Uptime Magazine - October/November 2008 - (Page 21)

Best Ultrasound Program – US Steel Gary Works, AMEX Maintenance Technology United States Steel Corporation, headquartered in Pittsburgh, Pa., is an integrated steel producer with major production operations in the United States, Canada and Central Europe, and an annual raw steelmaking capability of 31.7 million net tons. With an annual raw steelmaking capability of 7.5 million tons, Gary Works is U. S. Steel’s largest manufacturing plant (pictured below), and is situated on approximately 4,000 acres on the Lake Michigan shore. There are four operational blast furnaces at Gary Works, with a daily capacity of about 20,000 tons. Gary Works also operates three coke batteries, with annual production capacity of 1.6 million tons. All of the iron made at Gary Works is converted into steel in one of two basic oxygen process (BOP) steelmaking shops with total annual production capability of over 8 million tons. Sheet products and tin products are manufactured at Gary Works. Hot rolled, cold rolled, and galvanized The US Steel, Gary Works, AMEX Maintenance Technology Team sheet products are produced for customers in the automotive, metal building components, home construction and appliance markets. In their Ultrasound program, the AMEX Maintenance Group at Gary works has identified over 3,150 leaks, which cause an estimated loss of over $3 million. To date, nearly 1400 of those these have been repaired, which has led to over $1.3 million in savings. So far, the group has focused their efforts on pressurized gas leaks, but they are now expanding their program to include vacuum leaks as well, which will no doubt increase savings even more. Best Vibration Analysis Program - Orange County Sanitation District The Orange County Sanitation District (OCSD) is a public agency that serves 2.5 million people in central and northern Orange County and treats more than 230 million gallons of wastewater every day (enough water to fill Anaheim stadium nearly three times each day), making it the third largest wastewater treatment agency west of the Mississippi River. About 80 percent of the wastewater comes from homes, with the remaining 20% generated by business. The service area includes 21 cities and three special districts covering 471 square miles. Their are many positive aspects to the Vibration Analysis program at OCSD. Prior to the program, equipment was repaired as it failed, and put back into service with little documentation and no follow-up. Because of their increased use of Root Cause Analysis, they have implemented changes to avoid recurring failures and identify opportunities to make lasting improvements. Now work is planned and scheduled according to severity and priority. The team has also created a monthly vibration report that enhanced communication and cooperation between maintenance and operations. The PdM team at OCDS also actively promotes their effectiveness through formal internal presentations of their findings, case histories and documented savings . The Orange County Sanitation District is the third largest wastewater treatment agency west of the Mississippi River. OCSD Team Left to Right: Daniel Miranda, Dave Chafe, Simon Watson and Santiago Escobar www.uptimemagazine.com 19 21 http://www.uptimemagazine.com

Table of Contents Feed for the Digital Edition of Uptime Magazine - October/November 2008

Uptime Magazine - October/November 2008 Contents Upfront Upclose: An Asset Management Oasis in the Desert Information Technology: Streamlining Through Simplicity Lubrication: Phases for Framing a Solid Foundation Infrared: Do Your Homework Before You Buy Maintenance Management: Get It Together by Getting Together Motor Testing: Key Elements in Motor Decision Making Precision Maintenance: Shedding Some Light on Tolerances Reliability: RCM & the Mortgage Meltdown Ultrasound: A Multidimensional Tool Vibration: The Whirling Pump Mystery, Solved with ODS Upgrade: Are You Looking in the Right Place for Your Wear Debris?

Uptime Magazine - October/November 2008

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