October 27, 2005
Recent Advances in Synthetic Lubricants
LubricationWorld - Co-located with
The 20th International Maintenance Conference
December 6-9
Tampa Florida
Short Course led by Dr. Tim Nadasdi, ExxonMobil
This course will cover the major types of synthetic lubricants used in industry today. We will focus initially on the basic chemical nature of these lubricants as well as how they fundamentally differ from mineral oils. We will discuss the evolution of the term “synthetic” as it applies to lubricants, with special consideration to the impact hydroprocessing technology, leading to Group II and Group III base oils, has had on the use of the term synthetic. With a basic understanding of what the major types of synthetic lubricants are, we will discuss what properties they possess and how these properties affect lubrication. In this section, we will move from chemistry to the more important issue of lubricant performance. In looking at lubricant performance, we will turn our attention to matching lubricant capabilities with application needs, with a focus on when synthetic lubricants can offer an advantage, and when they may not. As we consider application needs, we will discuss the potential traps associated with comparing numbers from standard test methods and how these can be overcome. Throughout the course, we will look at examples of lubricants and applications to illustrate key points.
Attend this subject plus 50+ other short courses and learning zone sessions at LubricationWorld.
Discount hotel rooms are available at the Tampa Marriott Waterside until November 1 - so please book today!
To register or to request a brochure please call toll free (888) 575-1245 or…
October 27, 2005
Root Cause Analysis (RCA) Tips
5-WHYS: RCA OR NOT?
The 5-Whys tool has been around a very long time and was made popular by the Quality world. Its basic premise is that if you face an event that you can simply ask yourself the question “WHY” five times you will arrive at “the” root cause. While there are more elaborate uses of this concept, what I have described about is a very common use and paradigm of acceptability. There is a reason that you do not see investigators like the NTSB basing their conclusions on a 5-Why analysis.
The following are the reasons why the 5-WHYS is not considered true Root Cause Analysis:
A. It does not explore all of the range of possibilities that could have occurred, only what is obvious
B. It gives the impression that there is only a single linear path to failure
C. It gives the impression that there is only a single root cause
D. It often allows hearsay to fly as fact without requiring further evidence
Why is the “5-Whys” attractive to many managements? It is cheaper, quicker and faster, but that does not make it accurate!
Tip provided by the Reliability Center Inc.
http://www.reliability.com
Tel: 804-458-0645
October 27, 2005
Leak Detection Tip
Measuring the Impact of Compressed Air Leak Surveys
A rule of thumb for air system energy conversion is roughly 18kW/100 CFM (ref: US DOE Case Studies). In order to evaluate and identify the improvements to your compressed air system through an air leak survey, log kW demand readings from your air compressors through a standard operating cycle (load profile) using your power analyzer, current signature analyzer or electrical signature analyzer. This will set your baseline. Following the implementation of your compressed air leak survey, and corrections to air leaks, re-take your load profile and identify the kW reduction in consumption.
$avings = (kWorig – kWnew) x annual operating hours x $/kWh
Periodic load profiling will identify the continued effectiveness of your program by either identifying that the demand is maintained, improving, or will identify hidden problems by identifying increased demand.
Tip provided by Howard W Penrose, Ph.D.
http://www.motordiagnostics.com
Phone/Fax: 860 577-8537
Cell Ph: 860 575-3087
October 27, 2005
en Español: Confiabilidad.net - La Cultura de la Confiabilidad
Si usted prefiere obtener información sobre Confiabilidad y Mantenimiento en español, por favor visite Confiabilidad.net La Cultura de la Confiabilidad. Este sitio Web fue inspirado originalmente por nuestro trabajo en Reliabilityweb.com y Maintenance-Tips y ahora somos los nuevos Editores ! Lo que da vueltas - regresa.
Por favor visite el nuevo sitio y suscribase para el boletin de noticias gratis en Español.
October 27, 2005
Motor Testing Tip
Current Unbalance for Fault Detection
A common misconception within industry is that current unbalance can be used to effectively detect motor winding faults. Unfortunately, the ratio between voltage unbalance and current unbalance in a real-world application can be from a few times to a great many times (it has been published up to 14-21 times). The amount depends upon the motor circuit, distribution system, power quality and other loads/defects within the system. In the few instances where you are able to detect defects due to current unbalance, the condition is usually too critical for corrective action planning and result in a reactive condition.
Electrical Signature Analysis (ESA) is used to detect faults much earlier than gross current readings by utilizing FFT signature analysis. This can be related to the ability of gross vibration displacement readings versus displacement, acceleration, velocity and energy FFT’s. More detailed information can identify problems much sooner. Modern ESA devices provide voltage and current FFT analysis of the incoming power through driven equipment, providing a more complete analysis which, in some systems, include automated analysis.
Tip provided by ALL TEST Pro
http://www.alltestpro.com
Tel: 800 952-8776 or 860 395-2988
Visit the ALL TEST Pro Motor Testing Learning Lab at IMC-2005
October 27, 2005
There is still time to win a vb3000 Vibration Analyzer
To celebrate the grand opening of the brand new US office, Commtest is offering Reliabilityweb.com members and web site visitors a chance to win a vb3000 series vibration analyzer. To be eligible to win you must enter by October 31, 2005.
