March 23, 2006
Have you signed up for the PdM Program of Year yet?
If you do not blow your own horn - who will?
Uptime Magazine is inviting you to nominate your Predictive Maintenance program in any of the following categories:
• Vibration Analysis
• Ultrasonics
• Infrared
• Motor Testing
• Oil Analysis
• Alignment
There will also be a grand prize award for the best overall Predictive Maintenance program.
Entry is free and the initial form is very simple to complete so what are you waiting for? You have to be in it to win it!
March 23, 2006
Electric Motor Tip
A white “quick dry” paint stick is a handy tool to carry and use before disconnecting unmarked or illegible motor leads prior to offline motor testing in a motor control center. One mark for T1, 2 marks for T2 and three marks for T3.
It only takes a minute to do and the paint markings stay legible long term. Another quick, effective and inexpensive way to lessen the chance of hooking up a motor wrong.
Reader tip provided by Jim Zuidema, Electrician, Alcoa, Bettendorf IA
March 23, 2006
Maintenance Tip
When fishing items in a hollow wall, instead of using a fish tape, try using small fixture chain. It easily falls straight down and can be captured with a small wire with a hook on the end and then pull it out the opening. It is also usually strong enough to attach whatever you are trying to fish through the wall. Using this method will reduce the amount of time and aggravation normally seen during this type of task.
This Maintenance-Tip Challenge Winning Tip provided by Mike Hutson, Reliability Engineer, United States Gypsum Company, Norfolk, VA
March 23, 2006
LORD Launches Global Distributor Network
LORD Corporation – a leader in the management of motion, vibration and noise – has launched a distributor network to aid in the global distribution and services of their balancing systems and other technologies.
LORD currently has distributors in the United Kingdom, Spain, Portugal, Italy, Egypt, Turkey, India, Taiwan, Japan as well as a number of representatives in North America. The distributors have the ability to sell, install and service LORD Corporation’s proprietary balancing technology—a permanently mounted system that continuously monitors vibration levels and corrects unbalance while a rotating piece of equipment is in operation. The balancer has proven to increase the operating efficiency and production of a plant by drastically reducing conventional “off-line” balancing and maintenance.
LORD selected companies that are recognized as experts in their field and involved in Condition Based Maintenance (CBM). For a complete listing of distributors for LORD Balancing Systems, visit http://www.lord.com and click on “Find a Distributor.”
March 23, 2006
Ultrasonic Testing Tip
QUESTIONS TO ASK YOURSELF BEFORE TRENDING BEARINGS ULTRASONICALLY
No matter whose airborne ultrasound equipment you are using, you should always ask yourself these questions:
(1) Is my equipment “repeatable”? *Many of the makes & models today are not repeatable.
(2) Can I take two models of the same manufacturer and achieve identical or very similar readings (plus or minus 2-3 dB’s is acceptable)? *Only a couple of today’s airborne ultrasound manufacturers calibrate the contact probe to a known value that assures repeatability. The difference could be 2-3 or 15-16 dB’s or more.
(3) Is “sound quality” more reliable than trending dB’s?
*No. Trending a bearing overtime or using a comparative method will yield more information as to the condition of the bearing.
(4) Should bearings be lubricated before trending? *Yes. Lubricating the bearings before trending is a good idea. A non-lubricated bearing, can easily be mistaken for as a failure.
(5) If I lose a contact probe and purchase another, will my new readings be identical or very similar? *Possibly, not all contacts probes are calibrated to a known value. Check with your particular manufacturer and ask for assurances.
(6) Are bearing “contact points” identified? *Always retake readings at the same point as before. Consistency is important. Depending upon which unit you use, holding the instrument at the same angle and/or position is critical for repeatability. Try using a permanent marker to mark the point for future readings. Possibly, attach a washer to the surface to provide a non-slip point.
Tip provided by Jim Hall
Ultra-Sound Technologies
Tel: (770) 517-8747
http://www.ultra-soundtech.com
March 23, 2006
Root Cause Analysis (RCA) Tip
Optimizing your Root Cause Analysis efforts means that we should not be content and rest on our laurels that we have succeeded in eliminating the risk of recurrence of an event. True Root Cause Analysis optimization involves Knowledge Management (KM) of the information used to solve the problem.
