Resources for predictive maintenance

5 Time Wasters for Reliability Engineers to Avoid

2012-01-05T08:19:19-06:00

You’ve heard the catch phrases. You’ve read the success stories. You’ve seen the return on investment (ROI) calculations and the positive trending that reliability engineers bring. You’ve even lobbied upper management. Your argument has been so convincing that you’ve secured approval in this year’s budget to hire a reliability engineer. The hiring process has begun, and you can’t wait for the results: more reliable equipment, fewer failures and increased availability and production.

If only it were that easy. Building a reliability program led by competent professionals takes work. It requires setting expectations properly. Most of all, it requires time. How do you accelerate the process to ensure the maximum benefit in the shortest time? Avoiding these top five time wasters could help.

Lack of Vision

No, we aren’t talking about whether your reliability engineer could have been a fighter pilot or whether

Identifying Mechanical Faults with Motor Current Signature Analysis

2011-11-23T08:39:41-06:00

Motor current signature analysis (MCSA) has proven to be a highly valuable predictive maintenance tool. Although it is a relatively young, rarely utilized technology, it is rapidly gaining acceptance in industry today. Mechanical faults related to belts, couplers, alignment and more are easily found through the use of a demodulated current spectrum.

MCSA is simply the process by which motor current readings are recorded and analyzed in the frequency domain. It has been around since 1985 and proven itself well over the years in locating rotor faults and air gap problems in motors.

The motor current signature is recorded in a time domain format. The current is represented in a graph form with the amplitude shown on the “Y” axis and the time on the “X” axis. The result is a typical current sinewave shown in Figure 1.

In order to analyze the data, a Fast Fourier Transform (FFT) is

Why Vibration Troubleshooting Instruments are Inadequate for PdM

2011-11-07T09:51:41-06:00

This video explains the difference between troubleshooting instrumentation and the types of instruments and software that are used to implement predictive maintenance programs. Often providers of troubleshooting instruments confuse the industrial market as to the differences between their capabilities and true condition monitoring.

Maintaining a Predictive Maintenance Program

2011-10-10T08:10:23-05:00

“I finally have a predictive maintenance program off the ground. What do I need to do to keep it running? How do I build ‘trust’???”

Now that you have finished your lists, the work begins.

You have outlined the equipment you want to check, using Excel or some other program where you can create lists that are easily edited. With input from you conversations with the area experts, ask them the criticality of the equipment in their area that is on your list. This information will provide a starting point for the infrared, vibration, ultrasonic, etc., routes that you will develop.
You have taken those lists you created - in which you have broken out your high-priority items - for a second reading by the area experts. Ask if the lists fit their vision. If they do, ask them where they are having problems, and highlight those on your list.
You have realized this equipment becomes the critical components in

PdM Program Success Starts with Hard Work

2011-09-26T14:44:00-05:00

When you have developed a network of people — either through conference attendance or training classrooms, or through more informal avenues like blogs and predictive maintenance forums — you have a real sounding board for developing your PdM program. In my experience, though, the only way you are going to develop a true program for any of the disciplines (infrared, vibration, motor testing, ultrasound, etc.) is to put in some hard work yourself. You must determine what should be included and not included in the program and make some decisions on what the criteria will be to determine that.

This may or may not be a difficult task, but it is one that must be done. There is no simple way to do this. You will make some mistakes. These will not be earth-shattering ones — jus

Justifying a Predictive Maintenance Program

2011-08-29T16:18:53-05:00

“How do I quantify my PdM finds? Where do I go to establish my credibility?”

Grow a thick skin, fast. You have to develop some way of bringing some sense to the finds you have made in your predictive maintenance program.

Now that trust has been established and your routes are being executed, you wonder if the work you are doing is worthwhile. Are there any finds to report on to show you are doing a good job? How do you quantify the finds that have been reported and put a dollar sign to the finds to prove the system is working to the benefit of the company or department? How do you show that you are saving money and that the trust you have been afforded is well founded?

Nobody teaches us how to do this. It is one of the most difficult processes you have to establish in your PdM program, but it’s essential to justify your program’s existence. My way of quantifying a good find is simply to use a delay avoidance process. I take the cost per

Abanaki Releases New Edition of Oil Skimmer Facts Handbook

2011-04-12T13:38:22-05:00

In the M&R business, good enough never is

2011-03-04T11:42:23-06:00

About 15 years ago, I was fortunate to attend a conference where the keynote speaker's focus was quality. This person was a successful entrepreneur and had built a top-flight company over the past two decades. The company's success was based on making the best-quality, best-tasting cookie in the U.S. The person's motto was "Good Enough Never Is." The company was Mrs. Fields Cookies and the speaker was Mrs. Fields.

According to the company's Web site, Debbi Fields was a young mother with no business experience when she opened her first cookie store in Palo Alto, Calif., in 1977. People said she was crazy. No business could survive just by selling cookies. From those humble beginnings, Mrs. Fields became a global celebrity and her company became the premier chain of cookie and baked goods stores.

