January 17, 2008
Predictive Maintenance (PdM) Tip
Recruiting PdM Team Candidates
1) The best approach is to recruit internally
2) Identify those who express interest in a particular predictive technology (vibration,ultrasound,infrared etc...)
3) Give candidates ready access to the PdM equipment and the technicians that are currently in place (provide them with some basic PdM tools and see how well they do with them)
4) Do not exclude operators from the candidate pool
Tip excerpted from “Predictive Maintenance Management” by Jack Nicholas Jr. P.E. CMRP and R. Keith Young
January 17, 2008
Oracle Maintenance Summit 2008
Attend this FREE conference focused on the interdependence of software, systems and people in supporting a reliable Asset Lifecycle Management program.
You will hear from industry thought leaders, leading companies and content experts as they share best practices and insight into the latest solutions and service offerings.
January 30 – February 1, 2008
Gaylord Palms Resort and Convention Center
Kissimmee, FL
To register please call 1.800.820.5592 Ext. 4760 or…
January 17, 2008
Alignment Tip
Machine trains can be complicated jobs for alignment. Job preparation can save a ton of headaches while trying to align multiple gearboxes and spacer shafts.
One step I added only takes about 20 minutes to do but saved probably twice that.
Using a sheave aligning laser(or low tech version being a string) I attached it on a flat surface of the center gearbox and measure the shaft to the laser line, after loosening the entire machine train, we bump the gearboxes and shafts by hand until we are even to the laser.
Flip the laser pointing to the other half of the machine train and repeat. We then move the laser to one end and verify that the entire machine train is straight with a 1/8” end to end over a 15 foot length was done with in 20 minutes. Snug the bolts and begin laser alignment job as normal.
When we then proceeded with our laser alignment we were pleasantly surprised to find that we were in alignment horizontally down the entire length of the machine. Vertical adjustments were all that was needed to finish the job.
Reader tip provided by Joel Woodthorp
Vibration Analyst
Georgia Pacific
Green Bay, Wisconsin
Thanks Joel - and good luck to Green Bay this weekend! Your stainless steel, diamond plate, Reliabilityweb.com coffee mug is on the way.
Join the alignment and vibration discussion at MaintenanceForums.com
January 17, 2008
CMMS/EAM Tip
Stay out of the Weeds
In recently reviewing an organization’s CMMS implementation, the equipment numbering (hierarchy) went all the way down to individual input and output cards on the programmable logic controller (PLC) racks.
That’s way too deep in the weeds. The rule of thumb for implementing a new CMMS or fixing an existing one is to stop the equipment numbering scheme (hierarchy) at the level that where you no longer apply a maintenance strategy. The items below that level are simply parts. What maintenance strategy will be applied to the individual input or output PLC cards? They are parts.
Using a simple conveyor as an example, the parent equipment is the conveyor with the child equipment of a motor and gearbox. These children are the lowest level that a maintenance strategy is applied. The individual components such as the sprockets or pulleys, chain or belt, shafts, bearings, rollers, and conveyor belt are parts linked to either the parent or children as appropriate.
Tip provided by Jeff Shiver, CMRP, CPMM
People and Processes
January 10, 2008
Establishing a Competency Based Maintenance Training Program
MTrain-2008 Maintenance Training Conference
March 18-20 - Las Vegas
FREE Bonus Workshop March 17
Workshop #3
Establishing a Competency Based Maintenance Training Program by Perry Lovelace and Andy Page
When people work together towards a common goal, their interdependencies form a complex system. To analyze the training and competency of one person without considering his/her effect on the team doesn’t describe the effect of that person on the entire system or in this case…team.
Competency then, has to be considered at the team level as well as the individual level; we call this “Organizational Competency” (OC). The ability of a team or an organization to successfully deliver results rests not only with the individuals knowing their role and being capable of performing individually but also on the ability of all those individuals involved to work together as a cohesive unit.
Many organizations have tried to develop competency systems, and a few have been successful. The workshop leaders have experienced and studied several competency program successes and failures and will present tools and examples of that which works and pitfalls to avoid.
This workshop will provide the basic building blocks for Organizational Competency, including:
• Step-by-step change management process towards OC
• Using Bloom’s Taxonomy to translate the SMRP Body of Knowledge into Proficiency Reference Guides
• Methods of identifying proficiency levels for Job Families and/or Positions
• Individual competency assessment and review techniques and strategies
• Identifying critical skill gaps for your teams
• Creating individual and team development plans using training, OJT, and mentoring to close critical skill gaps
Early bird conference and hotel rates apply - so sign up today!
Call toll free (888) 575-1245 to speak to one of our conference specialists.
January 10, 2008
Transformer Testing Tip
When testing transformers with a Baker Surge/DC Potential/Kelvin resistance tester, here are some rules to help provide most accurate results:
1) Make sure taps or lug connections are free/clear of oxidation, varnish, oil, tape or corrosion, a good connection with the Kelvin resistance bridge is important. Cleaning solutions, sandpaper, emery cloth or filing could be required depending on the situation. Follow your company guidelines.
