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Chris Tindell
Alcoa Point Comfort Operations
“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.”
Why are we here?Learn how to implement an
ultrasound program to reduce costs. We have a program
but we are not getting the results
we expected
Benchmarking and Best practice
We want to expand our
program
Clearwater Beach
Learn how to align ultrasound with my other
CBM technologies
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
What makes up the HUMP
Resources
Complete Repairs
Generate Follow up Work
Training
Qualification Experience
Certification
Purchasing Equipment
Define Goals
Awareness Training
Getting Buy in
Aligning Vision
Defining Metrics
Budget
What not to do
Our Current Ultrasound ProgramPersonnel
Equipment
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
1 Ultraprobe 550
4 Ultraprobe 9000
8 Lube Caddy’s
1 Ultraprobe 15000
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
Applications
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)
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)
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
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.
Example Air Leak Route
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
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
Our Journey with Ultrasound Cont…
2011 Added one UP 15000 and Parabolic dish
Implemented ultrasound as part of our electrical distribution system inspections
Introduced ultrasonic scans for precursor to IR
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 goalRules: 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