More than a decade later, I still carry that simple motto, "Good Enough Never Is", with me in my daily work to improve maintenance and reliabil

Is there life after the death of predictive maintenance?

2011-03-04T11:15:25-06:00

It is sad how quickly a good predictive maintenance program dies, even though the program has gotten a manager promoted, convinced you and others that there is a lot of value in doing PdM to improve maintenance practices, saved money and gained credibility.

The demise of a good program is usually due to the loss of the program champion. He was promoted because he saved tons of money and improved his maintenance practices – just overall improved the company’s bottom line. With a new department manager, the program fundamentally has started from the beginning. The new leader may not have any experience in the PdM world and cannot identify the need for continuing the process; he just sees costs for new equipment, training, equipment calibration, equipment upgrades, etc. In today’s world, with such a severe downturn, this is even more prevalent. Cutting costs for everything is the rule – it’s a shortsighted rule, but it’s one that we live by today an

Using iPad application for vibration analysis

2011-01-19T13:49:44-06:00

PdMA tip: Swirl effect is useful tool for detecting broken rotor bars

2011-01-18T08:57:28-06:00

A useful spectral tool for detecting broken rotor bars is the swirl effect, which occurs just below the 5th harmonic of line frequency (300 Hz on a 60 Hz line frequency).

Global machine condition monitoring equipment market to reach $2.1B by 2015

2011-01-18T08:54:22-06:00

Growth in the world machine condition monitoring equipment market has long been driven by capital investments in industries such as chemicals, petrochemicals, pulp & paper, metals, and heavy equipment manufacturing, among others. Condition monitoring has gained importance, over the years, as companies critically focused on asset utilization and productivity. The need for eliminating catastrophic breakdowns and unnecessary maintenance costs in production processes has and will continue to drive the adoption of condition monitoring solutions across several industries.

How Solutia uses the Optalign Smart shaft alignment system

2011-01-17T16:07:56-06:00

A sales engineer at Ludeca Inc. introduces the Optalign Smart shaft alignment system. He then speaks with Nihal Raval, a maintenance reliability engineer from Solutia Inc., about how Optalign Smart helped him.

Animation explaining laser shaft alignment

2011-01-14T08:55:56-06:00

Up to 50 percent of the damage to rotating machinery is directly related to misalignment! So just see the advantages of laser shaft alignment and increase your machine availability, productivity and machine lifetime

How to laser align rotating shafts

2011-01-14T08:50:23-06:00

This video shows how to laser shaft align rotating shafts as quickly as possible with Fixturlaser's "True Position Sensing", available on the Fixturlaser XA and the Fixturlaser GO. Laser shaft alignment with Fixturlaser's dual laser, dual sensor design means the system tracks the shafts' true positions, allowing alignments to often be completed with just one set of measurements and adjustments. The XA and GO laser shaft alignment tools are available in the United States from VibrAlign Inc.

Wireless condition monitoring for rotating equipment

2011-01-06T15:59:36-06:00

Ron Kittle, a senior product analyst for the Timken Company, talks about the StatusCheck wireless condition monitoring system.

A poem about plant maintenance (you need to read this!)

2011-01-05T09:50:45-06:00

"Maintenance evangelist" Joel Leonard forwarded this poem to us at Reliable Plant. We thought it important enough to share it with you. Enjoy!

Guohua wind turbines choose SKF for remote monitoring

2011-01-03T07:32:58-06:00

When the fourth-biggest wind farm operator in China increases its installed capacity by 50 percent within one year, that indicates a company that knows its business. And one of the business aspects that all wind farm operators need to take care of is “turbine reliability” – keeping the turbines turning as much as possible and keeping maintenance activities down to a minimum. Reduced or controlled maintenance is always a valuable contribution to bottom-line profitability, but when you’ve got 2,000 megawatts of installed capacity, the target by end 2010 for Guohua Energy Investment Company, based in Beijing, China, then you are talking about huge amounts of money.

GE notes its favorite monitoring and maintenance apps of 2010

2010-12-29T12:39:32-06:00

GE has been in the app fast lane — from consumer-friendly apps such as healthymagination’s Morsel, which helps people chip away at unhealthy habits, to GE Lighting’s Mood Cam app, which let’s you snap a picture of a room and see how different lighting styles might look to CNBC Real-Time, the only free app that offers real-time stock quotes from the NYSE and NASDAQ before, during, and after market hours. (The professional version gives real-time information and analytics on over 100 international markets.) But three that particularly caught our eye this year are the ones that most people might not at first think of when it comes to apps — as they’re for planes, trains and electric utilities.

PdM software innovations lead to improved operating margins

2010-12-28T16:57:45-06:00

The capability of today's predictive software provides immediate answers, not merely data. By proactively using predictive maintenance, one automobile manufacturing plant realized savings of up to $112,000.

