Effective Maintenance Management: Risk and Reliability Strategies for Optimizing Performance
A new book by V. Narayan
… this book has the depth and content to really help maintenance organizations change and improve reliability. This is a book with true content, without having to own numerous other books to provide information one might need. Great book…Ricky Smith, Executive Director, Maintenance Solutions.
Providing a clear explanation of the value and benefits of maintenance, this unique guide is written in a language and style that practicing engineers and managers can understand and apply easily.
Effective Maintenance Management examines the role of maintenance in minimizing the risk of safety or environmental incidents, adverse publicity, and loss of profitability. In addition to discussing risk reduction tools, it explains their applicability to specific situations, thereby enabling you to select the tool that best fits your requirements. Intended to bridge the gap between designers/ maintainers and reliability engineers, this guide is sure to help businesses utilize their assets more effectively, safely, and profitably.
Order Your Own Copy Of Effective Maintenance Management
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Misalignment and unbalance are the most common causes of machinery malfunction. A properly aligned and balanced machine will save a factory between 40% to 50% on machine down time, replacement parts, inventory, and energy consumption,. The payback from aligning and balancing machinery to extend the operating life and optimize process conditions is very large.
SpectraQuest’s Alignment/Balance Vibration Trainer (ABVT) is designed for studying the vibration signatures that occur when two shafts are misaligned and/or rotors are unbalanced/eccentric/cocked or operating at a resonance condition. It is a hands-on trainer for maintenance professionals. It provides a unique mechanism for studying soft and sprung foot.
Call SpectraQuest at (804) 261-3300 or...
Visit The Alignment/Balance Vibration Trainer Web Page
With the D505 and D525 Easy-Laser alignment systems you can have precision shaft alignment and overall vibration level (inch/s) and bearing condition (g-value) all in one instrument.
Standard programs included will tackle any type of rotating machinery alignment task such as: Horizontal and Vertical machines, EasyTurn that only requires a 40 degree rotation of the shafts, Machine Train for multiple couplings, Thermal Growth Compensation, RefLock allows you to pick the “fixed pair of feet” if you are bolt bound, Values for checking straightness of foundations and Vibrometer.
With the Vibrometer program you will be able to take a “pre-alignment” vibration level check and a “post-alignment” vibration level after aligning the machine. Just remove the cable from the detector and plug it into the Vibrometer Probe and you can start measuring vibration level and bearing condition. Store each value in the software and include it in your alignment report with our Easy-Link software.
Order any alignment system through July and receive a FREE D80 Belt & Pulley Laser!
Call Alignment Supplies, Inc. toll free at (800) 997-4467 or…
Visit the Alignment Supplies web site
The Rolling Bearings Troubleshooter’s Guide consists of two tools that can help save you time, money, and your sanity. And you get both on the same CD-ROM.
• Bearing Failure Analysis System
• Bearings Reference Guide
What Does the Rolling Bearings Troubleshooter’s Guide Consist Of?
The Bearing Failure Analysis System is the quickest and easiest way for anyone to determine what caused a bearing failure. Adapted from the print version of the acclaimed handbook by bearing “guru” Ray Guyer, the most important aspect of the Bearing Failure Analysis System is it will explain…HOW TO PREVENT THE SAME TYPE OF PREMATURE FAILURE IN THE FUTURE.
Now, picture this. Instead of getting “chewed on” by the boss when the line is down, you’ll receive a pat on the back for helping him achieve the highest plant machine uptime levels ever recorded. Now that’s a much nicer picture.
Bonus on the same CD-ROM: Along with the Bearing Failure Analysis System you’ll receive the complete Bearings Reference Guide. This book on CD contains the complete contents of the materials students receive in Ray Guyer’s popular bearing workshop. This manual is literally the… Encyclopedia of Bearings.
Call VibrationSchool.com at 239.985.0317 ext 112 or...
