Simple Visual Inspection can be very powerful when coupled with experience. Visual inspection has the advantage of bringing one of the most powerful analytical tools available into play - the human brain!

The use of visual inspection during periodic system and equipment walk-downs can be very cost-effective. An experienced maintenance technician is often able to detect developing patterns which are precursors of failure. They also identify trends in color or texture change which are the gauges of deterioration.

Tip excerpted from “Predictive Maintenance Management” Course workbook by Jack Nicholas Jr. available at
http://www.masteringmaintenance.com

Register for Jack Nicholas’s PdM Managers Web Workshop June 29 - 11 am

When collecting route data on machinery, the measurement direction is important from the standpoint that many vibration related faults on rotating machinery are directional. Thus, an axial, vertical, and horizontal measurement is prudent to cover the potential faults.

In phase analysis these directional measurements are also important; however an additional complexity arises in that a “single” phase value is essentially meaningless. Phase analysis implies a “relative” phase relationship between two or more physical locations on the machine or structure. When performing directional phase measurements, the analyst is eliminating possible faults by evaluating the relative motions of the machine and/or machine components. Across couplings, belt drives, or along foundations or mechanically fastened joints, or even across the machine itself (bearing-to-bearing).

Many times the elusive answer lies in the not “what can it be?” but rather “what can it not be?” Happy hunting!

Tip by Dan Ambre, P.E.
Full Spectrum Diagnostics, PLLC
Phone: 763-577-9959
http://www.fullspec.net

More Vibration Analysis Resources

A PdM-2007 Workshop by Greg Stockton
Sept 11-13, 2007
Las Vegas Nevada

This workshop goes far beyond the typical infrared seminar and delves into many unique infrared applications that can greatly expand the benefit of any infrared program.

Areas covered are designed for plant thermographers and contract thermographers...as well as those who may be considering becoming a contract thermographer.
The workshop includes a detailed overview of many different applications, a candid discussion about the impact of NFPA 70E, a primer on how to buy and sell infrared services and which type of IR camera work best for a given application.

Attendees will learn more about the specifications that separate quality thermography from substandard thermography. The course will conclude with advances in infrared technology and a comprehensive look at the types of and imagers available on the market today.

Outline:

1) Electrical/Mechanical Apps: Quick Review

2) Beyond Switchgear: Unique Infrared Inspection Applications Explained

3) The Truth about NFPA 70E

4) Process Control and Infrared R&D

5) Buildings...Green-Thinking, Moisture Control and Quality-Assurance

6) Up on the Roof

7) How to Buy and how to Sell Infrared Inspection Services

8) IR Cameras – Current Technology Available

Space is limited - register today to reserve your seat. Please call (888) 575 1245 or…

Find Out More About PdM-2007 Workshops and Conference Program

Many do not think about the timeline between an incident (i.e. – tube rupture, leak in hazardous piping, etc.) and its ultimate consequences (i.e. – environmental release).

There is a span of time between the failure that initiated the consequence and the point in time in which the consequence was isolated.

Why is this important? Because the manner in which we respond to the initiating failure may influence the magnitude of its consequences. If that is the situation, a case can be made to add a MODE labeled something like “Improper Response”.

By addressing this MODE we will be forced to explore the appropriateness of our responses to the incident and see if we could have done things better and minimized the magnitude of the consequences. By not addressing this, we miss the opportunity to review our response systems and only focus on what lead up to the physical incident itself.

Tip provided by Bob Latino
Reliability Center Inc.
http://www.reliability.com

Find Out More About Root Cause Analysis (RCA) Training

Electrical Signature Analysis (ESA) and Motor Current Signature Analysis (MCSA) require specific information about the electric motor in order to provide accurate results with a high degree of confidence. By being able to identify the number of rotor bars, stator slots, line frequency and running speed of the machine, a lot can be identified including: Rotor eccentricity, static and dynamic; Broken rotor bars; Bearing faults; Driven equipment and supply issues; Loose coils and end-turns; and much more. This information can be obtained from a database, repair shop, manufacturer or by calculating the rotor bars and stator slots. Each method has its degree of accuracy.

Tip provided by Howard Penrose PhD, CMRP
SUCCESS by DESIGN Reliability Services
Ph: 800 392-9025 (USA) or 860 577-8537
http://www.motordoc.net

Find Out More About Electrical Motor Diagnostics Training

We all suffer from information overload - too much information or from not having enough information in the right place at the right time. Maintenance departments are expected to do more with less resources than ever before in today’s competitive environment. To remain effective - maintenance staff must have the right information at the right time.

