June 08, 2006 Ultrasonic Tip
From Ultrasonic War Stories by Jim Hall
http://www.ultra-soundtech.com
I had been called earlier in the month by a manufacturer of structural parts for Sidewinder Missiles for the sole purpose of instructing his people in the use of airborne ultrasound and the many applications.
This particular day the plant was manufacturing “fins” for sidewinder missiles. You know? Fins that help the missile stabilize in flight. Manufacturing these parts requires having a heat treat ovens, lots of ovens and tons of natural gas or propane.
So, there we were Julio, Chico and I, wandering the plant looking for anomalies. What I was trying to show them at the time, were tactics that I had used in the past.
Particularly, how I would leave the headphones on my head and the ultrasonic receiver in my hand as I walked back to the mechanics shop, after performing a maintenance task or pdm application.
Its important that anyone using airborne ultrasound, continue to use the instrument right up to the door of the maintenance shop and not just “lolly-gag” (goof-off) back to the shop. You should always keep watch and be alert for anomalies on electrical switchgear (stay outside arc- flash boundaries), air leaks (pressure or vacuum), conveyors, etc…
The smell of gas had been reported earlier that week, so we (Chico, Julio and I) quickly began scanning with ultrasonic receivers that were rated IS (Intrinsically Safe). Meaning, it can be used in an explosive atmosphere. As I started scanning the 8 heat treat ovens, all of which were operating at the same time I noticed an arcing sound that seemed to be coming from a low-voltage panel across the room (about 25 feet from the first oven). As I approached a 480 panel across the room, the arcing got louder. As we struggled to stay outside the “arc flash” boundary, we noticed a lower panel were the sound was emitting from. Not only could you hear the sound, you could smell smoldering metal or wire.
As Chico quickly got his Personal Protective Equipment (PPE) on to guard against Arc Flash, he then slowly opened the panel. You could actually see a live spark arcing across the connecting block and the aluminum wiring.
I thought to myself, how in the world could anyone still have “aluminum wiring” in a plant like this?
It was about this time that Julio came running up to me to tell me what he had found. He mentioned that he had found several leaks on an oven about 30 feet away.
At that time, (fearing fro my life and everyone else’s) I said, “that’s it!”, I’ve had enough, I ‘am outta here.......
The gas leaks were significant, but because they had fans sucking the contaminated air from the room, it was not as noticeable.
Needless to say, all the aluminum wiring was replaced and everybody lived happily ever after.
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Join Jim Hall for Web Workshop #3
Date: Friday June 16
Time: 11 am – noon EST (GMT -05)
Price: Free
Part 1 - 6 Steps to creating an effective Ultrasonic Analysis Program by James Taylor
and
Part 2 Introduction to Airborne Ultrasonics by Jim Hall
Space is limited so please use this link to enroll in this FREE workshop today!
June 08, 2006 Maintenance Tip
Slipping/Worn Belts
Use a pocket strobe in the field to identify belt related problems on equipment. The pocket strobe can be adjusted to the same frequency/RPM of the equipment. Damaged, worn or slippage in belts can be observed and reported for repair. If a belt has to be replaced, make sure to change the entire belt set and re-align it using a laser belt alignment tool, like the DotLine Laser.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com/dotline.htm
Tel: 305-591-8935
June 08, 2006 PdM-2006 Better - Not Bigger!
Predictive Maintenance Technology Conference & Expo
September 12-15, 2006
Chattanooga TN
Have you noticed the new trend in Maintenance Mega-Conferences?
900 attendees - 1400 attendees! How does a huge crowd benefit you - the attendee?
At Reliabilityweb.com, you told us you like smaller conferences that also create opportunities to meet and exchange information with other maintenance and reliability professionals. You also want the best subject matter experts and actual case studies of people like you who have “been there” and “done that” - like PdM-2006 speakers from Boeing, TVA, Alcoa, Dofasco, Cargill, US Navy, US Force, Unicem.
At PdM-2006 the Predictive Maintenance Technology Conference:
• Attendance is limited to 500 to ensure a quality experience
• 45 Case Studies and short courses
• Collocated with LubricationWorld
• 2 Events - 1 Price
• Meet the Uptime Magazine PdM Program of the Year Award Winners
• Sit for the CMRP Exam by SMRP, CLS/OMA Exam by STLE or the Vibration Institute Certification Exam
• Meet representative of SMRP, STLE, IEMD (new Motors group) and ISPOT (New Infrared Group)
• Learn how the Council for Certifying Organizations (CoCo) is unifying PdM Certifications
• Choose from 10 full day workshops
• Chance to win an Alienware Laptop
•Arnold Engineering Development Center Plant Tour
• Over 40 Leading PdM Vendors
• Save $200 on early bird registration
Watch for more program and event details in this month’s Uptime Magazine or use the link below to request a PdM-2006 brochure.
Please make plans to attend PdM-2006 today and take advantage of early bird savings. Group discounts are also available by calling toll free (888) 575 1245.
