Predictive Maintenance Technologies Spirit Aero Systems Inc Ed

Predictive Maintenance Technologies Spirit Aero. Systems Inc. • Ed Fenn– – – • Don Chrisman – – • Twenty-eight years with Spirit/Boeing Electrical background Twenty-four years facilities management Responsibilities include machine tool retrofit, facilities network, industrial controls and reliabilitycentered maintenance Retrofitted over 385 machines and responsible for one patent Thirty-one years with Spirit/Boeing Twenty-years experience maintenance mechanic Twenty-years experience as a vibration technician Level 2 vibration certification Todd Shepherd – – Twenty-nine years with Spirit/Boeing Twenty-five years experience maintenance electrician Four years experience thermography technician Level 2 thermography certified

Predictive Maintenance Technician Spirit Aero. Systems Inc. Oil Analysis Vibration Analysis Laser Alignment Ultrasonic Thermography

Mission Statement • To communicate accurate information through the use of trend analysis, pattern recognition, statistical process analysis and device limit ranges to aid in increasing machine life cycle and machine availability.

Oil Analysis • Affects on Machine Devices 1. 2. 3. 4. 5. 6. 7. 8. Pumps Oil tank Flow control value Pressure relief valve Cylinders (counter balance) Directional control valves Throttle valve Heat exchangers

Oil Analysis (cont. ) What we measure • Fluid Properties – Viscosity analysis – FTIR – Fourier transform infrared spectroscopy – Element analysis • Contamination – Particle count – Moisture analysis – Patch Test • Wear Debris – Wear debris density – Analytical ferrography – Elemental analysis

Vibration Analysis • Periodically collect and analyze vibration data on machine tools and components • Install remote collection boxes and permanent mount accelerometers • Field balancing on fans and blowers • In Shop balancing (Balance Stand) on fans, blowers and rotating components

Vibration Analysis (cont. ) • Laser shaft alignment on rotating equipment (except process pumps) • Laser sheave to sheave alignment • Acceptance Testing on new equipment and components • Assist shop personnel in troubleshooting suspect bearing and alignment problems • Ultrasonic testing

Thermography • Periodically inspect electrical components and control cabinets for heat related issues • Assist shop personnel in troubleshooting suspect electrical problems • New equipment acceptance testing

Thermography (cont. ) • Aids in identifying bearing and coupling problems in rotating equipment • Identify heat exchanger problems • Identify problems in heating and cooling coils • Identify insulation problems with ovens and furnaces • Identify problems with oven and furnace door seals

Effects of Vibration on Equipment

Vibration Issues - Loop Pump • Definition of resonance and demo • Base resonance - causing vibration limits to be exceeded during New Equipment Acceptance Testing

Vibration Issues – Loop Pump • First attempt to qualify new loop pump, concrete pad not adhered to floor • Second attempt, resonant condition in pump base identified & eliminated by creating animation to identify flexing points • Reasons for animation before adding gussets

Vibration Issues w/ Loop Pump First Attempt – Concrete not adhered to floor, noticed base moving during data collection. Contractors corrected by bolting concrete pad to concrete floor.

Vibration Issues – Loop Pump

Vibration Issues w/ Sump Cover • Resonance condition in sump cover causing premature failure of pump bearings

Laser Alignment Shaft to Shaft

Laser Alignment Sheave to Sheave

Balance Stand Balance rotating components

Thermography

LIEBERT UPS

MILL Fuse

STRECH PRESS Pump

COLD BOX

Questions