Please join maintenance expert and author Joel Levitt for a 2 hour audio course on CD that is packed with helpful procedures to organize and unlock the power of information for your maintenance organization.

In stock for immediate delivery. Click here to order

To overcome the problem of not implementing the results of an RCM study, make sure the study includes the following outputs:

Maintenance tasks grouped to a maintenance plan
Maintenance plan that identifies associated equipment and/or functional locations, with frequency and duration of tasks.

Ensure all tasks in the plan have work instruction documents so tradesman know what needs to be done.

For all tasks required by the plan, document what the failure modes are that the tasks address, so that when undertaken the maintainers know what to look for.

All maintenance plans should have a resource requirement prediction before loading to CMMS so you know you have enough people.

Make sure you also predict the level of unplanned or breakdown work likely to occur to guard against having to redeploy resources from important planned work to urgent breakdown work.

Make sure the plan will deliver plant availability required by the business plan.

Make sure the plan meets the corporate risk profile.

Make sure there are spares available to undertake both planned and unplanned work.

Finally, make sure you have a budget necessary to do both planned and unplanned work.

Tip provided by Michael Drew
ARMS Reliability

Learn more about developing smart asset strategies

After re-installing a two speed gearbox that had been overhauled off site, the routine oil analysis appeared to be out of specification. The commercial analysis lab was questioning if the proper oil had been used when the box was refilled. When compared to reference readings of the virgin gear oil used the levels of calcium, magnesium, phosphorus, and zinc were very different. A follow on oil change was performed to correct the situation, with the analysis now much closer to reference specs.

A few months later another gearbox was removed for overhaul. A supply of the refill oil was staged and clearly labeled for that gearbox to be used after installation. Again I experienced the same odd readings and questions. Something was going on and I needed to get to the bottom of it.

Samples of drums in storage were sent out for analysis to verify that it was not a problem coming from the supplier. Conversations were had with the suppliers Lube Engineers and research lab as to possible explanations of the analysis. What linked these two situations?

OVERHAUL! The facility that overhauled BOTH gearboxes was contacted to review their procedures. They stated that after any gearbox work the unit was flushed to remove any foreign material from the unit. It was then filled with a break-in oil and spin tested for operational problems. During testing the unit was piped to a filtered circulation unit for lubrication. Upon completion of testing the unit was drained, all openings plugged, and shipped back to the customer. An identification and analysis of the break-in oil used identified the source of the strange readings we had received from the lab analysis. The residual oil remaining in the lube system was the culprit.

In order to prevent a repeat of the past, a plan was formulated for future overhauls that we had the chance to implement a short time later. Another large gearbox was to be overhauled.

A full analysis of the oil in use was completed to determine its condition. With the oil in good shape, it was removed from the gearbox as part of the disassembly routine and pumped into clean, lined drums using a portable filtration unit. The oil was further filtered while recirculating in the drums while the gearbox removal was in progress. The drums were then sealed and shipped with the gearbox to the overhaul facility. The overhaul facility used the oil as a flushing and break-in fluid after repairs were completed.

As this routine is now standard procedure we no long need to change oil due to cross contamination conditions.

Reader Tip provided by Harold Matroni
Lubrication Technician/Analyst
Alcoa Mill Products
Lancaster PA

Thank you Harold - your Stainless Steel Maintenance Tips Coffee mug is on the way!

Benchmark Your Lubricant Delivery, Storage and In-Plant Handling

If “corona” is found while scanning substation or switchgear with your airborne ultrasound instrument, take action to clean-up the gear. Corona exists to find ground. It should always be taken seriously.

Tip provided by Jim Hall
Ultra-Sound Technologies
Sign Up For “Ultrasound War Stories” email newsletter
http://www.ultra-soundtech.com

Find Out More About Ultra-Sound Technologies Level I Certification Class - May 29-31 in Kennesaw, GA

Establish a Museum of Components and Samples pulled from service for cause.

Predictive maintenance analysts should be provided with the opportunity to study parts removed from the machines upon which they are reporting.

Selected parts, samples, photographs and other items reflecting Predictive Condition Monitoring achievements or failures should be placed on display for all to see.

Tip excerpted from “Predictive Maintenance Management” Course workbook by Jack Nicholas Jr.

Find Out More About The Predictive Maintenance Management Course book and PdM Program Assessment CD