May 19, 2005
Managing a Computerized Maintenance Management System by Terry Wireman
CMMS-2005 Pre-Conference Workshop
Computerized Maintenance Management Summit
July 26-29, 2005
Indianapolis Indiana
This workshop, by maintenance expert Terry Wireman, is designed to assist anyone investigating the possibility of using a computer in the maintenance function or for people seeking to get more productivity from an existing maintenance information management system.
The workshop provides the information needed to successfully evaluate, select and implement a system. It enables participants to discover how progressive companies are using computer programs to achieve cost reduction and control the maintenance of any facility.
A review of past CMMS benchmarking projects will also be included.
Each workshop participant get a hard cover edition of Computerized Maintenance Management Systems by Terry Wireman
Join Terry plus more than 35 other presenters, workshop leaders and learning labs directors at CMMS-2005.
To learn more please call toll free 888-575-1245 or…
May 19, 2005
Motor Testing Tip
Evaluating the condition of electric motor rotors is not a new concept. Electric motor repair shops have been using techniques such as growler testing, single-phasing, infrared, vibration and/or dye testing as methods used through the repair process. In the field, vibration, analog current tests and inductive testing has been used. Over the past twenty years, a variety of motor circuit analysis and current signature analysis technologies have entered the market providing even greater accuracy in the detection of rotor bars.
Growler testing is performed by applying power to a half-transformer with the rotor resting upon, or near, it. The induced current allows the repair person to check the rotor bars by using metal filings or magnetic paper. The term growler comes from its original purpose of detecting shorts in DC armatures. The power is induced into the armature and a hacksaw blade would be held just above the armature over each slot. If a short exists, the blade would begin to vibrate causing a ‘growling’ sound. The accuracy of growler testing on AC rotors is improved by heating the rotor in an oven to approximately 200 degrees F prior to testing in order to cause expansion of any fractures.
Single phase testing involves the application of approximately 10% of the motor voltage across a single phase (ie: T1-T2), in an assembled motor with a good winding, then rotating the shaft slowly with a current probe attached. If the value stays within 3%, as the rotor is turned, then it is in good condition. This test is considered potentially dangerous to the technician.
Infrared testing is performed by winding a coil of wire through, or around, the rotor and applying a voltage and high current. This causes the rotor to heat and will identify smeared laminations and loose or broken rotor bars. Hot spots, identified with infrared, greater than 10 degrees C above the ambient rotor temperature identify faults.
Vibration analysis is performed with the motor assembled and under load, usually at least 50% of rated load. Signatures of twice line frequency with pole pass frequency and peaks of the number of rotor bars times the running frequency, will indicate rotor bar problems. This normally requires some degree of experience by the operator.
Analog current meters on switchgear/MCC’s, or hand-held analog current meters, can be used by observing the meters for sharp pulsing of the current as the motor operates under load. This ‘ticking’ motion will occur at pole pass frequency and is a strong identifier of multiple broken rotor bars.
Inductance testing can be used by viewing a continuous measurement of inductance or periodic testing of inductance through an arc or full rotation of the motor shaft, of an assembled motor. A repeating pattern indicates a good rotor and impact of the peaks or valleys of a few of the patterns indicate a broken rotor bar problem, impacts on the slopes of the patterns indicate casting voids (in aluminum cast rotors). There should be one pattern per pole of the machine being tested.
Current signature analysis is a classical method for analyzing rotor bars. Side bands of twice slip frequency approaching ’35 dB down’ indicate severe rotor bar conditions, that must be addressed.
Tip provided by Howard W Penrose, Ph.D.
T-Solutions, Inc., Chesapeake, VA
http://www.tsoln-inc.com
May 19, 2005
Thermal Solutions - Call For Papers
Snell Infrared is looking for thermographers who are interested in presenting a paper at Thermal Solutions, January 23-26, 2006 in Sarasota, Florida.
