Rust is universally accepted as the signal for coating repairs but, rust is the final stage of corrosion a naturally occurring process that damages materials (usually metals) when exposed to the environment. Corrosion causes unplanned repairs, early replacement expense, and reduced trade-in and resale value.
Recoating based on visible rust is a form of reactive maintenance, when coating failure and rust formation are the reason for repairs or replacements.
Erosion is a far more effective reason for recoating. Erosion is the wearing down of coatings due to weathering, abrasion, and chemical contact but, erosion is extremely difficult to determine by traditional inspections. The following paper explains how erosion can be detected, measured, and controlled.
Maintenance based on erosion is a form of preventive maintenance where repairs are performed to prevent a more serious future failure.
Capillary Defects
The first sign of erosion is the creation of capillary defects. These are microscopic cavities formed in the top layer of coating. The size and number of these voids determine the coating’s permeability to moisture and oxygen. For new coatings the permeability may be low, but as coating ages, it increases due to exposure to the environment.
Sunlight is a major cause of capillary erosion. Sunlight contains 5% of UVA radiation. UV breaks down the resin binders in coatings leaving the pigments exposed. This process is known a photo-oxidation and is a major cause of coating failures.
Capillary defects create a hydrophilic surface that produces a polar attraction to moisture and oxygen. This causes dirt, grime, and carbon- based pollution to be absorbed into these voids where they are extremely hard to remove.
Cold Water Power Washing
Cold water power washing is popular because it is affordable and simple to use. However, cold water requires high pressure (2500 to 4000 psi) and chemical detergents to remove visible dirt and grime. The problem with cold water power washing is that it lacks the physical ability to remove complex chemicals used today.
Hot Water Cleaning
Hot water cleaning provides a number of benefits over cold water washing when the true costs of maintenance are taken into account. True costs include all labor, equipment, and supplies, plus the added value of complete and thorough cleaning.
Hot water cleaning replaces the high pressure of cold water washing with the thermal dynamic principals of energy where heat and temperature are used to improve cleaning performance. When water is heated the molecules absorb this energy and collide with soils. This increases their ability to dissolve and dilute contaminants for removal.
Steam Cleaning
Steam Cleaning provided additional benefits when compared to hot water washing alone. When water is heated in the sealed container of a steam cleaner, temperatures can be increased past the normal boiling point of 212° and still not boil or produce steam. This is because it is not allowed to expand. When this water is released from the spray nozzle it instantly expands into millions of tiny water droplets. At this point, hot water contains its highest concentration of cleaning energy.
Hot Water Power Washer
Industrial Steam Cleaner
Small steam cleaner for light commercial or residential cleaning
Strategic Maintenance
Hot water and steam cleaning are the most effective when included in a planned maintenance schedule. A critical part of any maintenance program is visual inspection of surfaces. Hot water/steam cleaning helps identify problems hidden by dirt, grime, grease, and oils.
pH Stabilization
Hot water/steam cleaning opens the door to an alternative to corrosion control by protective coatings for assets where design features, job size, and location prevent the use of traditional painting practices. This is based on pH stabilization to eliminate the conditions that cause coatings to fail rather than dealing with their long-term effects.
pH is the difference between a corrodible surface and a corrosion-resistant surface. pH Stabilization maintains the corrosion-prevention qualities produced at the factory and extends them throughout product life. Factory coatings are applied in a controlled environment, using quality paints and specialized application equipment. In addition, new metals and other materials will never be cleaner or in better condition when used to produce new products.
pH stabilization begins day one after products are put into service to maintain a passive pH value. This is accomplished by maintaining a rust resistant pH value of 7.0 to 8.2.
Hot water and steam cleaning provides the optimum performance when included in a strategic maintenance schedule designed to establish and maintain a level of cleaning quality previously not available by traditional practices.
Soy-based Pre-cleaner
Cleaning performance depends on the quality of its operation. For this reason, a special soy-based pre-cleaner is applied before hot water cleaning. This bio-based product provides excellent wetting properties to loosen soils from hard to clean surfaces.