Optimize wireless condition monitoring with Essential Insight.mesh

2010-12-22T07:00:59-06:00

Wireless condition monitoring is a key factor in plant health and safety, however; battery powered monitoring devices require maintenance and put limitations on data collection. Essential Insight.mesh 1.1, the latest version of the Bently Nevada product line’s wireless condition monitoring solution, has external power flexibility eliminating the need for batteries and associated maintenance. The external power also allows for the selection of more frequent data collection, meeting a broader range of applications, and it is the world’s first electromagnetic vibration energy harvester powering a sensor mesh network. This offering along with flexible mounting options provides easier installation that best meets specific application deployment needs with more flexibility than previous solutions.

How a printing plant uses infrared thermography to detect issues

2010-12-20T07:47:19-06:00

This video shows how a printing plant utilizes infrared thermography cameras to detect issues on press equipment.

When troubleshooting equipment, first impressions are important

2010-12-16T09:17:27-06:00

When troubleshooting a machinery problem, whether for an unusual vibration problem or a component failure such as a bearing or seal, first impressions from the initial machinery inspection are very important. Any troubleshooting exercise should begin with a thorough investigation of machine history - process, design, operation, maintenance, and all available machine details. These first impressions are necessary to make sure the troubleshooting team is fully armed with important data and minimize the chances of a misdiagnosis.

The importance of non-destructive testing and condition monitoring

2010-12-16T09:08:06-06:00

The British Institute of NDT is the professional institute for all those engaged in non-destructive testing and condition monitoring. It is concerned with the education and training of its members, and the advancement of the science and practice of the subject.

Vibration analysis at an AkzoNobel plant

2010-12-15T07:45:10-06:00

Structural vibration monitoring of wind turbines

2010-12-15T07:43:03-06:00

This video explores the subject of structural vibration monitoring of wind turbines.

How the Oglethorpe Power Plant uses vibration analysis

2010-12-15T07:40:20-06:00

Progress Energy targets uptime, costs with infrared cameras

2010-12-15T07:38:03-06:00

See how FLIR's P640 infrared camera is used by Progress Energy, a power transmission company, for predictive and preventative maintenance to ensure constant supply.

Orlando to play host to 2011 infrared thermography conference

2010-12-15T07:35:57-06:00

Organized by the Infraspection Institute, IR/INFO is the most important conference of the year for infrared thermographers. This year, the infrared conference will be held at the Disney Boardwalk Conference Center in Orlando, Fla. For infomation, visit www.irinfo.org.

Infrared cameras provide benefits for utility companies

2010-12-15T07:33:29-06:00

This video shows FLIR cameras in the field and why infrared thermal imaging has become a key tool for predictive maintenance programs for utility firms everywhere.

FLIR unveils i5 thermal imaging camera

2010-12-08T12:45:35-06:00

This video provides an introduction to the i5 Thermal Imaging Camera from FLIR Systems, a tool for predictive maintenance and problem spotting.

Machinery Health Monitor combines vibration and temperature monitoring

2010-12-08T10:34:27-06:00

Emerson Process Management announces the addition of a unique temperature module for the CSI 6500 Machinery Health Monitor. The new A6630 temperature module complements the vibration monitoring capabilities already available in the CSI 6500 and delivers critical bearing temperature measurements. The A6630 module accepts RTD and thermocouple signals directly, reducing the installation cost and complexity of temperature monitoring.

The history behind the OPTALIGN laser shaft alignment system

2010-12-06T08:41:46-06:00

Learn more about PRUEFTECHNIK, a leader in laser alignment technology, and its OPTALIGN laser shaft alignment system.

SKF device enables machine condition diagnosis

2010-11-29T12:58:06-06:00

The new SKF Microlog Advisor Pro gives maintenance, service and quality inspection technicians on-the-spot and easy to understand machine condition diagnosis. This stand-alone device does not rely on prior measurement data, and does not require advanced predictive maintenance software. As a result, users immediately benefit from a proactive maintenance approach without the need for vibration expertise, or prior setup of an advanced PdM route-based system. And with the ability to choose from a range of application modules, the SKF Microlog Advisor Pro delivers the functionality of several maintenance tools in one handheld device.

How a Nucor mill benefits from condition monitoring

2010-11-23T12:38:26-06:00

This article describes the justification, development, application and benefits of an integrated condition monitoring and diagnostics solution. Specific case studies at a Nucor Steel plant are presented along with discussions of deployment issues and barriers that have been overcome.

Using vibration analysis to test for bearing wear

2010-11-04T09:47:51-05:00

This article discusses an example of an outer race-bearing defect on a 1,250-ton air-conditioning chiller. The defect was detected using off-the-shelf portable vibration analysis hardware and software. The article discusses methods used to diagnose and trend the bearing defect using vibration spectra as an indicator of the bearing condition. The diagnostic methods covered are universally applicable to other types of machines (pumps, fans, gears) with rolling contact bearings.

