Speaker Bio • Plant Reliability Specialist - 06/2002 to Present Clearwater Paper Corporation North Las Vegas, NV • Quality Control Engineer: - 08/1992 to 06/2002 Mandalay Bay Resorts Las Vegas, NV • Aircraft Technician/Inspector 08/1980 to Present Airframe and Powerplant License with an Inspection Authorization • Successes with Ultrasound Millions of dollars in savings from mechanical, electrical and airborne inspections. • Interests Guitar, Aircraft, Motorcycles, Music
Speaker Bio • Level III Vibration Analyst • Level III Infrared Thermographer • Level II Ultrasound Certifications • Level II Machinery Lubricant Analyst • Level I Ultrasonic Testing Certifications • Level I Certified Building Thermographer • Level I Balancing Certifications • Level I Machinery Lubrication Certification • Airframe & Powerplant License w/IA Certification
Doing More With Less Using Ultrasound Technology to Increase Plant Reliability Richard Larmouth Plant Reliability Specialist Clearwater Paper Corporation North Las Vegas, Nevada
Objectives • Gain an understanding of the diverse applications of ultrasound technology in a reliability program • Realize the value of ultrasound in your reliability / PDM programs • Recognize the time savings of ultrasound in route or spot inspections • Recognize the value of ultrasound as a route inspection and screening tool
Ultrasound Overview • One technology can not cover all aspects of machinery problems • Ultrasound is a good stand alone inspection method for route based and spot type inspections • Ultrasound is an effective screening tool for speeding up the inspection process • Ultrasound is an effective tool for cross checking anomalies found with other technologies
What can we find with Ultrasound • Airborne – Compressed gas leaks and vacuum leaks • Electrical – Corona: Ionization of the air around conductors – Tracking: “Baby arcing” along damaged insulation – Arcing: High current discharge from conductor to ground • Steam – Airborne and mechanical • Mechanical – Friction in bearings, loose components, leaking valves, cavitating pumps
Airborne Leak Detection • Initially the use of ultrasound in our plant was only used for airborne inspections • Inspections were random and done only when a problem (leak) was suspected • Equipment was not to versatile in features • Minimal airborne ultrasound training from my aircraft experience • The need for better equipment and training was apparent
Airborne Leak Detection • Procured training with the top manufacturers of ultrasound equipment • Tested different manufacturers ultrasound equipment and software • Evaluated advantages and disadvantages • Purchased advanced ultrasound equipment • Found ways to reduce energy waste
Airborne Leak Detection • Started with air surveys on the paper machine and converting • Numerous air leaks found • Plastic hoses, cylinders, valves, rubber hoses, plugs, gages, oilers, lines, etc. were found to be leaking. • Once repaired the annual savings for this first audit was over $100,000.00 dollars. • Subsequent audits of the paper machine yielded similar savings and converting was significantly lower suggesting that some of the bigger leaks had not reoccurred.
Airborne Leak Detection Paper Machine Cylinder Shaft Seal Leaking Heavily
Airborne Leak Detection Paper Machine Loose Cap and Nipple
Airborne Leak Detection Converting Leaking Hose Fitting Calculated Cost $35,000.00 Annually
Airborne Leak Detection Converting Leaking Air Dump Valve Bypassing Internally Calculated Cost $15,553.00 Annually
Electrical Inspection • We perform ultrasound inspections in conjunction with our infrared inspections • The equipment is scanned before I open it up for our IR surveys for the added safety factor • We have been fortunate to have had only a few ultrasonic electrical anomalies • Ultrasound continues to be a vital inspection tool for detection of corona, tracking, and arcing in electrical equipment.
