Tipsblog

Maintenance Tip

When problems are reported, using a digital camera with a zoom and a Hi beam flashlight can bring steam valves and piping in low lighted ceilings a little closer without gathering man-lifts and equipment. It also serves as a good picture of a problem when you don’t have access to temperature detection equipment Case in point: A report of hissing from a ceiling area was made by production. We identified it as a steam valve and not an air leak using the flash light and camera. The job was scheduled during down time for repairs and a picture taken to show the exact area helped locate the exact valve.

Reader Tip provided by Phillip Weathers
Facility Planner
Sealed Air Corp - Cryovac Div.
Simpsonville SC

Thanks Phillip - your Maintenance Tip hat is on the way!

More Maintenance Resources

CMMS/EAM Tip

Editors Note: Last weeks CMMS/EAM Tip was incomplete. Here is the entire tip.

Previous Maintenance Tips have dealt with the importance of data collection and accurate reporting. This tip focuses on how to develop the accurate data.

Preparing to collect the data
Data collection and formatting should not begin before finalizing the purchase of the CMMS/ EAM system. The system itself will dictate what data it needs and how that data must be formatted. Also, before beginning data collection, select the implementation team and train the team members, along with the data-entry personnel. The implementation team should consist of members of departments affected by the CMMS/ EAM system implementation and at a minimum, maintenance, engineering, operations, stores, and purchasing. The purpose of the training is to ensure that everyone involved understands the CMMS/ EAM system data flows and formats. This knowledge is fundamental to understanding how analysis reports are developed.

Collecting the data
While it is possible to view data collection as the simultaneous collection of the various kinds of data, the process is rarely parallel; the serial process described here will produce better results. Consider collecting the data in the following order:

1. CMMS codes. The CMMS codes include information such as equipment types, noun descriptors, equipment hierarchies, and inventory identifiers. Since systems use these codes throughout, the codes need to be standardized before other data is collected. These codes are also extremely important in developing analysis reports for managing maintenance.

2. Nameplate information. Equipment nameplate information includes the relationships among equipment (commonly called hierarchies or trees), engineering information (such as purchase dates, design specifications, etc.), and bills of materials for spare parts. This information, including data that actually appears on nameplates, along with equipment numbering schemes allows users to track all repairs and costs of repairs.

3. Stores and inventory information.
This information supports the tracking of critical spares and spare-parts information. It includes part numbers, descriptions, and locations as well as on-hand quantities. If a company does not presently use a part-numbering scheme, it probably will need to develop one. If the CMMS/ EAM System does not automatically build a cross reference to the equipment, then the company may have to develop lists of equipment that uses each part.

4. Preventive maintenance (PM) tasks.
It is important to develop or modify data about each PM task as the data is gathered. Each task corresponds to a piece of equipment and may require spare parts. All of the data from the equipment and inventory databases play a role in the development of PM tasks. Realizing the relationships will allow for the planning of these tasks before they are entered into the CMMS/ EAM system. Information that will be required includes the steps to perform the maintenance, as well as safety instructions, spare parts needed, and task frequencies.

5. Personnel information. This data includes employee identifiers, craft designations, skill levels, and related personal information. This information is necessary for planning work orders and PM tasks. It allows the proper tracking of maintenance labor once the CMMS/ EAM system is in operation.

6. Other information. This data may include purchasing information, contractor information, engineering drawings, parts diagrams, etc. The type and amount of information required depends upon the CMMS/ EAM system selected. Some CMMS/ EAM Systems will require all of this information (perhaps more); others will not. Each vendor should be consulted for their specific requirements.

As each of these databases are developed, the ultimate focus of developing analysis reports and how they will be utilized to manage, not just maintenance, but the company’s assets must be maintained. Some companies have become so focused on data collection and input; they lose sight of real goal of implementing a CMMS/ EAM system; using the tool to manage maintenance and the company’s assets. Realizing this pitfall early in the CMMS/ EAM system project, will insure the success of the project.

Tip provided by GenesisSolutions
http://www.GenesisSolutions.com
Tel: (203) 431-0281

Test Your CMMS IQ

Infrared Thermographers and Motor Circuit Analysts Wanted

Snell Inspections has an immediate need for several multiple Level I and Level II infrared thermographers, as well as Level I and Level II Motor Circuit Analysts. Positions are located at multiple sites throughout the United States. Email or or call Lisa at 800-636-9820.

