Predictive Maintenance Technologies Spirit AeroSystems Inc.

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Predictive Maintenance TechnologiesSpirit
AeroSystems Inc.

• Ed Fenn-
• Twenty-eight years with Spirit/Boeing
• Electrical background
• Twenty-four years facilities management
• Responsibilities include machine tool retrofit,
  facilities network, industrial controls and
  reliability-centered maintenance
• Retrofitted over 385 machines and responsible for
  one patent
• Don Chrisman
• 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

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Predictive Maintenance TechnicianSpirit
AeroSystems Inc.

• Oil Analysis
• Vibration Analysis
• Laser Alignment
• Ultrasonic
• Thermography

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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.

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Oil Analysis

• Affects on Machine Devices
• Pumps
• Oil tank
• Flow control value
• Pressure relief valve
• Cylinders (counter balance)
• Directional control valves
• Throttle valve
• Heat exchangers

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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

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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

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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

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Thermography

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

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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

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Effects of Vibration on Equipment
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Vibration Issues - Loop Pump

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

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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

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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.
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Vibration Issues Loop Pump
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Second Attempt After flexing in pump base was
identified with the help of the animation,
contractors corrected by welding gussets in
proper location.
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Vibration Issues w/ Sump Cover

• Resonance condition in sump cover causing
  premature failure of pump bearings

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Laser AlignmentShaft to Shaft
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Laser AlignmentSheave to Sheave
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Balance StandBalance rotating components
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Thermography
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LIEBERT UPS
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MILLFuse
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STRECH PRESSPump
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COLD BOX
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Questions