Visit The Rolling Bearings Troubleshooter’s Guide Web Site
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MaintiMizer is a comprehensive computerized maintenance management system (CMMS) at home in a broad range of equipment and facility maintenance environments. MaintiMizer gives you the tools you need to easily and cost-effectively manage your most critical maintenance functions.
For example, MaintiMizer’s work order application efficiently tracks your maintenance tasks, labor hours, and inventory usage. The inventory application offers you quick, accurate retrieval of vendor references, storeroom and parts availability, and outstanding purchase order status. The vendor and purchasing application allows you to generate both requisitions and purchase orders and can be interfaced to many existing ERP applications.
We also offer Mobile MaintiMizer, which works on a handheld PDA. Mobile MaintiMizer allows you unprecedented access and ability to manage your maintenance functions in real time.
MaintiMizer reduces costs, increases productivity, and delivers a proven return on investment. According to independent sources, MaintiMizer™ is the most cost effective, value packed CMMS on the market today.
Call Toll Free 800.366.0793 or...
Visit the MaintiMizer™ CMMS Web Site
Oil purification does not have to be complicated or difficult. In fact, it can be very simple! There is an oil purifier on the market today that offers simple on/off operation and only requires one utility…power. This purifier can remove water, gases/hydrocarbons, and particulate, bringing your oil back to “like” new condition without impacting the oils properties or additives and significantly improving machinery reliability and MTBF.
Water Removal
Water is reported by many industries as the #1 contaminate found in oil systems…and it can be the most difficult to remove. Free water can be removed by most of the older technologies such as centrifuges and coalescers; however, to get the dissolved water out and stop the rust, corrosion and additive depletion you must use a technology that can remove all forms of water to very dry levels. Zero water = Maintenance Savings!!
Degasification
Seal oil leakage and the continuing problem of sour oil disposal can be a maintenance nightmare. Improved seal designs are the solution to this challenge however, until that machine comes down at turnaround…an oil purifier that can degas can save you major dollars by eliminating new oil purchases, sour oil disposal, and your employee’s handling this hazardous gas ladened oil. Keep the oil in the tank and send the gases to the flare…it’s that simple!
Call LSC to see a demonstration of the ThermoJet Oil Purifier at 713/464-6266 x 170 or...
Watch The Oil Purification Movie (Flash)
The new technology of GoatThroat™ Pumps make significant financial, environmental, and safety contributions to manufacturing sites by integrating safe chemical handling, pollution prevention, improved worker safety, VOC reduction, while providing substantial contributions to the company’s bottom line. GoatThroat™ Pumps are small, inexpensive, hand or shop-air operated transfer pumps, safe for use with over 700 commonly used industrial, automotive and agricultural chemicals. These pumps are extremely durable and will provide years of service. Made of chemical grade polypropylene, GoatThroat™ can pressurize any container from 2 to 55-gallons in seconds. The working pressure of 1-5psi produces consistent flow rate of 4.5gpm. A drip-proof faucet dispenses small amounts or gives steady flow. Containers remain upright, so there is no extra handling required for drums and little chance for accidental spills. Optional remote tap system delivers fluids to point of use 5- 10’ away from drum. Priced from $139 - $229.
Call GoatThroat™ Pumps at 646-486-3636 or...
Visit the GoatThroat™ Pumps Web Page
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The Bearing Expert provides an automatic Multiple Manufacturer Vibration Frequency Report. It is the only product that can produce multiple frequencies with one request and is the largest vibration frequency database available worldwide. The Multiple Manufacturer Vibration Report is generated from the same initial request for interchange data and requires no additional steps. The frequencies are calculated at the RPM (Revolutions per Minute) or CPS (Cycles per Second) value the user specifies. In conjunction with the Multiple Manufacturer Vibration Report, The Bearing Expert also features the Harmonics Report. The user may select the number of times they would like to have the frequencies calculated for each report. The default is for 10x's Harmonics.
