Acuren s Vision: To be a Trusted Partner by Providing Programs that clearly reduce our client s cost to operate.

Transcription

1 . Acuren s Vision: To be a Trusted Partner by Providing Programs that clearly reduce our client s cost to operate.

2 Acuren is a leader in inspection and asset evaluation with non-destructive evaluation (NDE, API), condition-based monitoring and reliability services, materials engineering & rope access solutions. We ve been extending client asset life for 30+ years with a strong regional presence in Canada and the US. Acuren employs over 3800 employees (over 1500 in Canada) equipped to effectively support and execute your asset management programs. Acuren/Tacten have 100 full time employees in Saskatchewan working out of two offices, Saskatoon and Regina. Acuren Group, Inc and Tacten Industrial, Inc are part of the Rockwood Group of Companies which is the largest and fastest growing inspection firm in the world. 2

3 Materials Engineering & Failure Analysis Alloy selection, write specifications Field or laboratory services Corrosion Engineering SCC & HIC tests Corrosion labs, field evaluations Welding Engineering Write & test weld procedures -- ASME, CSA, AWS Field repair procedures Fitness for Service Conditions detected by NDE API 579 remain, repair or replace Reliability Engineering Services Vibration and PdM condition monitoring services Advanced diagnostics of equipment and structures PM evaluation, asset criticality, failure modes and effects analysis, RCFA, RCM, SCORE gap assessment, etc. Structural Eng & Integrity Programs Design, asset management, remediation Structural assessment, severity, repair & work flow. Legal/Insurance & Fire Investigation Assess Damage, determine cause & responsibility Expert Witness Rope Access Inspection NDE/API/CWB inspection Maintenance solutions & trades work Insulation, Asbestos, Heat Treat, Welding, Electrical, etc. Scanning Electron Microscopy Fracture surfaces, particulate, elemental X-ray analysis Quality Assurance & Quality Control Materials, welding, coatings At manufacturing plants & in the field Stress Analysis and Strain Measurement Apply strain gauges on structures, pipes, etc. Rotating torsional assessments In-Situ Metallography & Mechanical Testing Microscopic examination in field or by replica Thermal degradation Tensile, bend, Charpy impact Chemical Analysis Field or laboratory spectrometers PMI for alloy identification Hardness Testing Field or laboratory Rockwell, Brinell, Vickers, Microdur Crane/Monorail Inspection & Certification Rope Inspection of Monorails Engineering Certifications Laser Scan Services API 653 Tank inspection survey Reverse Engineering In-plant redlines and CAD support 3

4 What is Condition Based Monitoring (CBM) Condition Based Monitoring is the process of continually monitoring equipment health using predictive maintenance technologies and programs. It is a predictive approach which allows for component deterioration to be recognized before unexpected failure occurs. Acuren s objective is to detect failures and communicate to the maintenance team for providing an effective maintenance strategy for successful work flow and virtually eliminating plant Downtime!

5 Condition-Based Monitoring The Journey to Excellence! Fix it & improve it Organizational Leadership World Class! Fix it after it breaks Fix it before it breaks Planned Proactive One good thing, descending should take less time and effort than climbing. Reactive Don t Fix it!

6 Condition-Based Monitoring The Journey to Excellence! A solid reliability program and condition-based monitoring program requires management leadership and buy in from EVERYONE. It s a real team effort and philosophy change! Management Operations Maintenance Quality Control Purchasing Rebuilders Procurement Engineering Even helpers!

7 CBM is the root of reliability success, companies are learning to be more reliable because: Poor Plant Reliability = Low Safety! Low Plant Reliability = Low Quality Reactive Maintenance is frustrating and costs at least double to achieve erratic overtime, can t find parts, no maintenance plan, total disruption. Unwanted downtime = Lost sales/revenue $$ Poor investor buy in, decreased stock value, lost jobs, higher insurance, lower capital investments, high employee turnover rate, smaller bonus, etc. 7

8 Reliable Equipment Will Save Money! Studies show moving towards predictive maintenance strategies can save upwards of $9/HP. In a mine environment this can easily equate to $500,000 in direct annual maintenance savings contributed to predictive maintenance. This is not accounting for plant downtime costs.

9 Reliability = SAFETY! DuPont reported that the most likely person to be injured is:* A maintenance technician, with less than two years experience doing reactive work. Exxon-Mobil reported that accidents are: Five (5) times more likely in maintenance when doing breakdown work than when planned and scheduled work** In 66% of companies, greater than 60% of injuries occur while doing reactive maintenance*** Pulp and Paper industry concluded you re 28% more likely to have an accident when maintenance work is reactive versus planned ***

10 Rotating Equipment Randomly Fails by up to 89%

11 Vibration Analysis Mechanical & Electrical Infrared Acoustic Ultrasound (Mech & Elec) Oil Analysis Motor Current Analysis 11

12 What is Vibration? Vibration is the result of a random or periodic excitation force that results in motion relative to a reference position. Only a 20% decrease in overall vibration will increase the life of a ball bearing by 100%

13 Vibration Analysis The of Condition Monitoring Narrow band Alarming Full spectrum and time wave analysis History Trending 13

14 Acoustical Ultrasound Acoustical ultrasound (airborne & structure-borne) is used for several applications such as electrical defects (corona, tracking & arcing), air/gas leak detection, bearing health condition and of course lubrication condition as seen below Bearing Needs Grease! Looking at Bearing in the Time Domain as it is Lubricated. UESystems Spectralyzer Software Bearing got Fresh Grease! Hear More.. See More..