2) If testing the primary windings, be sure the secondary windings are shorted out across their terminals, at the time of the test with alligator jumpers. In essence, any winding that is not connected to a Baker test lead, should be identified and shorted out.
3) The same rule applies for testing of the secondary windings. i.e. the primary windings should then be shorted across terminals with alligator jumpers.
4) Rule #1 also applies for Meg-Ohm, DC potential tests, and the Surge test, loose or bad connections can lead to sparking at the connections. Clean connections will improve accuracy of the test results.
5) Rule #2 and #3 also apply for the Meg-Ohm, DC potential tests, and the Surge test. Leaving the un-tested windings open circuited could result in an unknown voltage across the terminals of the secondary winding. If a weakness occurs in the winding, during a test, the transient voltages that could occur are damped by the shorting alligator jumpers.
6) The shorting jumpers can also provide a path to limit induced stray voltages from nearby conductors.
7) Remember, Baker Surge DC potential/Kelvin resistance testers are for testing de-energized windings, be sure to lock out the winding and follow all safety procedures provided by your company!
Tip provided by Baker Instruments, an SKF Group Company
Tel: (970) 282-1200
http://www.bakerinst.com
January 10, 2008
The essential foundation for a successful maintenance and reliability program
ABB’s PM30 Hosted Maintenance Management Service enables you to increase plant productivity through improved PM compliance and make better decisions with more complete and consistent information.
Implemented in only 90 days, PM30 reduces unexpected repairs, unplanned downtime and maintenance costs through:
• Analyzing failures to develop the right maintenance approach
• Implementing world-class business processes that accelerate maintenance and reliability improvement
• Optimizing maintenance staffing to meet workflow requirements by performing productivity analysis
Phone: 877-234-6756
Find out more about ABB’s PM30 Hosted Maintenance Management Service
January 10, 2008
Alignment Tip
The PASS mode and generators.
When using the laser system in the PASS mode (uncoupled) with turbines and generator sets, the turbine typically is easier to turn than the generator.
The problem is that in turning the generator with chain falls or other mechanical means, the shaft will deflect and cause repeatability problems.
Try this next time: If the sensor is attached to the generator and the laser to the turbine, place the red cap gently on the sensor, or block the beam by some other means as it passes in front of the laser. This will prevent any readings from being taken when the generator is rotated. Then remove the red cap from the sensor and rotate the turbine and take a reading. You will be taking half as many points, but this will eliminate shaft deflection and greatly improve repeatability.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
Read Article: Bracket Sag in Gas Turbine Laser Alignment (PDF)
January 10, 2008
Infrared Thermal Imaging Tip
When setting up to take thermal images in a new and unfamiliar setting, I initially set level & span in the following way:
1. Defocus the camera to one extreme or the other (close or far).
2. Aim the imager at the subject
3. Select auto-adjust and let level & span stabilize.
4. Restore the camera to manual setting.
5. Refocus on your subject.
Doing this usually puts the camera close to the level and span I want to use. Manual adjustment to achieve optimum settings are much quicker once I’ve done that.
Reader tip provided by Rocky Rutter
Freelance Thermographer
Norman, Oklahoma
Thanks Rocky - your stainless steel, diamond plate, Reliabilityweb.com coffee mug is on the way!
January 10, 2008
Advancing Reliability and Maintenance by Jack Nicholas Jr.
RCM-2008 Reliability Centered Maintenance Managers’ Forum
March 18-20 - Las Vegas
FREE Bonus Workshop March 17
Workshop #1
Workshop Outline
• History of RCM and rationale for its development and evolution in various organizations
• Economic factors and forces that led to the development of RCM Variants and Derivatives, the Society of Automotive and Aerospace Engineers (SAE) RCM Standard and its relationship to the SAE Failure Modes and Effects Analysis Standards
• Descriptions of various approaches to “Classical” RCM, Variants and Derivatives:
• Avoiding pitfalls in the execution of projects utilizing any of the above approaches and the obligations of both client and services providers to assure success
• Assessing readiness to successfully apply RCM to facilities or vehicles by internal self-audit of an organization
• Evolution and rationale for metrics to determine whether or not to perform any approach to RCM analysis on a particular asset and, when you decide to do so, metrics to use for three phases of an RCM Project (Analysis, Implementation and Benefits phases)
• Between 60 and 80 metrics will be defined for possible use in various venues
• Results of an RCM Survey conducted by Internet with over 200 participants in early 2005
• How RCM methodology fits into broader reliability and maintenance strategies with actual examples of strategy overviews presented
• How to link RCM with other maintenance and reliability processes and methodologies including, but not limited to Total Production Maintenance TPM), Six Sigma, various “maintenance scorecards,” and other elements of asset management and assessment
Early bird conference and hotel rates apply - so sign up today!
Call toll free (888) 575-1245 to speak to one of our conference specialists.
Find our more about the Reliability Centered Maintenance Managers’ Forum
