The Evolution of AI in Maintenance: From Expert Systems to Intelligent Agents
Ahmed Rezika, SimpleWays OU
Posted 8/6/2024
Maintenance teams have long been at the forefront of adopting intelligent systems, even before the term “artificial intelligence” (AI) became a buzzword. These systems, designed to mimic human intelligence and decision-making processes, have been integrated into various maintenance practices for decades, albeit under different names.
For instance, expert systems encoded human expertise into a set of rules and heuristics. They have been employed in Computerized Maintenance Management Systems (CMMS) since the 1980s. [1] These systems assist in tasks such as scheduling preventive maintenance, diagnosing faults, and recommending maintenance actions. Essentially, they are acting as digital maintenance experts, or more commonly, your digital assistant.
Growing Intelligence in Maintenance Assistance Tools
Maintenance teams have consistently embraced technological advancements, recognizing the importance of staying up to date on the latest tools and techniques. Smart alignment tools, for example, use laser or optical systems to precisely align rotating machinery. They are another example of intelligent systems that have been adopted by maintenance professionals. These tools often incorporate algorithms and decision-making capabilities to guide the alignment process and provide recommendations. Those recommendations come based on coupling type, equipment type, and system setup—effectively augmenting the expertise of maintenance technicians.
As the field of artificial intelligence continues to evolve, maintenance teams are poised to benefit from the latest advancements in generative AI. Generative AI models, capable of generating new content such as text, images, or even code, hold immense promise for maintenance applications. One potential use is in generating maintenance recommendations and reports. The end target is to generate tailored recommendations for maintenance tasks, repair procedures, or even predictive maintenance strategies. “Recommendations” is a key word in this target that we will explore later on. By training these models on historical maintenance data, expert knowledge, and best practices, they could prove to be a true asset. [2]
However, the adoption of generative AI in maintenance also raises concerns around many issues. One of them is: How will the maintenance team receive and accept this digital assistance? Another issue is the trust, interpretability, and the need for human oversight. The human supervision is crucial, as currently these models may exhibit biases or produce unexpected outputs. Nonetheless, as generative AI continues to mature, it presents an exciting opportunity for maintenance teams to further augment their decision-making processes and streamline operations.
What is AI? How does it work?
It is important for our maintenance teams to understand the foundations of the AI, how it works and its limitations. This way they will be well equipped for adopting some of these models in maintenance. Or at least they will be capable of dealing with it efficiently if adopted in the workplace.
Artificial Intelligence (AI) is a broad field that encompasses the study and development of intelligent systems and algorithms that can perform tasks typically requiring human-like intelligence. Examples of these tasks are problem-solving, decision-making, perception, reasoning, and even learning in advanced AI systems. This definition is a common one that captures the essence of AI and aligns our minds with the general understandings in the field.
At its core, AI aims to create systems that can acquire knowledge, process information, and make decisions. Then these systems take actions or generate a response based on that knowledge. AI systems are designed to mimic or augment human cognitive functions, such as learning, reasoning, and problem-solving. [3]
How does an AI system work?
In general, most AI systems work following a general process:
Building
Data Acquisition: AI systems require data to analyze, find patterns, recommend solutions, and learn. This data can come from various sources, such as sensors, databases, user inputs, or the internet for Generative AI. Just a note here, the data must be prepared to be useful. It is typically preprocessed and cleaned to prepare it for the learning process.
Feature Extraction: Relevant features or attributes are extracted from the raw data. These features represent the essential information that the AI system will use for learning and decision-making. Feature extraction in data is like summarizing a book. You take the raw data, which can be complex and lengthy, and identify the most important parts (features). These features are then used to make the data easier to analyze and understand by machines. That is crucial, especially for tasks like machine learning.
Model Selection and Training: An appropriate AI model or algorithm is selected based on the problem domain and the type of data. Further on we shall learn about the different models. The model is then trained on the preprocessed data and extracted features. During training, the model adjusts its internal parameters to learn patterns and relationships in the data. We will elaborate next on AI models.
Tuning
Model Evaluation and Validation: The trained model is evaluated on a separate test dataset to assess its performance and generalization ability. Evaluation metrics (e.g., accuracy, precision, recall) are used to measure the model’s effectiveness.
Deployment and Inference: If the model achieves satisfactory performance, it can be deployed in a production environment. When new data is provided to the deployed model, it can make predictions, decisions, or generate outputs based on the learned patterns. This process is called inference. Inference is like the AI model taking a test on unseen data. Basically, it’s the model putting its learned knowledge to work in the real world.
Continuous Learning and Adaptation – Updates: Many AI systems are designed to continuously learn and adapt as new data becomes available, enabling them to improve their performance over time. Otherwise we need to intend this to keep its output relevant.
In short, what is AI?
It’s important to note that while AI systems can exhibit intelligent behavior and perform tasks that would typically require human intelligence, they are ultimately complex algorithms and mathematical models designed to process and learn from data. The field of AI continues to evolve rapidly, with ongoing research and development aiming to create more advanced, adaptable, and reliable AI systems.
AI systems can employ various techniques and algorithms. An example of this is machine learning (supervised, unsupervised, and reinforcement learning). Another example is deep learning (neural networks) and natural language processing. The more handy examples are computer vision, expert systems, and optimization algorithms.
A Missing Term: The AI Agent
This term AI Agent is typically used in universities as a starting point for computer science students to help them comprehend AI and robotics concepts. However, when those AI models are introduced to users, we seldom listen to AI Agent. My first AI Agent that I programmed using Python could play tic-tac-toe. I followed it by another one that played Minesweeper.
So, let’s briefly understand the concept of an “AI Agent” even though it is being less explicitly mentioned nowadays. Because it was a central concept when studying AI, maintenance teams should know about it.
The idea of an AI agent refers to an entity that perceives its environment through sensors and acts upon that environment through actuators, with the goal of achieving some desired outcome or objective. An AI agent is essentially a decision-making system. It can observe, reason, learn, and take actions to maximize its chances of success in a given environment or task.
In the early days of AI research and education, the concept of an AI agent was heavily emphasized because it provided a useful framework for understanding and designing intelligent systems. It helped to conceptualize AI systems as rational agents that could perceive, reason, and act in an autonomous and intelligent manner, much like how humans and other intelligent beings operate in the world.
Why did the term AI Agent fade away?
As AI has advanced and evolved, the explicit mention of “AI agents” has become less prevalent, primarily for two reasons:
Abstraction and Specialization: As AI techniques and applications have become more specialized and diverse, researchers and practitioners often focus on specific subfields or tasks (e.g., computer vision, natural language processing, robotics) rather than discussing AI systems as general-purpose agents. The concept of an AI agent is an abstract and broad notion, whereas modern AI systems are often designed for specific, narrower tasks.
Integration and Ubiquity: AI technologies have become increasingly integrated into various systems, applications, and products, making the distinction between an AI agent and the overall system or application less noticed. Rather than explicitly referring to AI components as agents, the focus has shifted more towards the capabilities and functionalities added by AI, such as intelligent decision-making, automation, or adaptive learning.
While the term AI agent may not be as explicitly mentioned nowadays, the underlying principles and concepts remain relevant. Modern AI systems, whether they are explicitly labeled as agents or not, still possess the fundamental characteristics of perceiving their environment, reasoning based on that input, and taking actions or making decisions to achieve specific goals or objectives.
For example, a virtual assistant like Siri or Alexa can be considered an AI agent that perceives user input (speech or text), processes that input using natural language processing and other AI techniques, and then takes actions (providing information, executing commands, or controlling smart home devices) to fulfill the user’s requests. [4]
Do we still need the AI Agent?
While the specific use of the term “AI agent” may have diminished, the core concepts and principles behind intelligent agents remain deeply ingrained in the design and development of modern AI systems, even if they are not always explicitly labeled as such. That’s why it was important to bring those concepts here to you.
Why Should Maintenance Teams be Aware of AI?
As new technologies are continually introduced in production environments to improve productivity, efficiency, and tolerances, maintenance teams have had to adapt and acquire knowledge to maintain these systems effectively.
Those advanced technologies are introduced in the production realm first, they then extend to the maintenance and other services. That’s why we need to prepare the maintenance teams to welcome AI technology. This will take us to deeper discussions of different AI models, how they can fit into maintenance, and if any of them are already used in the maintenance realm. Moreover, will the AI era replace the Industry 4.0? I will share insights about all of this in coming articles.
References:
- Terry Wireman, 2013, Successfully Utilizing CMMS/EAM Systems – Maintenance Strategy Series, Industrial Press, Inc.
- Salama Mohamed Almazrouei, Fikri Dweiri, Ridvan Aydin, Abdalla Alnaqb, A review on the advancements and challenges of artifcial intelligence based models for predictive maintenance of water injection pumps in the oil and gas industry, Springer Link, Published: 21 December 2023, Volume 5, article number 391, (2023)
- Copeland, B.. “artificial intelligence.” Encyclopedia Britannica, Last updated June 14, 2024. https://www.britannica.com/technology/artificial-intelligence.
- Wolfgang Ertel, 2017, Introduction to Artificial Intelligence, Second Edition, 2017, Springer
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It never ceases to amaze me that no matter what industry you are in or how big or small of a company you work for, success is dependent on the ability to find, attract, hire, manage, develop and retain the right people. I continue to see companies disproportionately dedicate more focus and investment into non-people issues such as technology or equipment than focusing on getting “the right people on the bus.” I haven’t quite figured out why, but I believe it could boil down to one of three reasons:
Reliability and Current Best Practices - An Educational Journey
The concept of Best Practice is easy to describe and discuss – the more difficult part is determining your path towards reliability and maintenance Best Practice and more importantly, sustaining standards and developing a continuous improvement culture.
Reliability and Maintenance Implementation Model
Christer Idhammar of IDCON INC presents the implementation steps you need to take if you want to be successful in improving reliability and maintenance, sustain that improvement, and continue to improve after that.
Reducing Maintenance Costs in a Tough Economic Climate
The current economic climate dictates that cost management is a critical activity for many companies and their managers. Maintenance is very often seen as an area where cost cutting targets can be easily and quickly achieved. Many maintenance managers take the view that this type of philosophy always ends up with increased costs in the future. This is not true in many cases. 15 years of analysis and review of maintenance programs by the author shows that most maintenance departments are more reactive than they should be and because of this, they over spend and underperform.
Properly Aligning Projects to Corporate Strategy
Corporations throughout the world are losing billions of dollars in wasted project spending, and this waste is being carefully hidden from management and investors. A new global research report shows that one of the biggest contributing factors is the lack of alignment of projects with corporate strategy.
Professional Development: Driving the Economic Engine
There are numerous issues influencing our economic engine-many real, many politic, and many mysterious. We could discuss capital formation problems, balance of trade politics, over-wary management, and so on. However, I want to focus on the part that professional development plays in this scenario. And more importantly-the role that professional development will play in the future performance of our economic engine.
People Management - Workforce Shortage: Acceptance is the First Step
Baby Boomers are going to retire soon. There won’t be enough skilled labor to fill all the jobs. Employers aren’t prepared to handle the labor shortage. It goes on and on. So, is this workforce shortage thing for real? Well, YES! The numbers don’t lie. By 2012, the U.S. Department of Labor (DOL) estimates there will be 165 million jobs and only 162 million people available in the workforce.
OEE: Overall Equipment Effectiveness
Oh "Overall Equipment Effectiveness", I've heard about that before! Unfortunately, in many facilities, that's all OEE (Overall Equipment Effectiveness) is to the personnel. Something they heard of, talked about or read about. Many maintenance departments today still do not effectively utilize the OEE tool even though it's widely used among the world class companies.
Novozyme Leverages Results Oriented Maintenance and Highly Motivated Staff to Win the North American Maintenance Excellence (NAME) Award 2000
Novozymes North America, Franklinton, North Carolina, a company with Scandinavian roots and management style won the coveted North American Maintenance Excellence Award (NAME) 2000. A reporter (Michael Lippig) recently paid Owe Forsberg, Maintenance Manager, Novozymes North America, a visit to see how this came about.
Need of Motivation for Maintenance Staff
“Maintenance is a thankless job”, this is repeated by us every time and also sometimes, use it as a tool to be with the maintenance person. Many a times it's true. We don’t appreciate their efforts as we cannot get their direct results like the sales showing their numbers, production showing their targets achieved and crossed. The maintenance data is also recorded, tracked, presented and analysed, but it is viewed and understood only whenever the production or sales targets are missed due to some failure of the machine. In other words, we try to understand the maintenance data with negative approach and to understand its impact on the business loss.
Mechanical Quality Assurance: The Next Progression of Reliability
Reliability is not rocket science. It should be easy to achieve. Do things right the first time, from design, procurement, construction, installation, maintenance and operation, all the way through to decommissioning. Isn't this the goal of engineers? Still, in many cases we —industry in general—seem to struggle in achieving high reliability. One reason may be widespread inattention to Mechanical Quality Assurance (MQA).
Maintenance Business: Managing Maintenance as a Business
In most businesses, success is easily measured by looking at the bottom line; but what’s the bottom line in the maintenance business? To better understand how to evaluate maintenance business performance, it’s helpful to examine how businesses generate profits. Quite simply, businesses generate profits by providing goods and/or services at minimum cost and sold at a fair market price. Obviously, revenues generated from sales must exceed the costs. It is important to note that the customer determines the fair market price.
Maintenance Standards at Weyerhaeuser Company
The maintenance impact on manufacturing results has traditionally been measured in terms of cost. As equipment reliability became a focus area in our industry, the strategic value of maintenance effectiveness became apparent to business leaders. For mill leaders, this brought the dilemma of balancing a need to reduce costs with an expectation that reliability must improve. From a total corporation view, wide disparity among site results establishes the need to lead and support change in maintenance performance. It is this kind of variability among sites that provides the opportunity to improve performance.
Tips for Maintenance Planning
The work process we call maintenance planning can almost always be improved in any given mill or plant. In fact in most plants we visit maintenance planners don’t plan. Planners do all kinds of tasks except work order planning.
Maintenance Outsourcing: A Step Towards Product Service Systems
This paper considers Product Service Systems as an emerging approach to creating a win-win situation for OEMs and their customers, and discusses maintenance outsourcing as a step towards applying this new concept. Two key elements in successful maintenance outsourcing are to understand the risks to the service providers in taking responsibility for their customers' maintenance activities, and understanding the value that is delivered to the customers by the maintenance service provider. The concept of 'value in use' will be introduced. as an improved decision criterion for maintenance outsourcing, and the need for a too/ to assess value-inuse will be explained.
Maintenance Management - Defining, Clarifying "Reliability"
The purpose of this article is to raise questions and challenge plant leadership on strategy, vision and execution of plant reliability and overall maintenance management. To start, we need to define reliability. Often times companies want to improve reliability but when you ask them to define reliability and how it's measured, it's unusual to get a comprehensive answer.
Maintenance Management Legends
There are many paradigms and legends surrounding maintenance management in plants. Often, the legends are known to be untrue, but people live with them because it is politically correct, or simply convenient. To be successful in improving equipment reliability and maintenance management, plants must break the legends that exist in their organizations. Some of the legends will be addressed in this article. You may find that these legends are uncomfortably close to describing how your plant operates.
Maintenance Management as a Quality Process
Maintenance practices and technologies have evolved to meet the needs of the changing industrial environment. The function has evolved from a community of reactive fixers, to dedicated craftsmen, to proactive professionals. The next generation of personnel could well be based on practitioners of Quality Management Systems (QMS).
Maintenance Key Performance Indicators (KPIs)
It is often said that "what gets measured gets done". And getting things done, through people, is what management is all about. Measuring things that get done and the results of this effort is an essential part of successful management, but too much emphasis on measurements, or the wrong measurements may not be in your company's best interests.
"Lean" on your Maintenance Materials
A custom blueprint for streamlining internal processes, Lean has helped to increase production at many plants. Except, all too often, these plants don’t enjoy the maximum return on their investment. This is because managers often limit their Lean implementations to production-related processes. Such applications provide only a fraction of the benefit Lean is designed to offer and often deprive plants of achieving the true potential for growth and development.
How to Cut Your Maintenance Budget (Without Cutting Your Throat)
Regardless of the nature of the manufacturing process you maintain, the subject of your maintenance budget has doubtless come up in recent days—probably over and over. That's because most organizations still view the maintenance department as a cost center, and when it's difficult to locate the bottom line, senior managers have a tendency to look behind the maintenance budget to find it.
Hiring of Maintenance Management Personnel – Top 10 Mistakes
Whether your company is large or small, whether you're hiring an entry-level employee or a top executive, any one of the following mistakes can result in a hiring disaster for your organization. Recent Kennedy Information audio conference speaker Lori Davila and her co-author Louise Kursmark offer 10 key points for reviewing your organization's hiring procedures and making adjustments where needed.
The Danger of the Reduction of Workforce
When a forced layoff takes place in a unionized environment, the latest employees, in this case the apprentices were laid off; the plant had to lay off its future employees. Even sadder is that only four months after the lay offs the plant had to hire back many of the people they laid off. Many of them worked for a contractor who had contracted them to the plant after they were laid off! Soon this plant will start talking about a new improvement initiative and new management will wonder why it is so difficult to get people committed to improvement initiatives.
Global Indicators for Maintenance, Availability Performance
With the increased globalization and with companies acting globally, the need for a common understanding of the indicators to measure maintenance and availability performance is increasing, and there is no doubt that this activity in a short period of time will be a part in a global standard for maintenance indicators. This is highlighted by the fact that COPIMAN (Technical Committee on Maintenance of the Pan American Federation of Engineering Societies) is joining the comparison effort.
