October 11, 2007
Vibration Analysis Tip
Just another tip you can use to find where a vibration is coming from in a complex machine with a lot of different roll speeds belt speeds.
I was called to a paper packaging machine which has a lot of different rotating components in it. The machine operator had noticed a vibration through the machine that wasn’t present before. I was able to detect the frequency of the vibration by using a vibration analyzer, but because there were so many rotating components in the machine it was difficult to determine the exact cause of the vibration.
I decided to use a strobe light and set it to the frequency that I had picked up with the analyzer. I pointed it over different sections of the machine to see if anything was moving at that frequency and found that it was one of the belts that was loose. You could see it very clear by using the strobe light.
By using the vibration analyzer to determine what frequency the vibration was and then using the strobe to visually see what was causing it made it easier than working out all the belt speeds and different roll speeds in the machine.
Reader tip provided by Robert Burford
Vibration Technician
Kimberly Clark Australia
Mount Gambier
South Australia
Thanks Robert - you are upholding the fine tradition of great maintenance tips from the land down under! Your diamond plate stainless steel Reliabilityweb.com coffee mug is on the way!
October 11, 2007
Learn more about Oil Analysis with No Cost Book from Insight
Insight Services has put together a practical reference handbook on lubrication, oil analysis and sampling procedures. This easy to understand guide is a must read for any maintenance professional. Now on our third edition, this book has been circulated to more than 4,000 maintenance professionals throughout the country.
Don’t miss your chance to receive our book today compliments of Insight Services.
Receive this terrific reference tool valued at $19.95 ABSOLUTELY FREE. Complimentary to U.S. residents only.
1-800-TESTOIL
October 11, 2007
Infrared Inspection Tip
Improve the Classification of Hotspots: Create a Fault Tree!
During an infrared inspection, thermographers inspect a large number of assets that can be classified into distinct equipment types, such as motor control centers, switch gear, transformers and others.
It is useful to recognize that each of these equipment types has its own unique failure mechanisms and associated corrective action. Experienced thermographers can create a list of the equipment types that they most often encounter, and then list the most common failure mechanisms and recommendations for each.
For example:
Equipment: Motor Control Panel
- Diagnoses (recommendations):
• Improper crimp connection (check torque, replace, etc.)
• Load imbalance (check load, added test recommended)
• Open circuit (visual inspection, check load)
• Undersized conductor (replace)
Such a “fault tree” database permits organizations to standardize their thermography program and give thermographers of all experience levels the benefit of cumulative experience while adding new observations about asset behavior and repairs.
Look for infrared cameras that feature integrated asset database functionality to efficiently build your organization’s infrared expertise.
Tip provided by Electrophysics
Tel: W: (973) 882-0211
October 11, 2007
Reliability Centered Maintenance (RCM) Tip
If you are asking yourself the following:
*When should I use RCM analysis?
Then read on….
Somewhere between 4 and 10% of the equipment in your facility would benefit from RCM analysis. This is based on the 4/64 rule.
Using the Pareto principle we can agree that 20% of the equipment in the facility is probably causing 80% of the problems. If we apply the Pareto Principle to that 20% we can conclude that 4% of the equipment in the facility is creating about 64% of the problems.
Thus, RCM on that low percentage will typically yield a very favorable result.
From our perspective at Allied that means that 90-96% of the equipment in the facility could be subjected to prescriptive methods such as the Asset Health Matrix to get the remainder of the problems reduced to acceptable levels.
Tip provided by Bill Keeter
Allied Reliability
888-414-5760
October 04, 2007
Reliability Leadership Workshop at IMC-2007
Dec 4-7, 2007
Daytona Beach Florida
Reliability Leadership Workshop by Ron Moore, PE, MBA, Author, “Making Common Sense Common Practice: Models for Manufacturing Excellence”, and of “What Tool? When? Selecting the Right Manufacturing Improvement Tools”
What You Can Expect From This Workshop
Results-oriented companies have discovered the proven impact of manufacturing reliability – maximized uptime, minimized unplanned downtime, improved process control, enhanced quality, minimized maintenance costs, and improved supply-chain performance. Attend this seminar, and you can too.
You’ll learn how to apply the Reliability Process - design, buy, store, install, operate, and maintain for reliability. You’ll review your plant’s performance in light of best practices and benchmarks. And you’ll leave with the ability to develop a strategic reliability improvement plan for your plant.
Reliability practices will make you a low-cost producer by maximizing capacity while minimizing production and maintenance costs. And you can do it all without incremental capital investments.
Hotel and early bird conference discount available.
Registering 6 or more? Ask About Team Discounts
The only conference with a 100% Satisfaction Guarantee or your money back!
