So What`s the need for predictive maintenance
Transcription
So What`s the need for predictive maintenance
So What’s the Need for Predictive Technology? Terry L Haycraft National Reliability Manager Frito-Lay, Inc May 2010 Frito-Lay, Inc. All Rights Reserved Because……. -Every .1 of Equipment DT reduction gets tougher to get each year -Seasoned Mechanic Retirements - We can not afford a lengthy “learning curve” for new mechanics -No direct feedback on Corrective or PM Jobs -Need a tool to transition from Time/Usage PM’s to Condition Based PdM - The #1 reason for premature failure is Over Lubrication of equipment Frito-Lay, Inc. All Rights Reserved Equipment Demographic 61% of Plants Were Above 2% Equipment DT Pulaski 0.89 Orlando 0.88 0 – 1.0% FF East 1.85 Casa Grande 1.76 Brookhollow 1.74 Topeka 1.58 Kirkwood 1.46 Canton 1.71 FF Core 1.63 Perry 1.06 Fayetteville 1.01 Vancouver 1.63 Lethbridge 1.02 Beloit 1.61 1.1 – 1.5% 1.6 – 1.9% Arlington 2.59 Williamsport 2.44 Modesto 2.37 Jonesboro 2.36 Irving 2.32 W Valley 2.12 Killingly 2.05 Lauzon 2.26 Tabor 2.39 2.0 – 2.5% Charlotte 2.92 Wooster 2.79 York 2.70 Cambridge 2.69 Cucamonga 2.64 Kentville 2.86 2.6 – 2.9% Equipment Down Time Frito-Lay, Inc. All Rights Reserved 2005 Lynchburg 3.29 Aberdeen 3.23 Rosenberg 3.22 San Antonio 3.08 Kern 3.08 Denver 4.49 DBS 4.25 3.0 – 3.5% 3.6 and over Equipment Demographic Kirkwood .85 Perry .91 Pulaski 0.73 Orlando 0.65 Fayetteville .89 Casa Grande .88 Modesto .99 Williamsport .65 0 – 1.0% FF Core 1.17 Topeka 1.47 West Valley 1.20 FF East 1.11 Beloit 1.20 Wooster 1.20 York 1.38 Canton 1.24 DBS 1.25 Denver 1.05 Killingly 1.42 Brookhollow 1.56 Lauzon 1.33 Lynchburg 1.70 Jonesboro 1.84 Aberdeen 1.67 San Antonio 1.92 Rosenberg 1.69 Cucamonga 1.96 Cambridge 1.87 Lethbridge 1.61 1.1 – 1.5% 1.6 – 1.9% 80% of Plants Are Currently Below 2% Equipment DT Vancouver 2.36 Irving 2.46 Charlotte 2.11 Tabor 2.51 2.0 – 2.5% Arlington 2.81 Kern 2.84 Kentville 2.73 2.6 – 2.9% Equipment Down Time Frito-Lay, Inc. All Rights Reserved 2010 3.0 – 3.5% 3.6 and over PREDICTIVE SOLUTIONS SAVE $$ COST & TIME FOR REPAIRS $$ $$ Frito-Lay, Inc. All Rights Reserved COST OF DOING NOTHING $ 100xTHOUSANDS Replace machine Major outage Plant damage $ 10xTHOUSANDS TEMPERATURE VIBRATION TECHNOLOGY PARTICULATE MONITORING STRESS WAVE ENERGY TECHNOLOGY ULTRASOUND TECHNOLOGY Turn shafts Replace bearings Replace gears $ THOUSANDS Align shafts Replace bearings Purge particulates $ HUNDREDS Change lubricant Pack bearings “Predictive” Solutions we have Used -Running PM’s: Observation based -3rd Party Vibration Analysis-usually once a Quarter -Lazer Alignment -Temperature Reading -Electrical Condition Monitoring -Oil and Lube Analysis -Precision Balancing -Thermography Program -Ultrasound-UE 2000-Rolled out as RC Tactic Frito-Lay, Inc. All Rights Reserved What about On-Line Systems? $6,000 per Point vs. Average DT Cost of $500 per Hour Frito-Lay, Inc. All Rights Reserved ADVANTAGES OF ULTRASOUND •DIRECTIONAL •LOCATABLE •MULTIPLE APPLICATIONS FOR OUR SITES •UTILIZABLE IN ALL ENVIRONMENTS •EARLY WARNING FAILURE INDICATION •SUPPORTS OUR OTHER TECHNOLOGIES •Affordable………. Frito-Lay, Inc. All Rights Reserved Ultrasound Technology Ultraprobe 10,000 •Records and analyzes sound samples •Performs Condition Analysis •Stores test data •Trends Results •Allows us to review