The Bearing Expert is the source for Vibration Frequencies. It has the support of leading Condition Monitoring Software Providers, Consultants, and Bearing Manufacturers alike. The database is updated on an annual basis.
Call 239.985.0317 ext 112 or...
Visit the The Bearing Expert Web Page
Analysts' Quick Sampling System (QSS) valve is easily installed on a gear box, compressor, engine or oil reservoir and assures accurate and representative sampling without shutting down equipment. Call today and make oil sampling hassles a thing of the past. Available in 1/4 and 1/8 inch sizes, the low cost QSS valve operates with a patented double valve release insuring spill free and clean sampling. Entering our fifth decade in the lubricant analysis business, Analysts prides itself on the relentless pursuit of new and innovative technologies designed to provide the maintenance specialist with the latest equipment and cost savings available in the market. The QSS valve is just one more example of The Analysts Difference! For more information call 800 655 4473 or...
Visist the Analysts Sampling Supplies Web Site
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To go along with our standard Motor Alignment Stainless Steel Precut Shims. We make different kinds of pieces according to your needs.
Call us or fax your shim drawings and requirements for a fast, efficient quote and service.
Besides dimensions we need material and quantity of each thickness.
Mr. Shims can handle a variety of materials.
We’ve helped a number of customers obtain very specialized shims, gaskets and washers that have solved demanding application needs.
Remember, we’re only a phone call or a click away.
For any shim needs call Mr. Shims at 1-800-727-4467,
fax 630-832-5744 or...
Visit Mr. Shims Web Site
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D3R: The newest digital tester - lightweight and now with resistance testing
Our friends at Baker Instruments are offering one lucky web site visitor a chance to win a D3R: The newest digital tester - lightweight and now with resistance testing. This instrument is worth over $12,000 so enter today for a chance to win.
The D3R/D6R/D12R is the newest digital tester offered by Baker Instrument Company. This instrument is designed to maximize testing capabilities in a lightweight, sturdy format. Additional testing capabilities have been added to the tester, to make it a more comprehensive tool for predictive maintenance. As with the other Digital testers, the New D3R/D6R/D12R's high precision testing capabilities allows data collection in the shop or the field. The results can then be printed immediately or stored for later use. This tester demonstrates Bakers continual commitment to motor integrity and insulation testing.
Turning Maintenance into a Profit Center
Improve efficiency in maintenance operations with xmMOBILE™, software transmitting work orders to Palm OS® and Pocket PC handheld devices.
Eliminating the need for paper work orders, xmMOBILE allows you to send work orders and inspections electronically to your maintenance technicians. They complete tasks and update the work order right at the point of work performance in the field, plant floor, or wherever they need to travel to respond to maintenance requests. At the end of a work shift, xmMOBILE automatically updates the database for your MicroMain XM™ CMMS (computerized maintenance management system).
With xmMOBILE, maintenance staff can also create new work orders on the fly, track time as tasks are completed, and add parts and labor. Technicians and supervisors can easily enter comments on the handheld device, too.
xmMOBILE makes it easier to design and conduct any type of inspection. Enter inspection data including pass/fail, ratings, measurements, readings and asset conditions.
Use xmMOBILE with PDAs, Pocket PC handhelds, bar code scanners, and other devices including some mobile phones.
Affordable and easy to use, xmMOBILE gives you complete control of work orders and inspections … right at hand!
Call 512-328-3235 or...
Total Learning Time: 5-7 hours
Unit 1: Plant Maintenance Overview
Unit 2: Functional and Reference Functional Locations
Unit 3: Equipment
Unit 4: Maintenance Planning
Compressed air and gas leaks come in all shapes and sizes. To tackle a complete plant leak audit ultrasound inspectors need the right tools to do the job right, and fast. SDT’s Ultrasound Leak Surveyor’s Kit is designed with that goal in mind.