Abstracts are due by June 17 and can be submitted via e-mail at:
For more information call 800-636-9820 or…
May 19, 2005
Hydraulic Maintenance Tip
Hydraulic Maintenance Knowledge
People say knowledge is power. Well this is also true in hydraulic maintenance. Many maintenance organizations do not know what their maintenance personnel should know. I believe in an industrial maintenance organization that we should divide the hydraulic skill necessary into two groups. One is the hydraulic troubleshooter, they must be your experts in maintenance and this should be as a rule of thumb 10% or less of your maintenance workforce. The other 90% + would be your general hydraulic maintenance personnel. They are the personnel that provide the preventive maintenance expertise. The percentages I gave you are based on a company developing a true Preventive / Proactive maintenance approach to their hydraulic systems. Let’s talk about what the hydraulic troubleshooter knowledge and skills.
Hydraulic Troubleshooter:
Knowledge –
• Mechanical Principles / force, work, rate, simple machines
• Math / basic math, complex math equations
• Hydraulic Components / application and function of all hydraulic system components.
• Hydraulic Schematic Symbols / understanding all symbols and their relationship to a hydraulic system.
• Calculate flow, pressure, and speed.
• Calculate the system filtration necessary to achieve the system’s proper ISO particulate code.
Skill –
• Trace a hydraulic circuit to 100% proficiency.
• Set the pressure on a pressure compensated pump.
• Tune the voltage on an amplifier card.
• Null a servo valve.
• Troubleshoot a hydraulic system and utilize “Root Cause Failure Analysis”.
• Replace any system component to manufacturer’s specification.
• Develop a PM Program for a hydraulic system.
• Flush a hydraulic system after a major component failure.
General Hydraulic:
Knowledge –
• Filters / function, application, installation techniques
• Reservoirs / function, application
• Basic hydraulic system operation
• Cleaning of hydraulic systems
• Hydraulic lubrication principles
• Proper PM techniques for hydraulics
Skills –
• Change a hydraulic filter and other system components.
• Clean a hydraulic reservoir.
• Perform PM on a hydraulic system.
• Change a strainer on a hydraulic pump.
• Add filtered fluid to a hydraulic system.
• Identify potential problems on a hydraulic system.
• Change a hydraulic hose, fitting or tubing.
Tip provided by Ricky Smith CMRP
MAXZOR
843-762-3168
http://www.success-in-training.com
May 19, 2005
Vibration Analysis Tip
To save time while collecting routine vibration data, try using a feature called adaptive trigger. This is a feature offered on some data collectors that only collects spectral data if another criteria is met. For instance, if an overall vibration reading is above a certain level, say above the ISO alarm level, then and only then is a spectrum taken. For closely monitored equipment this is a great time saver.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
May 19, 2005
Practical Oil and Coolant Analysis for Maintenance and Reliability Professionals
Salt Lake City - June 6 - 9, 2005
Indianapolis - August 15 - 18, 2005
Houston - October 31 - November 3, 2005
Whether you’re just venturing into the world of fluid analysis or you’ve been managing a maintenance program for years, this course will not only expand your knowledge of oils and coolants, but give you a better understanding of fluid testing and analysis and the importance of doing it well.
You’ll learn to:
• Set attainable program goals based on realistic expectations
• Select the proper testing for the equipment and goals identified
• Take good, timely samples at the right intervals
• Select a quality fluid analysis laboratory
• Interpret test results and recommendations
• Manage your data and take decisive maintenance action
CAN’T ATTEND?
Polaris Technical Services will provide private training and consultation at your request. To find out more about scheduling on-site services, please contact us at 877-808-3750 ext. 229 or ...
May 19, 2005
Reliability Tip
Too often organizations today follow the most politically correct initiatives. Reliability has come into the limelight just over the past decade. Executives read about Reliability in Fortune, Forbes or other trade magazines and determine they want Reliability as well. They start a trickle down effect that puts the organization in a frenzy for those folks mandated to provide Reliability in a timely manner. Typically what will happen is Maintenance Engineers’ titles are changes to Reliability Engineers. However, the function does not change only the title does. Anyone chartered to do both Maintenance and Reliability will get very little Reliability work done.
