November 17, 2005
Producing IMC Proceedings - The Luckiest Job
Wow - I have been working on the production of the IMC-2005 and LubricationWorld Proceedings book and CD and have to tell you that I am blown away with the quality of the papers and presentations.
The maintenance and reliability knowledge and information that will be shared is deep and attendees will take away many new ideas for improvements and how to make them stick!
I cannot wait to see these presentations in person!
- Terrence O’Hanlon, CMRP
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This year IMC-2005 features a “Birds of a Feather” program to encourage more one to one networking. Each attendee can choose colored ribbons that indicate areas of interest such as “Maintenance Planning” or “Reliability Centered Maintenance” so others can spot people with similar interests. Lunch tables will also be marked by area of interest to make it even easier to meet other who face the same issue you do on a daily basis.
19 Days till IMC-2005 so please sign up today!
November 17, 2005
Acceleration v. Velocity Based Vibration Monitoring
The application of velocity based vibration monitoring is different from that of acceleration based. It is important to select a sensor that will provide usable data across the range and accommodate the amplitude range of the application.
The majority of rotating machinery runs at 600 cpm to 3600 cpm. The sensor frequency range required to monitor vibration caused by imbalance and reciprocating forces is between 600 cpm and 120,000 cpm (10 Hz to 2000 Hz). For these machines and this type of monitoring, a velocity output sensor is best suited due to its increased sensitivity to low frequency vibration and de-emphasis of high frequency vibration.
With acceleration based vibration monitoring, the sensor has increased sensitivity to higher frequencies. This allows more emphasis on the frequencies which are indicative of bearing and gear mesh condition. However, very high levels of high frequency vibration from impacting gear teeth or metallic impact can overload the range of the accelerometer. In these cases, the velocity sensor is used to de-emphasize the high frequency signals.
In general, velocity sensing is preferred for general condition monitoring. Acceleration monitoring can be used for general bearing condition monitoring. If the accelerometer overloads due to high frequencies, switch to a lower sensitivity sensor or a velocity monitoring sensor.
November 17, 2005
Oil Safe® Giveaway by PdMA
Our friends at PdMA offer in-stock inventory at great prices. Now they are offering one lucky Reliabilityweb.com member or web site visitor a complete set of 5 Oil Safe drums, including 5 lids and accessories for storing, dispensing and transporting lubricants!
The Oil Safe® container system is a safe, sure, easy to use method of storing and dispensing lubricants and lubricating fluids in a wide variety of applications.
November 17, 2005
Reliability Centered Maintenance (RCM) Tip
Overcoming Resistance to Your RCM Effort
In today’s world of manufacturing reliability we can attend several conferences a year and listen to one company after another describe the benefits they have seen from applying RCM to their assets. Despite the proven history or RCM there will still be people who firmly believe “it wont’ work here”!
I will offer the following advice for dealing with resistance to your Reliability Centered Maintenance effort:
1. Overcome Resistance with Drive and Persistence
• Develop a plan for success
• Identify and Measure the Reliability of Critical Assets
• Select one of these Assets for Analysis
• Perform the Analysis and Implement the Results within One Month
2. Advertise and Reinforce the Results of your Analysis
• Success in one RCM analysis breeds success in future analyses
• Clearly post the results of your analysis (Reliability Measures, Savings, Improvements)
• Send out e-mails that cover the progress of your efforts (What did we analyze, progress of implementation, savings resulting from the effort, plans for future analyses)
Remember, every company that has a RCM effort built their teams and performed their analyses while their critics waited for the effort to fail. In the end drive and persistence will always overcome resistance.
Tip provided by Doug Plucknette
Reliability Solutions
Tel: 585-349-7245
http://www.reliabilitysolution.com
November 17, 2005
Motor Testing Tip
Proper Offline Maintenance - Electric Motors
When testing motors off-line, it is a good practice to test them at the load side of the MCC or VFD. This method provides the technician with valuable information about both the motor’s windings and insulation and it’s supply cables. It is important to remove the leads from their connections at the MCC, or at least insure that power factor correction capacitors, spike arrestors and any other filters are disconnected before testing begins.
