LubricationWorld - Co-located with
The 20th International Maintenance Conference
December 6-9
Tampa Florida

Short Course led by Ricky Smith, CMRP, Maxzor

Hydraulics always seems to be a problem in many organizations and troubleshooting these systems in a timely manner is a problem, Ricky exposes some great concepts that anyone can put in place to troubleshoot hydraulic systems rapidly. Ricky uses his years of practical experience in hydraulics to drive this practical short course. Come and enjoy this great workshop and an experience you will never forget.

Attend this subject plus 50+ other short courses and learning zone sessions at LubricationWorld.

To register or to request a brochure please call toll free (888) 575-1245 or…

Learn more about LubricationWorld online

HYDRAULIC TROUBLESHOOTING MADE SIMPLE

Hydraulic problems cost companies millions of dollars in lost capacity because of troubleshooting problems. Troubleshooting hydraulic systems can be difficult and very frustrating to maintenance personnel. There is a simple process which can make the troubleshooting of hydraulic systems much less stressful. This process requires preparation for this imminent failure of a hydraulic system. This process involves two paths one must follow in order for this to work.

Path 1: This path decreases downtime and allows the root cause of hydraulic failure to be resolved quickly without the changing out of components unless the know cause of a function failure has been identified.

* Identify and mark fluid flow paths for pressure, return, and pilot lines by using colored markers on your hydraulic schematics.
- Red – Pressure
- Blue – Return
- Green - Pilot

* Develop a quick reference chart for troubleshooting. In order to develop this quick reference one must:
1. Identify each function a hydraulic system must perform (ex: Hydraulic Cylinders Extended)
2. Identify each valve that must be energized to perform this function(ex: Hydraulic Cylinders Extended, valves 3.1, 4.4)
3. Identify the timing (if required) in order for the cylinder to perform to standard (ex: Hydraulic Cylinders Extended, 12.1 seconds)
4. Identify the hydraulic flow and pressure required for the cylinder to extend to a specific timing (ex: Hydraulic Cylinders Extended, 12.1 seconds, 9 GPM at 1200 psi)
5. Train maintenance personnel in the use of this process and retrain on a quarterly basis (testing is essential in order to ensure knowledge has been transferred from instructor to the maintenance crafts person)

Path 2: This path can also make troubleshooting of a hydraulic system none existent or at least a rare occurrence. This path also requires DISCIPLINE in order for it to be successful.

* Develop a Preventive Maintenance Program for a hydraulic system that includes the following:
- Step by step procedures for each PM task that requires little if any training for one to meet the standard.
- ex: Task – Change Hydraulic Filter
Step 1: Clean around filter housing with cleaning solvent and wipe with lint free towels
Step 2: Remove bolts utilizing a ¼” allen wrench
Step 3: Remove cover along with used filter element and dispose of the element
Step 4: Open plastic wrapping enclosing the filter element. (warning: do not touch filter element with hand or glove)
Step 5: Insert new element without touching the filter element with hand or glove.

-Tools and Material Requirements should be listed for each task along with part number of material from stores warehouse.
- Determine the condition at which a PM Task is required. (time based can work but not preferred)

* ex: Filter differential pressure exceeds 10psi requires a filter change within 48 hours.

Implementing this two step process will prepare an organization to rapidly troubleshoot a hydraulic system and at the same time reduce the probability of a failure.

Tip provided by Ricky Smith, CMRP

Ricky brings a common sense approach to hydraulic solutions that many maintenance professionals face on a daily basis. Ricky has many years hands on experience as a practitioner troubleshooting hydraulic systems all over the world. Ricky is also the author of the well known book, “Industrial Repair, Best Maintenance Repair Practices”. He will lead a Hydraulic Troubleshooting Short Course at LubricationWorld (see next item below).

Buy Ricky’s Book: Industrial Repair, Best Maintenance Repair Practices

Every IMC-2005 and LubricationWorld Conference attendee will have a chance to win an Alienware Laptop Computer - one of the most reliable laptops available.

Ask for your Alienware Giveaway passport when you check in at registration to read the rules and get a chance to win.

Win an Alienware LapTop at IMC-2005

Calculating the true cost of an infrared camera

The offers for inexpensive cameras is growing and for many users these low price offers are a great way to begin using this valuable technology.

However the true cost of an infrared camera is much more than the purchase price.