Bioluminescence
The soy-based pre-cleaners produce a natural bioluminescence when exposed to blacklight UV energy. Blacklight has been used for decades to identify stress cracks, fluid leaks, and other defects that are difficult to see. Blacklight increases identification of sites that require additional cleaning attention. Steam cleaning and bioluminescence is the only practical way to clean complex surfaces to the microscopic level
NOTE: A truly cleaned surface protects paints and prevents rust.
Blacklight, UV Quality Inspections
One of the best UV lights for commercial applications is the “Beast”. The Beast increases the identification of cleaning defects up to 1000 percent when compared to normal human eye inspection. The Beast provides excellent results even under normal shop light.
Root Cause Analysis
Steam cleaning and blacklight UV monitoring allows maintenance personal to use root cause analysis to identify excessive wear sites and initiate design changes or modifications to improve product or overall maintenance performance. In most cases root cause analysis requires trained personal and specialized inspection tools. Steam cleaning and blacklight UV monitoring allow the average worker to use root cause analysis.
Renewable Clear Coat Protection
The application of micro-thin nanocoating immediately after steam cleaning extends clean cycles and reduces lifecycle cleaning costs.
These renewable, low cost, clear coats help prevent the build-up of dirt, grime, and chemicals by creating a surface that is smoother, easier to clean, and stays clean longer by coating modification at the microscopic level.
Conclusion – Coating
There is a definite economic argument for planned maintenance. Design engineers will continue to increase product life through improved material and parts development. For this reason, current coating formulations may not be able to provide cost effective and environmentally friendly solutions for future corrosion problems.
The argument for maintenance is simple it takes far less resource to maintain a coating than it does to repair or replace the surface it protects.
Jim Deardorff
Jim Deardorff is the President of Superior Coatings and has over 20 years in the application and of protective coatings for high value equipment and steel structures. In 2000, he realized it was virtually impossible to repaint products and structures to modern standards. In his opinion, the best course of action is to protect the original factory finish by precision cleaning and renewable thin film, nano-coatings. Jim’s maintenance program replaces reactive repairs with higher forms of maintenance support including preventive, predictive, and prescriptive programs including root cause analysis.
I was asked recently to give a second opinion on the cause of failure of an axial piston pump. The hydraulic pump had failed after a short period in service and my client had pursued a warranty claim with the manufacturer. The manufacturer rejected the warranty claim on the basis that the failure had been caused by contamination of the hydraulic fluid. The foundation for this assessment was scoring damage to the valve plate.
I was asked recently to give a second opinion on the cause of failure of an axial piston pump. The hydraulic pump had failed after a short period in service and my client had pursued a warranty claim with the manufacturer. The manufacturer rejected the warranty claim on the basis that the failure had been caused by contamination of the hydraulic fluid. The foundation for this assessment was scoring damage to the valve plate.
Root Cause Analysis has the potential of CHANGING people, IF the leader of the investigation knows of this potential. Far from “just another problem-solving exercise,”the root cause analysis should SLOW PEOPLE DOWN to the extent that they can see the truth of the incident under inquiry, WHATEVER THE TRUTH MIGHT BE. This paper focuses on two parts of our human nature which are large obstacles to root cause discovery, i.e., our unwillingness to slow down, and our unwillingness to let go of certain basic assumptions about life. Warning: This paper is designed to challenge the way you think about Root Cause Analysis.
Root Cause Analysis has the potential of CHANGING people, IF the leader of the investigation knows of this potential. Far from “just another problem-solving exercise,”the root cause analysis should SLOW PEOPLE DOWN to the extent that they can see the truth of the incident under inquiry, WHATEVER THE TRUTH MIGHT BE. This paper focuses on two parts of our human nature which are large obstacles to root cause discovery, i.e., our unwillingness to slow down, and our unwillingness to let go of certain basic assumptions about life. Warning: This paper is designed to challenge the way you think about Root Cause Analysis.
You have four opportunities to trouble shoot centrifugal pumps and each opportunity can offer you a clue as to what is wrong with the pump. Let's take a look at each of these conditions:
You have four opportunities to trouble shoot centrifugal pumps and each opportunity can offer you a clue as to what is wrong with the pump. Let's take a look at each of these conditions:
A laptop computer with PLC programming, communication, and operating programs is a necessary tool in today’s modern plant. Engineers, production supervisors, maintenance supervisors, maintenance technicians, electricians, instrument technicians, and maintenance mechanics all need to have PLC and computer knowledge, training and skills in troubleshooting.