Key Performance Indicators and Frontline Maintenance Leaders
You can develop, document, and preach your improvement plans as much as you want, but if those plans do not result in better front line maintenance performance, you have just wasted money and time. Maintenance managers cannot produce expected results without the help of others, especially the frontline. Those organizations that have experimented with autonomous teams lacking front line leadership often fail to deliver sustainable results. If you believe this statement is wrong, I am very interested in hearing back from you.
The Building Blocks to Creating an Effective Lubrication Program
The goal of every lubrication program should be to ensure that all equipment receives and maintains the proper levels of lubrication such that no equipment fails due to inadequate or improper lubrication. In order for this to happen, we must follow the 5R's of lubrication - right lubricant, right condition, right location, right amount, right frequency.
Evolution of the "Grease Monkey" to the Maintenance Professional
To compete in this adverse environment, companies switched mantras, from "do or die" to "do more with less or die." Every year, the bar of acceptable performance is raised. Employees are challenged to achieve these objectives with fewer resources. According to the U.S. Labor Department's Bureau of Labor Statistics, between 1981 and 1996, the total number of workers who lost jobs they held for three or more years because their plant or company closed or moved was nearly 18 million.
All Win - A Maintenance Partnership in Three Pulp Mills: Reasons, Results and Lessons
Virtually everyone has heard of and will express an opinion on outsourcing. There are clear global trends toward outsourcing and most are experiencing the joys in one form or another. In the maintenance world outsourcing extends from specialized services, contract labor and consigned spare parts all the way to a full, shared risk-reward, incentive-based partnership. There are many benefits in favor of outsourcing, but even with these benefits why would an operating company elect to form a maintenance partnership? What factors must be considered? What concerns? Most important - what are the results achieved and lessons learned after a full year of actual operation?
Maintenance Training - The Backbone of Cultural Change
The "Program of the Month" phenomena. I feel that there is somewhat of a misunderstanding of this issue. Mindsets such as these are often attributed to the fact that management are not fully behind the concept, or a coping mechanism for a workforce that has reached a saturation point in terms of the continual changes that they need to endure. While there is, of course, some validity in these arguments the prime reason, the reason that proven programs fail is generally due to the lack of adequate communication.
Too Small for a CMMS? Think Again
Many smaller companies feel maintenance management software is overkill for their organizations. Nothing could be further from the truth. In reality, even a one-person maintenance department can reap the benefits of maintenance management software. The same benefits realized by the maintenance crew in larger companies are there for smaller maintenance departments also.
The Role of Information Technology in Plant Reliability
Information technologies (IT), in the context of this paper, include all computer systems and networks, plant automation systems such as distributed control systems and programmable logic controllers, design drawing databases, procedures databases, and diagnostic monitoring systems. The role of information technology is critical for maintenance optimization because it relies on the ability of the plant personnel to bring all data together in a coherent fashion for optimum analysis and decision-making.
The Maintenance Storeroom: Keys to Efficient Maintenance Operation
Besides being the central hub for maintenance, the storeroom also provides functions that are absolutely critical to the maintenance operation. These functions are so important that when the storeroom is operating in a best practices mode, the rest of the maintenance operation can excel – the storeroom is the enabler. Put another way, if the storeroom is run improperly (such as poor inventory accuracy, parts unavailable when needed due to poor replenishment and procurement practices, etc), the rest of the maintenance operation has no chance of achieving high service levels of equipment availability and reliability.
The Future of CMMS
We now have the ability to automate many of our standard maintenance processes, analyse in detail various parts of our businesses, and the performance of our equipment. We are able to plan shutdowns, technical change projects and operational maintenance procedures down to a very fine level of detail. As maintenance management generally makes up around 40 - 50 % of operational budgets, the savings made possible from increased efficiency and reduction of waste are staggering.
The 8 Key Elements to Look for in Maintenance Software
Facility management personnel in all industries have waited a long time for computer technology to become applicable and affordable enough to implement in their respective maintenance efforts. In recent years, flexible, dependable and economical computerized maintenance management systems (CMMS) have become available to help fight the never-ending struggle to operate and maintain buildings of all shapes, sizes and functions.
Skimping on the Training Puts your CMMS Project at Risk
Training for users of a computerized maintenance management system (CMMS) is a multiple-phase process. There are three areas of training needs: basic training, application (CMMS) training, and internal training.
Elastopipe: Safety Pipe for Oil Rigs
Trelleborg has developed a product, that can withstand a jet fire - the cause of the Piper Alpha disaster. The product is already in use on several platforms, primarily in the North Sea. To date, some NOK 7 million in development costs- has been invested annually. These costs are shared by the project sponsors, comprising the Norwegian government and a number of oil companies. Continued development is not expected to be as costly and will focus more on handling other derivatives, such as gas and oil, and possibly being able to offer a material in other colors for customers who wish to customize their equipment using their own color schemes.
Reaping the Benefits of CMMS
The effectiveness of maintenance can make the difference between success and insolvency, between limping by financially and organizational excellence. Many companies and organizations consider their computerized maintenance management system (CMMS) and processes as catalysts for achieving a competitive advantage. Yet, good intentions are only part of the recipe for success.
RCM Success Starts with CMMS
The degree to which RCM analysis can contribute to profitability is directly variable with the quality and accuracy of the CMMS data on which the analysis is based. Because the technique is rigorous, its over-use will defeat the purpose and lead to cost overruns instead of savings. The way to optimize the RCM return is to apply the analysis strictly to the equipment and systems that will pay off from it, and to know this we must rely on the CMMS. This paper provides guidance for ensuring that the equipment data and history residing in a CMMS are complete and accurate; so that RCM analysis will be a success and positively impact a company’s bottom line, not hurt it.
Principles of Insulation Testing
Probably 80% of all testing. performed in electrical power systems is related to the verification of insulation quality. This Cadick Corporation Technical Bulletin briefly describes the fundamental concepts of insulation testing including – insulation behavior, types of tests, and some test procedures. For more detailed information, refer to the bibliography at the end of the paper.
Open Warehouse System
Management today is never the same what was yesterday. And India, undoubtedly, has been one place that has witnessed radical changes in Management - be it Man Management, Money or Material Management. And it goes without saying that concept of "Lean" in all fields is the name of the game. Lean Organization, Reduced Vendor base, Shorter Production Cycle, Market Micro-segmentation and Skinned Distribution Points are all globally accepted jargons of the present day cost conscious world.
Mobile CMMS: The Future Maintenance Team's BFF
Maintenance management is an around-the-clock challenge. Equipment failure can (and does) happen at inconvenient times–times when maintenance managers may be off-site and must rely on communication from technicians to convey problems and act efficiently. Mobile computerized maintenance management systems (CMMS) and applications provide live, synchronized status reports and other key features that can dramatically improve reaction time and efficiency.
Managing Spare Parts
Proper planning and control of spare parts inventory is a critical component of an effective asset management program. If the right parts are not on hand when needed for routine maintenance or repairs, downtime is prolonged. If too many parts are on hand, the enterprise absorbs excessive costs and the overhead of carrying the inventory.
Managing an EAM / CMMS Selection
The latest ARC Advisory Group study of the enterprise asset management (EAM/CMMS) software market profiles more than 80 maintenance application suppliers. This number of choices is enough to make any plant manager shudder. How can you pick the tool that is right for you? The tug-of-war between decision makers can make or break the success of an EAM/CMMS implementation. This article addresses the delicate balance of wants and needs, and how they apply in the application selection process.
Managing an EAM/CMMS Implementation
Now that the best EAM/ CMMS application for your business has been selected, the deployment phase begins. But an EAM system is not a plug-and-play application. Will you miss out on some real operational savings? Will the data be clean enough to provide value in a production environment? Will processes be tailored to match the new system, or will they be optimized to improve business? Is the vendor knowledgeable about your specific industry or regulatory requirements?
Fixing Maintenance
Energy utilities require optimization of asset management as never before. Maintenance personnel bear the burden of sustaining reliability and availability and are personally in the spotlight the instant an interruption or failure occurs. Yet without the right resources and tools at their disposal, one can argue that it is not the staff but the focus on maintenance that is broken. This article addresses some of the challenges faced by utilities today and reasons to recalibrate your maintenance priorities.
Few Make the Most of Their CMMS
A whopping 94.7 percent of plant maintenance managers feel they are not using their computerized maintenance management software system to its maximum capability, according to the results of a national CMMS survey conducted for Reliable Plant magazine by educator, consultant and author Kris Bagadia. “I knew that it was going to be a high percentage. I didn’t know it was going to be that high,” says Bagadia.
Failure Codes in Maintenance Systems - CMMS
What is a failure code? Quite simply, it is a code that illustrates why an asset failed or the reason that the asset failed. Codes can be a number which is cross referenced to a list of actual code descriptions or more conveniently a series of alphanumeric characters that are a logical abbreviation of their descriptions. However, with modern database technology and available disk space, the full descriptions are increasingly being used instead of alphanumeric codes.
Effective Maintenance Management at Doe Run
The new general manager at Doe Run’s South-east Missouri Mining and Milling Division determined that inaccurate and incomplete maintenance data was a major contributing factor preventing effective management of maintenance costs. Management then decided to obtain the necessary knowledge and tools which would allow implementation and operation of an effective maintenance management program. The company chose to pilot a program at one of the mines, and depending on its success, the program would be expanded to other areas within the division.
Eat an Elephant - Implement a CMMS
An elephant is a large animal and it is doubtful anyone would want to eat one. But the old proverb, with a little twist, has a similar paradox to implementing a computerized maintenance management system (CMMS). Not developing the proper steps to implementation may lead a company to failure.
Does Lubrication Belong in the CMMS?
Most, if not all, companies use CMMS systems to oversee their maintenance activities. From home-grown systems to complete ERP systems, leveraging technology allows companies to more efficiently and effectively manage their maintenance, repair and operations activities. So as a core maintenance function, surely routine, lubrication-related preventive and predictive activities such as regreasing motor bearings, taking oil samples, and executing oil top-offs and inspections belong in the CMMS system like any other maintenance task, right?
Developing CMMS Implementation Templates
In this year literally billions of dollars will be spent, in many different countries, on implementing CMMS and enterprise level systems. Some corporations, such as RIO TINTO and BHP, have attempted to circumvent a lot of this cost by developing implementation templates for use across their global operations.
Define the Need Before Software Installation
Defining the real need for new software and staying focused is tricky. There are so many variables along the way to a good software implementation that falling off the track is easy. There has to be a central theme to guide the decisions that will be made during the process. Simple steps early in the project keep decisions simple when times get tough.
Collaborative Production Management in the Process Industries
This call to action is being driven by reductions in resources, increased desire to maximize capacity utilization, the need to optimize operational performance, and the need to ensure that we are in compliance with company goals, targets and corporate responsibilities. We are being asked to do more with less. Data management is an essential element of the solution to this challenge.
CMMS Software - Selecting the Right CMMS
Good Computerized Maintenance Management Software (CMMS) that schedules preventive maintenance work orders on your equipment is an integral component of any efficient maintenance department. Preventive and scheduled maintenance, efficiently scheduled, will not only reduce your maintenance costs, but will minimize emergency repairs and downtime, resulting in an increase in overall profitability.
CMMS: Integrating Real-Time Information for Condition-Based Maintenance
Industry pacesetters use real-time equipment data to prioritize and optimize their maintenance resources. The process is straightforward in concept: use real-time data to determine the equipment health, but only inform the Computerized Maintenance Management System (CMMS) when maintenance is actually necessary. From there, the CMMS automatically produces the work order and uses the workflow that is already familiar to all maintenance personnel.
Calculating the Savings from the Implementation of a CMMS
CMMS systems, as we have come to know them, come basically from two distinct families. These are ERP systems such as SAP, JDE and the PRONTO system and EAM systems such as Epac, MIMS and a plethora of other systems. When most maintenance practitioners refer to CMMS systems they are in reality talking about EAM systems.
Barcode-Driven Tracking System Coordinates Toolrooms
To manufacture products on such a large scale means stocking a lot of equipment to maintain the operation. Fort Saskatchewan plant in Alberta, Canada, Roy Lura, process leader, estimated an inventory of more than 15,000 pieces of equipment. Until recently, however, there was no way to adequately track the items. With the help of a barcode-driven tracking system, this has changed.
Balancing CMMS User Configurability with Centralised Control
For most companies, gone are the days when users were forced to conform to a rigid framework dictated by the CMMS vendor and strictly controlled by the Information Systems department. Users today enjoy freedom to customise the content, look and feel of their CMMS environment on a variety of devices, from handhelds to desktops. With modern computers and software, users are overwhelmed with choices.
An Integrated Process for System Maintenance, Fault Diagnosis and Support
This paper presents an overview of an integrated process for system maintenance, fault diagnosis and support. The solution is based on Qualtech System, Inc.’s (QSI’s) TEAMS toolset for integrated diagnostics and involves several key innovations. As a showcase of the integrated solution, QSI, along with Antech Systems and Carnegie Mellon University (CMU), have recently completed a research project for the Information Technology Branch at the Naval Air Warfare Center–Aircraft Division (NAWC-AD) in St. Inigoes, MD. The entire system, termed ADAPTS (Adaptive Diagnostic And Personalized Technical Support), provides a comprehensive solution to integrated maintenance and training.
Maintenance Software Implementation
Much has been written in the past about the implementation of maintenance software (CMMS systems). This article takes a slightly different approach in that it attempts to explain some of the pitfalls associated with first time implementation in SME's. It suggests a "try before you buy" approach, which stages the maintenance software implementation to reduce both risk and cost. Tales of failed implementations abound and failure rates of 40% to 80% are commonly quoted. Real statistics are hard to come by but the following data is both relevant and current.
Maintenance Control - from Zero to Hero
Even when a company has both the will and the money to spend, it is difficult to know where to start when considering the implementation of maintenance management systems. Probably the majority of smaller companies are still at this stage, which effectively means the majority of maintenance people. The prospect of developing suitable maintenance control strategies and policies from a standing start is daunting. There are many questions such as how much will it cost, where will the resources come from and how will we cope?
Enhancing Overall Equipment Effectiveness Through TPM
In Total Productive Maintenance small group activities are interwoven in each other. Autonomous maintenance is one of the most important pillars of TPM. Autonomous maintenance aims to educate the participants in the concepts and philosophy of autonomous maintenance and to give m opportunity to develop their skills and confidence. Read the learn why implementing TPM to improve OEE was recommended to the plant in question.
Corrective Maintenance Task Generation
Corrective Maintenance Task. Generation is best performed by the. same personnel who perform corrective maintenance. The normal. technician’s time schedule does not. allow the time to document tasks in. detail. Some companies rely on the maintenance supervisor to document. and implement new preventative and corrective maintenance tasks.
Centralized Maintenance vs. Decentralized
Companies often ask if maintenance planning and scheduling will work if they have a decentralized maintenance organization. Yes, it will. In fact, they need planning and scheduling just as much as a centralized shop. Let's review why.
Can You Really Justify Reliability Centered Maintenance (RCM)?
Reliability Centered Maintenance is a step-by-step instructional tool for how to analyze a system's failure modes and define how to prevent or find those failures early. RCM become a very detailed study of things we already know, you will often hear the justification "it's to make sure we don't miss anything." If you are considering implementing a reliability centered maintenance program, you. should be aware of the problems you may run into.
Avoid Waste: Lean Maintenance Can Reduce Overall Costs
Why us, why now? In years past, the engineer, manager or superintendent was responsible for improvement ideas. Maintenance people were "hands" hired to do what they were told. Today, organizations are lean and mean; we need the capabilities of all maintainers. The downsizing craze, however, has left everyone in a managerial role with too many tasks and too little time. There's no one left to cut costs!
Availability in a Supply Constrained Environment is the #1 Issue for Refinery Executives
Availability in a Supply Constrained Environment is the Number One Issue for Refinery Executives according to the EPI Center.
What the Pump Was Designed to Do and Why it Doesn't Do it
Contrary to popular opinion, a centrifugal pump is not designed to develop one head at a single capacity as requested by the pump purchaser. In fact a pump is designed and produced to supply a whole range of head-capacity conditions as identified on it’s performance curve. The pump will operate on that curve if it is driven at the particular speed for which the curve is drawn.
What is Wrong with the Modern Centrifugal Pump?
Ask for a modern centrifugal pump recommendation from your favorite supplier and chances are he will recommend one of the standard pump designs that conform to either the A.N.S.I., I.S.O. or D.I.N. specifications. On the surface that might seem like a good recommendation, but the fact is that all of these designs will cause you maintenance problems. Refer to the illustration prior to diving into the details of the obvious problems found within these designs.
Weibull Point Process Applied to Repairable Subsystems
Let's suppose that we have recorded the time when each failure of a repairable subsystem has happened during a season. The arrangement of these failures (black points in Figure 1) along the time axis is called a stochastical realization of failure events.
Using Reliability Importance Measures to Guide Component Improvement Efforts
The component importance measure is an index of how much or how little an individual component contributes to the overall system reliability. It is useful to obtain the reliability importance measure or value of each component in the system prior to investing resources toward improving specific components. This is done to determine where to focus resources in order to achieve the most benefit from the improvement effort.
Top Tips for Selecting Pressure Measurement Transmitters
When selecting pressure measurement transmitters, the first stage is whether to opt for a transducer or a transmitter. Although the terms are often confused, there are several differences between transducer and transmitter devices. A transducer creates a low-level electronic signal in response to changes in applied or differential pressure. As with transmitters, transducers feature an internal sensor that converts the applied force into an electrical signal, from which the measurement is derived.
