Porres - XOM Open Gear Inspections

FES Americas Meeting July 2006, F. PorresExxonMobil Use Only

ExxonMobil Open Gear Inspection Tool KitExxonMobil Open Gear Inspection Tool Kit

FES Americas Meeting July 2006, F. Porres ExxonMobil Use Only

Agenda

Main Reasons / Customer Needs

Industries to Use the Open Gear Kit

Opportunities with the Open Gear Kit

Synthetics

Cd Open Gear to Help Optimize the Kit

Necessary Equipment to Perform OGI

Preliminary Information for OG Inspection

Open Gear Inspection Tool Kit

How to Get the Kit

Follow Up & Next Steps

Success stories

Questions ?

Agenda


Agenda Solve product application problems (adequate lubricant ?)

Determine accurate EHL (proper oil film and viscosity ? 460 cSt OK)

Resolve equipment failure, downtime and low production

Vibrations & Misalignment (temperature)

Noise

Load

Wear

Enhance Peak Performance of equipment

Implement predictive / preventive maintenance procedures to increase equipment reliability

Optimize consumption (No leaks)

Plant Expansions, Up grades, Major equipment repairs, improve TCO, Involved buyer that values service

Opportunity to sell synthetics and improve product mix.

Main Reasons / Customer Needs


AgendaMain Reasons / Customer Needs

Uphill end Dry ! See view down filling tube


AgendaMain Reasons / Customer Needs


Agenda Cement (Girth & Pinion)

Kiln

Cement Mill

Critical Gears

Sugar Industry

Gears in Grinding process

Mills speed reducer gears

Steel Mill Gears

Paper Industry Mills

Rubber Industries

Mining Industry

In general any industry with Gears !

Industries to Use the Open Gear Kit


Agenda

Determination of poor Alignment of shaft and components (reduce wear of equipment).

Improve any vibrations presence (to extend components life)

Evaluation of Correct Lubricant (adequate additives)

Determine accurate EHL (oil film)

Proper Load (retrofit of equipment for higher production, fatigue)

Optimization of Oil (no leaking guards or seals)

Reduction of Operating Temperature (reduce friction & extend components life)

Minimize Noise (proper contact of gears)

Mitigate Contamination (environmental issues)

Reduce TCO (currently using Kluber, Tribol or Fuchs technology), XOM SYNTHETICS !

Opportunities with Open Gear Kit (1/2)


Agenda Demonstrate ExxonMobil capabilities

Familiarize more with Equipment and components of customer

Emphasizes Technical Knowledge and Expertise with customer

Provide opportunities to develop Case Histories and POP’s

Develop a test site for future product enhancements

Improves and strengthens relationship with customer and equipment builders

Increases Company Profitability with a better product mix XOM SYNTHETICS ! Increases the opportunity to sell services to customers.

Peace of mind for customer !

Opportunities with Open Gear Kit, (2/2)


AgendaSynthetics way, OG Performance & Appearance

Synthetic products are much cleaner products, thus environmental socially friendly Extended Oil Drain Intervals are easily achieved, with Used Oil Analysis program in place Reduced unitary costs against competition products (Kluber, Fuchs, Tribol i.e.) Higher equipment disponibility and increased production Longer components life (Crown aprox. US $500K, 30/35 years; Pinion aprox. US $30K, 7/10 years)

Semi Fluid Grease Asphaltic Synthetic Mobilgear SHC 22M


AgendaCd to help you optimize the use of the OG Kit


AgendaWhat’s inside the Cd of Open Gears Training

Introduction to Open Gears Gear Fundamentals (Composition, Tooth forms and Manufacturing ) Technologies & Applications Open Gear Inspection Program Selling Strategy


AgendaWhat’s inside the Cd of Open Gears

Job Aids Lubrication Product Information OGIP Procedures Reporting Glossary Product Data Sheets Service Data Sheets (ESSO & Mobil)

Glossary of Terms within OGL (AGMA Definitions)


Agenda

What to wear ( Safety First )