A laptop computer with PLC programming, communication, and operating programs is a necessary tool in today’s modern plant. Engineers, production supervisors, maintenance supervisors, maintenance technicians, electricians, instrument technicians, and maintenance mechanics all need to have PLC and computer knowledge, training and skills in troubleshooting.
One of the most rewarding aspects of working as an electrician is taking such compelling evidence as “appears to be developing a problem,” determining what is actually going on, and making a sound decision on the correct course of action. Successfully troubleshooting a complex piece of equipment gives a technician a tremendous sense of satisfaction. Having an effective troubleshooting plan and following it can help obtain this feeling of satisfaction.
One of the most rewarding aspects of working as an electrician is taking such compelling evidence as “appears to be developing a problem,” determining what is actually going on, and making a sound decision on the correct course of action. Successfully troubleshooting a complex piece of equipment gives a technician a tremendous sense of satisfaction. Having an effective troubleshooting plan and following it can help obtain this feeling of satisfaction.
Examples of failure analysis are almost everywhere. Reduced wear and failure of machine components are a common occurrence, whether it is a minor maintenance failure or a disaster of national significance, anyone can learn from analyzing mistakes.
Examples of failure analysis are almost everywhere. Reduced wear and failure of machine components are a common occurrence, whether it is a minor maintenance failure or a disaster of national significance, anyone can learn from analyzing mistakes.
Root Cause Analysis (RCA) is rapidly becoming another one of those “flavour of the month” TLAs (Three Letter Acronyms). Like all TLAs, it is easy to get carried away with the hype surrounding the approach. Inevitably, then, the reality doesn’t live up to the expectations created by the hype. But nevertheless, the appropriate application of Root Cause Analysis techniques can yield significant organisational and individual benefits. This paper discusses some of the practical issues surrounding the implementation of Root Cause Analysis processes within organisations, and in doing so, attempts to give some guidance to those wishing to obtain success from their Root Cause Analysis program.
Root Cause Analysis (RCA) is rapidly becoming another one of those “flavour of the month” TLAs (Three Letter Acronyms). Like all TLAs, it is easy to get carried away with the hype surrounding the approach. Inevitably, then, the reality doesn’t live up to the expectations created by the hype. But nevertheless, the appropriate application of Root Cause Analysis techniques can yield significant organisational and individual benefits. This paper discusses some of the practical issues surrounding the implementation of Root Cause Analysis processes within organisations, and in doing so, attempts to give some guidance to those wishing to obtain success from their Root Cause Analysis program.
Too many organisations neglect the benefits of a clearly defined prioritisation system. Even when they realise the importance the focus is invariably at a department or functional level. I have seen organisations where there are up to three or more prioritisation systems. None of which are inter-related. Along with work order classification, failure coding and integration with business processes, this is one of the key determinants of a maintenance systems future operation.
Too many organisations neglect the benefits of a clearly defined prioritisation system. Even when they realise the importance the focus is invariably at a department or functional level. I have seen organisations where there are up to three or more prioritisation systems. None of which are inter-related. Along with work order classification, failure coding and integration with business processes, this is one of the key determinants of a maintenance systems future operation.
There is only one reason to support a planned maintenance program. Planned maintenance increases profits! The primary objective for any business is to produce profits for the owner. Profit oriented goals apply to an elderly couple operating a corner grocery store, as well as to large corporations. Even maintenance consulting firms have to operate at a profit.
There is only one reason to support a planned maintenance program. Planned maintenance increases profits! The primary objective for any business is to produce profits for the owner. Profit oriented goals apply to an elderly couple operating a corner grocery store, as well as to large corporations. Even maintenance consulting firms have to operate at a profit.
A few weeks ago, someone asked me, “How many hours should a planner plan for each week?” This is a great question, but I can only give a touchy-feely answer. A strict numerical approach to productivity might miss the point of why planners exist (to promote crew productivity). I want the planner to keep the unplanned backlog under control by adjusting the time spent on the level of detail put into each job plan.