The Full Circle of Engineering Education
This article has several related themes. The main purpose is to give an overview of the engineering education process, relating theory to practical application. As part of this overview, I express gratitude to the scientists, mathematicians, and engineers who have guided my own education. This education is the foundation of my engineering career, as my experiences demonstrate.
The Achilles Heel of Modern Electronics
Digital measurement technology certainly has taken the test industry forward, mostly with giant strides. The exact opposite may be true, however, when it is applied to testing for aging-related failure modes such as intermittency or no fault found (NFF). Digital abstraction devices, perfect for parametric testing, rarely synchronize to real-time, randomly occurring, anomalous, or intermittent age-related failure events. This shortcoming is especially acute when large numbers of circuit nodes require testing.
Developing Marketable Engineering Skills
For the foreseeable future, the “job of the future” will exist in a world that wrestles with issues of outsourcing, offshore design and manufacturing, and generally uncertain employment prospects. Among the job seekers, aspiring engineers need to develop effective ways of finding and keeping employment in this murky environment.
Sorting Out Flexible Couplings
When the time comes to specify replacements for mechanical power transmission couplings, it's human nature to take the easy path...simply find something similar (if not identical) to the coupling that failed, maybe apply a few oversizing fudge factors just to be conservative. Too often, however, this practice only invites a repeat failure...or more costly system damage.
Safety Circuits, Force Guided Relays vs. General Purpose Relays
The force acting on a general purpose relay is near the fulcrum of the arm. With a force guided relay, the force acting on the relay is about as close to the contact point as one can reasonably get.
Preheater Points Out the Value of Cooling Off
The moral: Even when you think you have found the best solution, put the problem aside and then ponder it again. A fresh look may lead to an even better solution. As for the integral desuperheater, it is too elegant a solution to go to waste. Perhaps you may have a use for it.
Mining Maintainability
Most efforts to decrease the frequency and severity of injuries to miners have stressed miner training and work procedures, improved work environments and safety and environmental control equipment, improved personal protective equipment, improved equipment control and display design, enhanced lighting and visibility-related research, and organizational issues. However, the industry has paid much less attention to the design of the mining machine itself with respect to maintenance cost or safety for the maintainer.
Maintainability Design Checklist
The following is a Maintainability Design Checklist for coal mining equipment. The purpose of the checklist is to provide a summary of design review points for the maintainability assessment of new or existing underground equipment. It specifically focuses on the identification of equipment design features, tasks, or procedures that impact equipment downtime, repair costs, labor hours and maintainer skill level requirements.
Engineered Building Maintenance
A team of technical experts will make a thorough review of the building and its operating history. Led by a professional engineer or architect, they will review the original construction plans and specifications, if they are available. Then they will develop a specific reoccurring maintenance program, as well as a cost estimate, for each of the building's systems and load it on their computers.
Energy Savings Through Pump Refurbishment and Coatings
Paul Maier, project manager of the NYSERDA study, states that "Pump sandblasting and coating should be a required step of any pump. refurbishment program." MCWA has also included interior pump coatings as a requirement in its new pump specifications. The goal is that. requiring coatings on the inside of. new pumps will eliminate, or significantly delay, the seemingly inevitable decline in pump performance and efficiency from internal corrosion and tuberculation buildup inside unlined pumps.
Digging Up Savings: Go with the Flow
It's important to find out if material flows are present or not throughout a bulk-processing facility; material cost savings and increased plant efficiency can offset an investment in monitoring. Most bulk solids processors can do this using low-cost acoustic emission-monitoring technology.
Design for Maintainability: The Innovation Process in Long Term Engineering Projects
In this paper we are concerned with design and innovation in the context of long-term service driven engineering projects. The cases reveal a number of ways in which new organisational arrangements have emerged from attempts to deal with these difficulties and also some of the mechanisms that have helped companies to identify the design implications of future maintenance requirements.
Design for Maintainability
Maintainability can be defined as the ease in time and resources of retaining equipment in or restoring it to a specified operational condition. It directly affects the bottom line because it can impact operations, downtime, maintenance costs, and safety. Maintainability is an important aspect of any system's lifecycle, but process plant engineers typically give it little direct consideration. This is primarily the result of a short-term view of capital project costs that fails to consider lifecycle costs and downstream activities.
Communications: The OEM Partnership
When maintenance is allowed to interact with the plant and production Original Equipment Manufacturer (OEM), a prosperous relationship for both parties will often ensue. This OEM partnership results in first-hand information for maintenance to set up its maintenance approach, and valuable operational and design feedback for the OEM. There are seven main circumstances in which maintenance will interact or communicate with an OEM and form an OEM partnership.
Chain Drive Design Recommendations
For optimum chain drive performance the following points should be considered when looking at chain drive design.
Carbon in a Metal Holder
Carbon Graphite is probably the best seal face you can use in most of your water and chemical applications. Its corrosion resistance and natural lubricity provides two of the features we need in a good seal face material. The question sometimes comes up about how to insert the carbon into the mechanical seal. Should it be captured into some type of a metal holder or would you be better off using a "monolithic" or solid version?
Classifying Chemicals to Assure Effective Sealing
The most common question asked by seal salesmen is "what are you sealing?" This is usually followed by asking about shaft size, product, temperature, speed, stuffing box pressure and any other operating conditions they can think of. The problem with this simplistic approach is that you would have to have a very large data bank of information to reference a particular problem so as to be able to make a sensible seal recommendation. There is a much more logical approach to the problem that we will be discussing in the following paragraphs.
A Guide to Matching Electric Motors with Hydraulic Power Units
Sizing electric motors correctly for hydraulic power units can save a sizable amount of money over the life of the equipment. If system pressure and flow are constant, motor sizing simply boils down to the standard equation: hp = QP / 1714EM
The Cost of Producing Electricity
The cost per kWhr, the "cost of producing electricity", is the cost of the energy which is taken out of the steam by the turbine generator system and converted into electricity. The following paper discusses calculation methods for determining this cost -- a critical step in the process of evaluating cogeneration feasibility.
Anatomy of a Boiler Failure—A Different Perspective
The power industry’s operating and maintenance practices were held up to intense regulator and public scrutiny when on November 6, 2007, a Massachusetts power plant’s steam-generating boiler exploded and three men died. The Department of Public Safety’s Incident Report investigation determined that the primary cause of the Dominion Energy New England’s Salem Harbor Generating Station Unit 3 explosion was extensive corrosion of boiler tubes
Anatomy of a Hydraulic Pump Failure
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.
Are We Willing to Hear What “Failure” Has to Say?
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.
Causes of Overheating in Cartridge Mechanical Seals
Too much heat can cause multiple problems with cartridge mechanical seals. Some heat problems are not seal design or seal installation related.
Centrifugal Pump Troubleshooting
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:
PLC 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.
Electrical Troubleshooting in 7 Steps
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.
Reduced Wear and Failure of Machine Components: Failure Analysis of Mechanical Components
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.
Gearbox Diagnostics Fault Detection
The paper deals with the method of gearbox diagnostics fault detection, and shows that using: design, production technology, operational, change of condition (DPTOCC) factors analysis leads to the inference of gearbox diagnostic information. In the paper is a review of the current possibilities for using mathematical modeling and computer simulation for investigating the dynamic properties of gearbox systems. Computer simulation of dynamic behavior of gearboxes is a powerful tool for supporting gearbox diagnostic inference.
Getting Root Cause Analysis to Work for You
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.
How to Conduct Effective Root Cause Analysis
There are many types of RCA tools available to organizations, including 5 Why?, Fault Tree Analysis, Interrelation Diagrams, Ishikawa Diagrams (Fishbone, Cause and Effect) and many others. A great example is the 5 Why? method: starting with the incident itself, an RCA team would continue asking “Why did this happen?” until they arrive at the root cause. Refer to the following example:
A Framework for Achieving Best Practice in Maintenance
This paper outlines the key factors that you should consider when establishing a Maintenance Change program in your organization. In doing so, it provides a framework which you can apply to increase the chances of success in your change efforts. The paper draws heavily on Price Waterhouse experience in implementing Maintenance change at many major organizations throughout WA, as well as our international experience in implementing change as articulated in our book "Better Change."
An Introduction to the Maintenance Scorecard
The Maintenance Scorecard is the first book to seriously tackle the issue of aligning asset management with other areas of corporate activity. This is a particularly relevant topic given the growing importance of the area as a source of strategic advantages and as a centre for risk management.
You Cannot Maximize Production or Reduce Costs Without the use of an Effective Planned Maintenance System
Planned maintenance is a maintenance concept developed over a span of time, and is made up of numerous functions, all designed to compliment each other. Planned maintenance, then, is a maintenance program designed to improve the effectiveness of maintenance through the use of systematic methods and plans. The primary objective of the maintenance effort is to keep equipment functioning in a safe and efficient manner. This allows production to meet production targets with minimum operating cost.
Wrench Time
Industry experts have for many years pointed to the low productivity levels in maintenance departments of most companies around the world. They cite anywhere from 30% to 50% as an average for “wrench time,” the productive time technicians spend actually repairing or replacing equipment, as opposed to walking to the job, receiving instructions, waiting for parts and other productive or non-productive activities. Do you know the average wrench time for your maintenance department and how it compares to others within and outside your industry?
Work Order Prioritization
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.
Work Order Execution and Data Capture
All of the work of backlog management, planning and priority targeted capacity scheduling are focussed on efficient execution. To ensure that the tasks that need to be done, as per the true requirements of the plant, are done in a timely manner with as little waste of human and material resources as is possible.
Work Flow Concepts
As a result of recent audits and reviews of various medium to large-scale industry. I have found the following to be a general observation regarding systems of work. As technology for maintenance has moved forward there has been an increasing demand on the time of the maintenance-planning department. All are key to progressing the maintenance delivery systems towards world-class status. Organisations may use various positions to analyse this function.
Why Planned Maintenance?
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.
The What, Why, How of Wrench Time
Wrench time is a measure of crafts personnel at work, using tools, in front of jobs. Wrench time does not include obtaining parts, tools or instructions, or the travel associated with those tasks. It does not include traveling to or from Obviously, it does not include break time. These non-wrench time tasks are often necessary to get work done, but are not "wrench time." The craftsperson is in a delay situation. We should also ask ourselves whether the crafts personnel perform tasks efficiently while they are on tools in front of jobs. This is a legitimate question, but not answered by wrench time. Nonetheless, if we increase the time employees are "on the job," we should get more work done.
Smart Shutdowns: Avoid Costly Mistakes with Your Outages
Historically, maintenance textbooks have defined a shutdown as "an unplanned equipment failure event that causes an operational production line, process, area or section of a plant to be temporarily turned off or closed for emergency repair, and resumed to operational status immediately following the repair of the failed equipment." Turnarounds are defined as "a planned event that required the closure of an entired operational plant or facility to perform one or many pre-planned technology or system upgrades, equipment upgrades, and maintenance restorations, within a defined time period."
Setting Disciplined Priorities when Prioritizing Maintenance Work
Priority, as defined in the Franklin Dictionary, means "coming before in time, order, or importance." When prioritizing maintenance work, one must consider its importance to the entire company in question. My experience shows that, in the real world of most maintenance departments, you can classify priorities in two groups: Emotional priorities and real priorities.
Proactive Approach to Shutdowns Reduces Potlatch Maintenance Costs
Effective shutdown management is critical to the operation of mills, for without well-planned and executed shutdowns, equipment reliability suffers, and the mill pays the price in poor quality and lost production. Becoming proficient at managing shutdowns is a way to reduce overall downtime costs so that shutdowns themselves do not consume the savings they are capable of generating.
Planned Work Predominance: Contribution to the Bottom Line
It’s common knowledge that increasing the share of planned maintenance over the time spent on breakdowns should be a top priority for forward-thinking maintenance organizations. The financial benefits of that strategy, however, may not be readily apparent.
Planned Hours: What's a good total?
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.
Mining Planning Department: Planning for Profits
Many who work in mine and site maintenance will probably tell you that chaos not only reigns but has moved in and set up shop. This is not for a lack of planning in maintenance because in fact, it's quite to the contrary as many mining operations have entire departments dedicated to maintenance planning. The problem in many instances is that the effort that goes into creating those plans is not matched by the support required to make them effective.
No-no’s for the Maintenance Planner Role
Organizations should have a clear work description of what a planner’s role is. The role may vary between organizations, mainly due to plant size. Some organizations have combined planners/supervisors. Some have dedicated planners for shutdowns/turnarounds. Many have people with a planner’s title, but no planning. So, how do we figure out a planner’s role?
Maintenance Planning in Underground Mining Operations
Underground mining operations, similar to many industrial enterprises, have long recognized the potential benefits of maintenance planning. However, underground mining operations’ efforts to implement maintenance planning have generally met with little success. One finds that after an initial period of enthusiastic support implemented systems and procedures fall to disuse. Most companies, upon the collapse of their maintenance planning, convince themselves that underground mining is so "unique" that to accurately plan, schedule and measure maintenance work is impractical.
Maintenance Planning and Scheduling
To actually realize potential increases in profits, maintenance must be taken a step further through planning and scheduling. In addition to identifying potential failures, we must also focus our resources to correct them before the failure occurs. With decreasing workforces and increasing responsibilities of those left at the facility, the efficiency of our resources easily becomes a second priority.
Maintenance Management - The Planned State
The maintenance department is one of the greatest levers of profitability that any capital intensive organisation has. An average of 40 - 50% of a capital intensive industries operating budget is consumed by maintenance expenditure. During the past twenty years the advances in technology available to the maintenance department to manage its processes has delivered the situation where it is within the reach of all maintenance operations to achieve a world class level of maintenance delivery.
'Ja, maar' Mentality Can Hurt Planning
While working this April in Holland, I saw a plant utilizing a marvelous Dutch phrase: "Ja, maar", which means "Yes, but ..." Seeing it first-hand helps me understand a principle of successful planning. Many plants can't implement successful planning because they assign the planners many worthwhile activities that are not planning. "Yes, planning is supposed to really help us, but we need the planner to do this other thing that really helps us." Ja, maar.
Improving Estimating Quality
Estimating lays the foundation for planning, scheduling, and management of business critical projects. It is also critical for budgeting, bidding and contracting. Achieving consistent, quality estimates is critical to business success. However, many companies lack systems and procedures to ensure consistency in estimating across the enterprise and easily define, benchmark, and refine corporate estimating standards. The potential long term benefits of instituting an effective solution to this problem are enormous.
Improve Basic Work Systems First
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.
How Project Management Software Can Smooth the Way
Scheduled shutdowns, however, can provide unique opportunities to a maintenance department not normally available during standard operation or even during short shutdown periods. Lost capacity can be restored to an overtaxed facility during an extended shutdown. Major equipment overhauls can be performed to help prevent future unscheduled shutdowns. Government mandated inspections and repairs can be accomplished during a shutdown, bringing a plant into better compliance.
Cutting Maintenance Cost Through Effective Shutdown Management
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.
Critical Component of the CMMS: The Repair Work Order
From the very start, the implementation of a computerized maintenance management system (CMMS) is a long and arduous process. One of the largest concerns is how to effectively get the correct data into the system in the first place, and then, how to get useful information out. The better and more consistently recording of repair activities is done, the greater potential for yielding greater and more specific information about an operation.
Backlog Management
Few tools are as useful to managing the maintenance workload and effectiveness as the Maintenance Backlog. In many companies today management of the maintenance backlog has been neglected. As a result they are generally drowning in their own data. A poorly managed system has a dramatic effect on the entire delivery of maintenance services.
Accurately Estimating Labor Hours
Planners struggle too much over developing an accurate estimate for each job. Many managers expect planners to develop perfect time estimates. They may even grade technicians and planners on actual field performance vs. the estimates. As a result, planners agonize over the estimates to the point where they don’t get all the jobs planned; even the ones planned still aren’t “accurate.”
Ceramics Win the War on Erosion
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.
What is Vibration?
In its simplest form, vibration can be considered to be the oscillation or repetitive motion of an object around an equilibrium position. The equilibrium position is the position the object will attain when the force acting on it is zero. This type of vibration is called "whole body motion", meaning that all parts of the body are moving together in the same direction at any point in time.
Why Record? Infrared Video
As the infrared industry continues to develop, documentation will become more important and required. Infrared video recording and data logging creates a database, making the thermographer and the end user accountable for all items surveyed, thereby reducing the liability and improving the quality for both the end user and infrared thermographer.
What You Should Know Before you Buy – A Guide to Buying an Infrared Camera
During Academy of Infrared Training courses, we see many students who have purchased an infrared camera that is not suited for their intended use. These students have put their trust in a camera salesperson, and, many times, that salesperson was solely interested making a sale. Later, these students are disappointed to find out that the camera is not truly suited for their application. This article aims to help the camera buyer understand what basic camera specifications mean, and also help them determine what type of camera and options are suitable for their application. If you note your answers to questions throughout this article, by the end you should have a custom list of applicable specifications and options.
Web Based Vibration Analysis Programs
A number of changes are occurring in the Condition Based Maintenance (CBM) market and in the realm of communications, Internet and database technologies that are resulting in the adoption of Internet based monitoring programs. The following paper will describe the technologies involved as well as the current market climate that is driving this change. This paper will focus on vibration analysis in particular, however, the forces involved are just as applicable to other CBM technologies and Maintenance planning packages.
Water Contamination
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.
Vibration & Ultrasound Technologies: A Possible Integrated Inspection Tool?
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.
Vibration Pen, Shock Pulse Measurement (SPM), & Vibration Analysis - What's the Difference?