Diagnosing a boiler pump motor with an ultrasound detector

2010-11-04T08:52:54-05:00

In this video, a maintenance technician uses the UL101, an ultrasound detector, to diagnose a thrust and non-thrust bearing in an injector boiler pump motor. He places the UL101 on the grease fitting and adjusts the UL101's gain to the lowest possible setting. Lowering the gain setting will isolate the ultrasound to only the bearing being tested. Maintenance teams use the UL101, ultrasound detector, for quick troubleshooting on mechanical components.

Case study: Diagnosing a low-speed gearbox problem

2010-11-02T10:28:22-05:00

This article explores the diagnosis of a suspected gearbox problem in a large plant connected with the paper industry. The lubricating oil in the gearbox was regularly subjected to analysis, and the last report stated that there were iron particles in the oil. The maintenance supervisor sought to determine the source of the oil contamination, and it was suspected that the metal was coming from one or more of the gears. The problem then became to identify the faulty gear (if any), so as to allow the maintenance effort to proceed without delay.

Using iPad technology in vibration analysis applications

2010-11-02T08:16:20-05:00

Thomas Hoenig, president of GTI Spindle Technology Inc., discusses how Apple's new iPad technology is changing the face of vibration analysis in manufacturing. Presented as part of Cutting Tool Engineering's Fast Track Seminar series hosted during IMTS 2010, Hoenig's seminar includes a brief demonstration of the iPad at work.

Thermal imaging for electrical and mechanical maintenance

2010-11-02T08:12:48-05:00

CBM and RCM help to maximize safety, uptime at YICT

2010-11-01T08:34:15-05:00

Being one of the biggest single container terminals in the world brings certain expectations from the operators and customers alike. Professionalism, reliability and efficiency are three of the most important and, coupled with a high regard for safety, are major focus areas for the Yantian International Container Terminal (YICT), in Shenzhen, southern China.

Fluke creates online glossary of vibration terms

2010-10-26T10:29:44-05:00

Fluke Corporation has made available at its Web site a glossary of the key vibration terms that those involved in equipment maintenance and vibration diagnosis may encounter when evaluating machine vibration.

Overview of a condition-based monitoring system

2010-10-26T08:23:42-05:00

This video provides an overview of the Infor Hansen CBM (condition-based monitoring) solution.

In today's global recession, you have to do more with less than ever before. Every dollar counts, every minute matters. Infor Hansen CBM connects your operational technology (automation devices and alarms) with information technology (Infor Hansen Asset Management System).

Infor Hansen CBM includes a "Virtual Employee" with every copy. His responsibility is to monitor your organization's equipment 24/7/365 and listen for any anomalies or early warning of problems, capture run-time hours and cycle counts, manage preventive maintenance intervals and predict equipment failures before they happen.

Vibration analysis and PdM with RFID tags

2010-10-26T08:20:20-05:00

This video outlines how maintenance technicians can perform vibration analysis and predictive maintenance with RFID tags.

Plant ensures reliability with predictive maintenance

2010-10-21T11:45:30-05:00

LCRA's utility operations are full of electronic and moving parts. Making sure all those parts stay in working order is the job of predictive maintenance crews. Heat-sensing cameras and vibration detectors are just of couple of the modern tools the crews use to ensure the power and water stay on. Watch as a crew gives an irrigation pumping plant an end-of-season check-up.

Pump vibration testing in the shop

2010-10-15T07:17:46-05:00

A basic principle of machinery vibration analysis is evaluating whether specific vibration amplitudes are excessive. The use of vibration equipment in preventive maintenance involves keeping a vibration history on individual pieces of equipment in a plant, keeping a record of all PM heat and when the unit was greased and what type of grease was used.

Bearing analysis kit provides oil and vibration condition monitoring

2010-10-11T13:36:30-05:00

The SKF Advanced Bearing Analysis Kit now is available, providing all the necessary equipment and consumables for oil and overall machine vibration condition monitoring. The kit is designed to provide fast, accurate results for multiple oil parameters, on-site maintenance decisions and assessment of overall machine condition.

You know you are in reactive maintenance if ...

2010-10-07T09:11:27-05:00

Have you ever wondered if your company is in reactive maintenance? Ricky Smith gives you some clues to determine whether you are there or not.

Phase analysis: Making vibration analysis easier

2010-10-05T11:11:06-05:00

There is one diagnostic technique which quickly gets to the source of most vibration problems. It is possibly the most powerful of all vibration diagnostic techniques. It has been around as long as vibration analysis itself yet hasn't gotten a lot of attention, and it's rare to find good information about the subject. What is this technique? It's called phase analysis.

Azima DLI and Fluke team up on vibration technology for better troubleshooting

2010-09-29T08:46:35-05:00

Azima DLI, a provider of predictive machine condition monitoring and analysis services, announced September 29 that its ExpertALERT automated diagnostic system (ADS) technology was selected by Fluke Corporation, a leader in portable electronic test and measurement technology. Fluke chose ExpertALERT’s ADS to power the rapid diagnostic capabilities featured in the Fluke 810 Vibration Tester, its newest, most advanced troubleshooting tool. Now, resource-constrained plants can anticipate machinery problems, address recurring failures and bridge the personnel skills gap required for effective vibration monitoring programs.