The Leak Surveyor Kit includes the Ultrawave 170 detector with a built-in ultrasound sensor for general plant tours. Complimenting the system is the 21” Flexible Wand. This “ultrasonic snake” bends and twists to get behind piping, inside instrumentation cabinets, and into tight areas where your hand can’t normally reach. For leaks in overhead ceiling pipes screw in the EDS Extended Distance Sensor. This unique shaped cone amplifies ultrasound signals and concentrates them onto the focal point of the sensor extending the range of the SDT 170 by up to 100’ or more.
Compressed air is the single most expensive utility in industry. It is also the most neglected. An investment in the SDT Leak Surveyor’s Kit is a sound one that will pay back the first time you use it.
Call (800) 667-5325 or ...
Visit the Ultrasound Leak Surveyor’s Web Page
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The Reliability Toolbox™ CD ROM is an organization-wide solution to improving and enhancing the weakest link in your CMMS program, maintenance procedures and documentation. Gain control of your maintenance and reliability programs, by capturing valuable machinery information and creating job aids for current and future employees. The value of machinery knowledge is immeasurable and is essential to a successful implementation of reliability programs. The Reliability Toolbox™ is an enhancement program that will help your company to obtain and secure this valuable information, provide consistency in job performance and training of employees. The Reliability Toolbox™ CD ROM program offers a reliability knowledge assessment and several live multimedia training modules that explain and demonstrate the use of various maintenance forms and procedures. This program also provides a collection of over 50 generic boilerplate maintenance forms, procedures, and job aids that can be used as is, or modified to meet the procedural requirements of an existing reliability improvement program. Customer can choose the forms in both Imperial and Metric Measurement Systems.
The Reliability Toolbox™ has four key areas that contain multimedia training, reliability knowledge assessment evaluations and maintenance procedures and forms: Maintenance Management, Condition Monitoring, Maintenance Practices, and Precision Alignment.
Call 239-985-0317 ext 112 or...
Visit the Reliability Toolbox™ Power Web Page
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Do angular soft foot problems have you “Chasing-Your-Tail” during alignments? If so, then you need to try Sof Shoe shim, the conformable shim designed to eliminate Angular Soft Foot problems. Its unique cold flow and set properties fill irregular gaps between the motor foot and base to ensure an accurate alignment. Precision Brand's Sof' Shoe shim acts like a conformable shim and fills angular gaps eliminating the need to step shim or re-machine.
Leaving angular soft foot uncorrected can cause misalignment, decreased bearing life, leaky oil seals, and even excessive coupling wear; any one of which can result in expensive downtime for you.
Some clues to detect angular soft foot are excessive vibration, inconsistent flat rise readings, spongy feet, motor walking, and generally difficult alignments.
Don’t waste any more time with problematic alignments caused by angular soft foot. Sof’ Shoe shim increases productivity, extends motor life and reduces maintenance costs.
Call the Precision Brand Products, Inc. customer service department at (800) 535-3727 or (630) 969-7200, mention this Reliabilityweb.com ad and we’ll send you a FREE sample of our Sof’ Shoe shim or…
When a piece of equipment arrives at the repair shop, the RepairTracker database can be searched to determine if this piece of equipment is already in the system. If not, the shop adds it to the database and can then begin entering repair findings, root cause analysis, comments, recommendations, and linked documents. Linked documents can be Excel spreadsheets, PDF vibration reports, or motor circuit test documents. When the repair is finished, the shop can add any final comments, indicate the cost of the repair, and when the repair was finished.
Plants can view the equipment currently being worked on was well as anything which was recently finished. This information is available regardless of which shop performed the repair. The database can also be searched for information based on one of several criteria: when the repair was performed, the purchase order number, a shop tracking number, or by the equipment specification (brass tag number, a power range, manufacturer and frame size, etc…).
The entire system is maintained by 24/7 Systems, and is an entirely web based HTML application. This means that no software other than a standard web browser needs to be installed on the user’s computer. All updates, modifications, and backups are performed by 24/7 Systems.
