March 16, 2006 Vibration Analysis Tip
Always make a routine backup of your vibration database and any other technology database files used in your predictive maintenance program. It is a good idea to store your database files on a network drive when possible. This will allow your site IT group to create a routine backup of your data. Otherwise, periodically copy your technology database files to a network drive or a back-up device.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
March 16, 2006 Free Expo Pass for the Reliabilityweb.com Pavilion in Chicago
Please stop by the Plant Engineering and Maintenance Expo at the Donald Stephens Convention Center in Rosemont (Chicago) Illinois. There are over 100 maintenance and reliability solution providers on hand to discuss your problems and demonstrate new ideas.
Expo dates:
Tuesday - March 21 - 10 am - 5 pm
Wednesday - March 22 - 10 am - 5 pm
Thursday - March 23 - 10 am - 3 pm
Bonus: Please visit Reliabilityweb.com Booth #34039 for a free Reliability Roadmap including:
• Contact information for leading hardware, software, training and service providers
• Best Practices Reliability Benchmarking Form
• Reliability Roadmap White Paper
• Reliability Resources Tutorial CD
• Free RELIABILITY® Magazine issue
• Free Uptime® Magazine issue
See you in Chicago!
March 16, 2006 The Reliability Game at National Manufacturing Week
Rosemont Convention Center
Monday, March 20, 2006
9:00AM - 4:00PM
Whoever Says RELIABILITY Can’t Be Fun Hasn’t Experienced The Reliability Game
The Maintenance Reliability Exercise is a very effective tool that demonstrates the financial impact and the importance of equipment reliability. It is used raise awareness of the need for rapid change - from a reactive to a proactive reliability environment.
What do you learn by playing the game?
* Understand the size of the financial opportunity associated with proactive maintenance
* Where the money goes
* How to stop spending the money
* How to make the transition from Reactive to Pro-active maintenance
Trying to change organizational culture is difficult even when it goes well. People have a hard time “seeing” the objective.
The Reliability Game clearly demonstrates to all stakeholders the value of good proactive reliability practices and the effect on the bottom line. It’s a great way to make your point and have fun in the process.
Price Per Person just $345
Bonus: get an additional 15% discount by using Code: EM171A
Follow the links to conference registration.
Register for the Reliability Game online at ManufacturingWeek.com today
Vibration Analysis Tip
Always make a routine backup of your vibration database and any other technology database files used in your predictive maintenance program. It is a good idea to store your database files on a network drive when possible. This will allow your site IT group to create a routine backup of your data. Otherwise, periodically copy your technology database files to a network drive or a back-up device.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
March 16, 2006 Motor Testing Tip
Why should you perform high voltage testing on motors?
Did you know that contactor bouncing on motor startup (mechanical or vacuum-type starters) causes voltage spikes 3-5 times operating voltage? Initial contact is made then the circuit is broken when the bouncing occurs, thus reducing current and increasing voltage. In the case of pwm vfds, high voltages come from very fast steep-fronted switching waveforms and reflected waveforms that build up. The dielectric strength of insulation is so good that not even 10% of it’s value is attained during a high voltage test. Credible and peer-reviewed industrial test standards, which have existed for years, guide predictive maintenance users to voltage testing levels. Such examples are IEEE 43, 95, 432, 522, 841, IEC 34-15 and NEMA MG-1. Modern high potential test equipment performs both a copper-to-copper insulation and a groundwall insulation test using high voltage and low current. A 12 kv tester only produces 15 Watts maximum, thus duplicating startup voltage at a much lower current than a real motor startup. High voltage testing is the only way to detect insulation problems weeks or months before failure while you can make a plan-of-action decision. Laws of physics dictate why this is true, but it’s a discussion for another day. Meanwhile, the motor is still operating.
Tip provided by Baker Instrument
Tel: (800) 752-8272
http://www.bakerinst.com
March 16, 2006 Ultrasound Tip
Tagging System Ensures Leaks Are Fixed
A 2-tag or 3-tag system manages found leaks and closes the loop from discovery to repair. In either system a brightly colored tag is attached to the leak to identify it for repair. On the tag itself there are two or three perforated sections with matching identification numbers. Section one needs ample space for a written description of the leak and its location in the plant. This section is removed by the ultrasound inspector during a leak survey and is used to generate a work order for repair. The second section is left at the leak site and only removed after the repair is completed. There is space on this section to describe the actions taken to affect the repair. Details may include name of repair personnel, parts required to make the repair, and the time required for the job. If a third section is used, it is left at the leak site. During the next tour by the ultrasound inspector the repair will be confirmed. If no leak is found the inspector removes the third tag to close out the job.
Finding leaks doesn’t save energy until they are repaired. Use a tagging system like the one described here to ensure leaks are not only found, but fixed.
This tip supplied by SDT North America
http://www.sdtnorthamerica.com
905-377-1313
March 16, 2006 Two-Day Lean Maintenance Workshop – by Ricky Smith
Learn how to achieve Lean Maintenance from Ricky Smith, experienced reliability expert and renowned author of the book “Lean Maintenance”. Ricky’s insightful, dynamic and engaging teaching method will help you to understand Lean thinking in Maintenance.
Attend this workshop to:
• Understand how lean thinking in Maintenance can help reduce the 7 Major Losses in production
• Bridge the gap between Lean Manufacturing and Lean Maintenance
• Learn how to achieve Lean Maintenance, step-by-step
• Participate in interactive group activities to build Asset Reliability Programs with Lean thinking, including the 5 S’s of Lean Maintenance
• Capture valuable Best Practices for Lean Maintenance and review Lean Maintenance Metrics
Don’t miss this opportunity to attend Ricky’s next Lean Maintenance workshop, May 11 – 12, in Houston, Texas.
March 16, 2006 Human Error Tip
When employees have had several days off in a row their mental state upon return to work is below what it was when they left. Supervisors should not give these employees jobs that require a higher awareness for detail on the first day back.
Tip provided by the Reliability Center Inc.
http://www.reliability.com
Tel: 804-458-0645
March 16, 2006 Alignment Tip
After having gone through the proper prealignment checks, recurring alignment problems can usually be traced to the concrete plinth or base. This is one of the most ignored sources of shaft alignment problems and, is very seldom considered when troubleshooting. If a new concrete base is to be poured, the wooden shutters must be strongly made and a jig made to locate the hold-down J-bolts accurately to avoid bolt binding later on when the baseplate is set. During the pouring of the concrete, the mixture must be vibrated to avoid water and air pockets forming. Because of the exothermic reaction during the curing period, the heat generated must be dissipated by placing wet gunny sacks over the concrete surface until the concrete cures.
The same precautions must be observed when pouring grout into the base plate. The generated heat can, and will distort the level of the base plate and it will become a constant problem. When the concrete foundation has set, check its natural frequency with a vibration analyzer and log the frequency reading. This can be a hidden source of resonance if the rotating component is operating at the same frequency. This is a more common problem than is generally realized.
This Maintenance-Tip Challenge Winning Tip provided by John C. Robertson, President, AMSCO Inc., Simpsonville, SC
