By Victor Foster Riley Carter Jared Prater Byron Janke

Transcription

1 By Victor Foster Riley Carter Jared Prater Byron Janke

2 Graduated from UTK RMC program as ME Certificate of Reliability and Maintainability Two R&M Internships - DuPont Dow Chemical Reliability Engineer - CPE Mechanical Engineer - Engage Plastic Reliability Engineer - Engage and EPDM Plastic Smurfit Stone Paper Company (Now RockTenn)(Now West Rock) Reliability Engineer - Panama City Mill Mechanical Reliability Leader - Division Cargill Sr Reliability Engineer - Corn Milling Lucite Chemical Reliability Engineer

3 Produces around 40% of world production of Methyl methacrylate (MMA) Subsidiary of Mitsubishi Rayon Also produces carbon fiber in the US MMA Sites Memphis TN Beaumont TX England China England Japan Soon to be Middle East

4 Lubrication Program Assessing Operations Criticality Cleaning/organizing CMMS Predictive Technology Extras projects December Intern Mobile Data Gathering

5 All oils/grease used on site have been documented by equipment number. list has been consolidated to one brand when possible Contacted shops/vendors to confirm what grease they use in our equipment.

6 - As we develop a lubrication program we want to make safeguards against improper oiling/greasing. - The one point lesson will be posted for operators and mechanics to reference.

7 Pumps and motors have been tagged accordingly to ensure proper lubrication is used. Other tagging options may need to be considered in the future. (Metal Tags, color-coded stickers )

8 Dirt and water in your oil can lead to frequent failures, therefore reduced production and increase of wasted man hours. 70% of mechanical failure are lubrication related. Metal containers are inherently dirty and promote condensation formation.

9 Work is currently underway to build a new oil storage/filtration room to house our lubricants in a clean, and organized way to prevent against dirt and water contamination. Insulation, Flooring, and electrical, AC unit has been installed. The storage/filtration components have arrived. Byron Janke Victor Foster Jared Prater

10 What we started with.. Empty Room Clean Room

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15 Oil Transfer Containers Stackable Tank Storage/Filtration Drum Topper Filtration Color-coded spouts

16 Equipment numbers and Possible failure modes of all items checked on rounds have been documented. Operator Round PMs, FMs, etc have been uploaded to CMMS

17 Rotameters were labeled poorly (wrote #1 in sharpie on plate to refer to position on operator rounds sheet) Large percentage of rotameters have been labeled correctly to ensure ease of identification for operators.

18 Installed visual vinyl film to gauges to provide visual help to operators.

19 A criticality assessment of all assets in MMA is has been completed with the help of James /Floyd /Jim. This will help us to analyze if our maintenance strategies are being focused in the right direction. Critical assets need to be observed with predictive technologies. Why do we have so many PMs on an asset with a low criticality ranking?

20 Criticality results on 1,584 assets were documented. 147 assets (6.8%) were deemed to cause some MMA production loss if failure occurred, ranging from hrs. 116 (5.4%) pieces of equipment were deemed obsolete/no longer in use. 42 (1.9%) pieces of equipment were renamed to provide more clarity.

21 SHE criticality deals with the safety, health, and environmental impact of a loss of containment from an asset. (vessels, piping systems) Business Criticality -The factors affecting this criticality include possible production loss or downtime, possible reduced rates or efficiency, and maintenance repair costs.

22 Another thing accomplished through criticality is documentation of the fluid/gas running through every piece of equipment, and the conditions its under.

23 CMMS has been updated to allow us to add Parents/children/grandchildren/ siblings to equipment This will allow quicker searching for equipment and parts in the new CMMS. Will also allow us to advance our FMEA capabilities by looking at parents and children of failing equipment. We have added parents to several hundred pieces of equipment so far.

24 34 man hours have gone into taking pictures of parts in the warehouse. This will help maintenance in ordering correct parts and avoiding confusion.

25 The use of predictive technologies allows us to determine possible failures before they occur, decreasing downtime and production loss Vibration Analysis Ultrasound Infrared Stroboscope

26 Measures temperature of objects by measuring emitted infrared energy. Can find leaks in piping systems/vessels. Can detect bearing and coupling temperatures. We currently use for electrical but operators will be trained to mechanical purposes.

27 Find compressed air leaks, bearing defects. Identify electrical emissions #1 tool for analyzing steam traps. Operators have been trained to use this technology.

28 Used to detect misalignment/unbalance in machines. Used most prominently to identify bearing failures. Jared Prater Motor & Fan bearing types have been documented in software.

29 Used to determine the speed of rotating equipment. Provides ability to observe rotating equipment as if it were stationary. Knowing the rotational speed of machine is critical in insuring machine is running within design parameters.

30 Tools will be part of planned 2018 operator and maintenance precision training

31 Operators have been trained on Ultrasound as well as basic oil/grease lubrication. Did you know grease is 80-95% oil? Exxon Mobile Lubrication & Grease 101

32 Pump Serial Numbers have been collected and sent to Centro/Flowserve. Centro/Flowserve will send all information they have for those pumps (pump curve, impeller size, etc.) Older M2 pumps will be replaced first. Pump info will then be uploaded to Lotus Notes.

33 Sheeting wanted to add 10x the weight. Made contact with engineers and received analysis to prove added weight would be safe.

34 Oleum tower pump suspected of running off curve Spoke to Weir Minerals, confirmed that the pump was running in it s curve

35 We are working towards building a tool to help us to record the suction pressure on pumps with a double seal pot. We will send the suction and discharge pressure to the manufacturer, and receive the correct pressure the pots should be running at. Once the seal pot pressures are fixed, we will label them with vinyl so that personnel on site will know if they are running at the correct pressure.

36 32,577 attributes uploaded to CMMS equipment files

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38 All Oil spares and containers labeled and organized with spill containment

39 $5800 Labor Savings vs contractor over 80 hours 106 Equipment area reclassifications 83 Equipment descriptions updated 44- Equipment pictures documented 22 Equipment name plate data documented Equipment Parent/Child Documented 44% - spare parts, owners manuals, and others documents documented in Lotus rotating equipment files for future FMEA (Will help to support Sinclair Process) Oil room organization and labeling. (Pic on cover)

40 168 Pump spare parts list review for critical capital long lead time spare parts review. List is now being reviewed by craft Goal is to submit a capital request to fill critical spare gaps in inventory for rotating equipment.

41 Custom forms with pictures All data upload to Google Docs

42 Questions?