inspection results •Allows us to manage the test data colleted Mechanical Inspection/Trending •Bearing Condition •Rubbing Conditions •Cavitation •Gears/Gear Boxes •Pumps/Motors •Lack of Lubrication UE SYSTEMS INC. All Rights Reserved Leak Detection/Energy Audits •Compressed Air •Compressed Gases (O2, NO, etc.) •Vacuum Leaks •Seals & Gaskets •Condenser Tubes •Hatches •Boilers •Heat Exchangers •Valves •Steam Traps Electrical Inspection •Arcing •Tracking •Corona •Switchgear •Transformers •Insulators •Relays •Bus Bars Ultrasound Technology Ultraprobe 201 Grease Caddy •The Ultraprobe 201 Grease Caddy provides visual/audible indication for controlling grease addition to bearings. •Prevents Over Lubrication of bearings •Audibly hear when grease is being applied •Multiple mechanics have been trained to successfully operate the grease caddy. •Extremely helpful in dictating the amount of grease needed to lube bearings •Will be used as a separate PM in Avantis •Recognize when to STOP greasing!! “Over Lubrication is the #1 Cause for Premature Bearing Failure”! UE SYSTEMS INC. All Rights Reserved LEVELS OF SEVERITY dB Levels over Baseline 8 dB LUBRICATION 12 dB MINOR DAMAGE-Microscopic faults 16 dB DAMAGE-Visual faults 35+ dB CATASTROPHIC FAILURE IMMINENT UE SYSTEMS INC. All Rights Reserved DBS Alpha Site What they did… • Baseline Overview of the technology • Purchased / Set up the Ultraprobe 10000 and software • Purchased Ultraprobe 201 Grease Caddy • Developed routes for all processing lines • Secured Level 1 Certification of Mechanic • Performed Surveys for Mechanical, Electrical, & RC • Secured job aids and tools • Routes include 2x month on critical equipment and 1x for others Frito-Lay, Inc. All Rights Reserved Route Development Steps • Walk line and identify equipment and parts to be measured • Input points identified into DMS software • Download route into gun • Walk route and take initial baseline measurements - Running PM’s with a Purpose Frito-Lay, Inc. All Rights Reserved DBS Routes • Baked Cheetos – Number of points (121) – Time to develop and measure baseline (24 hrs) – Time to execute route (1 hr) • Baked Lays – Number of points (319) – Time to develop and measure baseline (36hrs) – Time to execute route (3 hrs) • Baked Doritos – Number of points (247) – Time to develop and measure baseline ( 30 hrs) – Time to execute route (3 hrs) • Pretzels Line 3 – Number of points (209) – Time to develop and measure baseline (12 hrs) – Time to execute route (1.5 hrs) Frito-Lay, Inc. All Rights Reserved Condition Based PdM Findings Mechanical Inspection/Trending Frito-Lay, Inc. All Rights Reserved Condition Based Preventive Inspections Baked Cheetos – Clextral Extruder shaft block bearings – The bearings seals had blown out leading to under-lubricated condition of these critical bearings – Early detection saved a total of $5600 in parts and prevented 12 hours of unscheduled downtime Frito-Lay, Inc. All Rights Reserved Condition Based Preventive Inspections Baked Cheetos – Oven Exhaust Fan Motor – During periodic route checks a significant sound change was noted. Bearing on the motor was trending towards failure. – The motor was replaced and prevented 1 hour of unscheduled downtime Frito-Lay, Inc. All Rights Reserved Condition Based Preventive Inspections Baked Doritos – Sheeter Back Roll Motor – Ultrasonic measurement