There are three major types of tools for finding bearing defects using vibration techniques. Which of the tools should you chose for inspections of bearings? The best solution is often a combination of two or three of the tools, but it depends very much on how much rotating equipment you have in your plant, the criticality of that equipment, the speed of your rotating equipment, and how perceptive your organization is to training. A short description of the three techniques follows.
Vibration Analysis Reveals Poor Motor Mounting Structure
At the installation of a new 150 gal/min centrifugal pump driven by a 125 HP motor, high vibration levels were found immediately upon first start. After several days of alignment checks, pump teardowns, bearing inspections, motor uncoupled runs and vendor technical support, no solution was found. The plant maintenance manager asked the company's vibration analyst to take readings to troubleshoot the problem. After measuring extremely high vibration levels, resonance was suspected and was found at the motor support structure due to inadequate mounting design for the new installation.
Ultrasonic Leak Detection in Heat Exchangers
Ultrasonic leak detection has been used for a variety of applications ranging from energy reduction by locating compressed air leaks to quality assurance inspections such as locating wind noise and water leaks in automobiles. The secret to success is to understand the nature of what type of leak produces a detectible ultrasound and what does not, along with the techniques that can be used for effective leak identification.
Using Corrective Maintenance Work Plans to Improve Plant Reliability
There is another, often overlooked, type of preventive maintenance inspection which can not be scheduled at regular intervals. These inspections can and should be done in conjunction with corrective maintenance. Corrective maintenance is defined as maintenance work which involves the repair or replacement of components which have failed or broken down.
Understanding The Basics Of Balancing & Measuring Techniques
Why Balance? All rotating components experience significant quality and performance improvements if balanced. Balancing is the process of minimizing vibration, noise and bearing wear of rotating bodies. It is accomplished by reducing the centrifugal forces by aligning the principal inertia axis with the geometric axis of rotation through the adding or removing of material. In order to understand the basics of balancing it is necessary to define the following fundamental terms.
Understanding Shaft Alignment: Thermal Growth
Machine conditions change from the time the machine is off line to when it is running under normal operating conditions. Some of these changes are due to process forces (e.g., fluid pressures, airflow, etc.). The most notable of these changes is the change in the temperature of the machine bearings and supports. This is called the machine's thermal growth.
Ultrasound for Better Lubrication
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.
Top Ten Ways Not to be World Class at Machinery Lubrication
Begin by not reading this editorial. Most "old school" lube programs like to hold to the status quo. Editorials like this one threaten their comfort zone. After all, change takes guts . . . it takes imagination . . . it takes commitment. Who's got the time (and courage) for that?
Tips For Blower Maintenance
The article is intended to provide a few tips for blower maintenance to plant maintenance professionals in reducing the downtime and increasing the reliability of blowers. Generally the apparent reasons for blower failure are: Failure of Bearings and High Vibrations
3 Important Words for Success in Lubrication and Oil Analysis
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.
The Truth Behind Misalignment Vibration Spectra of Rotating Machinery
Misalignment is probably the most common cause of machinery malfunction. Considering the importance of alignment, the vibration spectra of alignment is not well documented. Various authors have reported different spectra. The goal of this research was to determine the unique vibration signature for misalignment at varying operating and design conditions such as speed, type and level of misalignment, coupling types and machinery dynamic stiffness.
The Hidden Cost of Oil Changes
Proper lubrication is an essential maintenance function and changing oil is one aspect of the process. Unlike changing the oil in your car based upon time or miles, oil changes for industrial equipment should be based on need where no other practical solution to restore proper lubrication is available. Too often, we schedule an oil change to rectify a contamination problem or when excessive wear is detected. In neither case is the oil change a certain correction of the root cause of the problem, and it wastes good money and further stresses the environment with hazardous waste.
The Effectiveness Equation for Infrared Predictive Maintenance Programs
To be able to truly evaluate the effectiveness of an infrared predictive maintenance program there must be an understanding of the relationship between the equipment that is to be inspected and the problems that are found and repaired. Too often the focus is on only the infrared images that the camera produces while the solutions that the data produced from the program can provide get lost. It all boils down to a simple but fundamental law that is expressed by the equation E = IR8 which focuses on measuring the effectiveness of the overall infrared program as well as on each of the individual components that contribute to its success.
The Case of Successful Filtration and Oil Analysis Implementation
Following this meeting, a professional consultant visited Schmid to determine if the right oil and lubricants were being utilized to meet maintenance goals. After much testing and analysis, the consultant determined that the oils in use were not as high quality as the company originally thought. With hard work and determined mechanics, every piece of equipment and every truck was changed over to the new brand of oil and the company seemed to have fewer lubrication related problems. Still, large amounts of money were poured into repairs and the desired results were not fully achieved.
The Basics of Lubrication PM Procedures
So, how does lubrication stack up? In this column, the first of a three-part series, I will look at the basics of lubrication preventive maintenance (PM) procedures. In Part 2, I'll talk about what I call "hybrid PMs", PMs that span multiple technologies. In Part 3, I'll discuss how you should use the information in the PM to maximum effect in the field.
Vibration Standards and Damage Factors for Machinery
The present study is aimed at establishing the vibration standards for precision machine tools. The machine tools are first segregated and then their vibration data are analyzed for determining the normal vibration level and damage factors (DF). After refining and fixing the vibration standards obtained, they can be used to assess the machinery health.
Standard Practices vs. Right Practices
Often, the perception of quality derives from the presence of a practice. The practice exists, therefore it is right. In reality, a scheduled task is often passed off as a standard regardless of rightness. This disconnect occurs because the relubrication portion of the CMMS deployment follows a troubled model. A flawed practice is coded into a program. This doesn’t make the practice functional.
Solving Electrical Problems with Thermal Imaging
Although thermal imagers may be simple to operate, they are most effective in the hands of a qualified technician who understands electrical measurement and the equipment to be inspected. For anyone using this type of imager, the following three points are especially important.
Smurfit-Stone Pursues Profitable Path with Fernandina Maintenance Program
Making money, not tons, has become the mantra of the pulp and paper industry in recent years. Consolidation moves in the sector have resulted in more effective management of inventories and supply, but the cyclical tendencies of the business remain. On top of that, the market is now a global one rather than being split up into regions. Managers today have to live up to the challenge of reducing costs to remain competitive in this global market. Mills face the real possibility of closure if manufacturing costs are no longer competitive in the global market economy. Future success will be achieved only by driving down costs and improving operating efficiencies.
Corrective Maintenance | Smart Methods in 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.
6 Easy Steps to Maintain Your Hydraulic Equipment
"What's the system's normal operating temperature? What's the system's usual operating pressure range?" If you can't answer these two basic questions about the vital signs of your hydraulic equipment I strongly recommend you make the effort to get to know your hydraulic equipment better. The information is easy to collect and can give valuable insight to the health of your hydraulic equipment.
Silent Assumptions of Bearing Reliability
There are several important silent assumptions of bearing reliability. However, before I address these assumptions, some even more basic assumptions and statements of fact must be established. While it might be a bit of a leap, I'm going to assume that the bearing is well-designed, well-manufactured, properly handled and stored, and finally, correctly selected for the intended application. With that said, we're now ready to talk about those silent assumptions that are in the maintenance function's domain.
Should Jack Screws be tight or backed off?
There has always been a debate on whether jack screws should remain tight against the side of the machine case after the machine has been moved into position or to back off the screws, so they do not touch. Should jack screws be tight or backed off? The answer is yes and no. In some situations you should leave the bolts tight against the machine and in other situations, it may be better to back off the jack screws.
Maintenance Crisis Song
The Maintenance Crisis Song written by Joel Leonard and Performed by Harley & the Hot Spots.
Shock Pulse Goes Spectrum
SPM Instrument AB, Sweden, launches a brand new diagnostic method in connection with Leonova™, a hand-held machine condition analyzer. Called the SPM Spectrum™, it is the result of an FFT on the time signal recorded with an SPM shock pulse transducer from a rolling element bearing. The individual bearing frequencies (BPI, BPO, 2*B2 and FT) and their harmonics are highlighted in the spectrum. This is displayed together with the measured shock value and a light signal, green, yellow or red that shows the result of bearing condition evaluation.
Selecting the Proper Offshore Lubricant
Choosing the right lubrication in the offshore industry is typically based on considerations such as performance and reliability, but this does not have to come at the expense of the environment. For any piece of industrial machinery to run smoothly, lubrication is a key consideration. In the offshore industry, where equipment may be stranded more than 100 miles from the shore, maximum efficiency is essential, so lubrication treatment must be carefully selected to ensure reliable performance. Where spares and replacement parts may be days away, ensuring that everything is fully functional is critical to the bottom line.
Reliability Of Critical Turbo/Compressor Equipment
A methodology is presented to evaluate and determine the necessary level of reliability for process equipment such as large centrifugal compressors and turbines in a refinery environment.
Refrigerated Air Dryers Can Be the Solution to Getting the Water and Moisture Out of your Compressed Air System
For many applications, a REFRIGERATED COMPRESSED AIR DRYER is one of your best solutions to getting the moisture out of your compressed air system. Look for these symptoms to tell when you need a Refrigerated Compressed Air Dryer...
Reducing Motor Bearing Failures: Modified Lubrication Procedures Improve Reliability at TVA
Overgreasing rolling element bearings in motors has been an industry problem for several years. More motors have bearing failures due to overgreasing than from undergreasing. For the nuclear power generation industry in particular, the Nuclear Regulatory Commission (NRC) provided guidance and direction. Their method delivered mixed performance results for the amount of resources that companies have had to devote to motor relubrication, motivating some organizations to develop additional improvements.
Protecting Mission Critical Electronics
Today's new control systems are delivering higher productivity to meet ever-increasing expectations of equipment performance. These systems typically contain more electronics, much of it adopted from non-industrial applications, and almost all of it more sensitive to electrical disturbances than the equipment being replaced. The following discussion provides information needed to develop a strategy for protecting sensitive mission critical equipment from the effects of a poor industrial power environment.
Proactive Maintenance for Hydraulic Cylinders
Damaged hydraulic cylinder rods and wiper seals are an eternal problem for users of hydraulic machinery. Dents and gouges on the surface of hydraulic cylinder rods reduce seal life and give dust and other contaminants an easy path into the hydraulic system. Many hydraulic cylinders also have bent rods, which cause distortion and ultimately premature failure of the seals.
Protection of Equipment During Storage, Standby and Decommissioning
Machinery can be idle from intermittent use, stand-by (redundancy), storage for spare parts, or for temporary decommissioning. This article looks at practices that protect equipment characterized as decommissioned, short-term storage or storage of stand-by capacity.
Practical Condition Monitoring for Preventive Maintenance
Condition monitoring (CM) is not a life-extending activity. Life-extending activities are things such as lubrication, alignment, balancing and operating procedures. It’s very important to keep this very basic fact clear in all communications within your plant; otherwise, too little importance may be placed on the planning and scheduling of corrective work orders originated in CM.
Power Transmission: Select Proper Re-Lubrication to Extend Bearing Life
Adding the correct amount of lubrication at each re-lubricating interval is essential to achieve maximum bearing life. An incorrect re-lubrication quantity, whether it's too much or too little, can actually decrease bearing life.
Power Company Foresees Failures
Predictive maintenance helps Calpine reduce forced outages and cut MRO costs. The challenge for energy producers to supply continuous, uninterrupted power to customers is constant. Forced outages, which usually occur because of unexpected component failures or systemic problems, can prove costly to the power supplier and undermine its effort to attract and maintain satisfied customers.
Power Quality Testing Can Reduce Costs
Predictive maintenance (PdM) techniques are commonly used on motors and drives. But how often is the power to the equipment inspected? Adding basic power quality measurements to equipment maintenance procedures can head off unexpected failures in both the equipment and the power system.
Outsourced Condition Monitoring Services
As part of a larger maintenance strategy, outsourcing the diagnostics and monitoring of critical machinery can be an effective tool in the battle to maximize asset availability and plant efficiency. In situations in which machine performance is critical but in-house analysis is not practical because of limited resources, outsourcing offers a cost-effective solution.
Optimizing Lube PMs
A number of common mistakes are made in selecting, scoping and carrying out lubrication PM tasks and intervals. I have outlined four common "wrongs" with respect to lube PM optimization, which can, with some effort and guidance, be turned into four "rights."
Online Condition Monitoring Reaps Benefits for Borealis
An important component of Borealis' strategy is that rather than using separate condition monitoring software for their online systems, they transmit the condition data from these systems to their DCS, allowing operators to see both asset condition information and process information within a single HMI (Human Machine Interface) environment. This eliminates the need for operators to learn an entirely different system and ensures that condition data and process data are available simultaneously on the process control system. This, in turn, helps ensure that asset condition receives as much attention as process condition.
Nine Lubrication Systems that Keep Chains Up and Running
Choosing a lubrication system to lubricate the chain can positively impact production as this process can be done while the chain is in motion. By implementing lubrication systems, additional savings can also be realized through improved worker safety and better housekeeping and or procedures.
New Generation IR Cameras
The demand for this equipment will undoubtedly continue, but many users – particularly plant engineers and the increasing number of new energy surveyors – have been calling for affordable and user-friendly cameras which previously had only been available to specialist thermoraphers due to cost and complexity of use. This market-led demand has resulted in a new generation of cameras that combine thermal imagery with digital photography.
Measure to Improve Bearing Lubrication
Rotating-element bearing manufacturers measure the reliability of their bearings using a Load-Life calculation rating, which is known as the L10 rating life. To achieve its design rating, the manufacturer assumes the bearing will be run in a clean operating environment. This takes into account providing an adequate lubricant film (adequate described as a film equal to, or greater than, the composite roughness of the two mating surfaces) of the correct viscosity for the designed maximum bearing speed and operating temperature ratings.
Management Aspects on Condition Based Maintenance: The New Opportunity for Maritime Industry
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.
Maintaining Process Control Field Devices
It is not necessary to totally restructure maintenance practices. A plant can start small and expand the use of process floor information as needs dictate and budgets allow. The key is to begin building a database from the smart devices now in operation and expand the use of the available information as the number of such devices grows. A scalable and expandable platform can grow into a plantwide system that supports the reliability and maintainability of all field instrumentation.
LubeRight: A New Tracking System for Manual Greasing
ASSALUB has introduced a new technology to help track manual greasing. This technology can help improve your lubrication program and ensure the practices you aim to implement are being completed. The LubeRight is a computer aided manual greasing system that offers the following advantages when compared to traditional manual greasing.
Longer Lasting Lubricants for The Aluminum Industry
This project, like so many others, had a humble beginning. About five years ago, after returning from a routine sales call to the smelter where a representative was selling synthetic and specialty greases, he challenged the authors to develop a series of lubricants that he could sell to the aluminum industry. In a discussion with a group of maintenance people at the smelter, he was told that if his company could develop longer lasting lubricants and protect equipment better than the current product, they would buy from him.
Keeping Things Moving… Capture Problems Faster With High-Speed Video Technology
Industrial Video Solutions (IVS) supplies high-speed digital video technologies to packaging, manufacturing and paper industries around the world. These systems combine the latest in GigE technology, digital video developments, efficient lighting and an intuitive, feature-rich user interface. The goal: keep that product moving!
Is Air a Contaminant?
When we think of contamination in lubricated systems, we often focus on particle and water contamination. The fact of the matter is that there are many other contaminants we should consider and attempt to control. Most contaminants, which include any material not contained in the lubricant's formulation, can potentially damage the oil and the lubricated components. Although air is always present in lubricating oil, it is often justifiable to adopt measures to minimize its presence.
Integrating Vibration and Wear Debris Analysis for Machine Condition Monitoring
Vibration and wear debris analyses are two key components of any successful condition-monitoring program and can be used as both predictive and proactive tools to identify active machine wear and diagnose faults occurring inside machinery. Integrating these two techniques in a machine condition-monitoring program provides greater and more reliable information, bringing significant cost benefits to industry.
Inspecting Seals with IR Thermography
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-Process Motor Testing Results Using Model Based Fault Detection Approach
Rapid progress in process automation and tightening quality standards result in a growing demand being placed on fault detection and diagnostics (FDD) methods to provide both speed and reliability of motor quality testing. This paper presents the findings of a decade long research and development efforts in the field of experimental modeling technique and its practical applications for the fault detection purposes, first in the fields of aerospace and defense, and now in the context of highvolume electric motor manufacturing. Underlying this patented technology is a set of proprietary algorithms that enable precise tracking of the parameters pertaining to the physical structure of the motor.
Infrared Thermography and Distribution System Maintenance
Infrared thermography is the science of seeing heat. Thermal imagers
have the ability to produce a visual representation of thermal patterns as heating systems’ components are identified and recorded. Maintenance strategies are then planned and carried out before system breakdowns occur.
Infrared Thermography
For a program to be effective it must be accepted by management as well as other maintenance personnel. Getting other maintenance people involved in Infrared Thermography is a good way of gaining acceptance not to mention the fact that, more people scanning equipment will find more problems, more quickly, resulting in payback more quickly for the plant. This paper discusses the approach which I am implementing with varying degrees of success at my client's plant sites and which could be implemented in plants with existing IR imagers.
Improving Rolling Mill Lube Oil Performance and Useful Life
The combination of high 'emulsified' water and high particulate levels create a perfect storm for bearing failure and reduced oil life! This article describes methods to improve lube oil performance.
Implementing an IR Thermography Maintenance Program
If thermography is new in your plant, the first few inspection cycles may yield a large number of finds. Subsequent inspections should go more smoothly. After about three cycles, reorganize the routes so they are more efficient, and add new routes and equipment into the inspection cycle as necessary. The optimum frequency of inspection will be determined by the needs of the equipment assets. As they age, are heavily loaded or are poorly maintained, inspections may become more frequent.
