02/20/09 Scott Glover Kapstone Kraft scott.glover@kapstonepaper

Bringing Precision Maintenance, Bringing Precision Maintenance, Vibration and CMMS together to Vibration and CMMS together to identify and eliminate true bad identify and eliminate true bad

actors in your plantactors in your plant

02/20/0902/20/09

Scott GloverScott GloverKapstone KraftKapstone Kraft

[email protected]

http://www.reliabilitysolutions.net/

Kapstone Kraft LLCKapstone Kraft LLC

My name is Scott Glover…My name is Scott Glover…A mechanical engineer, I have worked in the Charleston Paper A mechanical engineer, I have worked in the Charleston Paper Mill for 20 years as a Paper Machine Process Engineer, Power Mill for 20 years as a Paper Machine Process Engineer, Power and Utilities Maintenance Engineer, Machine and Rebuild Shop and Utilities Maintenance Engineer, Machine and Rebuild Shop supervisor providing support to the Mill. For the past 2 ½ supervisor providing support to the Mill. For the past 2 ½ years I have been the Precision Maintenance lead at the years I have been the Precision Maintenance lead at the Charleston Mill. Charleston Mill. More personally and still relevant, I enjoy doing Machine Shop More personally and still relevant, I enjoy doing Machine Shop work as a Hobby. I still can not pass a lawnmower in a trash work as a Hobby. I still can not pass a lawnmower in a trash pile with out picking it up to resurrect…pile with out picking it up to resurrect…E:\presentation\STEAMENGINE.MPGBottom line, I love Machinery and am excited be here today to Bottom line, I love Machinery and am excited be here today to share some of my experiences…share some of my experiences…

What is a Bad Actor?What is a Bad Actor?When I told a machinist this week what I was going When I told a machinist this week what I was going to be talking about today he was quick to tell me, to be talking about today he was quick to tell me, “anything on two legs walking around this plant.” “anything on two legs walking around this plant.” It is that equipment that you hear “is that thing down It is that equipment that you hear “is that thing down again? We just worked on it two weeks ago.”again? We just worked on it two weeks ago.”Another is “yeah, it lasted six months and that’s Another is “yeah, it lasted six months and that’s what we typically get from it.” what we typically get from it.” It is the P.I.T.A. equipment… Pain In the !@#. It is the P.I.T.A. equipment… Pain In the !@#.



Bad Actors $$$…Bad Actors $$$…Study from Reliability Solutions, Inc. of Maintenance Study from Reliability Solutions, Inc. of Maintenance Cost Data from 9 years and 10 paper mills…Cost Data from 9 years and 10 paper mills…Machines over 500HP typically comprise 2% of Machines over 500HP typically comprise 2% of machines in a mill and cost $11-13/hp/year to machines in a mill and cost $11-13/hp/year to operate.operate.Machines 500 to 100 HP typically comprise 13% of Machines 500 to 100 HP typically comprise 13% of machines in a mill and cost $22-26/hp/year to machines in a mill and cost $22-26/hp/year to operate.operate.Machines 100HP and less typically comprise 80% of Machines 100HP and less typically comprise 80% of machines in a mill and cost $49-63/hp/year to machines in a mill and cost $49-63/hp/year to operate.operate.


Precision Maintenance…Precision Maintenance…Simply put a process of doing maintenance Simply put a process of doing maintenance according to specifications which address according to specifications which address primary failure modes. primary failure modes. We generalize that equipment fails as We generalize that equipment fails as follows: follows: 30% fails due to Misalignment30% fails due to Misalignment30% fails due to Unbalance 30% fails due to Unbalance 30% fails due to Assembly Error30% fails due to Assembly Error10% fails due to Other10% fails due to Other


Alignment…Alignment…A good alignment program is key to rotating A good alignment program is key to rotating equipment reliability. Commonly missed are:equipment reliability. Commonly missed are:Soft foot Soft foot Pipe strainPipe strainThermal growth Thermal growth Angle and short foot Angle and short foot Belief that couplings will “accept” Belief that couplings will “accept” misalignmentmisalignment


Precision Maintenance: Balance Precision Maintenance: Balance

Car tire example… Not many in the room would spend $100/tire Car tire example… Not many in the room would spend $100/tire and then not spend $6-8/tire to have them balanced.and then not spend $6-8/tire to have them balanced.Specify all rotating assemblies be balanced to the “intent” of G1.Specify all rotating assemblies be balanced to the “intent” of G1.


