Speaker Bio Plant Reliability Specialist - 06/2002 to Present - - PowerPoint PPT Presentation

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
• nly 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
• f 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)

Steam Trap Good 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

• ne 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

Drive Pulley Housing Cover Bayonet Position

Top Pressure Screen

• Ultrasound provided the data I needed to

determine the condition of these bearings

Top Pressure Screen

• Ultrasound waveform indicated heavy

impacting

• Decibel level had been steadily increasing over

time

• Decision made to replace rotor section
• Monitored dB level until rotor replacement
• Rebuilt removed rotor and installed remote

sensors

Top Pressure Screen

• Bearing damaged and grease was burnt

Top Pressure Screen

• Bearing appeared to be starting to lock up
• The inner race also appeared to be starting to

move on the shaft

Top Pressure Screen

• Remote vibration accelerometers and

ultrasound sensors were installed

Accelerometer Shielded Ultrasound Sensor Drive Side

Top Pressure Screen

Opposite Drive Side Ultrasound Sensor Tri-axial Accelerometer

Top Pressure Screen

• Ultrasound provided us the ability to

determine the condition of the pressure screen shaft bearing when an accurate vibration method could not be used

• Ultrasound provided the data to show that

better vibration monitoring of this pressure screen shaft was needed

Yankee Exhaust Fan

• Noticed 1x’s impacting with ultrasound in

both fan bearings. Vibration was not showing anything significant at this point.

• Monitored level and noticed rms amplitude go

down and then back up in vibration.

• The impacting in ultrasound continued
• Ultrasound started showing 1x’s impacting

with a slight amplitude rise close to 1/2x’s

Yankee Exhaust Fan

01/15/16 02/05/16

Yankee Exhaust Fan

• Impacting in ultrasound had increased

significantly by 03/15/16 indicating 1/3x’s and 1/2x’s events

03/15/16

Yankee Exhaust Fan

• Vibration at this point was showing a

significant looseness signature

Yankee Exhaust Fan

Yankee Exhaust Fan

• Fan bearing caps were removed for inspection
• Excessive wear of liners noted with minimal

wear on shaft

• Oil filtering system found to be inoperative
• Water cooling system piping partially clogged
• System was cleaned, new bearing liners,

piping and oil was installed

• Fan was balanced

Yankee Exhaust Fan

Fan Side Bearing

Yankee Exhaust Fan

Smearing of Bearing Surface This Bearing Surface is Smooth Why ?

Yankee Exhaust Fan

Smearing of Undercut Bearing Surface

Yankee Exhaust Fan

03/15/16 03/21/16

Yankee Exhaust Fan

Yankee Exhaust Fan

• Early detection by ultrasound enabled us to stage parts

and tools needed to accomplish this repair, reducing the time required to complete significantly

• As we watched the defect progression, it gave us the

time to schedule the repair during a shut down

• With the advanced notice we were able to schedule

the help of the fan manufacturer

• We had the time to gather the proper documentation,

manuals, etc. to complete the repair to factory specifications

Yankee Drive Bearing

• Vibration signature change on 06/17/13
• Vibration amplitude was very low and

appeared to show a roller defect frequency with a few harmonics

• Amplitude and harmonics noticeably

increased one month later on 07/17/13

• Speed changes affected amplitude, noise and

harmonics levels some

Yankee Drive Bearing

06/17/13 07/17/13 06/13/14 08/21/15 09/16/15 09/23/15 06/09/15

Yankee Drive Bearing

• Vibration amplitude and harmonics levels did not

change excessively for almost two years

• Oil analysis started detecting higher copper levels

and ultrasound started detecting light impacting

• The vibration level started to increase again on

06/09/15 and ultrasound started detecting higher amplitude impacting

• Due to the impacting increase detected with

vibration and ultrasound the bearing change was scheduled

Yankee Drive Bearing

02/18/14 06/09/15

Yankee Drive Bearing

08/21/15 09/16/15

Yankee Drive Bearing

09/23/15 09/29/15

Yankee Drive Bearing

• Ferrous metal started to show up in the oil

just before bearing replacement

Yankee Drive Bearing

Yankee Drive Bearing

Yankee Drive Bearing

Yankee Drive Bearing

Yankee Drive Bearing

10/08/15 09/29/15

Yankee Drive Bearing

• The early detection and removal of this

bearing prevented any damage to the inner and outer races

• This saved us $30,000.00 in costs to rebuild

the bearing

• It potentially saved us millions in repair and

down time costs had the roller failed and spun the bearing on the shaft

Yankee Tad Supply Fan

• This fan had been showing a looseness

signature intermittently for some time

• I informed maintenance when looseness first

appeared

• Inspection revealed what was thought to be a

chattering guard

• Guard was fixed and next route data collected

did not show any looseness

Yankee Tad Supply Fan

• This same cycle went on until ultrasound

started detecting impacting on the opposite drive end fan bearing 11/06/15

Yankee Tad Supply Fan

11/06/15 01/08/16 01/13/16 02/10/16 03/15/16 03/18/16 04/28/16

Yankee Tad Supply Fan

Yankee Tad Supply Fan

• When ultrasound started to show impacting I

started to suspect another problem

• The guards were removed to determine if one
• f them was causing the impacting
• Impacting remained the same with guards

removed

• Collected more vibration and ultrasound data

to determine source

Yankee Tad Supply Fan

Yankee Tad Supply Fan

01/08/16 02/10/16

Yankee Tad Supply Fan

03/15/16 03/18/16

Yankee Tad Supply Fan

• Data collected on 04/28/16 shows that the

impacting had returned

04/28/16

Yankee Tad Supply Fan

• I suspected a damper problem and requested

an internal fan inspection ASAP

• I cross referenced impacting dates with

damper settings in PI

• Internal inspection and PI information

confirmed damper bearing damage, bushing damage, and missing nuts from rod ends

Yankee Tad Supply Fan

Missing Balls

Yankee Tad Supply Fan

Missing Balls Damaged Cage

Yankee Tad Supply Fan

Rod End Nut Missing

• n Top Damper Vane

Yankee Tad Supply Fan Damper Settings PI Chart

03/16/2016 03/17/2016 04/07/2016 04/21/16

Reliability Program Assets

Ultrasound Oil Analysis Vibration Motor Current Analysis Ultrasonic

Conclusion

• The use of ultrasound in our plant has saved us energy,

downtime, and equipment damage

• It has added a level of safety to our infrared inspections

that we did not have before

• It has speeded up the inspection process by acting as a

screening tool when inspection time is short

• It has added real value to our lubrication program by

allowing us to lubricate on condition instead of time and quantity intervals

• The real value of ultrasound is its ability to speed up

the inspection process and find the anomalies that the

• ther technologies do not

Questions?

Richard Larmouth Plant Reliability Specialist Clearwater Paper Corporation richard.larmouth@clearwaterpaper.com