How Unbalance Affects Bearing Life
Mass unbalance in a rotating system often produces excessive synchronous forces that reduce the life span of various mechanical elements. Unbalance is basically very simple case caused by an asymmetry in the rotating element that results in an offset between the shaft centerline and center of mass. Asymmetry can be an off-center weight distribution, or it can be a thermal mechanism that produces uneven heating and bowing of the rotor, or it can be an electrical effect that produces uneven magnetic field.
How to Use Condition Monitoring to Optimize Grease Lubrication
There are four primary components to precision grease lubrication for bearings: lubricant selection, application method, the volume of lubricant to be delivered, and the frequency with which it is applied. There are, of course, many different methods for specifying these values, and opinions can vary significantly as to which approach is best. Due to the variability of operating conditions and machine design, it can be very difficult to be truly precise without introducing the "condition-based" component to the formula.
How to Read an Oil Can Label
Just like nutrition facts printed on the label of every item in a grocery store, the symbols on an oil can label tell consumers the service rating and certification for that product. In the United States, the American Petroleum Institute (API) administers the licensing and certification of engine oils through a system that meets the warranty, maintenance and lubrication requirements of original equipment manufacturers. OEMs, oil marketers, additive companies and testing laboratories work together to establish engine oil performance requirements, test methods and limits for the various classifications and testing processes.
How The Eyes (and IR camera) Can Be Misled
The IR camera is a great tool used in our everyday predictive maintenance endeavors, but it can play tricks on our eyes if we do not investigate beyond what we are observing. Things truly are not always as they seem, here's an example:
How Effective is Your Lubrication Program?
The path to lubrication excellence can be difficult to navigate. It begins when individuals and organizations become aware of the importance of their lubrication program, its impact on productivity and its direct effect on the bottom line. Once this enlightenment has occurred, comprehensive training in best practices is acquired and the organization can consider what the lubrication program should be and where they wish to take it.
Ultrasonic Testing: Heeding the Screams of Sick Machines
Before bearings, valves and other mechanical parts fail, they usually scream for help. But their piercing wails usually fall on deaf ears because the sound frequencies are far too high for humans to hear. No wonder deteriorating components may go undetected until they break down completely. Now, however, a variety of tools using ultrasonic technology—ultrasound, as it is commonly known—are helping companies in a wide range of industries avoid wasteful replacements or costly breakdowns.
Handling, Storing and Dispensing Lubricants
This article provides 6 tips for lubricants concerning how they're handled, stored, and dispensed in facilities.
Greasing Bearings: It's a Whole New Ball Game
Manually greasing a bearing is another act that, at least on the surface, appears to be purely physical. One grabs the grease gun, pumps it full of grease or installs a cartridge, goes to the machine, attaches the gun to the grease fitting and pumps the lever to deliver grease - right? Regrettably, this is too often the case. When the act of greasing a bearing is viewed as a purely physical task, the plant has little chance of developing a world-class machinery lubrication program that delivers machine reliability, profits and competitive advantage.
Fast, Reliable Measurements Give Us An Effective Way of Planning Preventive Maintenance In Advance
"This equipment has given us completely new opportunities to plan maintenance activities in advance. This has meant that we've been able to minimize the number of breakdowns, thus increasing our profits." A look in the rear-view mirror tells us that before 1993, the mill suffered three or four breakdowns, caused by stock damage, every year. After installation of the SPM system, breakdowns have been very rare, which has made it possible to avoid production losses worth millions.
Everyone Needs a Playbook of Lube Procedures
I routinely ask my consulting clients and seminar students if they have lube procedures, and they sheepishly admit that they don't. They often look embarrassed to have to admit it, but I believe these folks represent the cream of the crop. If they are attending classes on lubrication, or are having their program audited, they must have good intentions.
Energy Waste You Didn't Know About...Do You Care?
How much energy waste is out there? Plenty. Professors Leon and Montañana carried out multiple field studies to confirm their hypotheses about the link between power-quality issues and the effect on energy waste.
Dynamic Movement White Paper
Regardless of the approach taken to measure true dynamic movement, coupled machines need to be set to cold alignment targets that will reflect the actual changes in the shaft alignment. This will lead to lower vibration levels, increased Mean Time Between Failures, decreased maintenance expenditures and increases in production. Much like the philosophical change from aligning shafts with dial indicators to aligning shafts with laser based systems, these types of measurements will take some time to be generally accepted and routinely practiced.
Documentation Tip – Document “As Found” Condition
Accept that you will sometimes be wrong and do whatever it takes to find out the “as found” condition. This is often difficult to accomplish but it is well worth the effort and in the best circumstances this should be implemented as a normal procedure.
Developing and Implementing an Infrared Predictive Maintenance Program
Westar is currently evaluating the implementation of a new database and route collection system. This new component to the infrared program will allow for Web-based tracking and trending of all infrared projects and will greatly enhance the efficiency of our program. It will also allow for simultaneous imbedding, reporting, tracking, and trending of the ultrasonic technology being brought into the thermography program.
Data Analysis Tip 3 – Compare Identical Machines
When troubleshooting or using vibration in a Predictive Maintenance program comparing identical machines to each other is often the best method to diagnose a problem – especially if you suspect a problem exists in one or more of the machines. When vibration data is collected on a bearing housing using an accelerometer, one is not only measuring vibration forces, but also the effect of the structure on these forces.
Data Analysis Tip 2 – Create a Vibration Test and Analysis Guide
A vibration test and analysis guide is a simple book or electronic document that contains a variety of information about the machine. Information should include: A simple schematic of the machine with test points identified, instructions for testing the machine (especially if loads and speeds must be manipulated or verified), name plate information and a simple schematic of internal components. This information is invaluable for conducting a proper diagnosis of the machine.
Data Analysis Tip 1 – Consider the Machine First and Then the Graphs
A common approach to looking at vibration spectra is to display the graphs and then ask “What is wrong with this machine?” Another common approach to analyzing vibration spectra is to display the graphs and then ask “What is this peak?” and “what is that peak” A better approach to analyzing data is to first ask “What faults can this machine have?”, “Which of these are most common for this machine?” and finally...
Electrical Corona & Testing
What is electrical corona? Corona is the ionization of the nitrogen in the air, caused by an intense electrical field. Electrical corona can be distinguished from arcing in that corona starts and stops at essentially the same voltage and is invisible during the day and requires darkness to see at night. Arcing starts at a voltage and stops at a voltage about 50% lower and is visible to the naked eye day or night if the gap is large enough (about 5/8" at 3500 volts).
Condition Monitoring of Steam Turbines by Performance Analysis
Many power generation steam turbine generators today are required in service well beyond their intended lifetimes. Dismantling for inspection is expensive, and owners need to consider all relevant information in making the decision. Application of condition monitoring in all the applicable methods is justified, with each showing different degradation modes. Performance analysis is less well publicised, yet unlike vibration analysis and oil debris analysis, it will show conditions which reduce machine efficiency and output, such as deposits on blades and erosion of internal clearances. The paper outlines, with examples, some condition monitoring techniques that have contributed to retaining some large fossil machines in service for up to 17 years without opening high-pressure sections.
Hydraulic Cylinder Failure Caused by the Diesel Effect
I was recently engaged by a client to conduct failure analysis on a large (and expensive) hydraulic cylinder off an excavator. This hydraulic cylinder had been changed-out due to leaking rod seals after achieving only half of its expected service life. Inspection revealed that apart from the rod seals, which had failed as a result of the 'diesel effect', the other parts of the hydraulic cylinder were in serviceable condition.
Hydraulic System Troubleshooting - Check the Easy Things First
In Part II of Insider Secrets to Hydraulics, I outline a logical approach to hydraulic system troubleshooting that begins with checking and eliminating the easy things first. The benefits of this approach are clearly illustrated by a troubleshooting situation I was involved in recently.
Implement a Cost Effective Root Cause Problem Elimination (RCPE) Process
The business process is most commonly named Root Cause Failure Analysis (RCFA) or root cause analysis. The name itself implies the largest and most expensive problem when implementing problem solving in an organization. The results wanted from the process are to eliminate the problem, not to analyze the failure. To convey the desired result to the organization, the name should therefore be changed to Root Cause Problem Elimination (RCPE).
Keeping Up to Date - Human Behavior Analysis Without a PhD
Savvy professionals in safety, quality, maintenance and reliability have long recognized that human performance analysis could be a bonanza for opportunities to improve and control operations. This article describes and explains a new approach to human factor analysis, an approach that provides a repeatable process and a practical methodology that can be used immediately by working professionals to deal with unwanted human behavior in the workplace.
Problem Analysis to Manage and Enhance Customer-Supplier Relationships
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.
Productivity Improvement Through Operational Reliability and Knowledge Workers
This paper presents a case study in a process industry that illustrates how industrial productivity may be increased and business objectives achieved by application of a process termed as REU (Reliability of Equipment Usage). REU basically concentrates on the process of improving operational reliability through knowledge workers. Operational reliability may encompass problems in equipment, process, system, spare parts, cost, purchase, material stocking and a host of other problems connected to business effectiveness. The process is briefly described. The results and benefits of such improvements are highlighted.
RCFA of Bearing Failure
When a bearing in a critical piece of equipment fails prematurely, a maintenance specialist knows the failure usually indicates there is more here than meets the eye. What the untutored eye sees is a failed bearing and little more. However, a premature bearing failure is symptomatic of other problems that, if left untreated, will cause the same kind of failure to occur again.
Condition Monitoring based on Acoustic Emission
For Condition Monitoring (CM) purposes a range of technologies are available, each having its own strengths and weaknesses, and it is usual to consider each of them as a tool in the CM toolkit. The Acoustic Emission (AE) technique has a 40 year history of use for machinery condition monitoring and although it got off to a slow start, in recent years it has gained very widespread acceptance across industry.
Condition Monitoring at Norske Skog
The first instruments for Condition Monitoring at Norske Skogn were purchased in 1971. Today we are using instrumentation of the 8th generation. We can see that each generation has given us an opportunity to improve the reliability of the CM program.
Coal Plant O & M: Condition Monitoring Cuts Mirant Mid-Atlantic’s Costs
Mirant Mid-Atlantic’s condition-monitoring team consists of a central group of four technicians and one team leader. The team’s primary responsibilities are the company’s four coal-fired power plants; as resources and priorities permit, the team also provides support to other assets.
Clean Oil Reduces Engine Fuel Consumption
The more I delve into this subject, the more I discover the pronounced impact lubrication has on energy and the environment. A case in point is the impact of clean oil on fuel consumption and emission in engines. There are many ways that a lubricant could fail to deliver fuel-efficient engine performance. Many of these are due to formulation issues as opposed to transient properties of the lubricant in service.
Change Your Lubrication Culture, Not Your Oil
We change a lot of oil in our plants, mills, mines and factories. What are we doing to change our lubrication culture? In their book Learning to Fly, Collison and Parcell, employees of British Petroleum (BP), suggest a predictable pattern in achieving sustained culture change, which is a function of effort and time.
Certification of Vibration Analysts in a Dynamic Job Market
There is still some controversy regarding the various certification levels, test questions and test procedures. These problems will hopefully be worked out in the future. However, despite these issues, certification is probably the glue that will be required to bind and network this group of analysts together in today’s dynamic job market.
How to Achieve Results Using Infrared Technology
As with many condition monitoring techniques, infrared thermography is a skilled art form that requires technician and engineeers to be educated in infrared physics, have a thorough understanding of applications and be able to develop their knowledge with continual field experience.
Beyond the Usual Applications for Infrared Thermography
There are many uses for infrared thermography other than inspecting electrical switchgear and mechanical components. Inspecting buildings for heat loss was one of the first commercial uses for infrared thermography.
Better Mixer Maintenance Ensures Cleaner Effluent at Smurfit-Stone
A preventive maintenance program adopted at the mill has clearly improved the reliability of 16 raft-mounted mixers that help stimulate the biological treatment process removing organic solids from process effluent. The proactive approach to maintaining the mixers, utilizing factory-authorized service, has corrected problems with the previously rebuilt units and delivered significant savings to the mill.
Bearing Failures Dry Up at Weyerhaeuser
Like all industry these days, the economics of running a plant requires a keen eye on operating costs. In an effort to increase uptime and reduce maintenance costs, the mechanical maintenance team at the Valiant plant undertook a program to reduce dryer bearing failures with lubrication management, which included aggressive contamination control and oil analysis.
Ball Bearing Lubrication in Centrifugal Pumps
The manufacturer using the bearing in his equipment, not the ball bearing manufacturer, determines the anticipated life of a ball bearing. This life, once determined, is called the L10 life of the bearing and it is based on the premise that 90% of the bearings will last a certain amount of revolutions before they experience metal fatigue.
Automated Bearing Wear Detection
The following paper will describe a methodology for automatically detecting and diagnosing rolling element bearing wear. The techniques involved have been proven in over 15 years of use in a huge variety of environments, machine types and applications. The techniques involved in diagnosing bearing wear will be described in detail and supported by a set of example graphs and an annotated diagnostic report.
Analyzing Mechanical Systems Using Infrared Thermal Imaging
Infrared Thermal Imaging is an excellent condition monitoring tool to assist in the reduction of maintenance costs on mechanical equipment. The technique allows for the monitoring of temperatures and thermal patterns while the equipment is online and running under full load. Most mechanical equipment has allowable operating temperature limits that can be used as guidelines. Unlike many other test methods, Infrared Thermal Imaging can be used on a wide variety of equipment including pumps, motors, bearings, pulleys, fans, drives, conveyors etc.
Machine Alignment: Alignment Pitfalls - How to Identify and Eliminate Them
In theory, machine alignment is a straightforward process, but in real world applications, it is often compounded by structural faults such as ‘soft foot’, piping strain, induced frame distortion, excessive bearing clearance or shaft rubs. These pitfalls can turn a simple job into an all day affair - frequently with unsatisfactory results despite a conscientious effort and a considerable investment in manpower and downtime. This paper will examine how to eliminate some of the typical reasons why alignments are unsuccessful.
Motor Condition Monitor and its Applications in Foundry Industry
Motor Condition Monitor has many successful applications in different areas of industry. In this section, three applications of MCM in foundry industry will be presented.
Adjusting Packed Centrifugal Pumps with Open Impellers
Open impellers are frequently used in centrifugal pumps which pump liquids that contain suspended solid materials (slurries, paper stock, etc). They do not plug as easily as closed impellers and usually have a simple external adjustment to maintain the correct impeller clearance as internal parts wear.
A Team Approach to World Class Lubrication at Eli Lilly
There are different thoughts of what constitutes a "world class lubrication program." It is our belief that a world class lubrication program consists of researching, documenting and implementing the best lubrication practices and regulatory requirements as defined by the leaders in the lubrication and reliability industry (Noria, SMRP, ICML, etc.) as well as regulatory agencies (OSHA, EPA). We have determined that for most programs, best practices can be summarized into the following categories:
Magnetic Plug Inspection Enhances Condition-Based Maintenance
While off-line filtering and particle analysis were key to Smoky Canyon Mine’s reliability improvements, the mine’s reliability team found that these techniques did not do enough to warn about catastrophic failures in the mine’s fleet of 785 Caterpillar haul trucks. Therefore, the team decided to include magnetic plug inspections in the 500-hour interval inspections. Smoky Canyon Mine’s magnetic plug inspections have raised its reliability maintenance program beyond contamination control to the next level.
Leaders in Maintenance: Parts 1 - 4
I previously explained the system and procedures that need to be set up in order to make people do what you want them to do. Since people can’t be more effective than the system in which they work, you have to start by building a system and procedures. However, if you as maintenance leaders are going to get people to do what you want them to do, you are going to have to use diplomacy and psychology.
Visible and Invisible Maintenance Cost Savings
The fix to the problem will take time, because it includes a cultural change. “Right now we have to save what we can in the short term so we do not have time to deal with this now, and on top of that it will cost money to improve our work system” is a common saying in this organization. The time and cost to improve is visible cost, the existing waste is embedded in the work system and invisible.
Can Maintenance and Operations Coexist? A Radical Process Change Story
One of the major European postal services decided in the late 1990s to make a change in their plant maintenance organization. In my own U.S. Postal Service, there had been talk for years of combining the operations and maintenance supervision and reducing the supervisory ranks. It is easy to say, but how do you do it? Be careful of what you wish for!
Contractor Management Controls
Circular logic is how many large, otherwise sophisticated manufacturing plants manage financial accountability over their industrial contractors. They create a PO, send it to the contractor, the contract performs the work, keeps track of expenses, and then submits an invoice. The planning and scheduling and execution of the works are excellent, but the financial control needs upgrading.
Effective Benchmarking in Pursuit of Better Maintenance Operations
Determine which functions hold the greatest opportunity for improving your maintenance operations, and look around for companies that show excellence in each target function. Summarized below are four of the more common functions that are of interest to modern maintenance operations, as well as sample target industries for benchmarking.
Energy Optimization
Using many of its own products and solutions, Schneider Electric was able to realize an energy savings from 2005 through August 2008 that totaled more than $5.1 million. In addition, the company’s goal of reducing energy consumption per employee by ten percent by 2008 was met two years ahead of schedule.
Focus On Results and Change the Culture Along the Way
The "breakthrough strategy" really works. Equipment becomes more reliable, costs go down, and behaviors change along the way. The key is focusing on results-the kind of results that will get people's attention on the plant floor as well as in the key decision makers' offices. Select the equipment that, if it ran better and was more reliable, would generate sizeable savings. But more importantly, choose equipment that would generate more throughput and revenue.