A few weeks ago, someone asked me, “How many hours should a planner plan for each week?” This is a great question, but I can only give a touchy-feely answer. A strict numerical approach to productivity might miss the point of why planners exist (to promote crew productivity). I want the planner to keep the unplanned backlog under control by adjusting the time spent on the level of detail put into each job plan.
Many organizations spend too much time searching for—and starting implementation of—new reliability and maintenance concepts, and very little time on implementation and improvements of what they just started. Let me give some examples of my own observations as they relate to the statement above. Some time ago I met with a group of supervisors, planners, and craftspeople—the front line of maintenance—in a mill.
Many organizations spend too much time searching for—and starting implementation of—new reliability and maintenance concepts, and very little time on implementation and improvements of what they just started. Let me give some examples of my own observations as they relate to the statement above. Some time ago I met with a group of supervisors, planners, and craftspeople—the front line of maintenance—in a mill.
Cutting costs has become a high priority, due to the recent economic conditions. Maintenance shutdowns are a major part of the annual budget at most mills, and are usually a target for cost reduction. Maintenance shutdown costs can be reduced by 30-50 percent from historical levels, with start up after the outage occurring smoothly and predictably. Using simple and effective shutdown management techniques can result in such improvements, creating savings equal to several weeks of additional production each year. This can be done without sacrificing any work, or canceling any scheduled downtime.
Cutting costs has become a high priority, due to the recent economic conditions. Maintenance shutdowns are a major part of the annual budget at most mills, and are usually a target for cost reduction. Maintenance shutdown costs can be reduced by 30-50 percent from historical levels, with start up after the outage occurring smoothly and predictably. Using simple and effective shutdown management techniques can result in such improvements, creating savings equal to several weeks of additional production each year. This can be done without sacrificing any work, or canceling any scheduled downtime.
Hidden from view in a typical coal-fired power plant is a battle that never ends. Coal attacks steel and alloy components when the fuel is transported about the plant. Predictably, over time, the abrasive nature of coal will prevail against any metal surface because metal will eventually erode. The only opportunity for metal surfaces to have a fighting chance is to advance the secret weapon: ceramics.
Hidden from view in a typical coal-fired power plant is a battle that never ends. Coal attacks steel and alloy components when the fuel is transported about the plant. Predictably, over time, the abrasive nature of coal will prevail against any metal surface because metal will eventually erode. The only opportunity for metal surfaces to have a fighting chance is to advance the secret weapon: ceramics.
Industry spends millions of dollars each year on improved filtration technology in an attempt to reduce particle contamination, with some of the more advanced companies reducing failure rates by up to 90 percent simply by controlling fluid cleanliness. However, in some industries and environments, water is a far more insidious contaminant than solid particles. Water contamination is often overlooked as the primary cause of component failure.
Industry spends millions of dollars each year on improved filtration technology in an attempt to reduce particle contamination, with some of the more advanced companies reducing failure rates by up to 90 percent simply by controlling fluid cleanliness. However, in some industries and environments, water is a far more insidious contaminant than solid particles. Water contamination is often overlooked as the primary cause of component failure.
The purpose of this paper is to introduce condition monitoring and reliability engineers to the principles of using ultrasound for the assessment of machine condition. Ultrasound can be a complimentary technology to vibration, thermography and lubrication monitoring. It must be emphasized that it is rarely successful as a stand alone technology for effective machine condition assessment and subsequent required maintenance planning. This paper concentrates on the use of airborne ultrasound as a complementary technique particularly for machinery that may be inaccessible due to guards or hazardous locations.
The purpose of this paper is to introduce condition monitoring and reliability engineers to the principles of using ultrasound for the assessment of machine condition. Ultrasound can be a complimentary technology to vibration, thermography and lubrication monitoring. It must be emphasized that it is rarely successful as a stand alone technology for effective machine condition assessment and subsequent required maintenance planning. This paper concentrates on the use of airborne ultrasound as a complementary technique particularly for machinery that may be inaccessible due to guards or hazardous locations.
Ultrasonic technology (UT) has become widely accepted for the detection of leaks in both pressurized and nonpressurized systems. Most compressor service companies and several manufacturers own some type of ultrasonic sensor for pinpointing leaks. It is easy to cost-justify the purchase of an ultrasonic sensor based upon the high cost of energy loss due to leaks. However, there is another application for ultrasound that consumers, nondestructive testing (NDT) organizations, and even developers and manufacturers of ultrasonic sensors are often not aware of or overlook. UT can be used as a means to detect early wear of components such as bearings and gears due to lack of lubrication or overlubrication.
