at pump coupling. Able to schedule alignment on a planned outage. Misaligment is a potential cause for premature machinery compenent failures (bearings, couplings, seals). IR scans of elastomeric couplings allow us to detect and rectify. Routine lube routes led to finding broken bearing lube line. It was also noted that there was noise coming from gear coupling. Press taken down to replace lube line and grease coupling to avoid potential failure. Helps to show that routine routes can detect issues with associated discipline as well as detecting other issues by using all senses. Vibration data indicated a defect on the motor OB bearing. Able to avoid unplanned equipment downtime/failure. Route based data detected early bearing defect. Equipment remained in service and continous monitoring allowed for detection of an increase in defect severity and equipment was scheduled for replacement. Found coupling during routes Was able to change out in a planned matter While collecting data on a month route found an bad coupling on the pump. Was able to talk with operators and have it taken down before failure UE data indicated pump OB bearing failing. Able to avoid unplanned equipment downtime/failure. Non-routine UE data collected due to audible noise showed high dB levels indicating bearing defects. Generic vibration data (not on routes) showed possible defect as well. UE data indicated pump IB bearing failing. Was able to change out motor before complete failure Was originally written up as a PdM2, had not been repaired in 3 months. Changed
  • ut to PdM1 , as motor was in a lot worse shape.
UE indicates IB motor bearing failure Was able to change out motor after shutdown was completed Noticed motor was making noise. Found the motor IB bearing was out. The motor is ran during shutdown, plus it has large amounts of ductwash that drains direcly on motor. Coupling wear from product build up Was able to change out during planned outage Coupling was noiticed to have uneven wear during monthly route. Cleaned guard , and inspected with strobe light to verify uneven wear. Ultrasound and Vibration call out of fan bearings Changed out fan bearing and water blasted fan during planned outage Fan bearing were called out to be replaced. Changed bearing out, and found fan runner was in need of cleaning. Had runner water blasted . Possible replacement of total fan in future, due to being wore out

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  • During a routine monthly oil check, water was found in the press gearbox oil.

The press seals were replaced and the gearbox oil was changed, avoiding tens

  • f thousands of dollars’ worth of damage.
  • We already had a grind shutdown scheduled for that afternoon. Replaced the

motor then (0 bushel loss) verses a potential loss of 15k bushels if motor had failed catastrophically. $40,000 savings

  • Had a controlled reduced grind (30k bushel loss) to replace the breaker.

Avoided potential loss of 370k bushels if the breaker had failed

  • catastrophically. $900,000 savings
  • Prevented failure of motor/blower bearings due to increased levels of
  • vibration. During the hot summer month these blowers are needed fulltime.

Any downtime on them causes problems for Waste Treatment which could initiate fines from the city or result in production slow downs.

  • Saved potential failure of the IB bearing of the press and damage to the press
  • screw. Had this failed it would have limited Germ system eventually leading to

grind reduction. $250,000 savings

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Summary

  • Proper oil filtration, storage, & handling
  • Oil analysis
  • Ultrasound
  • Infrared
  • Strobe
  • Running inspections
  • Preventive Maintenance

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Finally

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Thank you!