implementing ultrasonic testing in a world class brewery
TRANSCRIPT
Implementing Ultrasonic Testing In a World Class Brewery
Anheuser-Busch
• 14 Breweries• Started 1852• Quality Product• Profitably
Manufactured
Predictive Technologies
• 4 years ago• Dan Durbin,
Corporate Operations Engineering
• Vision to improve maintenance practices
Dan Durbin, EngineerCorporate Operations
Anheuser-Busch Companies
Focus
• Limited Initial Technologies to– Vibration Analysis– Oil Analysis– Infrared
Thermography – Ultrasonic Inspection
Where to Start?
• Develop Policies, Best Practices and Standards
• Develop In-House Training
• Establish Metric and Track Results
Hurdles
• Utilities Pays for Compressed Air
• Packaging and Brewing Use the Air
• Challenge: • Get Buy-in at the
Brewery Level
Solution
• Quarterly Scorecard• Leak Reduction is a
Corporate Program• Compliance is
Tracked on Scorecard• Improvement is
Awarded Thru Bonus
Documentation
• All Breweries Surveyed During Shutdown
• Developed Project Papers for Leak Detector Purchase
• Purchase 17 SDT 170 Leak Detectors
• Project ROI < 12 months
Challenge Met
• Program in Full Implementation
• Has Support to VP Level• Frequency is Driven by
Data• In House CBT Developed
and Mandatory
Implementation Guidelines
Implementation Guidelines
• Separate Brewery by line or cost center• Generate Repetitive Work Order• Perform Ultrasonic Scan• Document Potential Savings
Implementation Guidelines
• Determine Cause of Air Loss– Design Issue– Actual Leak
Implementation Guidelines
• Design Issue– Notify Reliability Mgr– Determine Cost
Effectiveness to Re-design
• Yes– Notify Corporate Liaison of
Re-design
• No– Stop
Implementation Guidelines
• Air Loss is a Leak– Can Leak be Repaired
Now?
• No– Generate Work Order– Schedule Repair
• Yes– Repair Leak
Implementation Guidelines
• Verify that Leak is Repaired
• Re-assessment and Follow-up
Conclusions and Summaries
• Objective– Lower Cost of Maintenance & Production
• Reduce demand for Air and Steam• Reduced waste of CO2
• Future Implementations– Condition Monitoring– Condition Based Lubrication
Final TipIt is often noted that
“finding a leak never saved a dime” and no truer words can be spoken on the subject of
ultrasonic compressed air leak detection. As satisfying as it may be to spend 8 hours identifying 100’s of compressed air leaks, there is no payback in wrapping a yellow ribbon around a leaking pipe fitting.
“It has to be fixed to save”
Contact Us
More Information? Contact:SDT North America
1-800-667-5325 Toll Free USA/Canada(905) 349-2020 [email protected]