Four on the Floor: Training Strategies - Many Paths, One Goal
All Maintenance Technology Reader Panelists agree that training is important. The need for it is ongoing, and it is a part of routine strategy for most operations. Today, its value is heightened as manufacturing operations face growing departures of experienced workers.
Get Where You Want to Go: Operator Driven Reliability
For decades, maintenance professionals have advocated and used information management systems, planned maintenance activities, emphasized preventive maintenance and assessed equipment utilization to eliminate non-essential assets (reducing numbers of equipment). These professionals also have been aware of the need for operator and mechanic training and, to some extent, decentralizing asset responsibility. Accordingly, they have been striving to build operator-ownership of equipment through basic care.
Go Execute the Continuous Improvement Plan!
So you have a plan, now what? It is now time to execute. Hopefully, you are using some great CI methodologies founded in Six Sigma and the Toyota Production System. Each of the items on your plan may need some additional analysis to see exactly what is involved in the improvement of those items.
How to Make TPM Everyone's Priority
I am from an automotive parts supplier in mid-western United States. Implementing TPM in a company is not easy. The philosophies of TPM are not that difficult to understand but are a some what difficult task to implement.
Is Your Plant Organization Ship Shape?
Over the years, I probably asked this of several hundred employees, and many of the answers related to the interaction of management within the plant. They wanted the magic fix to be management that worked together, shift changes that were transparent, maintenance to work with operations, supervisors to be knowledgeable about expectations, and to feel part of the team. In essence, they wanted to perform like the USS Lincoln.
Kinda, Sorta Lean…So What Comes Next?
After a couple of decades of testing, Lean business practices are now widely accepted as a major contributor to extraordinary customer service and profitable operations. But with this acceptance has come a new leveling of the playing field in many industries. The preemptive competitive advantages enjoyed by early Lean adopters have dissipated as more and more companies are “converted” to techniques that reduce waste and slash lead times. We have also come to the realization that only the most effective operations can position a company to compete with competitors who source off shore to suppliers in low cost labor markets.
Manufacturing Operations Management: How Processors can take a New Approach to Raw Material Price Inflation
Manufacturers in process industries are no strangers to raw material price volatility. Historically, price fluctuations of 15 to 20 percent have been common and threatened only the weakest companies. But when prices surge by 100 to 200 percent over the course of 12 to 24 months, the rules of the game change. And when those increases become systemic—not just cyclical—they threaten the viability of all processors– large and small. And that’s exactly where the industry finds itself today.
MRC Bearings' TPM Journey: From Totally Painted Machines to Taking Pride in Our Machines
Thinking back about the initial resistance to TPM, Don Russell laughs and says, "At first a lot of folks here defined TPM as 'Totally Painted Machines'. Now I can say we all define TPM as 'Taking Pride in our Machines'."
Mentoring
A mentor can assume many different roles including teacher, motivator, advisor, coach, door-opener. A good mentor has some traits that are conducive to their role. They are supportive, patient, secure in their position and achievers. They tend to be accepting of others, even their shortcomings. Mentors require the ability to listen and possess questioning skills and a passion for their work and industry. They provide constructive and positive feedback and are able to plan and make decisions.
Operations and Maintenance = Production - Parts 1 through 5
From my experience, it is more common than not to find that the working relationship between operations and maintenance is one of adversity instead of a relationship of close and productive cooperation. Operations often sees itself as the customer of maintenance, and, consequently, maintenance is viewed as a service provider. In such a relationship, it should be obvious that operations is responsible for the cost of the maintenance work it requests and gets delivered. However, in a bad relationship, this is not the case.
Operator Driven Reliability — Who Owns Your Mill’s Equipment?
Over the years, our quest for lower production costs through technology has drastically changed the role the operator in our mills. Once an operator spent the majority of his day “on the floor.” This provided a hands-on knowledge of how equipment worked and what are the signs of it starting to fail. In today’s world, most operators are running the mill via computer-controlled systems.
Process Improvements: Cutting Costs with OEM Parts
There’s lots more than purchase price to consider when replacing pump parts. Can your operations afford the risk of simply buying on the cheap?
Repowering or Replacement: What Is the Solution?
In addition to an increase in greenfield plants, Stone & Webster Management Consultants Inc. (Stone & Webster Consultants) has seen increased interest in solid fuel repowering of existing oil- and gas-fired boilers. The primary reason for this interest is that repowering an existing gas- and/or oil-fired power plant with solid fuel boilers potentially has a lower capital cost and lower development risk than developing a new greenfield solid fuel – fired power plant.
Reliability Business Case: Conversion Costs
A reliability effort does contribute to an increase in the return on assets. The most direct and easy-to-understand impact resides in the expenses section of the income statement. There, it is apparent that the greatest part of the reliability financial benefit lies in the operators home, reassign them to do something else or make conversion costs reduction.
Resistance to Change: Meet the ´Tators´
I've been fortunate in that I've been able to benchmark M&R improvement processes within and outside Cargill for the past decade. These visits have included trips all over the world. In a recent trip to one of our factories in Pennsylvania, I was introduced to a family of cultural change resistors that I'd like to share with you.
The Bad News Has Arrived: Your Plant is Undergoing Severe Curtailment/Closure
It’s happened … the announcement that a major portion of your facility is being closed for the foreseeable future. What do you do next?
The Fuzzy Side of Equipment Reliability
In nearly all of the 250 or so equipment intensive plants and facilities I have visited, taught at, and worked in over the past 30 years, I have observed the relationships between the skills of employees and the reliability of the equipment. These observations may provide helpful insights for plant and facility managers who are troubled with unreliable equipment and high maintenance costs. Here are a few:
Skills Shortage: The Perfect Storm Intensifies
Some of the characteristics that made us a strongly competitive and productive nation are in serious need of repair. Moreover, what is going largely unnoticed is that the maintenance skills shortage— which, very recently, was just a forecast of a perfect storm—has come down on us with a vengeance. Are you ready?
The Pitfalls of Planning and Scheduling
World-class organizations would not—could not—succeed without implementing an efficient and effective planning and scheduling process. It’s one of those cornerstone processes that can transform your organization into “Best-in-Class.” Here are some of the pitfalls regarding the deployment of Planners/Schedulers (Planners) that can keep you from getting where you want to be.
The Power of Single Minute Exchange of Dies (SMED)
There is an ongoing debate on the Superfactory web forum concerning SMED (Single Minute Exchange of Dies) as developed by Shigeo Shingo, and in particular about Shingo’s influence on Toyota. As someone who had the privilege of meeting Shingo a few times before his death in 1991 and who has taught Single Minute Exchange of Dies for 15 years, I would like to give my view on the importance of the SMED process.
TPM Concept and Implementation Approach
Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. This paper will define TPM history, benefits, strengths as a maintenance philosophy, its implementation approach, difficulties in its implementation and cost of implementing TPM. TPM is to Maintenance as Total Quality is to Production The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.
Writing a Set of Seal Specifications
It is extremely important for any modern process company to have a good set of seal specifications. When written properly the seal specifications will classify seals by operation condition.
7 Costly Causes of Nozzle Wear
Maybe you’re thinking to yourself that the waste and inefficiency caused by using worn spray nozzles just can’t be all that significant. If so, it’s time to change your thinking and determine if nozzle wear is a problem in your operations. Like many other processors, you may discover that you are wasting millions of gallons of water, thousands of gallons of chemicals and incurring many other unnecessary costs due to using worn nozzles.
Adhesives Assure Fastener Reliability
Threaded fasteners set and hold tolerances on assemblies ranging from light-duty equipment to heavy machinery. Loosening is one of the major causes of industrial equipment failure, and results in millions of dollars worth of unscheduled downtime costs each year. In many cases, fasteners that self-loosen during equipment operation may contribute to wear and fatigue, and result in poor operating tolerances, misalignment and even catastrophic equipment failure. Various types of differential stresses such as vibration and shock, thermal expansion and contraction, and micro-movement reduce clamping force on the assembly and ultimately cause failure.
API Plans that I Use. 15-05
The American Petroleum Institute (API) issues guide lines to help petroleum people select and then pipe various types of controls for mechanical sealing applications. These piping arrangements are described in a series of plans issued by the API. Although 17 plans are described, only a few are really needed. Any time you have 17 choices there is bound to be some confusion. In the following paragraphs I will describe those API plans that I use on a regular basis, where I use these plans and, in the process, hopefully simplify your selection decisions.
Bearings for High Temperatures
When rolling element or sleeve bearings operate under extreme conditions, it’s more important than ever to follow proper lubrication selection and maintenance procedures to maximize effective life and efficient performance. Long-term analysis of field data shows that the lack of proper lubrication is the most commonly cited cause of bearing failure and accounts for over 40 percent of breakdowns. Bearings for high temperatures must be properly maintained and lubricated to withstand high heat.
Bearing Repair: An Alternative to Replacement
Bearing repair is not a new concept, nor has it changed a great deal over the years — and that's good news. Repairing damaged bearings is a precise science that has been fine-tuned over time through careful and gradual enhancements to provide superior results.
Basis for Bearing Life Calculation
Bearing life is defined as the length of time, or the number of revolutions, until a fatigue spall of a specific size develops. This spall size, regardless of the size of the bearing, is defined by an area of 0.01 inch2 (6 mm2). This life depends on many different factors such as loading, speed, lubrication, fitting, setting, operating temperature, contamination, maintenance, plus many other environmental factors. Due to all these factors, the life of an individual bearing is impossible to predict precisely.
Cavitation
Cavitation means that cavities are forming in the liquid that we are pumping. When these cavities form at the suction of the pump several things happen all at once. The cavities form for five basic reasons and it is common practice to lump all of them into the general classification of cavitation. This is an error because we will learn that to correct each of these conditions we must understand why they occur and how to fix them.
Creating Reliable Electrical Connections
One of the important ingredients for making and keeping a reliable electrical connection is clean contact surfaces. When initial contact is made between electrical contact surfaces, no matter how smooth and level the surfaces, only a few high points touch. As the contact force increases, more points make contact until at optimum force most of the metal-to-metal contact has been accomplished. Contact theory tells us that these points are actually cold welds.
Comparing the Value of Single- and Double-Layer Insulation on Boiler Walls
My interest in writing this article was to explore one way to reduce the cost of manufacturing and installing new boilers: improved insulation practices within the boiler island. It is my opinion that the power industry requires a smarter and more economical insulation design on steam-generating boiler walls, especially when considering the rising cost and reduced availability of qualified field labor. Yes, the potential cost savings with improved insulation practices is small compared to the total plant cost, but every dollar saved is important.
DC Motor Brush Holder and the Performance of Carbon Brushes
A DC Motor carbon brush is an electrical contact which makes a connection with a moving surface. Optimal performance on motors, generators and other types of moving contact applications will be attained only when the carbon brush, the brushholder and the contact surface are properly designed and maintained. All three components are critical factors in a complex electro-mechanical system.
DC Motor Carbon Brushes for Elevators: Composition, Function, Solutions
The motor carbon brush has been a critical component in variable speed rotating equipment for over 100 years. The trend towards reduced maintenance has resulted in the elimination of many well established procedures related to carbon brushes. Today new technology is attempting to replace this component and permanently eliminate these maintenance costs. However, when subjected to the proper operating conditions carbon brushes do yield excellent life and perform an amazing function.
Double the Drive Life at One-Third of the Cost
Many drive systems go to an early grave after only about 10 years of operation. Reconditioning an existing drive system could enable it to operate reliably for another decade and can be achieved for just 30-40% of the cost of a new drive system. Peter Wright, Drives Products Service Manager for ABB in the UK explains how.
Drying Your Compressed Air System Will Save Real Money
The cost of replacement parts, labor, standby inventory, and downtime can have a devastating effect on a plant's bottom line. Eliminating even one of them by drying a compressed air system will offset the cost of installing and operating the equipment. When pneumatic components wear or become corroded as a result of moisture, they consume more compressed air - and lose energy efficiency. When this wear or corrosion becomes great enough, components must be repaired or replaced - increasing operating expense.
Effects of Aeration on Industrial Lubrication Equipment
Air can also be temporarily entrained into oil through bearing agitation. This can occur in healthy oil, but is more common in oil containing high amounts of moisture, as well as oil having other forms of contaminants. Air entrained in oil sumps of rotating equipment tends to rise out and re-enter the headspace over time. Read to learn some of the potential effects of air entrainment.
Energy and Life Cycle Cost Savings in Pumping Systems
In this paper the authors examine opportunities for energy savings at water treatment facilities in North America and how energy savings can be achieved. The authors discuss specific approaches, such as using variable speed drives and high efficiency motors as primary sources to realize increased payback of original equipment cost. In addition, this paper explored life cycle costing as a method to justify investment in equipment upgrades, moving beyond just simple payback periods. The authors use existing treatment facilities for reference throughout the paper.
Eliminate Belt Drive Problems
Use the proper tools and a good pair of eyes to eliminate almost all your belt drive problems. Did you know that premature belt drive failures can be attributed to just a half-dozen commonly encountered problems? Or that all it takes to solve these problems is just a few tools and using your head? Other than normal wear and use, the most common sources of belt drive failures are 1) improper tension, 2) misalignment, 3) handling, 4) hardware, 5) environmental factors, and 6) design factors.
Examining an Oil Purification System
This article presents, in layman's terms, information regarding a high-speed electrostatic kidney-loop system, designed to remove submicron particles and other foreign matter (varnish) from lubricating fluids. It is a culmination of more than 30 years of research and development, on-site beta testing, and trial and error, and it has resulted in seven electrostatic filter patents which significantly aid in the process of oil purification.
Extending Pump Motor Life in Liquid Level Applications
Many process systems operate by the storage, transfer, metering, and disposal of liquid materials. The pumps that move the liquid materials represent a point where maintenance failure can halt all other processes. Extending the service life of these critical process components can significantly reduce process as well as maintenance costs.
Gear Pump Operation and Maintenance
Gear pumps use toothed gears turning inside a close tolerance housing to draw-in liquid and then squeezing it out ahead of them. Paddle steamers used the same principle of operation. These pumps are positive displacement pumps and anything drawn into them will be forced out. As a consequence they can generate very high discharge pressures. Materials of construction vary from metals of various types and hardness through to plastics of various types and hardness.
Growing Reliability Down on the Wind Farm
When equipment fails, wind farms must deal with exorbitant crane mobilization expenses, lost energy production, soaring costs per kilowatt-hour and untimely delays in obtaining replacement parts in a burgeoning industry where the demand for necessary components routinely outstrips supply.
How Can I Extend the Performance Range of Standard Cartridge Mechanical Seals?
In today's global environment, the "one size fits all" approach is used for so many products that we expect it to apply to just about everything. In the mechanical seal industry, one problem with that philosophy is the definition of the word all. Mechanical seals must live in literally every environment under the sun-from extreme hot to extreme cold, wet to dry, solid to gas, acidic to caustic and so on. Until relatively recently, a vast variety of cartridge mechanical seals were needed to accommodate these pump applications.
How the Carbon/Graphite Seal Face is Manufactured and Where Carbon/Graphite Cannot be Used
Seal companies purchase carbon/graphite seal faces from one of several carbon manufacturers. The seal companies pay for the necessary molds and then retain the exclusive use of them. A good seal face would be a mixture of carbon, graphite and nothing else. The carbon is purchased as a byproduct of a manufacturing process while the graphite is mined with the main sources being in Canada and Madagascar.
How to Get the Best from Expansion Joints
Expansion joints for pipework are often made from corrugated metal, especially when handling liquids or for operating pressures significantly above atmospheric. Metal expansion joints are outside the scope of the ESA guide.
How Water Causes Bearing Failure
Most of us who have spent time in the lubrication field have been told that it takes only a small amount of water (less than 500 ppm) to substantially shorten the service life of rolling element bearings. There is indeed a vast amount of research that supports these assertions. Being a career-long crusader of clean and dry oil, I will certainly not argue the contrary. In fact, water's destructive effects on bearings can easily reach or exceed that of particle contamination, depending on the conditions. Water can even cause bearing failure.
Huge Cost Avoidance Using Oil Analysis at LTV Steel
SES Technical takes a "hands on" approach to all disciplines of predictive maintenance. The same Field Engineer who collects the data performs vibration, infrared, and ultrasonic analysis. This allows the engineers to develop an understanding of the equipment and develop a familiarity with its maintenance history. SES has also applied this principal to oil analysis.
HVAC Attack - How to Select the Right HVAC Filter for the Job
Good indoor air quality (IAQ) depends on a number of factors, including effective filtration, which provides the primary defense for building occupants and HVAC (Heating, Ventilating and Air Conditioning) equipment against particular pollutants. Today's higher standards in filtration, coupled with rigorous attention paid to HVAC filter selection, helps to produce cleaner, purer air and reduce IAQ-related problems.
Hydraulic Filters that Do More Harm than Good
Given that particle contamination of hydraulic fluid reduces the service life of hydraulic components, it would seem logical that a system can never have too many hydraulic filters. Well... not exactly. Some hydraulic filters can actually do more harm than good and therefore their inclusion in a hydraulic system is sometimes misguided.
Hydraulic Pump Life Cut Short by Particle Contamination
Contaminants of hydraulic fluid include solid particles, air, water or any other matter that impairs the function of the fluid. Particle contamination accelerates the wear of hydraulic components. The rate at which damage occurs is dependent on the internal clearance of the components within the system, the size, the quantity of particles present in the fluid, and the system pressure.