Precision Maintenance: Balance Precision Maintenance: Balance I should have know…I should have know…


Precision Maintenance: Assembly Precision Maintenance: Assembly Error…Error…

This category really captures what I describe This category really captures what I describe as good machine practice. as good machine practice.Cleanliness, proper tools, checking and Cleanliness, proper tools, checking and correcting fits, doweling, proper lube.correcting fits, doweling, proper lube.The “no hammer” rule. The “no hammer” rule. The shiny metal myth. My experience…10-The shiny metal myth. My experience…10-15% of the stuff you have on the shelve as 15% of the stuff you have on the shelve as spares…from parts to complete assemblies spares…from parts to complete assemblies are failures on the shelf.are failures on the shelf.

Other…Other…

The 10% “OTHER” category includes the The 10% “OTHER” category includes the more difficult mechanical failures…perhaps more difficult mechanical failures…perhaps the word should be more exotic or less the word should be more exotic or less frequent…frequent…Oil swirlsOil swirlsMotor rotor bar problem Motor rotor bar problem Electrical air gap problems Electrical air gap problems Operators…thoseOperators…those two legged bad actors… two legged bad actors…

Kapstone Paper LLCKapstone Paper LLC


Precision Maintenance Spec’s Precision Maintenance Spec’s Similar to and sync’d with engineering specs and documented. Similar to and sync’d with engineering specs and documented. Examples:Examples:Soft foot checked and no more than 0.002”, pipe strain the Soft foot checked and no more than 0.002”, pipe strain the same.same.No more than 4 shims under a foot No more than 4 shims under a foot Jack bolts to be installed on all equipment Jack bolts to be installed on all equipment Thermal growth calculated and applied to all equipment Thermal growth calculated and applied to all equipment Keyways turned 180 degrees and keys fittedKeyways turned 180 degrees and keys fittedAll bearing fits to be mic’d and in toleranceAll bearing fits to be mic’d and in toleranceG1 balanceG1 balanceTIR 0.002” or lessTIR 0.002” or lessProper bolt torqueProper bolt torqueProper Lube Proper Lube


Good Vibrations…Good Vibrations…

Vibration is one tool used to prioritize “Precision Vibration is one tool used to prioritize “Precision Maintenance work” and provide feedback for the Maintenance work” and provide feedback for the craftsman. craftsman. ““Experience suggests that reducing the overall Experience suggests that reducing the overall vibration level from 0.2 in/second to 0.1 in/sec can vibration level from 0.2 in/second to 0.1 in/sec can reduce maintenance costs up to 50%” (R.S. Inc) reduce maintenance costs up to 50%” (R.S. Inc) 0.1 in/sec overall vibration is consider a “good” 0.1 in/sec overall vibration is consider a “good” level, while 0.075 is considered “world class.” level, while 0.075 is considered “world class.” Above 0.25 in/sec is to be a suspected bad actor.Above 0.25 in/sec is to be a suspected bad actor.


Precision Maintenance Process FlowPrecision Maintenance Process Flow

Written process flow Written process flow diagramdiagramColor coded Color coded responsibilitiesresponsibilitiesIdentified path for Identified path for precision and non-precision and non-precision workprecision workPost in the areasPost in the areasHand out and review Hand out and review with everyone who has with everyone who has had traininghad training


Computerized Maintenance Computerized Maintenance Management Systems) CMMS:Management Systems) CMMS:

During my career I have led/and or During my career I have led/and or participated in the design and participated in the design and implementation of two CMMS (Maximo and implementation of two CMMS (Maximo and SAP).SAP).I did this not because of my love for I did this not because of my love for computers, but for the love of Tools and computers, but for the love of Tools and Machinery. Machinery. E:\presentation\DeWalt drill movie.mpeg

The Perfect CMMS The Perfect CMMS

You have accurate equipment records in You have accurate equipment records in searchable fields.searchable fields.hp, rpm, manufacture, model number, seal hp, rpm, manufacture, model number, seal type, etc. are populated.type, etc. are populated.Work Orders are written to the correct Work Orders are written to the correct functional location. functional location. Standing orders do not exist… Standing orders do not exist…


Fishing for bad actors…Fishing for bad actors…Surf your vibration database of using the vibration Surf your vibration database of using the vibration tolerances of 0.1 in/sec and above and then 0.25 tolerances of 0.1 in/sec and above and then 0.25 in/sec and above.in/sec and above.Take this list and pull up equipment work order Take this list and pull up equipment work order records. You are guaranteed to find some good, records. You are guaranteed to find some good, easily fundable maintenance work. easily fundable maintenance work. Do not necessarily get hung up on “bad” vibration Do not necessarily get hung up on “bad” vibration numbers if the work order history does not show numbers if the work order history does not show significant $$$. Some machines that would not significant $$$. Some machines that would not qualify as “precision,” infact do not need to be qualify as “precision,” infact do not need to be prioritized: Ex. Blowers, shaft mounted gearboxes, prioritized: Ex. Blowers, shaft mounted gearboxes, spring bases. spring bases.


