How equipment reliability delivers low cost, energy efficient assets at plants around the world!

Transcription

1 How equipment reliability delivers low cost, energy efficient assets at plants around the world!

2 Background on topic Savings Opportunities Incorporating Energy Management to Equipment Reliability Q&A s

3 It s about common sense & doing the right things! Energy Efficiency is a by-product of Reliability. It s about making more with less and doing our part to make our manufacturing companies more reliable, energy efficient, cost effective and competitive. This topic is about being smart, being responsible and being successful.

4 Energy KPI s are the key to driving behaviors. o o kwh/ton product, Gallons/ton product, etc. Total Site vs. Area vs. Specific Equipment Worth Repeating: o o Measurement is the first step that leads to control and improvement. If you can t measure something, you can t understand it. If you can t understand it, you can t control it. If you can t control it, you can t improve it.

5 In Clean, Green & Reliable we look specifically at 10 different areas or systems in which energy savings abound when focus is placed on equipment reliability. Today we are going to explore a couple of those systems to highlight the relationship between energy and reliability. o Compressed Air Systems (leak detection) o Hydraulic Systems

6 Compressed Air Systems: Approximately 70% of plants use a compressed air system to power machine tools, material handling equipment, separation equipment and spray painting equipment. Energy audits the DOE conducted suggest that more than 60% of compressed air systems at small to medium sized industrial facilities have mid-cost energy conservation opportunities.

7 More than 85% of the electrical energy input to an air compressor is lost as waste heat, leaving less than 15% of the electrical energy consumed to be converted to pneumatic compressed air energy (U.S. DOE-ITP EM, 2008). Most leaks are at threaded connection points, rubber hose connections, valves, regulators, seals, and in old pneumatic equipment.

8 VFD s. Inadequate maintenance can lower compression efficiency, increase air leakage or pressure variability and lead to increased operating temperatures, poor moisture control and excessive contamination. Better maintenance will reduce these problems and save energy! Things to do: Reduce demand, proper maintenance, monitor, reduce leaks, use electronic condensate drain traps, reduce inlet air temps, properly size pipes, heat recovery, and utilize

9 A chemical plant undertook a leak prevention program following a compressed air audit. The program found 100 leaks of 1/32 in. at 90 psig, 50 leaks of 1/16 in. at 90 psig and 10 leaks of 1/4 in. at 100 psig. Assuming 7,000 annual operating hours, an aggregate electric rate of $0.05/kWh and compressed air generation requirement of approximately 18 kw/100 cfm, the annual cost savings attributable to leak elimination would be in excess of $57,000. with the 10 leaks of 1/4 in. account for almost 70% of that total.

10 A typical predictive technology applied to compressed air systems is that of Airborne Ultrasonics. This technology and approach should be incorporated into a leak detection program and include all forms of media (i.e., Gases, Oil, Water, Steam, etc.). Implement a Best Practices Leak Detection Program with specific procedures!

11 Hydraulic Systems: when it comes to hydraulics there are two types of hydraulic systems; the first is clean, efficient and reliable, the second is dirty, inefficient and unreliable. What few people understand when it comes to hydraulic systems is particles as small as 2 microns can have a significant effect on the performance on hydraulic components and pump life.

12 As we look at hydraulic systems today over 80% of hydraulic system failures are directly related to the contamination or cleanliness of the hydraulic fluid. Contaminants within your hydraulic fluid result in increased wear to your pump, wear of the pump creates more contaminants within the fluid, particles in the 3 to 20 micron range pass freely through standard filtration systems resulting in erosion and abrasion of servo valves and ports.

13 Hydraulic leaks like the one pictured are a common occurrence with dirty, unreliable and inefficient hydraulic systems. It is important to understand that while the system is under pressure and warm the fluid leaks out, when it is shut down and cools the dirt collected around the leak site will be sucked into your system and result in abrasive wear of your system components.

14 A clean hydraulic system sets the groundwork for achieving a reliable and efficient system. Keeping your system clean begins with a filter cart and the education of your lubrication technician. Every ounce of fluid we put into our hydraulic system reservoir needs to be filtered to a cleanliness that meets or exceeds the ISO standard we set for our system.

15 So what is efficiency when it comes to hydraulic systems? Being efficient when it comes to hydraulic systems is being able to provide adequate hydraulic pressure and flow to operate our field devices in a way that uses the least amount of power with no health safety or environmental impact.

16 If you want an efficient hydraulic system, keep it clean. Keeping your fluid and system clean works not only for reliability but for efficiency as well, clean systems use less energy and because they are leak free there is no safety or environmental impact.

17 RECOGNIZE Pre-Work (duration: 2 days) RATIONALIZE Pre-Work (duration: 3 days) RATIFY Week 2 Management Awareness, Energy Team Selection Initial Site Walkthrough Historical Energy Data Analysis Carbon Footprint Analysis Improvement Opportunities Prioritized Energy Efforts Identify Plant Resources & Constraints to be Released Review System Production History System Specific Energy Analysis Tools / PdM Inspections Energy Savings Implementation Plan Prioritized Action Items R.A.S.C.I Development Development of Energy KPI s Work with Supervisors to Implement Action Items Installation of Metering Devices Review System Maintenance History Completion of Action Item Tasks Benefits Documented & Check Against Charter Leadership Alignment To Charter Sustainability Measures, Continuous Improvement RESOLVE Week 3 Rapid Action Team On-Site REALIZE Weeks 4-6

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19 As reliability engineers, we find it exciting that nearly every major company in the world includes pages in regard to energy efficiency and environmental responsibility on their corporate web sites. We re excited because we know that reliable systems, reliable processes, and reliable assets are both energy efficient and environmentally responsible.

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21 Doug Plucknette mobile: : DPlucky Chris Colson colsonc@alliedreliability.com mobile: : colsonchris Thank You!