indicated the motor bearings were starting to fail – The motor was replaced and prevented 1 hour of unscheduled downtime Frito-Lay, Inc. All Rights Reserved Condition Based Preventive Inspections Baked Lays – Sheeter utilizes 10 Reggiani gearboxes – Reggiani gearbox main bearing is prone to high wear and failure – Routine ultrasound inspection is enabling proper lubrication to prevent bearing/gearbox failure. – 6 week lead time on replacement gearboxes Frito-Lay, Inc. All Rights Reserved Condition Based PdM Findings Electrical Inspection Frito-Lay, Inc. All Rights Reserved Condition Based Preventive Inspections Main Switch Gear – Anomalies were heard during ultrasound inspection – A follow-up thermograph inspection confirmed high heat on 2 out of 3 phases – Based upon ultrasonic and thermo graphic information, the plant was scheduled down to replace the breaker – Continued operation, without the scheduled work, would have likely resulted in a plantwide unscheduled downtime event. Frito-Lay, Inc. All Rights Reserved Condition Based Preventive Inspections Main Transformer – Ultrasound Probe picked up evidence of Tracking – Transformer is 40 feet up on utility pole – Site contacted utility co. – Utility Co. confirmed. – They wanted to shut it down. – Scheduled shutdown found that the fuse holders had separated and caused the tracking. – DT Avoided est. at 2 days Frito-Lay, Inc. All Rights Reserved Condition Based PdM Findings Leak Detection/Energy Audits Frito-Lay, Inc. All Rights Reserved Resource Conservation • DBS had completed 104 air leaks repairs since May 2009 • Most common types of leaks found were fittings and regulators • Tags are tracked using works orders and spreadsheet Frito-Lay, Inc. All Rights Reserved Copyright 2008 by UE Systems Inc. Patent Pending. June 2009 Air Leaks Repaired Record Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Argon Leaks Repaired Helium Leaks Repaired Hydrogen Leaks Repaired Nitrogen Leaks Repaired CFM Cost CFM Cost CFM Cost CFM Cost CFM Cost 73.2 $7,592.72 0.0 $0.00 0.0 $0.00 0.0 $0.00 0.0 $0.00 Problem Description CYLINDER LEAKING REGULATOR LEAKING COPPER LINE IS LEAKING TRACKING REGULATOR IS LEAKING TRACKING REGULATOR LINE HAS LEAK TRACKING REGULATOR IS LEAKING AIR INLET FITTING IS LEAKING CYLINDER FOR WATER VLV FITTING AIR INLET BY THE COOKER IS LEAKING Repaired (Y/N) Y Y Y Y Y Y Y Y Y Work Order Schedule # 14704 14704 14704 14704 14704 14704 14704 14704 14704 TRACKING FILTER FITTING IS LEAKING AIR INLET FITTING IS LEAKING AIR INLET FITTING IS LEAKING FL710 FILTER FITTING IS LEAKING FL710 REGUALTOR FITTING IS LEAKING FL710 REGUALTOR FITTING IS LEAKING WATER VALVE AIR LINE HAS A HOLE MAC VLV BY THE COOKER IS LEAKING FITTING BY THE COOKER IS LEAKING AMBIC DSC PUMP GAUGE IS BUSTED Y Y Y Y Y Y Y Y Y Y 14704 14704 14704 14704 14704 14704 14704 14704 14704 14704 Group Name EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED Location Name L3 CYLINDER L3 KLN REG L3 KLN LINE L3 TRK REG L3 TRK LINE L1 TRK REG L1 AIR INLET L1 COOKER L1 PRF INLET EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED L3 TRK FITTING L3 AIR INLET L3 AIR FITTING L3 FL710 FLTR L3 FL710 REG L3 FL710 REG L3 COOKER L3 PROOF BLT L3 PROOF BLT L1&3 AMBIC Pressure at Type of Gas Leak dB Reading Air 75 63 Air 75 63 Air 75 53 Air 75 78 Air 75 85 Air 75 60 Air 75 75 Air 75 49 Air 