Fishing for bad actors…cont’dFishing for bad actors…cont’dIf your vibration data and/or experience suggests a If your vibration data and/or experience suggests a piece of equipment is bad actor, but the initial work piece of equipment is bad actor, but the initial work order review shows few $$$ spent…dig further.order review shows few $$$ spent…dig further.Sometimes, “Less is More” in data base searches. It Sometimes, “Less is More” in data base searches. It is quite possible that the significant repair costs you is quite possible that the significant repair costs you thought should be on that equipment are being thought should be on that equipment are being charged to a nearby piece of equipment or at a level charged to a nearby piece of equipment or at a level above in the work order system. above in the work order system. Service and Vendor records can be used Service and Vendor records can be used successfully when W/O’s fail. Windshield successfully when W/O’s fail. Windshield example… example…


Fishing for bad actors…cont’dFishing for bad actors…cont’dThe lack of precision maintenance is especially The lack of precision maintenance is especially telling in high rpm equipment. A 3600rpm telling in high rpm equipment. A 3600rpm application that exhibits high vibration will likely application that exhibits high vibration will likely have a history of high $$$. Review both your have a history of high $$$. Review both your vibration and CMMS data bases in this area for vibration and CMMS data bases in this area for opportunities. opportunities. It is particularly important to apply precision It is particularly important to apply precision vibration standards and repair work on equipment vibration standards and repair work on equipment with mechanical seals. with mechanical seals.



Case HistoryCase History First Base, $$$, History First Base, $$$, History


Case HistoryCase History Agitator, $$$, History, Base, Pack-ryteAgitator, $$$, History, Base, Pack-ryte


Case HistoryCase History Pump, $$$, history, pipe strain Pump, $$$, history, pipe strain


Case History.Case History. 25hp, 3600rpm high pressure water 25hp, 3600rpm high pressure water pumps. 0 to $42,0000 over 2-1/2 yearspumps. 0 to $42,0000 over 2-1/2 years


Case History.Case History. 800hp, $60,000 year steam savings, 800hp, $60,000 year steam savings, disk coupling disk coupling


Case History.Case History. 1000hp, FD Boiler fan, $$$, sootblower 1000hp, FD Boiler fan, $$$, sootblower


Case History.Case History. Plastic Precision – Poly-Shield Plastic Precision – Poly-Shield


Case History.Case History. Lineshaft bearings Lineshaft bearings


Case History.Case History. Lineshaft Temp monitoring, $$$Lineshaft Temp monitoring, $$$


Case History.Case History. Hydrapulper FeedHydrapulper Feed


Case History.Case History. Hydrapulper TubHydrapulper Tub


Case History.Case History. Hydrapulper New base, $$$Hydrapulper New base, $$$


Case History.Case History. Hydrapulper New base & jack boltsHydrapulper New base & jack bolts


Case History.Case History.New pump, jack bolts, pipe supportsNew pump, jack bolts, pipe supports


Case History.Case History.New base, jack bolts, pipe supports, New base, jack bolts, pipe supports, dog-house, 8 years, 0 $$$ dog-house, 8 years, 0 $$$


Case History.Case History. Good transition base…Good transition base…


Case History.Case History. Another Good transition base…Another Good transition base…


Case History.Case History. Another Good transition base…Another Good transition base…


Case History.Case History. Full base…Full base…


Case History.Case History. Full base…Full base…


Case History.Case History. Precision Maintenance at its best and Precision Maintenance at its best and worst… 3 years and running great…worst… 3 years and running great…

A few more good words…A few more good words…$$$...It is all about the money$$$...It is all about the moneyLearn how much it cost $$$ for you customer to run Learn how much it cost $$$ for you customer to run their process. Process $$$ information and their process. Process $$$ information and downtime, combined with maintenance downtime, combined with maintenance cost/vibration levels can be good places to look for cost/vibration levels can be good places to look for opportunities to shine.opportunities to shine.Know how much electrical power costs and use Know how much electrical power costs and use potential savings to drive reliability…especially in potential savings to drive reliability…especially in 24/7/365 operations. 24/7/365 operations. Talk to mechanics and operators to find bad actors…Talk to mechanics and operators to find bad actors…then confirm with your vibration data and CMMS. then confirm with your vibration data and CMMS.



Discussion…Discussion…

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02/20/09 Scott Glover Kapstone Kraft scott.glover@kapstonepaper