If other people in your organization are not made aware of your findings and conclusions, then they risk the same thing happening in their areas. Root Cause Analysis also involves putting such information at the fingertips of those that need it most!
Tip provided by the Reliability Center Inc.
http://www.reliability.com
Tel: 804-458-0645
March 16, 2006
Vibration Analysis Tip
Always make a routine backup of your vibration database and any other technology database files used in your predictive maintenance program. It is a good idea to store your database files on a network drive when possible. This will allow your site IT group to create a routine backup of your data. Otherwise, periodically copy your technology database files to a network drive or a back-up device.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
March 16, 2006
Free Expo Pass for the Reliabilityweb.com Pavilion in Chicago
Please stop by the Plant Engineering and Maintenance Expo at the Donald Stephens Convention Center in Rosemont (Chicago) Illinois. There are over 100 maintenance and reliability solution providers on hand to discuss your problems and demonstrate new ideas.
Expo dates:
Tuesday - March 21 - 10 am - 5 pm
Wednesday - March 22 - 10 am - 5 pm
Thursday - March 23 - 10 am - 3 pm
Bonus: Please visit Reliabilityweb.com Booth #34039 for a free Reliability Roadmap including:
• Contact information for leading hardware, software, training and service providers
• Best Practices Reliability Benchmarking Form
• Reliability Roadmap White Paper
• Reliability Resources Tutorial CD
• Free RELIABILITY® Magazine issue
• Free Uptime® Magazine issue
See you in Chicago!
March 16, 2006
The Reliability Game at National Manufacturing Week
Rosemont Convention Center
Monday, March 20, 2006
9:00AM - 4:00PM
Whoever Says RELIABILITY Can’t Be Fun Hasn’t Experienced The Reliability Game
The Maintenance Reliability Exercise is a very effective tool that demonstrates the financial impact and the importance of equipment reliability. It is used raise awareness of the need for rapid change - from a reactive to a proactive reliability environment.
What do you learn by playing the game?
* Understand the size of the financial opportunity associated with proactive maintenance
* Where the money goes
* How to stop spending the money
* How to make the transition from Reactive to Pro-active maintenance
Trying to change organizational culture is difficult even when it goes well. People have a hard time “seeing” the objective.
The Reliability Game clearly demonstrates to all stakeholders the value of good proactive reliability practices and the effect on the bottom line. It’s a great way to make your point and have fun in the process.
Price Per Person just $345
Bonus: get an additional 15% discount by using Code: EM171A
Follow the links to conference registration.
Register for the Reliability Game online at ManufacturingWeek.com today
Vibration Analysis Tip
Always make a routine backup of your vibration database and any other technology database files used in your predictive maintenance program. It is a good idea to store your database files on a network drive when possible. This will allow your site IT group to create a routine backup of your data. Otherwise, periodically copy your technology database files to a network drive or a back-up device.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
March 16, 2006
Motor Testing Tip
Why should you perform high voltage testing on motors?
Did you know that contactor bouncing on motor startup (mechanical or vacuum-type starters) causes voltage spikes 3-5 times operating voltage? Initial contact is made then the circuit is broken when the bouncing occurs, thus reducing current and increasing voltage. In the case of pwm vfds, high voltages come from very fast steep-fronted switching waveforms and reflected waveforms that build up. The dielectric strength of insulation is so good that not even 10% of it’s value is attained during a high voltage test. Credible and peer-reviewed industrial test standards, which have existed for years, guide predictive maintenance users to voltage testing levels. Such examples are IEEE 43, 95, 432, 522, 841, IEC 34-15 and NEMA MG-1. Modern high potential test equipment performs both a copper-to-copper insulation and a groundwall insulation test using high voltage and low current. A 12 kv tester only produces 15 Watts maximum, thus duplicating startup voltage at a much lower current than a real motor startup. High voltage testing is the only way to detect insulation problems weeks or months before failure while you can make a plan-of-action decision. Laws of physics dictate why this is true, but it’s a discussion for another day. Meanwhile, the motor is still operating.
Tip provided by Baker Instrument
Tel: (800) 752-8272
http://www.bakerinst.com