Call 24/7 at (865) 681.0282 or ...
Visit the Motor Repair Tracker™ Web Site
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The fully-radiometric, high performance Raytek ThermoView(tm) Ti30 thermal imager is a hit with users worldwide. Designed for predictive maintenance applications, the ThermoView Ti30 thermal imager scans targets quickly and smoothly, includes software for analysis and reporting, and comes with all the accessories needed to get the imager up and running quickly. A two-day imaging training session is also included.
Bill Gray, a maintenance reliability specialist at the Wausau-Mosinee Mill in Rhinelander, WI, an "early adopter" of the latest thermal imaging technology, said he's happy with his ThermoView imager.
He contracts annually with an outside thermal imaging firm to do a survey of his paper mill's electrical switchgear, and after the survey, repairs are made to any problem connections identified in the survey report. However, due to the expense, follow-up imaging by the contractor to verify repairs was not being done. But with the affordable ThermoView Ti30 imager-under $10,000--that's no longer the case.
"We weren't having operational problems or failures but the repairs we made didn't always help," Gray said. "(Without ThermoView imager) We would have had to wait another year to find that out."
Visit the ThermoView Ti30 Web Site
Silverlake Associates, featured product, SMMS is a comprehensive Computer Maintenance Management System (CMMS) solution, which helps organizations large and small with managing and maintaining production equipment and physical facilities. Using the system helps companies save money by improving quality, reducing downtime, and gaining operating efficiencies by keeping capital equipment in the optimal operating condition.
The SMMS modules include Work Orders, Equipment, Inventory, Labor, and Purchasing. In addition to extensive built-in forms capabilities, information can easily be sent to Microsoft Excel spreadsheets for further customization.
The SMMS solution is a user-oriented client-server solution that combines the reliability, scalability and security of the IBM iSeries (AS/400) midrange business server with an intuitive PC client interface. SMMS users can access the system using standard PCs connected directly to the network or via the web. SMMS supports bar code scanning devices as well as PDAs and PDTs.
As an IBM Developer Business Partner, Silverlake Associates offers onsite training, consulting, installation, data conversion and custom systems integration services. Ask about our free MAPICS inventory/purchasing interface.
For a SMMS information CD or to schedule up a Web-demo
Call Silverlake toll free at (800) 383-8177 or…
Visit the Silverlake Associates Web Site
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U.K. based Fluid Conditioning Systems Ltd has designed a magnetic filter that is capable of removing ferrous contaminants in fluids down to 1-micron without reducing flow. The filter forces the fluid through designated flow channels. On either side of the flow channels is a magnetic field that captures the ferrous particles as the fluid flows through. Going by the trade name Magnom, the product is not designed as a replacement for conventional filters, but rather as a way to effectively remove the most damaging of contaminants – ferrous particles.
Magnom filters are an excellent way to control contamination in any mechanical system that produces ferrous particles. Of special note is the fact that because Magnom filters do not cause a reduction in flow, they can be placed in areas that are not able to utilize conventional filters, such as the suction side of pumps.
Magnom filters have no moving parts, are fully scalable and can be cleaned and reused an infinite number of times.
If in North America, please phone Companion Products Inc. toll free at (800) 268-3558 or...
Visit the Magnom filters web site
WHEN RELIABILITY MATTERS
Advancements in the way portable filter carts are manufactured, has provided safer & cleaner ways to access and filter oils.
Gone are the days of open frame electric motors, fractional horsepower motors on portable filter carts with drip pans (collection trays for oil) and hose wands. They are no longer acceptable, because they can be unsafe for use and may add more contamination than they remove.
Portable filter carts are the very best way to keep oils clean and any "World Class" Reliability Program would begin with new & better oil handling practices. Keeping oils closed off at all times is paramount, for the reduction and control of contamination. World Class Reliability reduces the entry points (ingression) of contamination before it ever comes into contact with the oil.