When low meg-ohm values are detected at the MCC, it may become necessary to test the system at the motor’s junction box. However, the problem is often remedied by simply cleaning the connections in the junction box since these connections frequently collect moisture and other contaminates causing low meg-ohm readings. Wiping the connection points with alcohol or contact cleaner will usually improve the meg-ohm values dramatically and will eliminate the need to disturb the junctions themselves. Applying this simple technique may save many hours that would be required to disconnect the motor leads from the supply cables.
If, however, cleaning has not improved the meg-ohm readings, it may be necessary to separate the motor’s leads from their supply cables and test both the motor and the cables. Many times cables have become damaged due to age or environment and must be replaced. Bad cables can cause “downtime” just as surely as a motor failure and locating potential problem cables is essential. Motor supply cables will see the same voltage spikes as the motor so it is important to test them at the same test values as the motor.
Tip provided by Baker Instrument
Tel: (800) 752-8272
http://www.bakerinst.com
November 17, 2005
Have you heard about LORD's Online Balancing Systems?
For the past year - we have brought you information and case studies about the unique online balancing system from LORD.
Now you can learn even more by requesting a free CD that demonstrates how the LORD online balancing system works, the technology used and how it it has been applied at plants around the world.
Please request your complementary CD ROM “LORD Balancing Systems In Motion” by using the link below or call toll free in the USA (877) ASK-LORD
November 17, 2005
Documentation Tip
Documentation Tip Part 1 – Document “As Found” Condition
Archived at
http://maintenancetalk.com/blog.php/tipsblog
Many vibration analysts make repair recommendations or create work orders for machines but don’t (or can’t) follow up to see if their diagnosis was correct. This is unfortunate as a great deal of valuable and educational information is lost. Accept that you will sometimes be wrong and do whatever it takes to find out the “as found” condition when the machine is opened up for repair. This is often difficult to accomplish but it is well worth the effort and in the best circumstances this should be implemented as a normal procedure.
Ask for replaced bearings, cut them open and look at the wear. If you have a digital camera, take a photograph. If a balance or alignment job was called for, ask for the before and after values. Retrieve and inspect gears and impellers and photograph them. This serves two purposes. The first is you will learn something, hone your skills and become a much better analyst. The second is you will be able to educate others, justify your work and promote the value of what you do. Document your mistakes as well as your successes and you will become a much more successful analyst. You will also learn a great deal more about the machinery you are responsible for.
Tip provided by DLI Engineering
http://www.dliengineering.com
Tel: 206-842-7656
November 17, 2005
Oil Analysis Tip
Particle Quantifying Provides
Low-Cost Alternative to DR Ferrography
Particle Quantifying, or PQ, is becoming an increasingly popular method for measuring large ferrous wear particles in used oil samples. When used in conjunction with metals analysis by ICP to detect the presence of ferrous metals, PQ becomes an effective low-cost alternative to direct read ferrography.
HOW PQ WORKS
PQ exposes samples to a magnetic field. Those containing ferrous metals cause a distortion in the field, which is represented as the PQ Index, an arbitrary unit of measurement that correlates well with DR ferro large. The PQ90 is designed to monitor trends. It does not provide a ratio of small to large particles as does DR. However, if the PQ Index is smaller than an FE ppm by ICP, it’s unlikely that particles larger than 5 microns are present. If the PQ Index increases dramatically while the ICP’s Fe ppm remains consistent or goes down, larger ferrous particles are being generated and further testing or diagnostics would likely be recommended.
WHAT PQ CAN DO FOR YOU
Unlike DR, PQ does not require multiphase dilution for accurate results. The expense of using chemicals and the hazards of handling them are eliminated. Less material interference reduces both sample preparation time and the probability of human error, which not only improves repeatability, but makes trend analysis more reliable.
As a result, PQ has proven to be a very inexpensive way to regularly screen samples for ferrous metals and provides adequate information for recommending further testing on samples with potential problems. By far, it is considerably more thorough and cost effective to do PQ on a regular basis and run analytical ferrographs only on samples with potential problems than it is to run a DR on EVERY sample.