Ultrasonic technology (UT) has become widely accepted for the detection of leaks in both pressurized and nonpressurized systems. Most compressor service companies and several manufacturers own some type of ultrasonic sensor for pinpointing leaks. It is easy to cost-justify the purchase of an ultrasonic sensor based upon the high cost of energy loss due to leaks. However, there is another application for ultrasound that consumers, nondestructive testing (NDT) organizations, and even developers and manufacturers of ultrasonic sensors are often not aware of or overlook. UT can be used as a means to detect early wear of components such as bearings and gears due to lack of lubrication or overlubrication.
Using lubrication and oil analysis to enhance machine reliability is really too simple. Behind the appearances of complexity and vale of high science are the most basic of concepts. We can try to make it difficult, but why? With the right tools and a generous amount of training, a seemingly challenging task can be transformed into something almost mundane, but still powerful.
Using lubrication and oil analysis to enhance machine reliability is really too simple. Behind the appearances of complexity and vale of high science are the most basic of concepts. We can try to make it difficult, but why? With the right tools and a generous amount of training, a seemingly challenging task can be transformed into something almost mundane, but still powerful.
A long time ago, I discovered that most maintenance people like gadgets and smart methods, especially from within their fields. I must include myself in this group, and have learned to use the knowledge of a variety of maintenance methods to keep up my own enthusiasm while generating interest and commitment for implementing better preventive and corrective maintenance practices. Most of these methods are old, but they are very new to many, especially to people who are just entering the area of maintenance.
A long time ago, I discovered that most maintenance people like gadgets and smart methods, especially from within their fields. I must include myself in this group, and have learned to use the knowledge of a variety of maintenance methods to keep up my own enthusiasm while generating interest and commitment for implementing better preventive and corrective maintenance practices. Most of these methods are old, but they are very new to many, especially to people who are just entering the area of maintenance.
The maritime industry is in many aspects using maintenance strategies from the past. Land based industry used to take influence from shipping to organise the maintenance in the 70:ties. Now industry is perusing new strategies that give better reliability and are more profitable. By focusing on reliability the indirect effects from doing the wrong maintenance can be reduced considerably. Shipping industry has from a maintenance aspect been doing the wrong things correct for many years. The opportunity is now to do the right thing correct instead.
The maritime industry is in many aspects using maintenance strategies from the past. Land based industry used to take influence from shipping to organise the maintenance in the 70:ties. Now industry is perusing new strategies that give better reliability and are more profitable. By focusing on reliability the indirect effects from doing the wrong maintenance can be reduced considerably. Shipping industry has from a maintenance aspect been doing the wrong things correct for many years. The opportunity is now to do the right thing correct instead.
In today's industry, practices that were once acceptable are no longer even tolerated. Environmental concerns and EPA mandates are applying more and more pressure on businesses like the chemical industry to improve the manufacturing processes being used, to the point that not only is a slight drip from a pump seal not acceptable, but in 2004 the MACT will be enacted and only 500 - 1,000 parts per million vapor will be allowed and, eventually, no vapor at all.
In today's industry, practices that were once acceptable are no longer even tolerated. Environmental concerns and EPA mandates are applying more and more pressure on businesses like the chemical industry to improve the manufacturing processes being used, to the point that not only is a slight drip from a pump seal not acceptable, but in 2004 the MACT will be enacted and only 500 - 1,000 parts per million vapor will be allowed and, eventually, no vapor at all.
Who is to blame when a defect occurs? Is it the supplier who was contracted to produce a key component or supply materials, or is it the customer organization that created the specs and produced the final product? As more companies outsource parts of production and develop closer partnerships with key suppliers, finding blame can topple the delicate balance in even the best customer-supplier relationship.
Who is to blame when a defect occurs? Is it the supplier who was contracted to produce a key component or supply materials, or is it the customer organization that created the specs and produced the final product? As more companies outsource parts of production and develop closer partnerships with key suppliers, finding blame can topple the delicate balance in even the best customer-supplier relationship.
