March 24, 2005
Achieving Total Productive Maintenance (TPM) Distance Learning Course
Learn TPM without leaving home! Next course begins April 1!
TPM Expert Terry Wireman leads a coached 8-10 week course that includes:
• Narrated CD with detailed slides
• Hard Cover Text Book
• Weekly Assignments
• Weekly coaching with Terry Wireman
Learn how to put TPM to work for your company today!
Please call toll free (888) 230-5280 or…
March 24, 2005
Motor Testing Tip
PI >5000 Meg and Newer Insulation Systems
When performing a Polarization Index Test (PI) the 10-minute resistance-to-ground reading divided by the 1 minute resistance-to-ground reading should be between 2 and 5. A ratio below 2 indicates moist or dirty windings. A ratio above 5 may indicate brittle insulation. These numbers have been accepted for many years but recent changes to insulation designs require a re-evaluation of these numbers. Modern types of film-coated wire,
as well as epoxy and polyester-mica insulation systems routinely have a ratio of 1 to 2 for perfectly good windings. In response to these design changes, IEEE 43-2000 states that when “ 1 minute insulation resistance is over 5000 meg-ohms, the calculated PI may not be meaningful”. If equipped with test equipment able to measure very high insulation resistances, PI testing should continue for the normal ten minutes to support historical tracking of the PI Profile. However, the calculated PI, which will likely be less then 2, can be ignored.
Tip provided by PdMA
http://www.pdma.com
Tel: (813) 621-6463
Learn more about the 2005 Motor Reliability Technical Conference
March 24, 2005
Alignment Tip
I use the same device I use for balancing when doing vertical alignment without the aid of gravity assist (inclinometer). I measure the shaft and generate a 360 degree strip of paper that I tape to the pump shaft so that I can index the shaft against a stationary part of the machine.
The basic cad drawing is only done once. For subsequent applications, I change the scale of the drawing to match the circumference of the current project’s shaft. The drawing scale is divided into 10° marks.
The alignment program uses the pre-defined degree rotation I have asked for in the setup; I use 30° for a complete sweep. All I have to do is move the shaft to the corresponding mark and let the program know I am there. The alignment machine will then tell me the next angle to move the shaft to. This makes for quick measurements in some pretty awkward positions. It also gives me the flexibility to make less than 360° rotations easily. 90° is the minimum recommended by my equipment mfg. I just change the setup increments to 10° and take 9 readings.
Reader tip provided by Jon McFadden
Vibration Analyst
Kimberly-Clark Corp Conway Personal Care Facility
Conway Arkansas USA
Thanks Jon - your Maintenance-Tips hat is one the way!
March 24, 2005
Use of Active Balancing to Solve Serious Reliability
A Sponsored White Paper by LORD Corporation
This paper will discuss common vibration problems experienced on large centrifugal fans that lead to forced outages and unscheduled maintenance. This paper describes the use of an Active Fan Balancing System used to control unbalance related vibration levels in fans. The paper will also detail several active balancing installations and describe the benefits these users have experienced.
Request your Active Balancing White Paper now
March 24, 2005
Vibration Analysis Tip
Clean that Magnet
Taking accurate vibration measurements is critical to the success of any vibration program. The weak link in this process is often the connection between the accelerometer and the machine being measured. Following several simple procedures will enhance the accuracy and repeatability of your measurements.
1. Avoid taking vibration measurements through paint. Direct metal-to-metal contact on a flat spot is vastly superior for transmitting vibration to your accelerometer. This may require spot facing and possibly gluing on a metal slug using a high metal-content epoxy potting compound similar to Belzona Super Metal.
2. Do not slap a magnet-mounted accelerometer onto the measurement surface. This can cause the magnet to ring for several seconds, which can adversely affect your measurements. Set the magnet down softly on a corner or edge of the magnet then rock it flat making sure it is seated solidly.
3. And finally, clean that magnet, and clean the surface onto which you will place it. Small metal shavings, metal dust and greasy dirt tend to stick to the magnet. Wipe off the magnet with a rag before placing it on a measurement location. This will help ensure a solid interface with the machine and further enhance the consistency of your measurements.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
iPresentation Invitation: Issues Affecting Accurate Data Collection (10 minutes)
March 24, 2005
Infrared Thermal Imaging Tip
How often do I need to calibrate my thermography camera?
As a manufacturer we are often asked, both at point of sale and after delivery: “How often do I need to calibrate this camera?” That is a great question. There actually can be numerous answers to this question and it is a matter of the camera as well as your company practices and methodology.
