TRP

“Reliable Equipment Starts With
Reliable Attention”
Total Reliability Professionals
Technologies Division
Proposal for Predictive Maint.

Industries Serviced
Pulp & Paper
 Aluminum
 Food
 Plastics
 Pharmaceuticals
 Waste Water & Treatment
 Power & Energy
 Mining
 Steel
“Reliable Equipment Starts With Reliable Attention”

Customer List
 TBD  TBD

Services Provided
 Vibration Analysis (Our Core Competency)
 Thermography
 Mechanical
 Electrical
 Ultrasonic Leak Detection
 Air & Gas Leaks
 Steam Trap Testing

Services Provided (cont.)
 Lubrication Services
 Program Setup
 Auditing
 Oil Analysis

Future Endeavors
 Maintenance Program Audits
 TBD

Individuals Who Will Be Involved
 John Ciulla, Sr. Reliability Engineer
• Level III ASNT vibration analysis
• Level I in thermography
• Level I in ultrasound
• Background in Total Reliability Practices
• Masters Degree in Mechanical Engineering
• Six Sigma Green & Black Belt
• 10 years experience in reliability field
• Vibration Analysis Committee member of ASNT

Maintenance Strategies
 Run-to-Failure: (A maintenance policy that allows a machine to run until it breaks down, at which point
reactive maintenance may be performed).
 Preventive Maintenance (PM)(Care and servicing by personnel for the purpose of maintaining equipment
and facilities in satisfactory operating condition by providing for systematic inspection, detection, and
correction of incipient failures either before they occur or before they develop into major defects).
 Predictive Maintenance: (PdM) (Techniques help determine the condition of in-service equipment in order
to predict when maintenance should be performed. This approach offers cost savings over routine or time-
based preventive maintenance, because tasks are performed only when warranted. The main value of
Predicted Maintenance is to allow convenient scheduling of corrective maintenance, and to prevent
unexpected equipment failures).
 Reliability-based /centered Maintenance: (RCM)(Reliability centered maintenance is an engineering
framework that enables the definition of a complete maintenance regime. It regards maintenance as the
means to maintain the functions a user may require of machinery in a defined operating context. Successful
implementation of RCM will lead to increase in cost effectiveness, machine uptime, and a greater
understanding of the level of risk that the organization is managing).
 Total Productive Maintenance: (TPM) (TPM is a management process developed for improving
productivity by making processes more reliable and less wasteful.TPM is an extension of TQM(Total Quality
Management). The objective of TPM is to maintain the plant or equipment in good condition without
interfering with the daily process. To achieve this objective, preventive and predictive maintenance is
required. By following the philosophy of TPM we can minimize the unexpected failure of the equipment).
Which strategy are you currently employing?

PdM vs. No PdM
Programs with PdM programs generally
have maintenance costs that run below
their budgets.
Programs without PdM programs generally
have maintenance costs that contain
peaks and valleys. The peaks can exceed
budget constraints when catastrophic
failures occur.

Vibration Analysis
 Identifies defective
bearings and
gears, looseness, rubs
, misalignment, imbal
ance, etc.
 Cost of program
startup is offset by
the results!

Case History
• This bearing is on a large
washer roll at a pulp mill
• Inner race frequencies were
detected (top spectrum)
• The bearing was reported
and the maintenance
department replaced it during
a short outage
• A new baseline was
acquired after the bearing was
replaced (bottom spectrum)
• If this bearing were to fail
online, total production dollars
lost would be estimated at
$25,000-$40,000.

Thermography
• Thermography provides the quickest return on investment of all the predictive
technologies.
• Can be used for electrical and mechanical inspections.
• Useful for roof and insulation leaks.

Case History
• The fuse from this disconnect was approaching 400 degrees.
• The case was reported but the fuse had blown before maintenance could
schedule repairs.
• Image of the fuse after it had blown is shown on the right.

Ultrasound Leak Detection
 Air and gas leak detection
 Leaks occur at high frequencies that can be detected in the
ultrasonic range.
 Generated reports will include approximate savings upon repair.
Steam trap inspection
Ultrasound can be used to detect steam traps that are stuck open
or closed.
 Generated reports will include approximate savings upon repair.

NDT – Visual Inspection
Most basic and common
inspection method.
Tools include fiberscope's,
borescopes, magnifying
glasses and mirrors.
Robotic crawlers permit
observation in hazardous or tight
areas, such as air ducts, reactors,
pipelines.
Portable video inspection unit
with zoom allows inspection of
large tanks and vessels,
railroad tank cars, sewer lines.

NDT – Penetrant
• A liquid with high surface wetting characteristics is applied to
the surface of the part and allowed time to seep into surface
breaking defects.
• The excess liquid is removed from the surface of the part.
• A developer (powder) is applied to pull the trapped
penetrant out of the defect and spread it on the surface
where it can be seen.
• Visual inspection is the final step in the process. The
penetrant used is often loaded with a fluorescent dye and
the inspection is done under UV light to increase test
sensitivity.

NDT – Magnetic Particle
The part is magnetized. Finely milled iron particles coated with a dye
pigment are then applied to the specimen. These particles are attracted to
magnetic flux leakage fields and will cluster to form an indication directly over
the discontinuity. This indication can be visually detected under proper
lighting conditions.

Magnetic Particle Case Histories

Power Loss Due to
Angular Misalignment
For example, a 500 HP ID Fan
that is operating 24/7 (or 8760
hours) at a misaligned condition
of 10 mils at a cost of $0.11 per
kilowatt would have an effective
power loss of $3,595.00 per year
500HP x 7.19 = 3,595
Aligning the shaft to 0.50 mils
would result in a power loss of
$180.00 per year. This results in
a savings of $3,415.00 per year.

Equipment Set-Up
Obtaining information from machine components
is critical in the accurate diagnosis of a machine.
Important information includes:
• Speed
• Bearing numbers
• Number of vanes/blades
• Gear tooth counts
• Machine configuration
• Load
• Sheave sizes
• Belt lengths

Reporting
Standard report includes machine sketch or image with
all necessary information included:
• Survey Date
• Machine ID
• Machine Area
• Severity Code
• Findings
• Recommendations
Reports can be altered to meet our customer’s needs

Reporting – Asset Health
All reports include an asset health spreadsheet that
contains information on every asset that is analyzed in
the plant. It includes:
• Color codes based on severity
• Percentage of assets in alarm
• Machine ID’s and area
• Machines that were not in operation during the
survey
• Overall plant vibration (in the case of a vibration
survey)
Reports can be altered to meet our customers’ needs

Emergency Reporting
• Many times a report is needed immediately after a
machine has been analyzed.
•TRP Reliability Engineers carry field service reports
for these occasions.
• They provide the maintenance department with a
report for those crucial meetings where timely
decisions need to be made.

KPI’s for Measuring Success
 Cost savings analysis
 Emergency repairs as % of scheduled repairs
 Planned and scheduled work completion
 Maintenance overtime as % of overall time
 PM hours completed on time as % of
scheduled PM hours (Refer back to benchmark
data)

Cost Savings Analysis

Questions?

TRP

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