Lets begin by comparing the capitalized cost of cameras costing $10,000 and $20,000 over a typical 5-year depreciation period. (Without factoring finance costs)

The $10,000 camera costs $166/month
The $20,000 camera costs $333/month
Differential is $167/month

The fully burdened cost of an camera operator is $35/hour or $73,000/year The $20,000 camera will likely have functions that reduce labor costs (less training, automatic report generation, field data information collection,
etc.)

Assuming a 20 hours/week of use and 3 hours of time-savings using the more expensive camera.

Weekly savings = $700/week or $2800/month

Conclusions

1. Cost of camera is a very small portion of the expense of
thermography program.
2. Always compare the productivity of cameras and their ability to convert field work into work orders
3. Compare the ease of use and costs for new operator training.
4. Labor costs are dominant in thermography PdM program

Tip provided by Electrophysics
USA Based Makers of the new HotShot IR Camera

Register to win a new Harley from Electrophysics

Our friends at PdMA offer in-stock inventory at great prices. Now they are offering one lucky Reliabilityweb.com member or web site visitor a complete set of 5 Oil Safe drums, including 5 lids and accessories for storing, dispensing and transporting lubricants!

The Oil Safe® container system is a safe, sure, easy to use method of storing and dispensing lubricants and lubricating fluids in a wide variety of applications.

Click here for rules and to enter before November 30, 2005

IMC-2005 Expo Dates and Hours:

Wednesday December 7 - 10:00 am - 3:00 pm
Thursday December 8 - 10:00 am - 1:00 pm

Price: Free for Reliabilityweb.com and Maintenance-Tips subscribers. $25 for general public.

Meet over 100 Reliability Solution Providers at the IMC-2005 and LubricationWorld Expo at the Tampa Convention Center in beautiful Tampa Florida.

Speak with leading vendors, software providers, training organizations and service companies offering:

* Reliability Centered Maintenance
* Root Cause Analysis
* Asset Management
* Total Productive Maintenance
* Predictive Maintenance
* Maintenance Planning
* Vibration Analysis
* Computerized Maintenance Management
* Ultrasonic Detectors
* Infrared Cameras
* Oil Analysis
* MRO Inventory Solutions
* Lubrication
* Motor Testing
* Laser Alignment
* Balancing

For a free IMC-2005 Expo Pass - Register online here

The following tips are extremely helpful in identifying natural gas engine problems that could result in failure. Keeping in mind that natural gas engines function quite differently than diesel engines, a combination of both oil and coolant analysis and diligent cooling system maintenance can identify problems before they become catastrophic failures.

1. Know the correct operating procedures and schedules for both in-service and standby units. It is important to know at what temperature and how often a particular engine typically runs. Standby engines should be run long enough to reach an operating temperature of 190°F so that any moisture that has accumulated while the engine was idle is burnt off. Moisture can become acidic and form nitric acid which leads to metal pitting.

2. Electrical ground problems can be detected through coolant analysis by monitoring nitrite/nitrate levels. If nitrites drop significantly while nitrates increase, stray electrical current could be present.

3. Closely monitor sulfate and nitrite levels through oil analysis. If flagged, these levels are too high and could be an indication that combustion gases are present.

4. Do not use an automatic battery charger on a natural gas engine with an electrical starter. Stray current can cause significant starter damage.

5. If grounding two starters for a particular engine, be sure to ground them both on one side of the engine to the frame—not to the engine block—to prevent the engine from becoming an electrical conduit.

Tip provided by Polaris Labs

Click here to learn more about oil analysis and cooling system maintenance

The only reason for having MRO inventory is to support operations and maintenance in their efforts to sustain safe, efficient production. The objective is to preserve high availability without having excessive inventory. Unfortunately, once overstocks exist typical inventory management systems are not designed to identify them or stop more from being purchased.

Until now the only way to prevent excess inventory was to rely on the expertise of long-term very knowledgeable employees. But because eighty to ninety percent of MRO items are Low/No Use items with a historical average usage of less than one unit per month, expecting even the most seasoned maintenance professional to prevent overstocks is unrealistic. The low incidence of demand for these items requires unique insights and technology for proper management.

The good news it that there are tools and services proven to help you make better stocking decisions regardless of your experience. By knowing today which items should not be replenished, maintenance can make better stocking in the future.

For an interesting investigation of Murphy’s Law of perpetual overstocks, attend The Prudent Advantage Group (TPAG) International Maintenance Conference learning zone session on Thursday, Dec 8 at 11:00.
http://www.maintenanceconference.com/imc/sessions.htm

For more information, view the Prudent Advantage Group iPresentation: Too Much and Too Little (MRO Inventory)