Please call toll free (888) 575 1245 to register or…
Find out more about the 22nd International Maintenance Conference
October 04, 2007
Vibration Analysis Tip
Here is a simple tip to find resonance in a machine you are trying to diagnose.
If the problem is not obvious, try taking a coin from your pocket and running the coin along the equipment horizontally, vertically, and axially.
Sometimes you will find that you can feel the nodes and anti-nodes indicating that you may have a problem with resonance.
Reader tip provided by Luke Williams
Production Technician
Consolidated Edison of NY
New York NY USA
Thanks Luke - your diamond plate stainless steel Reliabilityweb.com coffee mug is on the way!
October 04, 2007
Choose OPTALIGN SMART for easy, accurate and reliable shaft alignments!
Obtain alignment results in 3 Easy Steps:
1) Enter Dimensions
2) Measure with our patented Continuous Sweep Mode -start and stop at any position
3) View Results
LUDECA, INC.
305-591-8935
http://www.ludeca.com
October 04, 2007
Lubrication Tip
Rigorously defined engineering principles are used in every stage of manufacturing development: machine design, building design, machine installation, process measurement, process control, etc… Every facet, that is…, except machinery lubrication program development and control. There is not, to my knowledge, another area that is as important to overall plant productivity as lubrication (is), that is also as poorly controlled as lubrication (is).
This is a mystery. Personnel involved in the decision to specify, manage, and perform lubrication practices are in agreement that this function, when done poorly, can directly and significantly increase machine failure rates and repair requirements. At the same time, when it comes to making a decision to ‘quantify’ the practices and expectations, and then hold everyone (management, engineering and labor) accountable for the results, there is often a collective sigh and resignation over the difficulty of the task.
But it isn’t difficult. It just takes time and persistence.
• Performing the fundamental calculations is not difficult, particularly with Excel.
• Adjusting the calculated estimates for changes in production environments in not difficult
• Scheduling the work, and verifying completion of the work is not difficult but is time consuming.
• Modifying the machines to prevent ingression of contaminants is neither difficult or expensive
• Modifying machines to allow for fluid condition control is neither difficult or expensive
• Modifying machines to allow for highly controlled sampling and analysis is neither difficult or expensive
• Making reliability-centric test slate selections, and applying limit values, is time consuming, but again is not terribly difficult
• Making decisions for improvements based on the oil analysis data is challenging, but can be taught and learned
• Setting program expectations, goals and objectives, and supporting those decision is not difficult, but requires diligence and consistency
So, would anyone like to speculate as to why there is still a low level of order and definition for your plant lubrication practices? My theory is that we have a long-standing habit of accepting undefined practices, and we have not looked at the value of improvements long and hard enough to justify the time and energy to make the change.
This doesn’t mean that the value isn’t here. It just means that we looked for it yet.
Tip provided by Mike Johnson
AMMRI
Participate in a Lubricant Technical Selection Practices Self Assessment
October 04, 2007
Infrared Inspection Tip
Too often thermographers get stuck using the same image palette over and over again. While you’ll typically use one or two palettes, it is important to get to know ALL of the color palettes in your camera so you are able to use the one that best suits your application.
A black and white or monochromatic palette (examples are “Grayscale”, “Iron Bow” or “Hot Metal") can be interpreted easily by thermographers of any skill level. Rainbow palettes have a powerful impact when used for reports or during presentations but are more difficult to work in and may also be more difficult to interpret.
Sharp focus, which is critical, may best be first adjusted using either a grayscale or monochromatic type palette.
Saturation palettes or isotherms are useful on a black and white image to show an object over or under an alarm temperature such as when inspecting a refractory. Inverted palettes, where “white” represents cold and “black” hot, can be useful when showing smaller areas of warm temperature, but note it carefully as this palette is not normally used.
The bottom line? Palette choice is a personal decision. Use the one which enables you to capture and display the best possible images.
Tip provided by John Snell
Snell Infrared
http://www.snellinfrared.com
Attend Thermal Solutions...the conference for professional thermographers
October 04, 2007
What should you get from your EAM/CMMS vendor?
At AssetPoint, we have 5 distinctive qualities that sets us apart from the crowd:
1. Satisfied Customers. Our clients are loyal and stay with us for many years.
2. Certified Professionals. Certifications include CMRP, PMP, MSCP and others.
3. Certified Products. TabWare is certified by Microsoft Corporation for their Windows platform and Vista Operating System.
4. Proven Methodology. Our methodology has been proven in hundreds of projects.
5. Relationships That Work. We partner with you to bring effective solutions to your maintenance, inventory and procurement operations long after the sale.