Emerson delivers wireless first with vibration spectrum for detailed machinery analysis

2010-09-23T11:54:31-05:00

Emerson Process Management, a leader in wireless technology for mainstream process manufacturing, has expanded the capabilities of its CSI 9420 Wireless Vibration Transmitter to deliver more detailed information for machinery analysis. In addition to sending operators direct alerts on high vibration caused by faults like cavitation or bearing defects, the CSI 9420 can now also use Emerson's reliable Smart Wireless network to send high resolution spectra to vibration experts for detailed diagnosis of machinery issues.

Arch Coal recognized for excellence in predictive maintenance

2010-09-22T08:41:39-05:00

Arch Coal Inc. on September 22 announced that its predictive maintenance program has been named as the best overall program among mobile equipment fleets from around the world by an industrial trade magazine.

Using thermal imaging for roof inspections

2010-09-17T14:35:25-05:00

How infrared thermal imaging is used in the utility industry

2010-09-16T10:04:17-05:00

This video shows your FLIR infrared thermal imaging tools are used in the utility industry.

Using the iPad for vibration analysis

2010-09-15T13:44:29-05:00

GTI Spindle reveals its new vibration analyzer built on the iPad mobile computing platform.

Azima launches WATCHMAN Intensive Care condition monitoring services

2010-09-15T09:49:22-05:00

Azima DLI, a provider of predictive machine condition monitoring and analysis services, on September 15 announced the launch of its WATCHMAN Intensive Care condition monitoring services. The services are enabled by the new Sprite Roamer Intensive Care Unit (ICU), a portable, online monitoring system that can be quickly deployed by plant personnel to machines that are in need of attention by professional condition specialists and comes with 24/7 support.

Testing air brakes with an ultrasound detector

2010-09-08T08:36:50-05:00

A technician uses an ultrasound leak detector to test a truck's air brakes for leaks. CTRL Systems Inc. manufactures the UL101, a handheld ultrasound detector. Applications include leak detection and detecting mechanical failures in bearings, gears, pumps and valves. The UL101 ultrasound detector is used for predictive maintenance, condition-based maintenance, energy savings (leak detection) and for quality control inspections.

Shell mechanical team supervisor comments on compressor reliability at his facility

2010-09-07T13:11:07-05:00

Doug Husen, mechanical team supervisor at Shell, talks with SkillTV's Joel Leonard about compressor reliability at his facility. The interview took place at Noria Corporation's RELIABLE PLANT 2010 conference in Nashville, Tenn.

Vibration analysis is like winning the lottery

2010-08-24T09:39:46-05:00

Life would be so easy and carefree with a crystal ball. And, wouldn't your maintenance job be so much simpler if you could just identify machine damage in time and predict the point at which repairs really become necessary? This article describes how it was possible to keep a damaged bearing running for several months until a scheduled annual outage came around – naturally under close observation.

Asset-based condition monitoring software for infrared cameras

2010-08-17T09:55:45-05:00

Condition RED fully integrates your infrared camera and analysis package to form an automated report generation system. Condition RED helps you manage your infrared predictive maintenance program by keeping track of your entire asset inventory in an easy-to-operate powerful database. Create infrared surveys in your own facilities using the power of this unique IR camera and asset management system.

Learn machinery lubrication best practices at RELIABLE PLANT 2010

2010-08-17T08:07:43-05:00

Take home best practices from these lubrication case studies, which will be featured at Noria Corporation's RELIABLE PLANT 2010 conference and exhibition. The event will be held August 31-September 2 in Nashville, Tenn.

That's amore! Italian power plant loves new filter strategy

2010-08-16T20:08:06-05:00

Remote monitoring solution enables Centro Energia Teverola S.p.a. facility to improve its machinery efficiency, plant efficiency and predictive maintenance.

System for non-destructive testing and measurement

2010-08-13T09:19:38-05:00

This video outlines a new low-cost system for non-destructive testing and measurement, including vibration analysis, of materials and components.

How to prevent costly downtime from power outages at petrochemical plants

2010-08-09T15:39:31-05:00

Unplanned downtime at petrochemical plants due to electric power failure is more common and costly than the total of fires, floods, earthquakes, network outages, service failures and hardware problems combined. Recent economic studies estimate the cost of downtime to the U.S. economy due to power outages exceeds $150 billion annually.

Dynamic movement on a boiler feed pump

2010-08-09T11:17:26-05:00

This video will give you an overview of the dynamic movement on a boiler feed pump and the the benefits of measuring and correcting.

The cost benefits of laser shaft alignment

2010-08-09T11:13:50-05:00

This video will give you an overview of the cost benefits analysis of laser shaft alignment.

An introduction to Extech infrared thermometer

2010-08-06T13:50:26-05:00

This video provides an introduction to the 42509 Color Alert Infrared Thermometer from Extech. This dual-laser IR thermometer has high/low alarms with a visual and audible indicator when the temperature exceeds or goes below the set temperature.

