Transcript Slides 1- 15

SFR (GB) Ltd
Bodymaker Presentation
Beverage & Food Can
Manufacturing
BODYMAKER PROBLEM
•
Poor oil condition
•
High oil consumption
High filter use
High main ram seal pack use
Main ram seal pack failure
High lee jet use
High amount of lee jets requiring cleaning
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Increased maintenance cost
Increased wastage in production
Increased downtime
Difficulty in controlling Tramp oil levels
Host oil low in the additives required to control
contamination
CAUSE OF PROBLEM
•
Overall Bodymaker design makes the control of
contamination very difficult
•
Current filtration is poor and unable to effectively deal
with high levels of contaminants (Micron size often 25
microns on existing filter.)
•
Coolant is entering oil reservoir via main ram seal pack
•
Oil is entering coolant via main ram seal pack
•
Main ram seal pack is not compatible with coolant
•
High levels of condensation being formed in Bodymaker
Results of SFR Programme on
Beverage Can site
Examples of Bodymakers not treated after ingress of
water and condensation
Results of SFR Programme on
Beverage Can site
Example of seal pack failure in Bodymaker
Results of SFR Programme on
Beverage Can site
Bodymakers after SFR programme
SOLUTION
•
New main ram seal pack
•
Introduce off line filtration @ 3 micron to remove
contamination
•
Introduce desorber filtration unit to remove water caused
by coolant ingress and condensation
•
Apply specific oil technology to existing Bodymaker oil to
clean Bodymaker and assist in controlling both water &
particle contamination
•
Introduce oil analysis to measure results
Bodymaker 7 – Three-Month Trial Summary
Water
As you can see from the results the water content as be maintained at a level of approx 200
PPM. The target performance for this type of oil is approx 300 PPM.
The desorber unit when it was attached immediately reduced the level of water
contamination from 5000 PPM to 220 PPM in 48 hours.
The average content of water in Bodymaker seven for the preceding three years has been
over 4000 PPM compared with the 200PPM during the three months the desorber unit as
been applied. According to SKF and Exxon this will be increasing the life of the equipment
components by a factor of SIX.
Dirt Contamination (ISO 4406)
The ISO 4406 reading for Bodymaker seven during the trail has been a consistent 15/12.
The ISO standard for this type of oil is 16/13 which means that your oil currently exceeds
the standard.
The average level of contamination over the previous three years as been 20/17. When
following the ISO standard this should equate to a life expectancy increase of the
equipment of a factor of FOUR.
At 20/17 your oil will be handling in excess of 5,000 PPM of contaminates;
at 15/12 it is a little over 200 PPM.
A significant achievement in this type of equipment.
Results of SFR Programme on
Beverage Can site
ISO 4406
Oil Cleanliness
First number PPM 4-16 microns
BEFORE
Bodymaker 11
640
Bodymaker 12
2500
Bodymaker 22
5000
Bodymaker 23
1300
5000
4000
3000
2000
PPM 4-16 MICRONS
BEFORE
PPM 4-16 MICRONS AFTER
1000
0
Bodymaker Bodymaker Bodymaker Bodymaker
11
12
22
23
ISO 4406
Oil Cleanliness
0
000
5
4 00
40000
35000
30000
25000
20000
15000
10000
5 0
PPM 4-16 MICRONS
BEFORE
PPM 4-16 MICRONS AFTER
er
1
dy
m
ak
er
Bo
2
dy
m
ak
er
Bo
3
dy
m
ak
er
Bo
4
dy
m
ak
er
Bo
5
dy
m
ak
er
6
PPM 16 MICRONS AND
ABOVE BEFORE
PPM 16 MICRONS AND
ABOVE AFTER
Bo
dy
m
ak
Bo
PPM 16 MICRONS AND