Cover all with long sleeve is preferred

Safety Boots

Leather Gloves or surgical gloves for camera, etc

Safety Hard Hat

Safety Glasses and hearing protection

Camera (Digital or 35mm, must have macro facility)

Spare batteries for equipment and fully charged equipment too

Adhesive tape (Scotch 3M Magic Tape)

Necessary Equipment to Perform OGI (1/3)


Agenda

Carbon paper

Meter (metric system is preferred)

Scissors

White bond paper

Torch or Flashlight (helmet mounted gives hands free)

Metal and/or permanent marker

Heat (Infrared), Gun



Agenda

Photographs format record

Wipe or Rags

Clipboard (Support board for taking notes and writing)

Degreaser Soap / solvent and cream, (hand lotion and paper towels)

Vibration Gauge

Strobe Lamp

Technical information and POP’s



Agenda

Equipment Maintenance History

Hours, Months or Years of Equipment

Hours, Months or Years of Lubricant

Corrective maintenance / repairs of equipment

Lubricants that equipment has used

Current Operating conditions

Temperature of Lubricant

Speed of Gears

Preliminary Information for OG Inspection (1/3)


Agenda

Gears Dimensions (No. of teeth, rotation, etc)

Environment (humid, contaminated, etc)

Load

Maintenance Practices

Oil drain interval

Inspections performed and periodicity of Inspections

Repair costs

Components costs



Agenda

Lubricant cost

Labor cost and repair labor cost

Downtime costs (if unscheduled)

Lead time to obtain spare parts for repairing components

All the above and previous information is required in order to perform a successful Open Gear Inspection.



AgendaOpen Gear Toolkit

Durable field-grade case with custom-cut foam insert to protect the equipment and a compartment for literature, collateral ,material and a clipboard


AgendaToolkit Elements

Clipboard

Collateral Material

Stroboscope

Infrared Gun

Torch Light

Vibration Gauge

Meter

Permanent markers

OGL Samples

Chargers / Others




Agenda

Key Features:

Digital

Tachometer

Battery operated

Rechargeable with either 115V or 230V charger, as specified by the ordering affiliate

Digital Stroboscope

Toolkit Elements



Key Features:

Infrared thermometer

Non-contact

Laser sighting

12:1 distance to spot size ratio

Infrared Gun



Key Features:

Battery operated

Readings both in mm/sec or in/sec

Full-color chart report included

Vibration Meter


Agenda

Compartment has been designed to store collateral material, literature and the clipboard which will be identified with the logo of the Program. This clipboard is really useful when running inspections in the field.

Toolkit Elements


AgendaToolkit Identification

For Illustrative Purposes Only

Final logo to be defined as per logo selected for the open gear inspection program. Brand identification to be defined as well


AgendaHow to get the Open Gear Tool Kit

Distribution Specialists Incorporated ( DSI ), sells the kit

AddressDistribution Specialists, Inc.43671 Trade Center PlaceSuite 110Sterling, VA 20166-2118

Contact: Anne Marie Phone: (703) 996 – 8142 Fax: (703) 996 – 8142 E – Mail: [email protected],

"Distribution Specialists, Inc." <[email protected]>, [email protected], [email protected]

Cost is of US $3,225 per kit FOB Sterling Virginia, USA ( DS-K12).Lead time of 3 – 4 weeks, from date of final order.

mailto:[email protected]


Agenda

Write Complete and thorough report with benefits & savings

Discuss observations, photographs and data with customer prior to submit final report

Explain to customer all areas of improvement, thus savings

Discuss current condition of Gears with customer (wear, failures, etc)

Commit with customer for next OGI and compare with previous inspections to obtain trend and value of Inspections.

Follow Up & Next Steps after OGI


Agenda

Cemex Plants in USA, Mexico & CCA, plus around the world

Holcim Plants in USA, Mexico & CCA, plus around the world

Greg Sadowski’s examples . . .

Success Stories and Inspections -> Savings !


Agenda

THANKS for your attention !!!

Questions !!!

Documents

Porres - XOM Open Gear Inspections