Steam Trap Inspection • ½” main steam header condensate drop leg steam trap valve (Inverted Bucket) Good Steam Trap Bad
Airborne Mechanical Defect Detection Paper Machine Loose Hydraulic Shut Off Handle
Airborne Mechanical Defect Detection Paper Machine Loose Boiler Plate Clamps
Airborne Mechanical Defect Detection Consumer Products Division Damaged Vacuum Pump Belt
Airborne Mechanical Defect Detection Consumer Products Division Case Conveyor Leak and Loose Rollers Detected From the Ground
Using Ultrasound for Lubrication • The most influential cause of bearing failure is lubrication related • This includes using the wrong lubricant along with improper lubrication practices such as not enough or too much lubricant • Ultrasound is the best method for administering the correct amount of grease • According to recent studies up to 80% of bearing failures are lubrication related
Using Ultrasound for Lubrication
Using Ultrasound for Lubrication
Using Ultrasound for Lubrication
Using Ultrasound for Lubrication
Using Ultrasound for Lubrication • Started implementing acoustic greasing techniques on forming (wet) section of paper machine utilizing existing route based accelerometers and ultrasound • Immediate success in determining lubrication condition of each roll bearing • Procedure indicates condition and need for lube and/or repair
Using Ultrasound for Lubrication • Sensors accessed through remote interface boxes mounted away from wet forming section
Using Ultrasound for Lubrication
Using Ultrasound for Lubrication
Using Ultrasound for Lubrication
Using Ultrasound for Lubrication
Using Ultrasound for Lubrication • As can be seen on the spread sheets. Lubrication patterns start to become evident • We can see the inner wire return roll does not decrease to an acceptable level even after many greasing cycles. • We can also see the inner wire guide roll is doing the same thing • Note: There is some amplitude variations due to speed changes
Using Ultrasound for Lubrication • The inner wire return roll grease system was inspected while greasing to find any abnormalities • The following video shows what was found:
Using Ultrasound for Lubrication
Tightness Testing
Mechanical Borne Ultrasound • I set up my ultrasound routes to be identical to my vibration routes Ultrasound Vibration
Mechanical Borne Ultrasound • This enables me to collect ultrasound and vibration data on the same points in the software at the same route location • Having the software tree structure similar decreases the time it takes to collect and analyze data • This is particularly useful when doing random inspections with both ultrasound and vibration
Mechanical Borne Ultrasound • I carry all of the ultrasound routes with me so I can change routes as needed. • This lets me look at any piece of equipment on any route as needed • There are different styles of SD card holders that are available • I purchased a few different styles and carry the one that works best for my routes
Mechanical Borne Ultrasound
Mechanical Borne Ultrasound • I also have modified the ultrasound equipment to be more user friendly • Initially the mechanical sensor would have to be held or removed from the gun and carried some other way • I wanted to be able to carry both the ultrasound gun and vibration analyzer with one hand and still be able to use that hand to climb on the equipment
Mechanical Borne Ultrasound • To free up my hand I attached a metal vibration pad to the bottom front of the gun with Loctite 330
Mechanical Borne Ultrasound • This lets me carry both with one hand
Mechanical Borne Ultrasound • As soon as I started carrying them this way I sometimes would loose the SD card from the gun • I incorporated another modification
Upper Calendar Roll • Calendar rolls were modified previously. Did not have current vibration data set up on the rotary joints • Random ultrasound inspection picked up heavy impacting in the rotary joint • I monitored until removed for repair • Joint had significant damage but was still functioning
Upper Calendar Roll • The water siphon tube had come loose and was rubbing on the housing
Upper Calendar Roll Bad
Upper Calendar Roll Good
Top Pressure Screen • Vibration did not indicate any significant anomalies • The points being used for vibration were attenuating the signal from the shaft bearings • I started using ultrasound to determine the condition of these bearings • I used a bayonet style extension probe to reach the shaft housing cover
Top Pressure Screen • No significant changes in vibration
Top Pressure Screen
Top Pressure Screen • The points being used for vibration were attenuating the signal from the shaft bearings Pressure Screen Tank Original Vibration Point
Top Pressure Screen • I used a bayonet style extension probe to reach the shaft housing cover Housing Cover Bayonet Drive Position Pulley
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