ABOVE BEFORE
PPM 16 MICRONS AND
ABOVE AFTER
AFTER
320
320
160
300
SecondN
um
berPPM16m
icronsandabove
BEFO
RE
AFTER
Bodym
aker11
80
40
Bodym
aker12
160
80
Bodym
aker22
1300
40
Bodym
aker23
160
80
First number PPM 4-16 microns
BEFORE
Bodymaker 1
40000
Bodymaker 2
20000
Bodymaker 3
5000
Bodymaker 4
5000
Bodymaker 5
10000
Bodymaker 6
20000
AFTER
5000
2500
640
320
320
2500
SecondNum
berPPM16m
icronsandabove
BEFORE
AFTER
Bodym
aker1
5000
640
Bodym
aker2
10000
640
Bodym
aker3
5000
320
Bodym
aker4
5000
640
Bodym
aker5
5000
320
Bodym
aker6
1300
80
Results of SFR Programme on
Beverage Can site
Improvements in TAN of oil
TAN
Total Acid Number
TAN
Total Acid Number
3.00
1.4
2.50
1.2
1
2.00
BEFORE
1.50
0.8
BEFORE
AFTER
AFTER
0.6
1.00
0.4
0.50
0.2
0.00
Bodymaker
23
6
ak
er
5
BEFORE
B
od
ym
ak
er
4
od
ym
B
B
od
ym
ak
er
3
er
ak
od
ym
ak
od
ym
B
B
od
ym
ak
er
2
0
B
Bodymaker
22
1
Bodymaker
12
er
Bodymaker
11
AFTER
BEFORE
AFTER
Bodym
aker 11
0.54
0.41
Bodym
aker1
0.81
0.62
Bodym
aker 12
2.83
0.67
Bodym
aker2
1.11
0.76
Bodym
aker 22
0.62
0.42
Bodym
aker3
1.15
0.58
Bodym
aker 23
0.83
0.52
Bodym
aker4
0.62
0.84
Bodym
aker5
0.66
0.62
Bodym
aker6
0.91
0.71
Results of SFR Programme on
Beverage Can site
Volume of water removed
WKF
Water Measurement PPM in Oil
WKF
Water M easurement PPM in Oil
12000
7000
6000
10000
5000
8000
BEFORE
6000
AFTER
4000
4000
BEFORE
3000
AFTER
2000
1000
2000
Bodym
aker11
516ppm
166ppm
Bodym
aker12
9689ppm
1080ppm
Bodym
aker22
449ppm
350ppm
Bodym
aker23
1475ppm
638ppm
6
ak
er
5
Bo
dy
m
ak
er
4
dy
m
Bo
dy
m
ak
er
3
er
ak
Bo
dy
m
dy
m
Bo
Bo
AFTER
Bo
dy
m
ak
B
BEFORE
ak
er
1
er
ak
23
er
22
od
ym
ak
er
12
od
ym
B
B
od
ym
ak
er
11
er
ak
od
ym
B
2
0
0
BEFORE
AFTER
Bodym
aker1
976ppm
372ppm
Bodym
aker2
927ppm
628ppm
Bodym
aker3
701ppm
383ppm
Bodym
aker4
182ppm
374ppm
Bodym
aker5
5941ppm
231ppm
Bodym
aker6
858ppm
672ppm
Results of SFR Programme on
Beverage Can site
O
il C
onsum
ption
C
urrentP
rogram
m
e
perB
odym
akerper
year
C
ost
S
FR
P
rogram
m
e
C
ost
1875gallons@
$5
pergallon
$9,375
937gallons
$4685
FilterU
se
$2125
8hrs@
$350per
hour
24hrs@
$350per
hour
LeeJets
S
eal P
ack
E
ngineeringS
pend
E
ngineeringTim
e
$2,800
2H
rs
$700
$8,400
6H
rs
$2,100
$6,500
18hrs@
$350per
hour
$38,200
Saving:
YearO
neCosts:
Payback:
$1062
$24,553
$8130
ThreeM
onths
$9,000
$3,000
6H
rs
$13,647
$2,100
Results of SFR Programme on
Beverage Can site
Oldregim
e
SFRProgram
m
e
Saving
Oil consum
ption
$68,143.68
$1,728.00
$66,415.68
Pum
pFailure
$17,280.00
$1,440.00
$15,840.00
Filter Costs
$16,297.20
$9,778.32
$6,518.88
Threem
onths
m
aintenance
$266,112.00
$133,056.00
$133,056.00
Leejets
$44,352.00
$1,584.00
$42,768.00
Seal packfailure
$33,264.00
$4,752.00
$28,512.00
Total
Total Cost for Year One - $66,043.80
Savings for Year One - $293,110.56
Pay Back – Three Months
$293,110.56
Results of SFR Programme on
Beverage Can site
O
il C
onsum
ption
C
urrent
Program
m
eper
B
odym
akerPer
year
480G
allons@
$5per gallon
FilterU
se
SFR
Program
m
e
C
ost
$2,400
280G
allons@
$5per gallon
$1,680
$2,000
4hoursper year @
$1,400
$350per hour
20hoursper year
$7,000
@$350per hour
LeeJets
Seal Pack
EngineeringSpend
EngineeringTim
e
$400
1hour per year
$350
6hoursper year
$2,100
$5,000
24hours@$350
per hour
$26,200
Saving:
YearO
neCosts:
Payback:
C
ost
$13,570
$10,428
N
ineM
onths
$8,400
$2,500
16hoursper year
$12,630
$5,600
CHANGES IN MAINTENANCE COST
PRE SFR
POST
OIL
USE/BM
566
206
HP FILTER
1.5
0.4
BM MECH
$41,841
$16,838
2
0
MAINT
LEE JETS