Chris Tindell Alcoa Point Comfort Operations

Transcription

1 Chris Tindell Alcoa Point Comfort Operations

2 I m not claiming expertise in the subject of ultrasound. I am only sharing what we are doing and I am here to learn and improve our process.

3 Why are we here? Learn how to implement an ultrasound program to reduce costs. Learn how to align ultrasound with my other CBM technologies We have a program but we are not getting the results we expected We want to expand our program Clearwater Beach Benchmarking and Best practice

4 Audience Poll Condition Based Maintenance? Ultrasonic Vibration Infrared Electrical Signature Oil Analysis Asset basic care inspections? Operational Checks Precision Operational Procedures Precision Maintenance Procedures? Assembly Procedures/Checklists Installation Procedures/Checklists Defined quality control process with acceptance testing

5 What makes up the HUMP Getting Buy in Complete Repairs Awareness Training Qualification Experience Generate Follow up Work Certification Training Aligning Vision Resources Defining Metrics Purchasing Equipment Define Goals Budget

6 What not to do

7 Our Current Ultrasound Program Personnel 10 Level 1 Technicians 2 Power House Supervisors 8 Machinery Lubrication Techs 11 Level 2 Technicians 4 Operator PdM Techs 6 Mechanical PdM Techs 1 Electrical PdM Tech Equipment 1 Ultraprobe Ultraprobe Lube Caddy s 1 Ultraprobe Applications Steam Trap Inspection Air Leak Survey Ultrasonic Greasing Bearing db Trending Slow Speed Equipment Analysis Diagnostics Electrical Survey Vacuum Pump Packing Inspection Conveyor Inspection Air slide conveyors Dust collector bag inspection Base Line Acceptance Testing

8 Our Journey with Ultrasound 2003 compressed air study Purchased UE 550 and utilized summer intern to survey plant (not much focus) 2005 Conference 2006 Steam Trap Survey (Tags didn t fix our problems) 2007 Steam Trap Survey (Most traps failed CLOSED)

9 Challenges with Steam Trap Program Lack of standardization with steam traps Vendor surveys & repairs added a variety of trap types Scaled Accumulators (Pockets) Installation errors Insulation over traps Piping issues Master trapping Traps installed backwards Process traps (system issues)

10 Our Journey with Ultrasound Cont 2007 Introduced Air leak Survey wkly routine Small 2hr routes Limited pathway to control chasing rabbits 2008 Focused making Air and Steam programs evergreen Trained three technicians Added one UE 9000 Scheduled instrument use

11 Air leak Program Challenges Creating Route maps It is hard to stay on a focused route because of the tendency to chase air leaks off path. Routes were inefficient due to off route losses (chasing rabbits) Training We originally skipped on a formal training class and opted for some hands on instruction. Scheduling work We tagged all leaks that were found and generated a list sighting tag locations. We originally scheduled repairs on one work order that referenced the list of repairs to be made. We determined that repairs that could not be made during the survey would require some advance planning to coordinate scheduled shutdown or isolation. Now we generate an individual work request for each leak to be scheduled and we can track repairs in our maintenance system.

12 Example Air Leak Route

13 Our Journey with Ultrasound Cont 2008 Focused lubrication initiative Engineering study to calculate a lube strategy for all assets 2009 Introduced Ultrasonic Greasing Purchased a ultraprobe 201 Grease Caddy Ultrasonic greasing trial 2010 expanded program Purchase 8 UP 201 units

14 Our Journey with Ultrasound Cont 2010 Added three additional UP 9000 s Assigned 4 Operator PdM techs to perform Air and steam inspections. The operator techs also use handheld computers to document weekly trends of the db levels for several rotating assets. Evaluating use of these trends for condition based bearing greasing Trending Waveform Crest Factor

15 Our Journey with Ultrasound Cont 2011 Added one UP and Parabolic dish Implemented ultrasound as part of our electrical distribution system inspections Introduced ultrasonic scans for precursor to IR

16 Summary Invest in continuous training and development Align program goals to organizational goals Keep it Simple Use the simplest most cost effective means to achieve your goal Rules: Ensure that activities at the task level are clearly defined and are repeatable Content, sequence, timing and outcome Customer and supplier communication is direct, binary and paced Pathways are simple and pre specified Outcomes are measured and problems are easy to identify and resolve at the activity level