75 55 Air Air Air Air Air Air Air Air Air Air 75 75 75 75 75 75 75 75 75 75 55 42 33 63 26 38 71 61 58 102 CO2 Cost Avoidance Identified Repaired $7,592.72 $7,592.72 % complete 100% NO SO2 Identified Identified Identified 179368 181 389 CO2 SO2 Identified Energy NO leaks Cost Size of Leak Avoidance Avoidance Avoidance Avoidance Avoidance CFM (kWh) (lbs) (lbs) (lbs) $421.57 4.1 7026 9959 10 22 $421.57 4.1 7026 9959 10 22 $325.41 3.1 5424 7687 8 17 $580.49 5.6 9675 13713 14 30 $660.24 6.4 11004 15597 16 34 $391.86 3.8 6531 9257 9 20 $547.37 5.3 9123 12931 13 28 $289.33 2.8 4822 6835 7 15 $343.98 3.3 5733 8126 8 18 $0.00 0.0 N/A N/A N/A N/A $0.00 0.0 N/A N/A N/A N/A $343.98 3.3 5733 8126 8 18 $229.68 2.2 3828 5426 5 12 $160.05 1.5 2667 3781 4 8 $421.57 4.1 7026 9959 10 22 $111.99 1.1 1866 2646 3 6 $197.70 1.9 3295 4671 5 10 $504.23 4.9 8404 11912 12 26 $401.68 3.9 6695 9489 10 21 $372.46 3.6 6208 8799 9 19 $867.56 8.4 14459 20495 21 44 Condition Based PdM Findings “Saves” Impact Full Year Location Baked Cheetos Baked Cheetos Baked Doritos Baked Doritos Baked Lays Main Switch Gear Utility Pole Equipment Clextral Block Bearings Exhaust Fan Motor Sheeter Back Roll Motor Lower Plenum Blower #3 Reggiani Gearboxes Main Circuit Breaker Transformer Frito-Lay, Inc. All Rights Reserved Issue Seals blown Bearings Bearings Bearings Bearings Tracking Tracking DT Hrs 12 1 1 2 1 144 288 449 % DT at % DT 1/2 the Avoidance Impact 2.28% 1.18% DBS Best Practices “Things we learned along the way” Frito-Lay, Inc. All Rights Reserved DBS Best Practices • Notebooks/binders with pictures to identify routes and equipment in order by name and number. • Every point on a route is labeled to ensure consistency in measurement location. Frito-Lay, Inc. All Rights Reserved DBS Best Practices • Priority listing on what to check and not check on route development • Items that are considered critical: – Motors – Gearboxes – Drive bearings / Tail bearings / Pinch and Tension bearings – Pumps • Items that are less critical: – Plastic housing bearings (hard to hear) – Idle bearings (can prolong the route) – Bearings that do not make a full rotation Frito-Lay, Inc. All Rights Reserved DBS Next Steps • Optimize scheduling PM’s based on Ultrasound readings to determine required lubrication and inspection • Condition Based vs. Time/Usage • Increase utilization and knowledge of sound signatures to recognize impending failures • Continue modifying machine guards to facilitate safe ultrasonic measurements without guard removal. • Increase Level 1 Certifications Frito-Lay, Inc. All Rights Reserved Observations / Recommendations • Precision Based Equipment (i.e. modules, gun) • Training on the UE 10,000 is critical to properly using the equipment. If routes are developed, it should take no more than 2 full days to bring a mechanic up to speed. • Marking inspection points on parts has proven to be difficult as bearings and motors are replaced. • Some equipment may already be near failure and will affect the initial baseline • Air/Gas Leak finds will be large at first. • The DBS Team Recommends moving to 3 Beta Sites with this Technology. Frito-Lay, Inc. All Rights Reserved Beta Site Deliverables • Diligent Selection of Ultrasound Point Person • Set up and coordinate 2.5 Day Implementation • Attendees to include: Point Person and MX BUL or Resource • HQ is picking up the cost of the equipment and implementation. Site picks up the labor costs. • Insure equipment is secured and well maintained • Development of Site wide game plan for PdM Routes • Documentation • Document findings and “saves” • Record changes in PM set up-conversion to Condition Based PM’s • Document before and after reading on equipment rebuilds Frito-Lay, Inc. All Rights Reserved Beta Site Roll-Out Success Frito-Lay, Inc. All Rights Reserved Condition Based Preventive Inspections Muncho Department – Muncho Pellet Belt Drive – Ultrasonic measurement indicated the motor/gearbox was starting to fail – Prevented 1 hour of unscheduled downtime Condition Based Preventive Inspections Fritos Main Oil Circulation Pump – Ultra Sonic Identified Bearing Failure – Planned Motor Change for Change Over – Prevented 4 hours total downtime Frito-Lay, Inc. All Rights Reserved Condition Based Preventive Inspections UTC Corn Cook Kettle – Kettle Agitator Gearbox – During periodic route checks a significant sound change was noted. – Changed bevel gears during shutdown saved 6 hours of unscheduled downtime Frito-Lay, Inc. All Rights Reserved Resource Conservation Copyright 2008 by UE Systems Inc. Patent Pending. Frito-Lay, Inc. All Rights Reserved Air Year to Date $14,834.14 Month Identified leaks Cost Avoidance Repaired Leaks Cost Avoidance % Comple te CFM Cost Dec-09 $2,684.75 $2,684.75 100% 25.9 $2,684.75 Nov-09 $5,839.94 $5,278.83 90% 50.9 $5,278.83 Oct-09 $6,309.45 $3,444.39 55% 33.2 $3,444.39 $11,407.97 81.5% Leaks Repaired Condition Based Preventive Inspections PC #2 – Replaced coupling on submerger motor – $30 part, prevented 8 hrs of down time, a hot rinse, and bent paddles. Frito-Lay, Inc. All Rights Reserved –Early detection saved a total of $2020 in parts and prevented 8 hours of unscheduled downtime. Condition Based Preventive Inspections PC #1 – Combustion Blower – Found fan had dirt buildup causing an imbalance. – Cleaned fan and replaced motor. Frito-Lay, Inc. All Rights Reserved –Repaired motor for $650 saving $850 and prevented 3 hours of unscheduled downtime. Potential Reduction of PM / Labor Hours Preventative to Predictive Shift Hrs/pd reduced PM 6.8 5.75 4 7 23.55 4 4 4 4 5 8 8 6 2 0 45 68.55 Change Running Corn Conveyor PMs Running PC Conveyor PMs FCC Thermographic PM Warehouse Pickbelt Running PM's Mechanic hours already reduced per period changed to quarterly from every 6 weeks. 19 entities at 1 hr each changed to quarterly from every 6 weeks. 16 entities at 1 hr each Cancelled. It was set up biweekly for 2 hrs Cancelled. 2 hrs every 8 weeks PC PC back Allens Running Checklist PC PC middle Allens Running Checklist PC PC front Allens Running Checklist PC 2 Running Checklist PC 1 Running Checklist TC 2 Running Checklist TC 1 Running Checklist FCC running Checklist PC Thermographic PM Kroma Sort routine idle end bearing replacement Possible Mechanic hours reduced per period Currently Monthly. 4 hrs Currently Monthly. 4 hrs Currently Monthly. 4 hrs Currently Monthly. 4 hrs Currently Monthly. 5 hrs Currently biweekly. 4 hrs Currently biweekly. 4 hrs Currently biweekly. 3 hrs Currently Monthly. 2 hrs Currently set to trigger every 6 months. Total Potential Reduction of hours identified Frito-Lay, Inc. All Rights Reserved Questions? Thank You…… Frito-Lay, Inc. All Rights Reserved