September 01, 2005
Infrared Thermography Tip
Automate Report Generation with In-Camera Data Logging.
The ratio of time spent conducting in the field inspection to time spent generating reports has transitioned from 1:3 prior to thermal cameras featuring digital image recording; to about 1:1 with advances including digital visible camera and advanced report generation software products.
Additional time saving can be found using your thermography cameras data logger functionality. Electrophysics HotShot camera for example, features the ability to enter typical field notations such as equipment name, location, diagnosis, repair recommendation and severity rating using the touch screen graphical user interface. This data is stored with the thermal image. During report generation all field information is automatically placed in a wide range of report templates. Additionally any analysis performed in the field such as temperature rise analysis or area temperature analysis and stored with the image will automatically be reproduced in the infrared report.
The result is the ability to automatically generate reports with field notes, visible images and temperature analysis. A number of real-world tests demonstrate a reduction in time to generate reports of nearly 80% or a new benchmark ratio of 1:0.1.
Users can create custom equipment, diagnosis and repair recommendation lists and upload them to the camera using available report software XML database tool.
Tip provided by Electrophysics Corp.
Phone: (973) 882 - 0211
http://www.electrophysics.com
September 01, 2005
Enterprise Asset Management (EAM) Tip
Who’s Your Daddy? - Building a Useable Asset Hierarchy
When was the last time you tried to gather data for a report you had to give, or cost information on a particular area, building, or line, only to find that you had to go to four, five or even ten different places to get ALL of the information you needed? In most cases this is the result of either a non-existent or poorly structured asset hierarchy.
Asset hierarchy management allows the tracking of all assets and their associated locations using a “family tree” that forms relationships between physical locations, production lines and assets. These relationships facilitate data collection and analysis for asset movement, maintenance and costs for individual assets, a grouping of assets or a production area.
Your entire business can be represented in a breakdown structure that allows you to define hierarchical relationships between areas and different assets. Once the structure has been defined you can consolidate information up the hierarchy. For example, you can view labor costs across a complete area, which itself is made up of any number of layers of assets on which maintenance work orders are being executed.
Development of an accurate asset hierarchy is the first step to organizing data for utilization. For existing facilities, this may involve walk-downs to both verify and add additional information. Basic data for equipment is also gathered to enhance descriptions in the hierarchy and for use when developing Bills Of Materials (BOM).
The basis for development of asset hierarchies is the current P&IDs, functional block diagrams, electrical diagrams or instrument loop schedules. These typically provide the operational structure of the system. A key question in determining how deep to drill down in the hierarchy should be “To what level do we want to track costs?” You may only want to track down to the primary component (pump, motor) level.
To determine if your hierarchy is properly structured, choose an asset and ask the question – “WHO’S YOUR DADDY!”
Tip provided by Michael Bolig
Ashcom Technologies, Inc.
http://www.ashcomtech.com
September 01, 2005
PdM-2005 4 day Pass for Infrared and Ultrasound
The Predictive Maintenance Technology Conference
September 19-22, 2005
Atlanta GA
Learn how and why you should add Infrared and Ultrasonic technology to your machinery condition monitoring program
Day 1 - Introduction to Infrared Thermal Imaging by John Snell - This full day workshop explains the basics that you need to develop a solid understanding of this valuable machinery condition monitoring technology. Infrared Technology advances have created lower cost instruments with increased capabilities in a small convenient packages making them an affordable addition to any maintenance program. Learn how Infrared can enhance your reliability program. Other workshops include Vibration Analysis and PdM Management.
Day 2 - Six Condition Monitoring Short Courses on Vibration, Oil Analysis, Ultrasound, Motor Testing and Infrared Thermography and 15 learning zone presentations supporting Predictive Maintenance.
Maintenance Expert John Schultz will also deliver “The Business Case for Reliability” Keynote. All PdM-2005 Conference attendees are also invited to the Casino night for food, fun and prizes.
Day 3 - Six more Condition Monitoring Short Courses on Vibration, Oil Analysis, Ultrasound, Motor Testing and Infrared Thermography and 15 learning zone presentations supporting Predictive Maintenance.
The day wraps up with the Alienware Laptop giveaway drawing for one lucky PdM-2005 conference attendee.
Day 4 - Introduction to Airborne Ultrasonics by Jim Hall - This full day workshop builds a thorough understanding of using high frequency ultrasonics for bearing testing, lubrication monitoring, electrical inspection, leak detection, steam trap testing and much more. Like Infrared, Ultrasonic technology has become easier to use and more powerful in recent years and should be included in any plant maintenance program. Learn what you need to know to get started in this full day workshop. Other workshops include Motor Testing and Advanced Vibration Analysis.
2 Special Offers:
* Buy the PdM-2005 4 day Pass for $1485 and save $300
* Register three people from the same company and get the fourth person free - an additional 25% savings.
Workshop space is limited so please call toll free at 1-888-575-1245 to register or…
September 01, 2005
Reliability Tip
“Your system is perfectly designed to give you the results that you get.” This quote from the late W. Edwards Deming speaks volumes about the reasons for the lack of success that many organizations have with their reliability program. All too often, an organization will attempt to implement the latest tool such as a new CMMS or a predictive maintenance technology, hoping it will be the “silver bullet” that dramatically increases reliability. In reality, it’s the system that produces the results; the processes by which work gets done and the behaviors of the individuals working within those processes. If we want different results, we have to change the system. How we manage this change affects both the speed and the magnitude of the improvements.