Tip provided by Polaris Labs
Tel: (317) 808-3750
November 10, 2005
Hydraulic Troubleshooting - Rapid Troubleshooting Techniques
LubricationWorld - Co-located with
The 20th International Maintenance Conference
December 6-9
Tampa Florida
Short Course led by Ricky Smith, CMRP, Maxzor
Hydraulics always seems to be a problem in many organizations and troubleshooting these systems in a timely manner is a problem, Ricky exposes some great concepts that anyone can put in place to troubleshoot hydraulic systems rapidly. Ricky uses his years of practical experience in hydraulics to drive this practical short course. Come and enjoy this great workshop and an experience you will never forget.
Attend this subject plus 50+ other short courses and learning zone sessions at LubricationWorld.
To register or to request a brochure please call toll free (888) 575-1245 or…
November 10, 2005
Hydraulic Tip
HYDRAULIC TROUBLESHOOTING MADE SIMPLE
Hydraulic problems cost companies millions of dollars in lost capacity because of troubleshooting problems. Troubleshooting hydraulic systems can be difficult and very frustrating to maintenance personnel. There is a simple process which can make the troubleshooting of hydraulic systems much less stressful. This process requires preparation for this imminent failure of a hydraulic system. This process involves two paths one must follow in order for this to work.
Path 1: This path decreases downtime and allows the root cause of hydraulic failure to be resolved quickly without the changing out of components unless the know cause of a function failure has been identified.
* Identify and mark fluid flow paths for pressure, return, and pilot lines by using colored markers on your hydraulic schematics.
- Red – Pressure
- Blue – Return
- Green - Pilot
* Develop a quick reference chart for troubleshooting. In order to develop this quick reference one must:
1. Identify each function a hydraulic system must perform (ex: Hydraulic Cylinders Extended)
2. Identify each valve that must be energized to perform this function(ex: Hydraulic Cylinders Extended, valves 3.1, 4.4)
3. Identify the timing (if required) in order for the cylinder to perform to standard (ex: Hydraulic Cylinders Extended, 12.1 seconds)
4. Identify the hydraulic flow and pressure required for the cylinder to extend to a specific timing (ex: Hydraulic Cylinders Extended, 12.1 seconds, 9 GPM at 1200 psi)
5. Train maintenance personnel in the use of this process and retrain on a quarterly basis (testing is essential in order to ensure knowledge has been transferred from instructor to the maintenance crafts person)
Path 2: This path can also make troubleshooting of a hydraulic system none existent or at least a rare occurrence. This path also requires DISCIPLINE in order for it to be successful.
* Develop a Preventive Maintenance Program for a hydraulic system that includes the following:
- Step by step procedures for each PM task that requires little if any training for one to meet the standard.
- ex: Task – Change Hydraulic Filter
Step 1: Clean around filter housing with cleaning solvent and wipe with lint free towels
Step 2: Remove bolts utilizing a ¼” allen wrench
Step 3: Remove cover along with used filter element and dispose of the element
Step 4: Open plastic wrapping enclosing the filter element. (warning: do not touch filter element with hand or glove)
Step 5: Insert new element without touching the filter element with hand or glove.
-Tools and Material Requirements should be listed for each task along with part number of material from stores warehouse.
- Determine the condition at which a PM Task is required. (time based can work but not preferred)
* ex: Filter differential pressure exceeds 10psi requires a filter change within 48 hours.
Implementing this two step process will prepare an organization to rapidly troubleshoot a hydraulic system and at the same time reduce the probability of a failure.
Tip provided by Ricky Smith, CMRP
Ricky brings a common sense approach to hydraulic solutions that many maintenance professionals face on a daily basis. Ricky has many years hands on experience as a practitioner troubleshooting hydraulic systems all over the world. Ricky is also the author of the well known book, “Industrial Repair, Best Maintenance Repair Practices”. He will lead a Hydraulic Troubleshooting Short Course at LubricationWorld (see next item below).
Buy Ricky’s Book: Industrial Repair, Best Maintenance Repair Practices