Hydraulic Valves - Preventing Cavitation Damage
A client recently asked me to advise them on the possibility of repairing a large hydraulic valve off a 400 ton excavator, used in open-cut mining. The valve in question was a spool-type directional control. It had been badly damaged as a result of cavitation, which had occurred over a long period in service.
Electrical Motor Diagnostics: Impact of Electric Motor System Maintenance and Management
he application of motor systems maintenance and management programs have the potential impact of saving industry an initial $26.5 Billion in electrical energy costs while reducing greenhouse gas emissions by over 3,000 Mega-Tons per year. The individual impact on production availability is also significant, by reducing troubleshooting and evaluation time by over 50%, motor repair by over 30% and general motor-system related labor by up to 50%, following the application and sustainment of the program. In this article, we are going to cover three opportunities obtained through the application of the Electrical Motor Diagnostic component of an overall program.
Increasing Pump Reliability and Life
The majority of the failure mechanisms that significantly reduce the reliability and life of a centrifugal pump are caused by operation away from the pump best efficiency point (BEP). To achieve best-in-class life, it is essential to either operate close to the pump BEP (which is always the preferred method) or to provide provisions that anticipate the various effects of off-BEP operation and attempt to mitigate these consequences.
Steam Maintenance: Inspect Steam Traps for Efficient System
Unfortunately, when it comes to steam traps, people often ignore them. There's a complacency about them that is costing steam users much more than they realize. The hard reality of a plant maintaining its boiler and forgetting about the rest of the steam system can be a horribly wasteful proposition. Losses can include not only wasted energy but replacement of damaged equipment and misuse of man-hours. It is not uncommon to discover system losses in the hundreds of thousands of dollars.
Installation Errors Shorten Bearing Life
Installation and mounting errors are responsible for 27% of all bearing failures, second only to lubrication problems. Most installation errors can be avoided through proper training, correct procedures and selection of products with design features that are compatible with operating conditions of the application.
Is a Repaired Motor Less Reliable?
Is there is reason to suppose a properly repaired motor is less reliable than a new machine? This article will define reliability and repairability to help you answer this question.
Keeping Compressed Air Dry
Air systems without compressed air dryers severely restrict the life expectancy of any equipment they operate. You must keep your compressed air dry. One of the most effective ways of drying compressed air is to cool it, collect the moisture that condenses, then reheat the air to the ambient temperature. That is exactly what the cool winter weather did for your compressed air system.
Leaky Shaft Seals
Many people operate rotary screw compressors with oil seeping from around the shaft. This housekeeping nuisance and waste of expensive oil can be avoided with a better understanding of the shaft seal. The mechanical seal and lip seal are the most common types of shaft seals used on Rotary Screw compressors. The following provides further information specific to each of these styles.
Magnifying Mini: Microelectronics Miniaturization
One of the most pervasive trends in fluid handling today is that of miniaturization. The call for smaller and smaller flow control devices is evident across the industry. Regarding hydraulic and pneumatic components specifically, the extraordinary mass-to-power and mass-to-response features of such technologies are enabling miniaturization.1 But as hydraulic and pneumatic devices continue to go mini, the manufacturing process has become more finite and certain design vulnerabilities have become more pronounced.
Maintain Pumping Systems Effectively
Effective pump maintenance allows industrial plants to keep pumps operating well, to detect problems in time to schedule repairs, and to avoid early pump failures. Regular maintenance also reveals deteriorations in efficiency and capacity, which can occur long before a pump fails. Wear ring and rotor erosions, for example, can be costly problems that reduce wire-to-water efficiency by 10% or more. The amount of attention given to maintenance depends on how important a system is to a plant’s operations.
Maintenance and Troubleshooting of Electric Motors
The key to minimizing motor problems is scheduled routine inspection and service. The frequency of routine service varies widely between applications.
Maintenance Equipment: Basic of Centrifugal Pumps
The fact of the matter is that there are three types of problems mostly encountered with centrifugal pumps: design errors, poor operation, poor maintenance practices. The present article is being presented in 3 parts: covering all aspects of operation, maintenance, and troubleshooting of centrifugal pumps.
Maintenance Management of Your Company's PLC
You need to read this article on maintenance management of PLCs. Why? Because the PLCs (Programmable Logic Controllers) are the brains of your operation. When the PLC is not functioning properly, lines shut down, plants shutdown, even city bridges and water stations could cease to operate. Thousands to millions could be lost by one little PLC in an electrical panel that you never even knew existed. But most importantly, damage to machine and personnel could result from improper maintenance management of your company’s PLCs.
Maintenance of Bearing Seals
So what is going wrong with the lubricant and bearings in our pumps? We do not get a service life any where near those numbers. It turns out that most bearings fail prematurely for only two reasons: High heat that caused the lubricant to "varnish" and then form "coke" that will introduce solids into the lubricant, and contamination of the lubricant by water, moisture, and solids.
Maintenance Theory: How do Motors Work?
The development of the electric motor has given us the most efficient and effective means to do work known to man. The electric motor is a simple device in principle. It converts electric energy into mechanical energy. Over the years, electric motors have changed substantially in design, however the basic principles have remained the same. In this section of the Action Guide we will discuss these basic motor principles. We will discuss the phenomena of magnetism, AC current and basic motor operation.
Non-Destructive Exposing of Buried Energized Lines
In the past few years, Hydrovacs and "daylighting" have gained industry acceptance by minimizing the challenges of exposing underground pipelines, fiber-optics, and utilities. "Daylighting" is a non-destructive process using pressurized water (hydro) and a vacuum system (vac) to remove soil cover, thereby allowing a visual observation of underground lines. Hydrovacs expose these facilities to daylight, thus the term "daylighting".
Pitfalls of Pump Piping
There are 3 major problems associated with poor pump piping. 1) There is a scarcity of accessible information available on the topic. 2) No one pays any attention to it when installing a pump. 3) It can remain undetected and cause repetitive pump failures for many years.
PLC: Programming in List on a Mitsubishi PLC – Part 1
First of all, despite the fact that the PLC was designed as a direct replacement for relays, its logic is actually quite different. Relays are 100% parallel logic. Every single part of a relay control system operates simultaneously. If you were to draw several rungs on a relay diagram and put one coil on each line with no contacts on any of the lines, every relay would energize at the same time when power was applied. This makes relay logic blindingly fast by nature (its only the relay's mechanical limitations that make it slow) but it’s often a source of trouble
Pump Cavitation Solutions: Polymeric Solutions for Pumps Suffering from Cavitation
Pump cavitation is defined as the phenomenon of formation and consequent implosion of vapor bubbles in a region where the pressure of the liquid falls below its vapor pressure. Cavitation can occur in any fluid handling equipment, especially in pumps, one of the most important components of industry today. Technological advances in industrial protective coatings and repair composite materials have made it possible to repair pumps suffering from cavitation rather than simply replacing them.
Practical Automation: Understanding Pneumatic Power Circuits
Pneumatic directional control valves and cylinders are most commonly used in power circuits, with the valves controlling cylinders that, in turn, provide work. As we learn about a few of these circuits, other accessory valves will be introduced, along with some interesting ways of using them.
Pump and Driver Alignment 14-3
In the pump business alignment means that the centerline of the pump is aligned with the centerline of the driver. Although this alignment was always a consideration with packed pumps, it is critical with sealed pumps especially if you are using rotating seal designs where the springs or bellows rotates with the shaft. A little misalignment at the power end of the pump is a lot of misalignment at the wet end, and unfortunately that is where the seal is located in most pump applications.
Suction Bell Upgrades for Vertical Turbine Pumps
How long should a vertical pump's suction bell last? That was a question a plant manager asked me during a recent consulting assignment for a power plant. A pump manufacturer's typical response to such a question is, "it depends." So what does it depend on?
Refurbishing Aged MCCs Proves Beneficial
In 1999-2001, the New Jersey International & Bulk Mail Center (NJI&BMC) in Jersey City, one of the largest United States Postal Service facilities, was concerned about its eight 33-year-old motor control centers (MCCs). Events forced a decision to pursue options for replacing or refurbishing the 276 cells that provide power primarily to 58 heating, air conditioning, and ventilation air handling units (HVAC AHUs) for the 1.8-million-sq-ft facility.
Barrier or Buffer Fluid: The Liquid we Circulate Between Dual Seals
Consumers use the term "flushing" to describe six different methods of bringing fluid to the stuffing box area of a centrifugal pump. Experienced seal people use different terms to differentiate between the methods. Water is one of the best barrier or buffer fluids because of its high specific heat and good conductivity. Petroleum oil is probably one of the worse because of its low specific heat and poor conductivity. Keep this in mind when you select a barrier or buffer fluid for your seals.
Revitalizing an Aging Grounding System
In 1997-98, the facility was considering replacing the aging (1972-73) high, medium, and low voltage equipment because of several operational and maintenance problems with the breakers. We also were concerned about the overall grounding scheme of the facility. To find out the existing status of the grounding system, we procured architect/engineer (A/E) services to check and confirm the overall validity of the facility-grounding scheme.
Saving Energy with Bearing Isolators
Non-contacting labyrinth seal bearing isolators for industrial rotating equipment can be a key to energy conservation -- and saving money. By changing from contact lip seals to non-contact seals in industrial rotating equipment, the U.S. could save billions of dollars in electrical power costs and conserve over 5,500-MW of energy each year.
Skills Development of Craftspeople
Unless you're lucky enough to own your own paper mill, chances are you sometimes have to live with management decisions that differ from those you might have made on your own. So let's move forward and assume your company is going to implement pay-for-knowledge. It's not all bad. Not only are there various ways to cut your potential losses; there are even some positive benefits you can achieve if you do things right.
Solving Hydraulic System Overheating Problems
I was asked recently to investigate and solve an overheating problem in a mobile hydraulics application. The hydraulic system that was overheating comprised a diesel-hydraulic power unit, which was being used to power a pipe-cutting saw. The saw was designed for sub-sea use and was connected to the hydraulic power unit on the surface via a 710-foot umbilical. The operating requirements for the saw were 24 gpm at 3000 psi. Heating of hydraulic fluid in operation is caused by inefficiencies. Inefficiencies result in losses of input power, which are converted to heat. A hydraulic system's heat load is equal to the total power lost (PL) through inefficiencies.
Some Dangers of Batch Processes
"At the end of every batch, my pump wants to go home!" These were the words said to me in halting English by a maintenance manager of a major brewery in Manilla during one of my trips to the beautiful Philippines. Although I was accompanied by a translator, the manager insisted on trying out his limited English. As we were obviously having some kind of communication breakdown, I asked the translator to verify the comment. Sure enough, back it came, accompanied by a big grin and lots of head nodding. "At the end of every batch, my pump wants to go home." Obviously, this was a pump I just had to see!
Strive to Improve Your Gearbox Performance
In industry, power consumption in the manufacturing environment accounts for approximately one-third of all energy consumed annually in the U.S. In the enclosed-gearing industry, questions, such as "how efficient is product X," are becoming increasingly common. Several factors influence how efficiency is lost during the operation of the gearbox system. Let's get started and first take a look at the effect oil seals and lubricants can have on gearbox efficiency.
Let's Clear Up the Confusion About Flushing Seals 3-6
Consumers use the term "flushing" to describe six different methods of bringing fluid to the stuffing box area of a centrifugal pump. Experienced seal people use different terms to differentiate between the methods.
Temperature Shock of Hydraulic Components and How to Avoid it
When there is a significant difference between the temperature of a hydraulic component and the fluid being supplied to it, rapid, localized heating of the internal parts of the component can occur. This causes individual parts of the component to expand at different rates, resulting in interference between parts that normally have fine clearances.
Test for Pumping System Efficiency
A pump’s efficiency can degrade as much as 10% to 25% before it is replaced, according to a study of industrial facilities commissioned by the U.S. Department of Energy (DOE), and efficiencies of 50% to 60% or lower are quite common. However, because these inefficiencies are not readily apparent, opportunities to save energy by repairing or replacing components and optimizing systems are often overlooked.
The Affinity Laws for Rotary, Positive Displacement Pumps 13-6
The affinity laws accurately predict the affect of changing the speed of a centrifugal or rotary pump, and they also do a fairly good job of predicting the affect of changing the diameter of a centrifugal pump. In another paper (02-01) we discussed the affinity laws as they apply to centrifugal pumps, but in this paper we will look at their use with rotary pumps.
The ANSI Pump Standard 14-5
ANSI is an acronym used to describe the American National Institute Pump Standard. The standard evolved from the American Voluntary Standard (AVS) that was first proposed by the Manufacturing Chemists Association in the nineteen fifties. It is a set of inch dimensional standards that describe the envelope dimensions of a back pull out, centrifugal pump.
The API Gland
The seal gland is that part that holds the stationary half of the mechanical seal and attaches to the stuffing box. The most universally used gland is labeled the American Petroleum Institute (API) gland. The API (American Petroleum Institute) gland incorporates several important environmental controls and safety features. It should be specified for all petroleum refinery service because of the danger of an explosion or fire, but should also be recommended any time you are pumping any type of dangerous product. The gland has several features you need to understand.
The Dual Seal Arrangement
Dual seals are recommended for a variety of purposes, but in this paper we will be considering the use of dual seals as an environmental control to prevent the sealed product from either opening the seal faces, or damaging one of the seal components, the two reasons any mechanical seal ever failed.
The Non Seal Pump
Non-leak pumps have been the dream of pump designers ever since the first pump was invented back in the dark ages. We all want a non leaking pump for the obvious reasons. Because of this desire there are a number of companies willing to supply just about any kind of "Voodoo" you are looking for. Let's take a look at the non seal pump subject and see if this type of pump make sense in your application.
The Pump Affinity Laws 2-1
There are occasions when you might want to permanently change the amount of fluid you are pumping, or change the discharge head of a centrifugal pump. There are four ways you could do this, of the four methods the middle two are the only sensible ones. In the following paragraphs we will learn what happens when we change either the pump speed or impeller diameter and as you would guess other characteristics of the pump are going to change along with speed or diameter.
The Role of Fireside Corrosion on Boiler Tube Failures
One of the primary challenges of reliably burning coal is managing the corrosion experienced by the furnace heat transfer surfaces. Fireside corrosion remains a leading cause of failure in superheater and reheater tubes. Also, tubes affected by the fireside corrosion mechanism may lose 15 mils per year (mpy) and more in extreme cases. Five case studies (three presented here in Part 1) examine the different failure modes experienced by tubes located throughout the furnace.
The Role of Fireside Corrosion on Boiler Tube Failures: Part 2
One of the primary challenges of reliably burning coal is managing the corrosion experienced by the furnace heat transfer surfaces. Fireside corrosion remains a leading cause of failure in boiler tube, in both superheater and reheater tubes. Boiler tubes affected by fireside corrosion also may lose 15 mils per year (mpy), or more in extreme cases
The 7 Secrets of Pump Reliability
Contrary to popular opinion, a centrifugal pump is not designed to develop a specific head at a certain capacity as requested by the pump purchaser. In fact a pump is designed and built to produce a whole range of head-capacity conditions as identified by it’s performance curve. The pump will operate on that curve if it is driven at the designated speed.
The Trouble with Torque in Electrical Connections
The secret to making and keeping reliable electrical connections is contained in two elements: start with clean contact surfaces, and apply high force. Clean contact surfaces are a function of cleaning procedures, including joint compounds, and will be covered in a future article. Application of high force is the subject here. The trouble comes about because the terms "torque" and "force" are incorrectly used interchangeably. Force is NOT torque. Force is a function of torque.
Fire Sprinkler Corrosion: The True Threat of a High Corrosion Problem to a Fire Sprinkler Line
The most critical piping for any building
property or plant operation is unquestionably at the fire sprinkler system. Corrosion problems at tower water, chill water, steam, or other HVAC and plumbing piping may produce a loss of service, inconvenience, property damage, shutdown, and even millions of dollars in monetary losses, but the failure of a fire sprinkler line always threatens the loss of human life.
Understanding the 'Diesel Effect' and How it Damages Hydraulic Cylinders
I was recently engaged by a client to conduct failure analysis on a large (and expensive) double-acting cylinder off a hydraulic excavator. This cylinder had been changed-out due to leaking rod seals after achieving only half of its expected service life. Inspection revealed that apart from the rod seals, which had failed as a result of the 'diesel effect', the other parts of the cylinder were in serviceable condition. The diesel effect occurs in a hydraulic cylinder when air is drawn past the rod seals, mixes with the hydraulic fluid and explodes when pressurized.
Understanding Shaft Alignment: Basics
Part one of a four-part series that will cover alignment fundamentals and thermal growth, and highlight the importance of field measurements through two case studies. Despite the best efforts to precisely align rotating machinery shafts, dynamic movement (commonly believed to be due to the thermal growth of the machine casings) has resulted in machines operating at less than optimum alignment conditions. This vexing problem has plagued machine reliability professionals for decades.
What is a valve?
The valve is one of the most basic and indispensable components of our modern technological society. It is essential to virtually all manufacturing processes and every energy production and supply system. Yet it is one of the oldest products known to man, with a history of thousands of years.
Who Should Recondition My Seals?
Such a question often comes up when it is time to recondition a mechanical seal: We use several different brands of mechanical seals in my plant. When a pump is taken out of service, we usually send the seal back to the original seal manufacturer for reconditioning. One of my suppliers has offered to recondition all of my seals, regardless of brand. Is this a good idea? Most process plant maintenance departments return their used mechanical seals to the original seal manufacturer (or Seal OEM) for reconditioning.
Why Should I Upgrade to a Programmable Logic Controller (PLC)?