Learn more about Snell Inspections

Maintenance Planning & Inventory Tip

As you work toward reducing storeroom inventory, as you eliminate parts that are not for the most critical equipment, you are also helping the maintenance planning effort. Once the parts are gone, planning is the only way to get jobs done. You win!

Tip provided by Dave Krings, CMRP
Instructor: 5 Pillars - Maintenance & Reliability Professional Review Distance Learning Course
MasteringMaintenance.com

Learn More About the 5 Pillars Distance Learning Course

Maintenance Tip

There is anecdotal evidence that plants with the highest level of plant availability don’t necessarily make the highest level of profits. Availability is just like any other aspect of facility operation. It must be managed to insure that the achieved level of operational availability maximizes the business’s goals for profit, safety, and environmental impact.

Decisions impacting equipment availability are made at every level from CEO to the mechanics and electricians working directly on the equipment, and at every stage in the life of the facility from design through decommissioning. It is important to understand the complex relationships that create equipment availability and manage the individual parts in order to achieve the level necessary to meet your business goals.

Learn about these complex relationships by following the link below and downloading the pdf of Bill Keeter’s article “Managing Availability for Improved Bottom Line Results”.

Tip provided by ARMS Reliability Engineers - USA
Phone: 888-673-8360
http://www.armsus.com

Managing Availability for Improved Bottom Line Results Download

Introducing HOTSHOT®, the world’s first thermographic camera/data logger

Electrophysics is very proud to introduce HotShot, a new class of thermographic camera designed for infrared predictive maintenance inspection surveys. HotShot represents a paradigm shift in thermography camera design and delivers best-in-class ergonomics and overall value to thermography professionals.

HotShot is a super lightweight (1.9 lb) high performance infrared camera that incorporates an uncooled microbolometer image sensor and motorized focus lens into our unique articulating infrared eyeball.

HotShot’s miniature tablet design and data logger software functions bring new levels of inspection productivity to thermography inspection programs.

See a HotShot flash demo and sign up to win a Harley Davidson Motorcycle

Alignment Tip

Choosing the correct Averaging Value for rough field conditions If you are not getting good repeatability in your alignment readings using a continuous sweep measure mode, it may be best to switch to a multipoint mode, where you can take discrete readings at desired rotational positions, and with full control over each. Assuming no mechanical looseness, such lack of repeatability may be due to vibration from surrounding running machinery, or heat waves in the path of the beam, steam, or other causes of air density differences in the path of the beam. Most good laser alignment systems offer the user a detail screen where the actual coordinate values of the beam’s position within the sensor can be seen. Look at these coordinate values, and if, while just sitting there, they are changing by more than 0.5 thousandths of an inch (0.0005"), increase the averaging time to a sampling rate of 128 or 256 or about 0.75 to 1.5 seconds per reading, until the coordinate values steady up. You will then find noticeable improvement in your repeatability and accuracy of readings and moves.

Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935

More Alignment and Vibration Case Studies

Vibration Analysis Tip

Collecting Good Data 2 – Sensor Mounting Pads and Frequency Response

Besides assuring one is always collecting data in the same location, sensor pads also provide higher quality data, especially at higher frequencies. One problem with using a sensor with a magnet mount is that one can never be sure that data is being collected in the same location every time, nor can one be sure the magnet is making good contact with the test surface. This is especially true if the surface is curved, painted or dirty. Sensor pads for use with magnets help to resolve both of these problems. In the best case however, most magnetic mounts will only provide valid data up to about 2 to 3 kHz. The best case is when they are used with a smooth, clean sensor pad.

Threaded sensor pads are even more beneficial. First because they can be used with a triaxial sensor which reduces the number of times the sensor must be moved and therefore the total data collection time. Second because they provide more reliable data at higher frequencies. Threaded bronze or stainless steel sensor pads will deliver valid data up to about 7 kHz in the direction radial to the pad and slightly lower in the other axes if a triaxial sensor is being used. Data is more repeatable as it is easier to be certain the sensor was well seated in the pad.

This tip provided by DLI Engineering
http://www.DLIengineering.com
Tel: 206-842-7656

Check out DLI’s Application Notes Library

Important Infrared Thermal Imaging Survey

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Vibration Tip

Have your portable sensors calibrated every two years to ensure their performance. Heavy impacts (as in magnetic mounting applications), exposure to high temperatures above their specifications and exposure within a high DC field can cause degradation in their performance. It is a good idea to have your data collector checked and re-linearized at the same time.

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)