Print out your pass for the RELIABLE PLANT 2010 conference

2010-08-06T08:42:07-05:00

Here's your printable pass for the Reliable Plant 2010 Conferences and Exhibition, in Nashville, Tenn., August 31 to September 2.

Static and dynamic testing as part of PdM programs

2010-08-04T11:41:38-05:00

Periodic static testing and more aggressive dynamic testing of motors are essential parts of predicting the potential for a motor to continue a safe and successful operation. Tracking and trending the results of electric motor testing on a regular schedule is the most effective method of making intelligent predictions.

Measure surface flatness with products from Ludeca

2010-08-02T10:54:03-05:00

Measure surface flatness and level with precision and convenience. Take a look at the new INCLINEO high-precision inclinometer and the new 3D color graphics in the ROTALIGN ULTRA Flatness featuring the LEVALIGN rotating laser.

Maximize your PdM efforts with oil analysis skills training

2010-07-29T09:43:42-05:00

Detecting an air leak with ultrasonic equipment

2010-07-23T08:02:50-05:00

CTRL's ultrasound detector, the UL101, is designed to be a multi-purpose maintenance and diagnostic tool. One of its core applications is leak detection.

Creating a lean but effective oil analysis program

2010-07-21T13:26:24-05:00

Whether it's a budget issue, management buy-in, lack of individuals or just a small company with limited funds, there are ways to establish an effective oil analysis program with minimal startup and operation costs.

Get your Noria training coupon with RELIABLE PLANT conference registration!

2010-07-21T10:51:14-05:00

Performing infrared thermography on motors

2010-07-15T15:48:53-05:00

TEGG Services talks about using infrared thermography to perform predictive maintenance on motors.

Datastick announces machine vibration seminar in California July 20-23

2010-07-15T09:08:36-05:00

A four-day Machine Vibration seminar with hands-on practical experience will be held on July 20 through 23 in San Jose, Calif. Attendees can become certified as Level I vibration analysts by taking a test on the last day.

UE launches Ultraprobe 15,000 Touch

2010-07-15T08:56:38-05:00

Using knowledge based on three decades of experience, the engineers at UE Systems have developed an entire ultrasonic condition monitoring laboratory – to fit in the palm of your hand.

Kaman and Predict Service announce distribution agreement

2010-07-15T08:45:01-05:00

Kaman Industrial Technologies, a leading distributor of industrial parts, and Predictive Service, LLC, a global leader in providing predictive maintenance and engineering services (reliability services) announced a collaboration between the two companies, whereby Kaman will distribute reliability services from Predictive Service in the industrial distribution market.

Electric motors tip on spectral band alarms

2010-07-07T09:20:32-05:00

When reviewing spectral data rich with peaks from an unknown origin, consider establishing band alarms around these peaks. Properly designed and applied band alarms allow varied severity indications for a range of frequencies. If the application being monitored is operating in an otherwise healthy condition, then an increase of 25 percent, 50 percent and 100 percent from baseline could be used for observe, caution and severe setpoints, respectively.

Owens Corning employee chooses Fluke thermal imaging for PdM

2010-07-07T09:02:01-05:00

Hear what one Owens Corning employee says about how thermal imaging has helped them maintain their equipment, both electrical and mechanical, and why they chose Fluke thermal imagers to get the job done.

Why you need vibration analysis

2010-07-02T15:58:42-05:00

Alan Richardson, president of Preventive Vibration Analysis Corporation, explains the importance and benefits of vibration analysis.

Noria lubrication video training sale ends June 30

2010-06-28T08:59:58-05:00

Take advantage of this limited time sale and quickly introduce your entire team to Noria lubrication and oil sampling best practices. Order online or call 800-597-5460 ext. 104.

Audible, visual and tactile inspections for PdM personnel

2010-06-22T10:35:18-05:00

Data collection is the backbone of any vibration monitoring effort, yet opportunities to gather additional data while at the machine are typically ignored. Is the vibration industry finally beginning to feel the effects of the pure data collector who has not transitioned into the reliability group from the mechanical trades? What about the site operators and craftsman? This article covers basic inspection techniques that can be applied to optimize time spent in the field.

Azima DLI ensures reliability of Panama Canal locks using vibration monitoring

2010-06-21T08:23:48-05:00

Azima DLI, the leader and premier provider of predictive machine condition monitoring and analysis services, announced that its advanced vibration monitoring capabilities will be used by the Panama Canal Authority (ACP) to achieve important equipment reliability and uptime goals associated with the operation of its lock system. The ACP is the autonomous agency of the Government of Panama in charge of managing, operating and maintaining the Panama Canal.

Using infrared thermography for tanks and vessels

2010-06-18T11:56:18-05:00

This presentation discusses how infrared thermography is used for tanks and vessels.

A sneak peek at the Ultraprobe 15,000 PdM tool

2010-06-11T13:33:33-05:00

An introduction video of the new Ultraprobe 15,000. This this ultrasonic device, predictive maintenance and energy conservation are made easy.