June 08, 2006 Lean Maintenance Tips
Laws of Manufacturing Maintenance
• Properly Maintained manufacturing equipment makes many quality products
• Improperly maintenance manufacturing equipment makes fewer products of questionable quality
• Inoperable equipment makes no products
From Lean Maintenance by Ricky Smith and Bruce Hawkins
June 08, 2006 Planning Tip
6 Basics Principle to Keeping Planning and Scheduling Simple – Tip 1
By Sam Slade
I believe most of you can keep planning and scheduling simple without making radical changes to your current maintenance program. I always liked the phrase “Keep it simple stupid”. In fact studies have found that most companies struggle with planning and scheduling because they try to make it too complex. You will find very few companies (less than 5%) perform planning and scheduling to the full extent. I am offering a simple solution to companies that need help now and currently have no planner/schedulers.
If you would like to improve your workforce efficiency (direct work time or wrench time) by 10-30% then follow these simple principles (I call this process crawling before we learn to walk).
1. If you do not have a planner and scheduler, identify one person in your maintenance workforce to be one.
- Identify one planner/scheduler for every 7-15 maintenance personnel (this number is flexible)
- Look for a person who can sit at a computer and work for long hours focused on doing a good job without someone holding their hand (I like electricians for this job best).
2. Write a blanket work order covering his/her time.
3. Have the new planner/scheduler focus on scheduling work one day out. No planning just scheduling the work for each person along with coordinating with production/operations. Additional points:
- You will want to expand the scheduling to a full week once the planner/scheduler feels comfortable with the scheduling process.
- Warning: Maintenance supervisors remain in control of their work telling the planner/scheduler what work he/she wants done the next day and who does it.
Planner/schedulers can make recommendations however.
4. Have the planner/scheduler order/expedite emergency parts for the maintenance supervisor or craft personnel as needed.
5. Do not allow the planner/scheduler to return to their tools. You will want them focused on scheduling work (maybe start planning jobs that takes over 4 hours)
6. Measure your scheduled compliance by week. Scheduled Compliance: Measure the number of scheduled (not emergency work) work orders completed on scheduled and divide this number by the total number of work orders scheduled for one week. Track and trend this information and watch the schedule compliance grow along with equipment problems decreasing. Post this data on your maintenance bulletin board.
Your scheduled compliance may start at below 20% however it will grow. At some time, maybe 6 -12 months, you will need to improve this model to a more proactive one. In my series of titled “Keeping it simple” you will be provide many ideas on how to improve this process. In conclusion, the process above will provide results quickly if you follow all of my simple rules. I have seen this process work at many maintenance operations.
Tip provided by Sam Slade, Maintenance Planner
June 08, 2006 Infrared Breakthrough: Multi-Band Cameras Image Through Flame
“Look, Ma, no cryogenics!” – That’s the brag from engineers who have saved $50,000 or more over a cryogenic midwave IR camera by using Mikron Infrared’s new MikroScan 7400 portable camera or M7500 process imaging camera. These unique cameras use a standard uncooled microbolometer to image in both midwave and long-wave bands.
The MikroScan 7400 is getting rave reviews from the power generation industry, where it’s used for predictive monitoring of electrical hardware in the 8.0-14 micron long-wave band, then filtered for the 3.9 micron band for through-flame monitoring of boiler tube condition. The camera serves two roles, in two different IR bands, for the price of one single-band camera. This saves thousands for a cryogenically cooled midwave camera that can only do half the work – that’s ROI!
The new M7500 process monitoring camera is also a technology “first.” It can be configured for midwave or longwave imaging and four different temperature bands. Patent-pending “spectral tuning” enables the M7500 to image in the midwave bands of 3.9 microns (furnaces and boilers through flames) and 4.8-5.2 microns (for glass), in a temperature range of 400° to 1600°C. For widest process monitoring flexibility, the M7500 features two standard temperature ranges of 40° to 120°C and 0° to 500°C in 8-14 micron long-wave mode, ideal for typical monitoring applications, because it’s unaffected by sunlight or factory lighting. It provides temperature accuracy of ±2°C for applications in glass, ceramics, food processing, paper, textiles, electronics, hydrocarbon/chemical processing and others.
For more information on these spectacular products or to find your local sales professional, call 1-888-506-3900 or email
June 08, 2006 Electrical Inspection Tip
Pre-infrared scan inspection
Avoid possible arc flash situation by taking the load off of electrical cabinets and inspecting the components for possible problems.
Loose or broken wires, signs of arcing or flashing, animals or bug nests, loose components such as breakers, transformers etc., a pre inspection could save your life.
Reader Tip provided by Jim Barker, Maintenance Technician, Phelps Dodge, Morenci Arizona
Thanks Jim - your Maintenance-Tips hat is on the way!
June 08, 2006 Maintenance and Management Tech Tip
The most common methods that Reliability and Maintenance (R&M) personnel use for justifying recommendations and needs is cost avoidance and simple payback. Individual findings reported by these R&M groups are often presented as over-conservative numbers as R&M technicians often become concerned and cautious about the high calculated values. As a result, significant findings that can have a positive financial impact on business and operations are ignored as decision-makers, who may deal with values far more significant that those reported, have to make financial risk-based decisions. Technicians, in the meantime, often end up frustrated with management because the decision makes common sense to them and they cannot comprehend why management cannot see the importance of the recommendation or request.
Tip provided by Howard W. Penrose, Ph.D., CMRP, SUCCESS by DESIGN
