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Implementing Ultrasonic Testing In a World Class Brewery

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.

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Implementing Ultrasonic Testing In a World Class Brewery

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  1. Implementing Ultrasonic Testing In a World Class Brewery

  2. Anheuser-Busch • 14 Breweries • Started 1852 • Quality Product • Profitably Manufactured

  3. Predictive Technologies • 4 years ago • Dan Durbin, Corporate Operations Engineering • Vision to improve maintenance practices Dan Durbin, EngineerCorporate OperationsAnheuser-Busch Companies

  4. Focus • Limited Initial Technologies to • Vibration Analysis • Oil Analysis • Infrared Thermography • Ultrasonic Inspection

  5. Where to Start? • Develop Policies, Best Practices and Standards • Develop In-House Training • Establish Metric and Track Results

  6. Hurdles • Utilities Pays for Compressed Air • Packaging and Brewing Use the Air • Challenge: • Get Buy-in at the Brewery Level

  7. Solution • Quarterly Scorecard • Leak Reduction is a Corporate Program • Compliance is Tracked on Scorecard • Improvement is Awarded Thru Bonus

  8. Documentation • All Breweries Surveyed During Shutdown • Developed Project Papers for Leak Detector Purchase • Purchase 17 SDT 170 Leak Detectors • Project ROI < 12 months

  9. Challenge Met • Program in Full Implementation • Has Support to VP Level • Frequency is Driven by Data • In House CBT Developed and Mandatory

  10. Implementation Guidelines

  11. Implementation Guidelines • Separate Brewery by line or cost center • Generate Repetitive Work Order • Perform Ultrasonic Scan • Document Potential Savings

  12. Implementation Guidelines • Determine Cause of Air Loss • Design Issue • Actual Leak

  13. Implementation Guidelines • Design Issue • Notify Reliability Mgr • Determine Cost Effectiveness to Re-design • Yes • Notify Corporate Liaison of Re-design • No • Stop

  14. Implementation Guidelines • Air Loss is a Leak • Can Leak be Repaired Now? • No • Generate Work Order • Schedule Repair • Yes • Repair Leak

  15. Implementation Guidelines • Verify that Leak is Repaired • Re-assessment and Follow-up

  16. 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

  17. Final Tip It 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”

  18. Contact Us More Information? Contact: SDT North America 1-800-667-5325 Toll Free USA/Canada (905) 349-2020 International www.sdtnorthamerica.com info@sdtnorthamerica.com

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