15 Thermography Infrared thermography can be used for literally 1001 different inspections but in heavy industry it s renowned for electrical inspections on loose connections, contactors, fuses, phase imbalance, heater coils, breakers, etc. In mechanical applications; motor casings, pillow block bearings, gearbox casings, etc. Electrical Mechanical Special Applications: Steam Generator inspection, GasFindIR, Furnace Scanning, Operations Checks, Tank Levels, etc.

16 Oil Analysis and Lubrication Best Practices: Oil analysis is an integral part to help confirm the asset health of several components. Before good oil data can be sampled from the field a considerable effort towards lubrication best practices should be achieved. Good lubrication practices is a foundational element to a solid reliability program. Good sampling techniques Lubrication Assessment & Strategy Good Data

17 Motor Current Analysis (MCA): Often electrical defects are the root cause of failure, even if the apparent cause is mechanical. Critical motors should be tested upon shipping/receiving, while in service and after rebuild. MCA can help detect: Stator condition Power Quality Rotor Condition Power Circuit Integrity Air gap concerns Insulation condition Bearing Defects

18 COMMUNICATIONS! You need a common place for common data Using several PdM technologies, software programs & department interaction requires a common place or system for reporting and recording asset health status. Most current CMMS systems are not designed to accommodate a reliability program with the proper key performance indicators, asset health dashboards or the details & history required to fix recommendations correctly the first time. Communication is KING! 18

19 Key Performance Indicators: Having a CMMS that can automatically provide KPI s and program measurements is an integral part to a reliability CBM program. You can t improve what you don t measure! 19

20 Advanced Vibration Diagnostic requirements are triggered from CBM history: 20

21 STRUCTURAL INTEGRITY SERVICES 21

22 Fixed (Stationary) Assets Structural Integrity Another Reliability Incentive Acuren has extensive knowledge and a competitive advantage of inspecting any type of stationary equipment in the field from accessible entries or from rope access (Tacten). As part of your risk based inspection program for structural steel, a strategy is needed for: PLAN: Follow a RBI strategy, issue the right type of NDE/visual method for the least cost and max pay back. DO: A safety walk-down, inspect the components using a certified crew & calibrated equipment. Issue a report and supply quantitative data if possible. CHECK: verify conditions using quantitative measurements (UT thickness or other) and a structural engineer to assess severity. ACT: Issue repair sketches, redline drawings, client interaction and discussion, implement maintenance workflow for repair. 22

23 Structural Inspection - Determine Severity: 23

24 Structural Integrity Crews Consists of: Team lead Coordinator(s) Data entry/document control CAD technicians Rope Access Crew, Scaffolding or Man-lift NDE/API/CWB Inspectors Structural Engineer support 24

25 There are severe consequences and business risks involved if you forget structural integrity is also a part of a reliable facility! Safety may be jeopardized! Huge downtime consequences Lost revenues & increased insurances Large maintenance costs. Struggle for spare materials/parts. Lost revenues & increased insurances. It Pays to Inspect! 25

26 CASE STUDY: Failed Pinion Bearing for a Rotary Dryer 26

27 Structure-borne ultrasound readings detected a problem. 27

28 Vibration analysis measurements also detected a problem. 28

29 Thermography detected a slight temperature change. Bearing 8 Good bearing Temperature Difference of only 5.7 C Bearing 6 defective bearing 29

30 Visual damage was seen after removing the pillow block cap. Spherical Roller Bearing was pushed out of the outer race due to high axial thrust Bearing outer race defect 30

31 After further investigation it was found to be a successful finding. The true value of Condition-Based Monitoring! Spherical Roller Bearing Bearing Outer Race 31

32 Cost Avoidance for this Case Study: PREDICTIVE STRATEGY Labour: 9 hours x 3 persons Materials: one pillow block ass y Downtime: 13 $50,000/hr TOTAL: $654,000 REACTIVE STRATEGY Labour: 336 hours x 3 persons Labour OT: 168 hours x 3 persons Materials: two pillow block ass y one machined/hardened shaft one pinion Sub-contracted services: Alignment of rotary drum Grinding of support ring (misaligned). Downtime: 14 $50,000/hr TOTAL: $17,000,000 CBM can Save Money! 32

33 ACUREN Condition Monitoring Services Hughes Arseneau, Dean Stephens, Andrew Costain November 6 th, 2014