Building the Ultimate Reliable Plant

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Aubrey Moore
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1 Reliable Process Solutions It Can Operate Forever GreenHunter Bio Fuels Inc. Houston, Texas Building the Ultimate Reliable Plant Presentation for UE Systems Conference 2009

2 Terry Harris, CMRP Certified RCM Facilitator Predictive/Proactive Maintenance Training. Lubrication Audits. Lubrication Excellence Training Programs Detailed Equipment Failure Modes training. Training Programs for Oilseeds Industry. Asset Criticality software, assessment, training Environmental, Health, & Safety software/assessment Maintenance Audits Project Management Services Cost Effective Training articles/power points

3 Bruce Baughman GreenHunter Energy Inc. Vice President of Engineering Bio Fuels Division

4 PP Reactive Equipment Performance Heat Feel Noise Smell Smoke Time FF

5 PP Equipment Performance Mechanical Ultrasound Predictive Vibration Analysis Oil Analysis Wear particle testing Thermography MCE NDT Reactive Heat Feel Noise Smell Smoke Time FF

6 PP Equipment Performance Proactive Lubrication Excellence Precision Maintenance Alignment, Balance, etc. Select Suppliers Supplier Specifications Metrics Equipment Ranking RCM TPM RCA/FMEA RCD Training Programs Written Procedures Job Planning/Scheduling Mechanical Ultrasound Predictive Vibration Analysis Oil Analysis Wear particle testing Thermography MCE NDT Reactive Heat Feel Noise Smell Smoke CMMS System Time FF RCA

7 PP Equipment Performance Proactive Lubrication Excellence Precision Maintenance Alignment, Balance, etc. Select Suppliers Supplier Specifications Metrics Equipment Ranking RCM TPM RCA/FMEA RCD Training Programs Written Procedures Job Planning/Scheduling Mechanical Ultrasound Predictive Vibration Analysis Oil Analysis PM Tasks Wear particle testing Thermography MCE NDT Reactive Heat Feel Noise Smell Smoke CMMS System Time FF RCA

8 PP Equipment Performance Proactive Lubrication Excellence Precision Maintenance Alignment, Balance, etc. Select Suppliers Supplier Specifications Metrics Equipment Ranking RCM TPM RCA/FMEA RCD Training Programs Written Procedures Job Planning/Scheduling Mechanical Ultrasound Predictive Vibration Analysis Oil Analysis PM Tasks Wear particle testing Thermography MCE NDT Reactive Heat Feel Noise Smell Smoke CMMS System Time FF RCA

9 What is Reliability Reducing the chance of failure of equipment by eliminating failure modes of the components. Equipment components can last many times longer than manufacturers life expectancy by understanding these failure modes.

10 Why is Equipment Reliability Important? Equipment reliability insures that equipment will last many life cycles longer and this in turn reduces the cost of ownership and the life cycle costs of maintenance.

11 Accepted Beliefs Millions of Revolutions Thirty Identical 6309 Deep Groove Ball Bearings Run to Fatigue Failure Under Test Load Conditions Bearing Number From: Ball and Roller Theory, Design, & Application. Eschmann, et al John Wiley & Sons, 1985 Figure 1-2: Bearing Life Scatter

12 Equipment Life Its important to understand that equipment can last and function properly for many more cycles than we have been trained to believe!

13 Why is Reliability Important Customer Satisfaction Lower cost of maintenance Longer equipment life cycles Less risk of collateral damage Less risk of customer downtime Less maintenance related labor costs Less risk of E,H,&S exposure Future sales success stories It has a payback!!!!

14 What s it Worth? Equipment reliability has value, it is something else to sell. It is worth 10-30% more to all designed, built, and sold equipment. It can be guaranteed not to fail for a longer period of time.

15 What are the Factors of Equipment Life Cycle Improvement Engineering Design Fabrication Installation Operations Maintenance

16 Engineering/Design 25-35% of equipment reliability issues are engineering and design related. Poor equipment selection Motors, Pumps, Couplings, Equipment Options, Pump Bases Improper sizing of equipment/components Improper piping design practices Elbows on inlet flanges Pipe strain on equipment Torque methods on fasteners Poor base/foundation designed/structures Understanding of factory Alignment/Balance

18 Engineering/Design Who makes the best motor? Who makes the best pump? Who makes the best membranes? Who makes the best cartridge filter? Who makes the best actuators/valves? Who makes the best coupling? Who makes the best pump base? Knowing the answer to these questions is what adds life and reliability to the equipment.

19 Engineering/Design When to purchase/design for: The best motor The best pump The best membranes The best actuators/valves The best couplings The best pump base

20 Considerations for Design Who is the customer? Are we maintaining the equipment? What do they want? What is the risk? Is there another sale? Who are we and what is our mission?