NV Energy installs wireless solution to increase plant reliability

2010-06-10T14:26:26-05:00

Wireless condition monitoring systems have helped to improve overall plant reliability and efficiency at NV Energy's Fort Churchill Operating Station in Yerington, Nev., by extending condition monitoring to a broader array of essential assets that were previously underserved and classified as mid- to low-criticality.

Oil and fuel quality monitoring on power gen equipment

2010-06-10T14:20:44-05:00

Determining oil quality in real time with embedded and portable oil assessment devices operated by mechanic personnel provides the operational flexibility and rapid means of screening oil quality that is key to establishing a real-time condition-based monitoring program.

Check out the new issue of Noria's Machinery Lubrication magazine

2010-06-10T09:24:14-05:00

Download the new SDT ultrasound App for iPhone

2010-06-10T09:07:55-05:00

One of the more perplexing things for new (and old) ultrasound inspectors is what conclusions to draw from their data and trends. The new i-Phone app from SDT North America is designed to make sense of ultrasound trends and baseline increases. For instance, if your baseline is 20dBµV and today's reading is 26dBµV and you want to know what the 6dBµV increase represents, tap it on your iPhone and you'll know the increase is a factor of 2X.

Ludeca 'Laser Align' iPhone App now available for download

2010-06-09T11:19:01-05:00

Ludeca Inc., a leading provider of laser alignment and condition monitoring solutions, presents “Laser Align” a free reference tool for shaft alignment of rotating equipment. With this iPhone application, you can access important reference material and learn about key laser shaft alignment concepts.

Detect machine problems early: Best practices for operators

2010-06-03T14:26:15-05:00

When working around equipment for a long time, it is easy to become accustomed to it working as it should. It can make us numb to potential problems, especially if they come on gradually. This article presents some techniques that will allow you to detect problems early, and hopefully eliminate downtime and/or reduce maintenance costs. Further, it will give insight into what is in common driven equipment and their drivers. How a centrifugal and positive displacement pump works will be explained in the simplest of terms. Some important relationships of flow, heat and horsepower are highlighted so troubleshooting can be improved.

Measuring health with motor circuit analysis

2010-05-19T14:09:29-05:00

This video shows a demonstration of motor circuit analysis - low-voltage testing on a 2,500-horsepower, 4,160-volt stator only and a set of coils. The first demonstration is to show the operation of the instrument, and the second is to show the impact of epoxy varnishes on the circuit capacitance by viewing impedance measurements.

Access this 4-minute, 40-second video by clicking on the link below.

Vibration analysis as a key component of a PdM program

2010-05-07T08:14:45-05:00

Mike Anderson of Newark, Ohio-based Anderson Engineering describes the technologies of a predictive maintenance program and the benefits such a program can bring to the modern factory.

Access this 6-minute, 17-second video by clicking on the link below.

Ludeca debuts blog on predictive, preventive maintenance technologies

2010-05-06T10:32:55-05:00

Ludeca Inc., a leading provider of laser alignment and condition monitoring solutions, has launched a blog for maintenance and reliability professionals dedicated to helping companies learn and understand predictive and preventive maintenance technologies such as laser alignment, vibration analysis and balancing. The main purpose of the blog (www.ludeca.com/blog) will be to guide companies on how to effectively integrate predictive maintenance into their maintenance and asset management strategies.

SDG&E improves operations and safety, extends asset life

2010-05-04T14:25:30-05:00

Emerson Process Management's Smart Wireless technology is helping San Diego Gas and Electric (SDG&E) increase throughput, extend asset life, and improve process efficiency and safety at its Palomar Energy Center in Escondido, Calif.

Vibration tester keeps the good stuff flowing at Alpenrose Dairy

2010-05-04T13:04:17-05:00

At Alpenrose Dairy in Portland, Ore., operators process raw milk into a dozen varieties of milk, six cultured products and 31 flavors of ice cream. It's a challenge to keep the complex production facility, with its hundreds of motors, pumps and gearboxes, running butter-smooth. But thanks to a new vibration tester, it's easier today to maintain Alpenrose as the cream of the crop.

Doing what it takes to maintain custom textile equipment

2010-04-28T14:51:40-05:00

In 1838, the Martin family began dyeing and finishing canvas for applications such as luggage, awnings, boxing ring covers, theater curtains, hunting apparel and medical bandages. To satisfy so many different customers, the family's company has designed and built a wide range of custom machinery. But when a machine breaks down, Martin Corporation engineers and technicians cannot simply call in a service engineer from the manufacturer. They must fix it themselves, as soon as possible.

Increase profits and reduce maintenance costs for your facility

2010-04-28T11:00:31-05:00

Phase analysis is one of the most overlooked capabilities that can be used to identify and locate unwanted equipment defects such as structural looseness. Therefore, phase analysis is a very valuable diagnostic tool available to the vibration analyst and can be easily used to identify the root cause of many equipment problems.