A standard 2100 Series filter cart incorporates the following, as standard features; 1HP-TEFC Electric Motor, 25FT Electric Cord Reel, Water Removal & 3 Micron Absolute Filters (Both with differential visual indicators), 7FT Clear PVC Transfer Hoses with Female Quick Disconnects and Dust Plugs.
Call Y2K Fluid Power toll free at (888) 925-8882 or...
Visit the Y2K Fluid Power Web Page
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With the D505 and D525 Easy-Laser alignment systems you can have precision shaft alignment and overall vibration level (inch/s) and bearing condition (g-value) all in one instrument.
Standard programs included will tackle any type of rotating machinery alignment task such as: Horizontal and Vertical machines, EasyTurn that only requires a 40 degree rotation of the shafts, Machine Train for multiple couplings, Thermal Growth Compensation, RefLock allows you to pick the “fixed pair of feet” if you are bolt bound, Values for checking straightness of foundations and Vibrometer.
With the Vibrometer program you will be able to take a “pre-alignment” vibration level check and a “post-alignment” vibration level after aligning the machine. Just remove the cable from the detector and plug it into the Vibrometer Probe and you can start measuring vibration level and bearing condition. Store each value in the software and include it in your alignment report with our Easy-Link software.
Order any alignment system through July and receive a FREE D80 Belt & Pulley Laser!
Call Alignment Supplies, Inc. toll free at (800) 997-4467 or…
Visit the Alignment Supplies web site
Sprite™ is a low cost, modular, easy to install wireless vibration monitoring system that integrates seamlessly with DLI’s ExpertALERT™ software and portable data collection systems. Sprite™ is not an alarm system but an advanced diagnostic system that tells you exactly what mechanical fault is present in your machine, the severity of the problem, and a recommendation of what to do about it. Never has condition monitoring been so easy.
Look Ma, No Wires!
Don’t get up! Sprite™ will transmit information right to your desktop whether it is located in the plant or on the other side of the world. Each Sprite™ can handle up to 512 inputs of either dynamic or process data including DC voltages and 4-20 mA current loop sensors. Dynamic data include; vibration time waveforms, spectra, envelope demodulation, full spectrum, phase, speed and overall amplitude for a total picture of machine condition. BUT, why cable up 512 sensors to a central unit when it is far more cost effective to install multiple Sprite™ modules near the machines and link them wirelessly to your network?
Look Ma, No Software!
Sprite™ is also compatible with DLI’s Web Connect™ Internet based monitoring which makes raw data, expert diagnostic reports and reviewed reports available to anyone with the proper credentials via a standard web browser. Not only that, but DLI’s licensed engineers would be happy to review your data for you if desired. Why not? We’ve been doing this for other clients worldwide since 1966!
Call DLI toll free at (800) 654-2844 or...
Visit the Sprite™ Wireless Vibration Monitoring Web Site
The MikroScan 7400 represents another milestone in innovative infrared thermometry. This fully-radiometric camera with its high-temperature functionality makes it the perfect tool for PPM inspections and radiometric inspections of internal furnace/boilers.
The MikroScan 7400 is ergonomically designed for comfortable one-handed point-and-shoot operation, includes on-board digital voice recording, and can simultaneously record high-definition 14-bit thermal images with digital visual images. It also includes a high temperature range, specialized infrared filtering capabilities, radiation shield, and protective window assembly, which allows the imager to be used to measure temperature of tube walls inside a furnace without the interference from combustion flames.
The MikroScan 7400 is completely self-contained in a splash-proof metal case, is battery operated, and stores images and data to PCMCIA cards. Images can also be viewed in real-time via the video output or through an optional built-in IEEE 1394 (Firewire®) interface. It comes standard with extensive onboard image processing software and can also be remotely controlled from a PC using optional software developed by Mikron, which provides additional analysis and reporting capabilities.
This is truly one tool that can do it all.
Call toll free (888) 506-3900 or …
Visit the MikroScan 7400 Web Page