Why automate, why improve? They're all about the same question, so after covering the more general area, we'll zoom in on the specifics of PLCs. "Why improve?" Because your competitors are, and you will not be in competition with them very long, if you don't. "More and better" are today's bottom line. With the customers being better educated, and having better availability of the product they seek, you have no choice.
World Standard Maintenance Skills through Assessment and Multi-Skilling
What makes the difference between success and failure in meeting maintenance task deadlines? How can equipment reliability and maintenance task completion times be improved? These and other maintenance related questions can be answered by the UCC International's Skills Assessment and Multi-skilling approach to maintenance training. Certified Trades and Technical staff at the University College of the Cariboo have developed a process by which maintenance supervisors and decision makers can adequately address maintenance skills weaknesses within their organization.
Pumps: You Get What You Pay For... Or Do You?
One of the most costly mistakes that almost every company makes with its pumps is to actually buy the wrong pump. Sadly, this is a situation that occurs with much more frequency than anyone would care to admit. The ramifications are truly enormous—and they are magnified even more in tough economic environments. Efficiency drops. Reliability plummets. Maintenance costs rise dramatically. Even in the best of times, you couldn't afford to gamble on the efficiency and reliability of your pumping systems. Don't start now.
RCFA: How to Select the "RIGHT" Root Cause Failure Analysis
With RCFA being a buzzword of the 90’s, companies are faced with a slew of new vendors with numerous RCFA methods and practices to help you attain quantum results. How do you decide who is going to make you money versus who is going to take your money?
Developing a Root Cause Analysis Work Process - Part 1
Root Cause Analysis (RCA) is a valuable tool for reliability improvement in manufacturing and production operations. Yet, most efforts to implement an RCA program fail to achieve meaningful results despite significant investments in employee training. What needs to be done to assure that RCA becomes a functional work process in organizations?
Developing a Root Cause Analysis Work Process - Part 2
From my own RCA experiences at industrial sites and manufacturing facilities, I have found that there is little consensus regarding what constitutes an Root Cause Analysis activity, what it is supposed to accomplish, how it will be applied, who should do the activity, when it will be applied, etc. Very little agreement exists on these basic RCA points. Ask these RCA questions in your work environment and listen to the diversity of opinions you will hear in reply.
Developing a Root Cause Analysis Work Process - Part 3
Root Cause Analysis represents one of the greatest challenges in reliability program development, requiring a broad understanding of management processes, structured problem solving and behavior. Developing a Root Cause Analysis work process will require effort and persistence as well as new thinking about organizational structure and resource priorities. The potential improvements from developing an effective Root Cause Analysis work process are significant. Most manufacturing processes have opportunities for improvement and cost reduction that have not been obtainable with current efforts. In some cases, these opportunities could represent competitive advantages in manufacturing strategies and processes.
Root Cause Analysis Chronic Events: Panning For Gold
What we need to do today is make management aware through education and awareness that our cultures live with these chronic events that typically end up costing 100 times more than the occasional sporadic event. Unfortunately, the sporadic events get all the attention. When our cultures are enlightened, we will begin to enjoy the fruits of our efforts in the form of return on investment (ROI) figures as high as 7000-8000 percent. Then the believers will come.
RCM for Medium Sized and Lean Organizations
RCM may have been thought of as a strategy best left to large organizations. That may have been a perfectly logical assumption. Small-to medium-sized enterprises (SMEs) and lean operations simply seem to have less money to invest in and fewer resources to cope with the many activities required for RCM success. Now, however, out of joint academic/industry collaboration in Spain, comes information that may help begin to put these types of popular misconceptions to rest. The RCM methodology described in this overview of the Spanish research has been adapted to meet the specific needs of today’s smaller, leaner organizations. And it is not just a theory, either. The practicality of this approach is being confirmed through actual testing in SME and/or lean companies.
Examples of Root Cause Analysis
If I have an unwanted situation which consumes resources and tends to happen in a repeated fashion then there is a possibility that it might be beneficial to figure out what is really causing this situation to occur and remove it so the situation does not occur again. This is generally referred to as Root Cause Analysis, finding the real cause of the problem and dealing with it rather than simply continuing to deal with the symptoms.
Root Cause Analysis Guidance Document
DOE Order 5000.3A, "Occurrence Reporting and Processing of Operations Information," investigation and reporting of occurrences (including the performance of root cause analysis) requires the and the selection, implementation, and follow-up of corrective actions. The level of effort expended should be based on the significance attached to the occurrence. Most off-normal occurrences need only a scaled down effort while most emergency occurrences should be investigated using one or more of the formal analytical models. A discussion of methodologies, instructions, and worksheets in this document guides the analysis of occurrences as specified by DOE Order 5000.3A.
Root Cause Analysis: Will It Find the Weak Link?
As a teacher and a practitioner of root cause analysis, I see not only the physical motions of going through such an effort, but also the psychology behind what makes or breaks it. When you consider the effort that goes into determining root causes and developing recommendations, why should it be such a hard sell to get something done?
Case Study: Root Cause on Seal Failure in Refinery
Many different factors contribute towards the failure of a pump. Some factors that did not seem to have contributed to earlier failures were not examined or considered and may become the cause of failure under other situations. Failures do not occur suddenly. Usually there are many symptoms, which signal a failure situation and are generally termed as potential failure modes. The ignorance of such symptoms almost always leads to failure. Below are two case studies pertaining to mechanical seal systems, a vital component of pumps operating in running process plant.
7 Points to Successful Root Cause Analysis (RCA)
Root Cause Analysis (RCA) is a useful tool for trouble shooting breakdowns and efficiently coming to a solution. I propose the following seven points for successful implementation of RCA that will naturally result in increased profits.
The Latent Causes of Industrial Failure
Hidden but powerful forces within our organizations are causing people to make serious mistakes. Until someone deals with these forces, they will continuously but unpredictably snare people into doing things they should not do. These forces are like a "trap," waiting to catch the next person. The most proactive of all industrial action might be to identify and remove these latent traps. But all our attempts to identify and remove these latent causes of failure start at the human. Humans do things "inappropriately," for "latent" reasons.
Troubleshoot AC Motors
The following charts will give you multiple pathways to assist when you are attempting to troubleshoot AC Motors. The 4 problems covered are: Problem A - Motor won't start or motor accelerates too slowly, Problem B - Motor runs noisy, Problem C - Motor overheats, Problem D - Motor bearings run hot or noisy
Troubleshooting Hydraulics
Personnel should follow a system when troubleshooting. The following articles outlines the STOP System and seven things to consider when troubleshooting hydraulics.
Troubleshooting Paper Machine Problems Through Thermal Imaging
The Paper Industry has numerous processes that can provide a thermal imprint. The papermaking process is based on water removal through drainage, mechanical pressing and, the application of heat. We will review four case studies to represent only a few of the opportunities to troubleshoot the process.
Troubleshooting Valves
Listed below are areas that you can diagnose in hydraulic valves. When working on a specific machine, refer to a machine's technical manual for more information.
Martin Sprocket and Gears: Maintenance and Troubleshooting Guide
Martin Sprocket & Gear Inc's Maintenance and Troubleshooting Guide. This guide covers chain drives, gear drives, chain couplings, jaw couplings, quadra-flex couplings, synchronous drives, v-belt drives, and screw conveyors.
The Process of Troubleshooting Mechanical Seals - Part 1
The 9 articles in this series will outline common issues with mechanical seals, how to notice them, and troubleshooting tips. The series addresses: wide wear track, centered/miscentered, even/uneven wear track, scoring, chipping, coking, heat cracking or checking, and blistering.
Troubleshooting Mechanical Seals | Wide Wear Track | Part 2
Part 2 of 9 on Troubleshooting Mechanical Seals: Wide Wear Track - symptoms, causes, failure modes, and solutions.
Troubleshooting Mechanical Seals | Centered/ Miscentered | Part 3
Part 3 of 9 on Troubleshooting Mechanical Seals: Centered/Miscentered - symptoms, causes, failure modes, and solutions.
Troubleshooting Mechanical Seals | Even/Uneven Wear Track | Part 4
Part 4 of 9 on Troubleshooting Mechanical Seals: Even/Uneven Wear Track - symptoms, causes, failure modes, and solutions.
Troubleshooting Mechanical Seals | Scoring | Part 5
Part 5 of 9 on Troubleshooting Mechanical Seals: Scoring - symptoms, causes, failure modes, and solutions.
Troubleshooting Mechanical Seals | Chipping | Part 6
Part 6 of 9 on Troubleshooting Mechanical Seals: Chipping - symptoms, causes, failure modes, and solutions.
Troubleshooting Mechanical Seals | Coking | Part 7
Part 7 of 9 on Troubleshooting Mechanical Seals: Coking or Crystallized - symptoms, causes, failure modes, and solutions.
Troubleshooting Mechanical Seals | Heat Checking or Cracking | Part 8
Part 8 of 9 on Troubleshooting Mechanical Seals: Heat Cracking or Heat Checking - symptoms, causes, failure modes, and solutions.
Troubleshooting Mechanical Seals | Mechanical Seal Blistering | Part 9
Part 9 of 9 on Troubleshooting Mechanical Seals: Mechanical Seal Blistering - symptoms, causes, failure modes, and solutions.
Troubleshooting Premature Bearing Failure
In a properly operating bearing the race ways and rolling elements will become dull in appearance. This dullness is not an indication of wear and has no affect on the life of the bearing. These dull surfaces form the visible paths that I will be referring to in the following paragraphs, so their appearance and location is important in analyzing any type of bearing failure.
The Top 10 Reasons Why Root Cause Analysis Sucks in the United States
Lately, I’ve been asked to provide root-cause analysis training more than ever before in my 14 years as an independent quality/lean consultant. This is interesting in the age of Six Sigma, especially because “analyze” is the heart of DMAIC (define, measure, analyze, improve, control). I find this interesting in this age of lean, in which the lean tools that are taught to so many people are only possible solutions to good root-cause analysis. I began to wonder, “Why does root-cause analysis suck?,” and I came up with the following possible root causes. You decide which apply to your company by asking “Why?” somewhere around five times until you find the systemic reason(s) that it sucks at your company. Drum roll, please . . .
Why Do Pump Bearings Fail?
What do we mean by good bearing life? Most of us change the bearings every time we disassemble the equipment to replace the mechanical seal or the packing sleeve. Is this really a sensible thing to do? If you think about it for a minute there is nothing in a bearing to wear out, there are no sacrificial parts.
Why Some Root Cause Investigations Don't Prevent Recurrence
To successfully carry out this mission, a root-cause investigation needs to be evidence-driven in accordance with a rigorous application of the bedrock of all root-cause methodologies: the Scientific Method. Consistent with the Scientific Method, underlying assumptions have to be questioned and conclusions have to be consistent with the available evidence, as well as with proven scientific facts and principles. Sometimes root-cause investigations fail to fulfill their primary mission and the failure recurs. In that regard, diagnosing the root cause of root-cause investigation failures is, in itself, an interesting topic. Here are three common reasons why some root-cause investigations fail their mission.
Lube Routes vs. Combo PMs: What's Best? What are the Issues?
In an ideal world, the lube route is the perfect answer. Group activities based on commonality of frequency, task type (e.g. motor regreasing) or area of the plant and execute in one block. It's efficient, effective and cuts down on paperwork by having just one work order for tens or even hundreds of tasks. The key here is "ideal world" - few if any of us live in this utopia, which causes some very real problems when it comes to executing what I tend to call "macro" lube routes.
Brinelling of Bearings
Drop a bearing (oops!), impact an interference fit hub, coupling etc., that seized onto a shaft (hammer time oops!), beat a bearing onto a shaft or into an housing, hit the machine with the big hammer to move it (no jacking bolts oops!), let that spare machine sit on the warehouse shelf or in the field for months or even years with no rotation (oops!)? And the list could go on and on…we’ve all probably been guilty of at least one or more of these infractions at some point. “What’s the big deal anyway?”
Hydraulic Troubleshooting
Many problems with hydraulic systems occur on start-up of a new system, after a repair or overhaul, after a new component is added, or when a component is adjusted or some other form of change occurs. In any machine, particularly in hydraulics, any change in one part of the system will affect all the other parts of the total system. This will result in problems that will require trouble shooting.
Factors which Influence the Speed of an Air Cylinder
It is very difficult to calculate and predict the speed of an air cylinder; there are too many variables which influence speed and on which it is difficult to gather accurate data. We must rely mainly on good design practices and use the benefit of past experience. It is better to have the cylinder speed too fast to begin with because it can always be reduced with a speed control valve, but if it is too slow to begin with, it is more difficult to increase its speed later.
Hydraulic Testing & Diagnostics
The 7 Basic Steps of Hydraulic Testing & Diagnostics. Testing with gauges or a hydraulic analyzer is the most effective way to pinpoint troubles in the system. However, here are some preliminary checks you can make without using a tester or prior to using one.
Logical Troubleshooting in Hydraulic Systems
It would be a virtually impossible task to try to document the cause and remedy of every possible fault that could occur on even the simplest hydraulic system. For this reason it is necessary to adopt a logical approach to troubleshooting, in order to locate a fault as quickly and accurately as possible. Down time on modern production machinery is very expensive, so an hour saved in locating a problem may make hundreds, or sometimes thousands, of pounds worth of saving in los production.
Hydraulic Filter Condition Monitoring
Continuous monitoring of the filter elements in a hydraulic system can provide valuable clues to the performance of the filter and the condition of the system. Before I discuss this, let's consider some of the advantages and disadvantages of common filter locations in a hydraulic system.
Three Simple RCA (Root Cause Analysis) Facilitation Tips
I have heard one manager in a plant that has stipulated a maximum of two hours for an Root Cause Analysis to be conducted in his organisation. Another expects at least “brainstormed” solutions before the conclusion of day one – within 6 or 7 hours. It is not uncommon for a draft report to be required within 48 hours of the RCA. The following three tips may assist to meet tight deadlines and when time expectations are short. One advantage of the Apollo RCA process is that it is a fast process but the “driver” has to be on the ball to achieve the desired outcomes – effective solutions.
Planning and Scheduling in the Process Industry
Since there has been tremendous progress in planning and scheduling in the process industry during the last 20 years, it might be worthwhile to give an overview of the current state-of-the-art of planning and scheduling problems in the chemical process industry. This is the purpose of the current review.
How Do Variable Speed Drives Impact Mechanical Seals?
Whether the mismatch was due to the variation in required pump output or incorrect sizing of the pump, there is no question that the ability to easily vary pump speed has been a major advance in the overall performance of a pumping system. This has increased the energy efficiency, as well as the reliability of the equipment. Problems—such as cavitation or shaft deflection—can be alleviated by running the pump at optimal system speed. But how do variable speed drives affect mechanical seals?
The ‘Maintenance Crisis’ and Innovations that are Changing it
A couple months ago, I wrote an article about the top five careers in facility management. I interviewed a broad range of professionals for that story. But it was during an interview with Joel Leonard, President of SkillTV, that I started to ponder what he referred to as “the maintenance crisis”–a depletion of skilled workers in the maintenance management workforce caused by baby boomers retiring and too few young professionals entering the field.
Flow through Orifices
The chart shows approximate pressure drops which may be expected at various flows rates through sharp edge orifices for petroleum type hydraulic oil. It may be used for designing limiting flow orifices in hydraulic systems. Chart values must be considered as approximate because a number of factors such as specific gravity, orifice efficiency, plumbing ahead of and behind the orifice may cause variations from the values shown.
Carbon Brushes for DC Motors and Generators
Carbon brush grades are usually classified according to the manufacturing processes and the types of carbons, graphites, and other ingredients used. The 4 main brush grade families are carbon-graphites, electrographitics, graphites, and metal-graphites.
Matching a Hydraulic Motor to the Load
On the design of a new machine which is to be run with a hydraulic motor, a determination of required speed and horsepower must be made so a model with suitable ratings can be selected. This article describes several methods of making such a determination. Designers who are experienced only in selecting electric motor drives need to be careful in designing hydraulic drives because of important differences between these two motors.
Creating Reliable Equipment Information
Deficiencies in the integrity of equipment data and difficulties in accessing this data are costing asset-intensive companies millions of dollars a year in equipment downtime and business inefficiencies. Waste in the work management processes appears in the form of extended searches for parts and materials; wasted effort due to missing, inaccurate or out-of-date equipment data; procurement errors; and an inability to easily access data from a reliable source. The result can be expensive to these organizations.
Figure Out the Dollars Behind CMMS Automation
When exploring CMMS automation opportunities in your facility, there are many factors to consider. These include cost versus benefit by automating, cash-flow impact, organizational readiness, ease of implementation, availability of resources, technological maturity and availability, as well as probability of success.
Disc Couplings Dump Downtime
Want to expand coupling life? Who doesn’t? You may want to look into advanced-design disc couplings. These couplings feature discs with optimized profile and thickness to provide a higher torque-to-outside-diameter ratio, higher service factors and up to 50 percent greater misalignment capability. All this provides for smaller reactionary forces on bearings compared to conventional disc couplings, which helps achieve infinite coupling life in properly specified applications.
Leading Change: Why Transformation Efforts Fail
Over the past decade, I have watched more than 100 companies try to remake themselves into significantly better competitors. They have included large organizations and small ones, companies based in the United States and elsewhere, corporations that were on their knees, and companies that were earning good money. These efforts have gone under many banners: total quality management, reengineering, right sizing, restructuring, cultural change, and turnaround. But, in almost every case, the basic goal has been the same: to make fundamental changes in how business is conducted in order to help cope with a new, more challenging market environment.