Tip provided by the Reliability Center
(804) 458-0645
http://www.reliability.com
May 19, 2005
Maintenance Tip
Optimizing Predictive Maintenance
Companies today are under tremendous pressure to reduce costs while maintaining production. The goal of Predictive Maintenance is to assist the plant management in optimizing the maintenance expense. Downtime costs money. Excessive maintenance also costs money. Companies must have data to operate, but at what cost and how much data is required? Insufficient data leads to downtime. Too much data drives up costs without yielding more effective data, and cloud the decision process by having an information overload.
In the middle is optimized maintenance.
Dynamic or conditioned vibration data can be collected. Dynamic vibration analysis systems that reduce the data to vibration spectra require an analyst to make decisions regarding the data acquired. The spectra allow an analyst to predict faults well in advance of a failure. Additional costs associated with online monitoring of dynamic data include data collection and custom software.
Signal conditioners produce a single value for the vibration (from dynamic data) and output that through a 4-20 mA process loop signal. A typical value produced represents the overall vibration of the machine. The 4-20 mA signal is generally taken into the plant’s DCS or PLC. Increasing trends alert a change in overall vibration without the investment and learning curve commonly associated with monitoring dynamic data. Failures will be limited and costs will be lower.
Cost and risk must be balanced.
Signal conditioning represents an opportunity to minimize the cost of an online PdM program, providing adequate warning of impending failure for critical machines and dual output of dynamic data to pinpoint the cause of fault. If optimized maintenance means balancing risk versus cost, then signal conditioned vibration data may represent the right balance between costs and benefits.
Please go to http://www.wilcoxon.com for information on Wilcoxon’s 4-20 mA vibration monitors, including the new iT Series and expanded line of Loop Powered Sensors (LPS™).
May 12, 2005
Mastering Computerized Maintenance Management at CMMS-2005
Computerized Maintenance Management Summit
July 26-29, 2005
Indianapolis Indiana
Pre- and Post- Conference Certificate Workshops include:
• Managing a Computerized Maintenance Management System by Terry Wireman
• Maintenance Planning, Scheduling and Coordination by Joel Levitt
• Guide to Predictive and Preventive Maintenance by Joel Levitt
• Utilizing a CMMS to Develop and Support Key Maintenance Performance Indicators by Terry Wireman
To learn more or to register call toll free (888) 575-1245 or…
May 12, 2005
Training Tip
MAINTENANCE SKILL EXODUS
“most large companies will be losing most of their senior skilled crafts personnel in the next 3-5 years”
Many companies are losing their skilled maintenance workers in the next 3 -5 years and they are panicking. First, there are two things “not to do”.
1. Hire anyone that is breathing – The type maintenance person you need must have a mechanical aptitude and must be able to read and comprehend above 14 years of college minimum (most new technology requires a 16 year reading comprehension level in order to read and comprehend technical documentation).
2. Don’t try to find a quick fix. The purchasing of training books and manuals will not provide the skills. Skills can only be provided through application of knowledge hands on. Nothing replaces the hands on training.
There three things “you can do”: (you must have a short term solution and a long term solution and they are dealt with differently)
1. Short Term - Identify current skill gaps through trending your CMMS data. If your bearing purchases are going up you may need bearing maintenance training. Review your MTBF of equipment along with MTTR and look for trends that indicate skill problems also.
2. Short Term and Long Term – If you do not have comprehensive Preventive Maintenance and Corrective Maintenance procedures then write them now while you still have senior maintenance personnel. Train your new workers to these procedures and enforce the use of these procedures.
3. Long Term – Develop an apprenticeship program. Hire the right people and train them in a 4 year program that requires classroom and hands on training with testing all the way through the program. This program must be comprehensive and expect to loose 20-30% of these trainees.
Tip provided by Ricky Smith CMRP, CPMM
MAXZOR
http://www.success-in-training.com