Tip provided by Life Cycle Engineering
http://www.lce.com
Tel: 843.744.7110 x267
September 01, 2005
Vibration Analysis Tip
Considerations when setting up measurements (Part 4 of 4) Archived at
http://maintenancetalk.com/blog.php/tipsblog
The last of our considerations is the resolution needed to accomplish our goal.
We must determine the resolution needed to clearly distinguish between normal mechanical frequencies and the frequencies of interest. For example we may have a bearing that has a BPFO primary frequency that occurs at 6.12 times rotational speed. We would need enough resolution to separate this frequency from 6 times rotational speed. Another example would be 2x AC line frequency and 2 times rotational speed on a 3600 RPM motor. In this case two readings may be necessary depending on the resolution capability of the analyzer being used. One measurement to capture the overall condition of the motor and the second to focus on the separation of the line frequency component from running speed.
If we consider these factors:
* Type of equipment
* Variable or constant speed
* Frequencies of interest
* And resolution
We will know what f-max to set and what resolution setting to use.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
August 25, 2005
Motor Tip
Locating your spare motors is of critical importance. Motor spares are an investment in space and a prevention of production downtime. If properly stored, these spares can be as reliable than the original motor.
1. Ensure that the motors are stored in an area with temperatures above dewpoint. This will ensure that bearing components and the shaft do not rust, nor damage to the insulation system;
2. The shaft must be rotated periodically to reduce false brinelling. This should be performed quarterly. One method is to place a two-color tag on the motors with one color facing out for one quarter and the other for the alternate quarters. Turn the shaft then turn the card;
3. The motors must be stored in an area that is exposed to low vibration. This means, in an area of low truck, heavy equipment or operating machinery. This will reduce the opportunity for false brinelling;
4. The machined surfaces, including shaft, should have a coating of masking grease or oil added. If there is the opportunity for the motor to be exposed to dew point issues, then space heaters may have to be installed;
5. Periodic insulation resistance or MCA tests should be performed to monitor for degradation of the insulation system.
Tip provided by Howard W Penrose, Ph.D.
T-Solutions, Inc.
http://www.tsoln-inc.com
Phone/Fax: 860 577-8537
August 25, 2005
Infrared Tip
Prepare for IR Inspections During Installation
Metal objects, such as bus bars, are typically low emissivity materials. When doing a high voltage installation, put electrical tape around the metal bus bar, that way it’s there for future IR inspections. Using electrical tape can make a poor emitter appear to be a good emitter with a viable emissivity value. Now use the IR camera to capture a true temperature reading where the electrical tape is. Emissivity of the metal object can then be determined by matching the temperature found on the electrical tape. Move the temperature cursor just off the electrical tape. Change the IR camera’s emissivity setting until the temperature on the metal object matches the temperature measured on the electrical tape. The true emissivity of the object is discovered at the matching temperature point found on the electrical tape.
This thermography tip provided by Infrared Solutions, Inc.
Toll Free: 1-800-760-4523
http://www.infraredsolutions.com
August 25, 2005
Fastener Tip
Another tip for removing rounded out allen head bolts is to use a ball peen hammer to tap around the top of the bolt to flatten out the area where the wrench goes into the bolt. When done correctly your wrench should fit good and snug again. This works especially well on button head allens.
Reader tip provided by Doug Crabill
Maintenance Coordinator
Crown Battery
Fremont OH
Thanks Doug - your Maintenance-Tips hat is on the way!
August 25, 2005
Condition Monitoring Tip
Collecting Good Data Part 4 – Test Frequency
Archived at
http://maintenancetalk.com/blog.php/tipsblog
Testing machines too often costs money and wastes resources. Testing machines too infrequently can result in missed faults and catastrophic failures. The key is to find the middle ground and this will depend on the machine, its history and its criticality. Some high speed machines can devolve from perfect health to failure in a matter of minutes. These will require continuous monitoring protection systems. Other machines may run for years without problems. These should be tested quarterly or biannually with test frequency increasing as incipient faults begin to appear. Although a small pump may be inexpensive to repair or replace, if its failure causes a million dollars of product to be ruined, it can be said to be quite critical and worthy of more frequent testing.
The best approach is to spend some time researching the machines, their history and their use. Understanding how the machines fail often gives some indication of how long it will take them to fail after faults begin to appear. A good deal of resources can be saved and better appropriated if records are kept over time and the schedule adjusted as more machinery history and knowledge becomes available.
Tip provided by DLI Engineering
http://www.dliengineering.com
Tel: 206-842-7656
August 25, 2005
Bring Your Team to PdM-2005
Mark Your Calendar!
Predictive Maintenance Technology Conference & Expo
September 19-22, 2005
Atlanta, Georgia
Register 4 team members and a get the 5th team member pass FREE!
The Predictive Maintenance Technology Conference is designed for beginners and seasoned professionals alike.
Learn about new technologies and techniques for Vibration Analysis, Motor Testing, Infrared Thermography, Precision Alignment, Airborne Ultrasonics, Oil and Wear Particle Analysis from industry experts.
PdM-2005 is great place to motivate your PdM team and jump start your condition monitoring program. You could also win an Alienware Laptop!
To register, please call toll free 1-888-575-1245 or 305-735-3746 or…