21 Precision Alignment Precision Alignment starts with a well designed base

22 Shaft Deflection

23 Shaft Deflection Rule: Always verify the shaft length/diameter rule L3/D4 constant should never be over 50 Length to the 3rd divided by diameter to the 4 th Example: Pump is 7 from bearing to impellor Shaft diameter is 1 7/8 L3 = 343, D4 = = 27.8 Shaft cut down to 1.5 for a sleeved shaft = 68.6

26 Engineering/Design When do we use the best? What is the criteria for buying top of the line equipment? Can you sell it? What will it cost you to maintain it?

27 Fabrication 10-20% of failures are contributed to equipment fabrication Improper Piping Practices Elbows on inlet flanges Pipe strain on equipment Torque methods on fasteners Improper welding procedures on steel Improper welding procedures on plastic Improper Fabrication Practices Un level base structures Base structures in stress Improper/lack of anchoring points Inadequate piping supports

28 Fabrication Improper Handling of Completed Equipment Pick points, Shipping points, Tie Down Points, Support Points Improper shipping methods Large items in box trucks Over tension when strapping down equipment Tie downs on critical parts Lack of tie down, moving sliding on thr truck

30 Installation 15-25% of failures are poor installation practices Improper Handling Practices Pick points, Moving practices, Storing Improper Anchoring Techniques Un level floor anchoring, Looks level to me!!! No Grout, Improper grouting methods, Improper Grout material Improper anchoring bolts and torque, Not enough anchor points Improper Piping Practices Field piping strain, Piping thermal strain, Conduit strain Coupling Alignment Poor or no alignment methods

31 Non Precision Installation

33 Installation cont. Poor Lubricant Selection Proper viscosity for application Proper lubricant for application Poor Lubricant Application Using the lube from the plant Putting dirty lube in the equipment Using dirty lube application equipment Using wrong grease in motors No desiccant breathers Combo Bad Practices Precision grout install and no Precision alignment or Balance. Precision methods and high vibration due to inlet water flow.

34 Installation Failures

35 Operations 10-20% of failures are from operational issues Starting equipment under full load Could be equipment or programming Closing discharges valves to quickly Not monitoring thermal conditions Not monitoring physical vibration Not monitoring visual oil changes Operating equipment in manual Lack of fluid to pump on startup Water on components Lack of a TPM program

36 Maintenance 20-30% of all failures are directly contributed to maintenance. Improper inspection of components Improper lubrication practices Improper/contaminated lube Too much lube No lube analysis, Visual/Testing No/poor Preventive Maintenance Program No/poor Predictive Maintenance Program No/poor Proactive Maintenance Process No/Improper training of maintenance No procedures, training programs, follow up, retraining

37 The Reliable Plant The plant is a new 105 MGY Biodiesel plant in Houston, Texas. The process is a new process developed by Bruce and his engineering team. Plant makes crystal clear Biodiesel from vegetable oils or animal fats. No boilers, cooling towers, and minimal water discharge.

39 Equipment Equipment includes pumps, fans, mixers, etc. 65 pumps 15 fans 7 dry vacuum pumps 8 mixers

40 Equipment Specifications Reliable motors on critical equipment Balanced impellers on critical pumps ISO 68 synthetic oil in all pumps Desiccant breathers on all pumps, gearboxes Precision alignment on all connected equipment, following all rules of alignment Well designed base structures/supports Thermal growth calculations on every component

41 Startup Check out and start up of equipment went well. Plant work through initial check out and start with very few mechanical issues. Were at 65% capacity and making inspect product until September 11 th Ready to order UE 10,000 and vibration tool for baseline measurements.

42 Hurricane Ike Plant was flooded with 13ft of water. 1.5 ft over the 100 years flood plane Over 30 pumps and motors under water Tanks from 15K to 1 million gallons moved creating bent broken piping, pumps, etc All spare pumps, motors, seals, lubricants under water. Rebuild process begins

43 Starting Over Motors had to be pulled for dry out and rebuild Pumps had to be drained, flushed, refilled Electrical equipment needed to be changed out and tested Insulated systems were stripped and replaced Piping systems were replaced due to tank movements Equipment was realigned

44 Summary Extremely reliable plants can be designed by understanding how the equipment fails. Engineering, fabrication, installation, operation, and maintenance all have a part in reliability. Improving your knowledge improves reliability. Learning about Mechanical Ultrasound and other predictive technologies can reduce reactive maintenance and collateral damage. Establishing baselines on new and existing equipment helps catch imminent failures.

Maintenance Issues for Local Fluid Fertilizer Plants

Maintenance Issues for Local Fluid Fertilizer Plants Presented by Greg Logue Vice President of Operations Plant Nutrient Group The Andersons, Maumee, OH 8 December, 2015 If you don't like something change