The vb3000 is an all-in-one tool suitable for every level of vibration analyst, from novice through to expert. The Ascent® software contains the collective experience of over 25 years of expert in-depth machine fault analysis.
Users with no prior experience or without previously recorded vibration history can now establish a measurement program utilizing proven baseline values from ISO standards and “The Proven Method” from Technical Associates.*
Bonus: The winner also gets an iLearnVibration interactive vibration training program from Mobius!
October 27, 2005
Alignment Tip
Laser Alignment Readings: Direction of Rotation
If your laser alignment system allows you to turn the shafts in any direction, always turn in the direction of rotation of operation of the machines. This will prevent undesirable consequences (such as unscrewing pump impellers) and lets the shaft ride in its accustomed wear path within the bearings, resulting in more consistent repeatable readings.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
Learn about the Rotalign ULTRA alignment system
October 27, 2005
Maintenance Tip
Sorting Project Work From Maintenance Work
Some maintenance organizations believe that all work being performed is considered maintenance work, but in reality, some of the work being accomplished could fall under the category of Projects.
To better comprehend the difference between Project and Maintenance Work, one needs to understand the definition of the word Maintenance: “The act of maintaining.” and the definition of the word Maintain: 1. “Keep in existing shape.” 2. “Preserve from deterioration or decline.” 3. “Protect from failure.” Maintenance related activities are identified as Calibration, Corrective, Preventative, Predictive and Emergency. In contrast, project work is associated with new equipment installations, process improvements, as well as, equipment upgrades and may be identified by key words: “Build, Move” or “Modify.”
Project work is assigned to the engineering organization and is generally managed by a Project Manager or Engineer, whereas maintenance work is assigned to the maintenance organization and is supervised by maintenance supervisors. Project work should be planned, scheduled and executed, after ensuring that all planned maintenance work has been covered and if labor resources are available. If in-house labor is not available, project work can also be assigned to an outside contractor.
By properly categorizing and prioritizing Work Orders, maintenance work will not be confused with project work and in turn will ensure that maintenance work will be planned, scheduled and executed first. This will also guarantee that the maintenance organization’s primary obligation, of ensuring the reliability of the existing equipment, is being addressed. The process for categorizing and prioritizing all maintenance and project work should be established in an approved maintenance Standard Operating Procedure (SOP).
Anders Bergh
Ashcom Technologies, Inc.
http://www.ashcomtech.com
More Maintenance and Reliability Resources
October 20, 2005
Data Analysis Tip
Data Analysis Tip Part 2 – Create a Vibration Test and Analysis Guide
Archived at
http://maintenancetalk.com/blog.php/tipsblog
A vibration test and analysis guide is a simple book or electronic document that contains a variety of information about the machine. Information should include: A simple schematic of the machine with test points identified, instructions for testing the machine (especially if loads and speeds must be manipulated or verified), name plate information and a simple schematic of internal components. This information is invaluable for conducting a proper diagnosis of the machine.
Access to testing instructions may lead the analyst to recognize bad data caused by improper test conditions. Test location information allows the analyst to determine what graphs to consult when looking for particular faults. A simple internal schematic of the machine is invaluable as one wouldn’t want to diagnose ball bearing wear in a machine with only sleeve bearings! (Believe me, it happens!) Additionally, faults present themselves differently depending on how the machine is configured. A common example is that unbalance in a fan with a supported rotor looks different from unbalance in a fan with an overhung rotor. It is essential to have this information visually in front of you when conducting data analysis.
Tip provided by DLI Engineering
http://www.dliengineering.com
Tel: 206-842-7656
October 20, 2005
Contamination Control In Hydraulic and Lubricating Systems Short Course
LubricationWorld - Co-located with
The 20th International Maintenance Conference
December 6-9
Tampa Florida
Short Course led by Leonard E. Bensch, Ph.D., P.E., Vice President, Pall Corporation
Contamination in hydraulic and lubricating system fluids is generally recognized as the single most important factor in reducing the reliability and longevity of the equipment. The decrease in reliability because of fluid contamination has a major impact on maintenance costs as well as machine productivity. In order to increase system reliability, a program should be established for cleanliness control. Such a program involves machine design to exclude built-in and ingressed contaminants, proper filter selection to maintain the operating cleanliness, and good practices to ensure minimal contamination is introduced or remains after maintenance is performed.
This short course provides a fundamental understanding of contamination control principles, starting with particulate contamination, including how to measure and report contamination levels. Typical damage caused by contamination is presented as well as benefits achieved by controlling contamination to desired levels. Fundamentals of filtration for contamination control are discussed, including a review of historic and modern filter rating methods. Finally, guidelines are given for determining cleanliness requirements, filter selection, and filter location.
Contamination control is much more a science than several years ago. Through proper implementation of a total cleanliness management program, the goal should be to reduce or eliminate contaminated related failures. With technology available today there is no reason to continue to allow dirt to be the major machine life limiter.
Attend this subject plus 50+ other short courses and learning zone sessions at LubricationWorld. Discount hotel rooms at the Tampa Marriott are available till November 1 so please book today.
To register or to request a brochure please call toll free (888) 575-1245 or…