Most “radiometric” thermography cameras (meaning calibrated for temperature measurement) are calibrated to NIST standards. The National Institute of Standards and Technologies (or sister organizations outside of the US) states that to claim that a thermography camera is traceable to NIST standards, the blackbody references that are used in the calibration must be calibrated/verified at least once annually. In addition, and taking this a step further, for the camera to maintain that NIST (or similar) traceable mark, it must also be either verified or calibrated at least once per year against NIST (or similar) traceable sources.
This is the reason why most thermography camera manufacturers suggest that the camera users perform an annual calibration.
Does this mean that on day 366 after receiving a thermography camera that the camera is out of calibration? Not necessarily and probably not at all. This simply means that if you want your instrument to be traceable to a government standard, it needs to be verified/recalibrated annually.
Whether you do this or not depends on the internal practices and standards your own organization has set up. Those companies that are ISO certified will need this level of traceability and certification. Other companies may not need this as a matter of practice.
Make sure that you understand your organizations requirements to determine the need for such calibration testing. Also, understand that the manufacturer’s state that annual calibration is “recommended” and not necessarily mandatory.
If you are unsure of the calibration of your system, you can perform a simple test. If you look at a cup of boiling water it should read (after correctly adjusting emissivity) 100ºC (212ºF) and if you look at a cup of ice water (that is at equilibrium and also correcting for emissivity) it should read 0ºC (32ºF.) If your camera reads within the specs (usually +/- 2% or 2ºC) then you should be good to go.
You can never go wrong by having your camera recalibrated, however, just insure that you need to.
This tip provided by Electrophysics
Manufacturer of EZTherm and EZTherm Pro Cameras
http://www.electrophysics.com
Tel: 973-882-0211
March 17, 2005
Tracking Production Losses: A critical step to maximizing asset performance
A Sponsored White Paper by Meridium
Asset performance management focuses on enhancing plant production efficiency. Full utilization of your assets leads to both capital and operating efficiency: Un-reliability hinders both. Do you have a corporate or plant requirement to measure un-reliability? Tracking production losses will identify, and quantify your opportunities for improvement. After all, what gets measured gets managed. Author Guy Gimlen of Gimlen Consulting, shares his 30 years of experience in refining in this paper that describes the what, why, and how of repeatable work processes to track production losses.
You are invited to download this white paper sponsored by Meridium
March 17, 2005
Airborne Ultrasonic Testing Tip
Consistency
Sensor Placement – How consistent are you when it comes to sensor placement with your ultrasonic data collector? Does your ultrasound program have a written procedure that addresses sensor placement from the same position, with the same angle of contact? Is the surface cleaned before contact? are there multiple layers of paint, oil, grease, dirt, or all of the above? Are you using the best ergonomic sensor for the job, or is your ultrasonic probe too big and bulky to access the inspection area? There is a sensor for every job.
Everyday variables can be problematic to your data collection if they are not dealt with procedurally. Part of your implementation plan should include the identification of variables that could affect your data. Make a list and then decide on a strategy to eliminate the variable. Publish the strategy as part of your ultrasound program and training, and eliminate variables from the equation.
Tip provided by SDT North America
(905) 349-2020 Tel
(905) 349-2552 Fax
http://www.sdtnorthamerica.com
March 17, 2005
University of Dayton's Maintenance & Reliability Courses
Maintenance is a Reliability Function & the University of Dayton’s reliability seminars prove education drops profits to the bottomline.
Start March 16-17, Ron’s Moore’s Reliability-Based Maintenance; followed by William Steele’s Reliability Centered Maintenance - APRIL 12-13
Enroll two in Emerging Leaders in Reliability - save 47%. Buy the 21 training day plan, save 33%.
Web: http://www.competitivechange.com
Phone: 937-229-4632
March 17, 2005
Reliability Tip
Before embarking on a reliability improvement initiative, ensure you have a business case
A business case is a tool that supports decisions to invest or embark upon a project, which strategy to employ and when to implement. It establishes the need, justification and alternatives to resolving a business issue or strategic objective and includes projections of future returns to justify the cost of the project.
A business case for reliability improvement focuses on the impact of improved asset reliability on the organization’s bottom line. It answers the questions: What are the likely financial and business benefits of improved asset reliability? What is the cost and effort required to implement a reliability strategy? (ie. how are we really going to make this happen) What are the consequences of not going forward with the initiative?
An organization must have a clear understanding of its maintenance performance as it compares to best-in-class standards, as well as the benefits that can be reasonably anticipated. A reliability-based approach to asset management makes good business sense. However, ensure you quantify the financial impact - develop a business case - the cost/benefit justification for the solution that fits your needs.
This tip provided by Ivara Corporation.
http://www.ivara.com
