A Few ideas for the Press Maintenance Professional A Webinar with Al Kennedy

A Few ideas for the Press Maintenance Professional A Webinar with Al Kennedy

The Extrusion Press Maintenance Manual is now FREE Online at www The Extrusion Press Maintenance Manual is now FREE Online at www.pressmaintmanual.com

May be downloaded to tablets & smart phones for access in the plant This means that: Procedures Diagrams Schedules Etc. May be downloaded to tablets & smart phones for access in the plant

Please thank the sponsors listed on the website for providing this free access!

Manual Sponsors Belco CMD Butech Amcol RL Best Carlesa NDE Castool Compes Granco Clark ADS

Webinar outline: Maintenance Impact on Productivity Maintenance Principles Press Alignment Metallurgical Issues Energy Cost Control Technical Tools

Maintenance Impact on Productivity

Reliability: Equipment available when scheduled for production Maintenance Impact on Productivity Reliability: Equipment available when scheduled for production

Scrap minimized: butt & billet scrap, run-out and saw scrap Maintenance Impact on Productivity Scrap minimized: butt & billet scrap, run-out and saw scrap (primarily a function of equipment design)

Maintenance Impact on Productivity Maximum “contact time”: time the dummy block is in contact with the billet (dead cycle & other delays such as lubing billets, flashes, etc.)

Equipment working as designed Maintenance Impact on Productivity Equipment working as designed Temperature calibration (die ovens, billet/log oven, container) Log shear or saw accuracy Puller, hot saw, run-out

Maintenance Principles

Breakdown vs. Planned? Breakdown (also called Reactive): Only one problem is fixed Skilled people are not available Spare parts and test equipment are not available Production workers are idle

Breakdown vs. Planned? Planned: Many problems are worked on at the same time Skilled people will be available Spare parts and test equipment will be planned to be available Production workers are scheduled off

Preventive Maintenance Interval-based: Regular, scheduled downtime Weekly, monthly, etc. Make detailed inspections Perform pre-planned repairs Keeping records of downtime will allow better planning to improve reliability

Maintenance Basics

Predictive Maintenance Condition-Based: Determine condition of a machine Predict best time to make repairs Examples: Hydraulic oil analysis Magnetic particle & ultrasound test of tie rods Infrared scans of electrical equipment Vibration monitoring

Magnetic Particle Inspection

Infrared Scan of Electrical Parts

Oil Analysis

A sound maintenance program combines both interval-based and condition-based practices

Maintenance Basics Spare Parts: See Chapter B for important points on recommended spare parts & their storage Obtain and save equipment information – drawings, part numbers, diagrams

Google for answers!

Press Alignment

Importance of Alignment Process reasons Uniform loading is critical to die performance Equipment reasons Avoid uneven wear and impacts

Methods for Press Alignment: On the Press Manual website Conventional “millwright” methods Date from the 1970’s Recommended tolerances Use traditional mechanic’s tools: Piano wire & straightedges Levels Feeler gages & dial indicators Special jigs and fixtures

Methods for Press Alignment: New Technologies Using modern surveying equipment and 3D laser tracker Some info from ET16 and Press Manual website Two specialists: ADS Measurement Services CMD Cunningham Mechanical Services

Metallurgical Basics

Metallurgical Issues Failure modes tension shear torsion compression fatigue

Metallurgical Issues Fatigue (n) fa-tēg′: weakening or failure of materials under the action of repeated stresses.

Fatigue Failure Images

Metallurgical Issues Fatigue: Press components quickly experience millions of stress cycles. Cracks progress to catastrophic failure. Replacements are costly and long-delivery.

Metallurgical Issues Fatigue: Component testing for cracks is mandatory, increasing in frequency as cracks progress. Types of inspection: Visual Dye penetrant Ultrasonic Magnetic Particle

Visual

Dye Penetrant

Ultrasonic

Magnetic Particle

Metallurgical Issues Fatigue – repairing cracks/failures Weldability: Forged steel - very good Cast steel - good Cast iron – poor & very technical Mechanical patches: very temporary

Metallurgical Issues Stems

Metallurgical Issues Stress relieving stems

Metallurgical Issues Fixed dummy blocks May be repaired by welding with proper procedures Avoid excessive preheating – as with dies, limit preheat time and temperature

Help? Metallurgical Issues Consulting metallurgist – university? Tooling suppliers Press component suppliers Component testing specialists Manual sponsors www.pressmaintmanual.com

Webinar Feedback from 2014 webinar press alignment new equipment coming out production optimizing post this PowerPoint online more presentations & topics

Energy Cost Control Make partners of your utility suppliers (gas, water, electric) They usually have a different business outlook

Energy Cost Control Regulated utilities usually have a fixed profit limit Increasing profit may not be their concern They may not care whether their profit comes from you or from another customer Even “regulated” utilities often have secret rates

Energy Cost Control Regulated utilities are more concerned with leveling their load around the clock, to maximize use of their facilities Uninterrupted service to residential customers is a high priority Power generating companies must provide “spinning reserve” equal to a certain factor above actual demand

Energy Cost Control Understand the thought process of your energy supplier Build cooperation with your supplier by regular contacts Develop solutions that help both parties meet their goals

Energy Cost Control Fit all gas-fired equipment including billet heaters and age ovens with gas meters (of course cast house furnaces and boilers as well).

Energy Cost Control Simple meters are OK for this purpose … no need for pressure and temperature compensation. Turbine-type meters are OK Remote reading is convenient A quick payback is guaranteed!

Energy Cost Control Read every meter every Monday morning and track total Btus and Btu/lb Graphing these values will identify cost saving opportunities and will highlight when problems arise.

Energy Cost Control Metering electric power is more complicated and less rewarding Consider voluntary load reduction when requested by the power company Consider load reduction by frequency variation, soft-start, etc.

Energy Cost Control Electric power is generated in plants that are 38 to 40% efficient, and there are further i2R losses during transmission Keep this in mind when evaluation gas vs. electric heating applications Induction heaters are always more expensive than gas, but offer better process temperature control

Technical Tools

Technical Tools Vibration Analysis and Balancing

Technical Tools Vibration Analysis and Balancing Ludeca.com

Technical Tools Alignment

Technical Tools Alignment

Technical Tools Infrared Thermal Imaging

Technical Tools Infrared Thermal Imaging

Technical Tools Infrared Thermal Imaging

Technical Tools Infrared Thermal Imaging

Technical Tools Smartphone Microscope

Technical Tools USB Microscope

Technical Tools USB Borescope

Technical Tools USB Borescope

Technical Tools maintenancetechnology.com

Machines’ sensors will talk to us through Bluetooth Future developments? Machines’ sensors will talk to us through Bluetooth

Bluetooth was named after a 10th-century king, Harald Bluetooth, King of Denmark and Norway. He was known for his unification of previously warring tribes from Denmark, by getting them to talk to each other.

Summary www.Pressmaintmanual.com Maintenance impact on productivity Maintenance principles: interval-based & condition based Press alignment Metallurgical basics Energy cost control Technical tools

Watch for info on the Press Maintenance Workshop, in Atlanta, April 2018

This presentation will be available for download at the following site: www.alkennedy.net/id84.html

Thanks for attending. Follow-up questions are welcome Thanks for attending! Follow-up questions are welcome. Call or email: alkennedy@usa.net 770.304.1000 www.alkennedy.net

This presentation will be available for download at the following site: www.alkennedy.net/id84.html