SDT North America delivers powerful ultrasound for PdM pros

2010-04-26T11:10:07-05:00

The new SDT270 ultrasonic device from SDT North America represents an evolution for predictive maintenance and reliability professionals. Sporting many firsts, the SDT270 is consistent with SDT’s mission to design progressive and smart instruments.

Martinelli’s pursues the sweet taste of safety

2010-04-22T13:25:31-05:00

The health and safety of his fellow workers is a daily issue for Keith Morin, the facilities electrician at S. Martinelli & Company's apple cider production facility in Watsonville, Calif. Morin believes that a solid industrial safety program is vital to keep accidents and all sorts of health problems at bay.

Kinetic Systems offers vibration surveys for sensitive equipment

2010-04-22T09:19:44-05:00

Kinetic Systems Inc., a manufacturer of vibration-control workstations and optical tables, offers vibration surveys for new buildings or existing facilities.

An introduction to machinery vibration

2010-04-20T10:47:44-05:00

Vibration in industrial equipment can be both a sign and a source of trouble. Other times, vibration just "goes with the territory" as a normal part of machine operation, and should not cause undue concern. But how can the plant maintenance professional tell the difference between acceptable, normal vibration and the kind of vibration that requires immediate attention to service or replace troubled equipment? Read this article to find out.

Vibration analysis for condition monitoring of blowers and compressors

2010-04-14T13:54:28-05:00

Aerzen USA technical manager Ralf Weiser explains vibration analysis for condition monitoring of positive displacement blowers and screw compressors.

Access this 6-minute, 52-second video by clicking on the link below.

Using PdM technologies to determine, optimize lube condition

2010-04-13T11:49:04-05:00

Improper lubrication creates energy that manifests itself as mechanical stress energy and thermal energy (heat). By analyzing this energy using predictive maintenance (PdM) technologies, much can be learned about the bearing lubrication condition. This article discusses and compares the use of ultrasonic analysis, conventional vibration analysis and advanced vibration signal processing techniques as means toward determining lubrication state and achieving optimum lubrication.

Ultrasound World VI announces presenter lineup, agenda for conference

2010-04-13T11:43:39-05:00

The Ultrasound World VI conference, launching May 10, will feature four days of presentations, workshops, classes and an optional CMRP exam with a strong emphasis on application based case histories using ultrasound as part of a profitable predictive maintenance strategy.

10 steps to prepare your company for the return of business

2010-04-13T10:36:10-05:00

The 10 steps outlined in this article offer a cohesive approach to cost-effectively prepare your company’s physical assets and mitigate the risk associated with higher levels of demand for the return of business.

Azima DLI unveils enhanced machinery condition assessment software

2010-04-05T15:19:08-05:00

Azima DLI, a leader and provider of predictive machine condition monitoring and analysis services, on April 5 announced a significant upgrade to its advanced machinery condition assessment software, ExpertALERT 3.40. Manufacturers now have the ability to improve plant performance by better prioritizing machine repairs while remaining focused on reliability and uptime priorities based on the ability to more rapidly collect and process data, and access accurate results through the Azima DLI WATCHMAN Reliability Portal.

Poll finds challenges with PdM sustainability can overshadow successes

2010-04-01T08:11:22-05:00

Azima DLI, the leader and premier provider of predictive machine condition monitoring and analysis services, on April 1 announced the results of a survey aimed at gaining insight into the state of predictive maintenance and condition monitoring programs among U.S. plants. Overall findings show that while a majority (76 percent) of respondents is satisfied with current programs, more than half of those surveyed agree that it’s difficult to know exactly what solutions and tools are needed to maintain a successful program. Combined with insufficient staff, limited in-house expertise and poor training as the top factors negatively impacting results, plants must re-examine existing programs now in order to ensure sustainability and the ability to meet long-term productivity and reliability goals.

Fluke performs drop test on thermal imaging cameras

2010-03-24T08:00:33-05:00

Fluke Corporation performs a drop test on several infrared thermography cameras.

Access this 1-minute, 51-second video by clicking on the link below.

Detecting material accumulation in equipment with infrared

2010-03-16T09:42:15-05:00

Infrared technology is one of the most important tools that can be used in a successful predictive maintenance program. This technology is not just for finding abnormalities with electrical components and equipment based on elevated temperature; it can also find potential problems based on lower-than-normal temperatures. Locating material buildup in baghouse hoppers, coke gas lines and flue gas ducts are a few instances where you aren't looking for the hottest temperature, but instead, the coolest.

Consistency plays critical role in Ash Grove reliability program

2010-03-16T09:29:17-05:00

With a solid predictive maintenance program already in place, Ash Grove Cement approached Timken to take it to the next level. The results? Ten "saves" in the first 10 months and consistent data reporting that is helping the cement producer optimize equipment uptime.

Diagnostic technology helps nuclear plant avoid unplanned shutdown

2010-03-15T11:29:37-05:00

The Wolf Creek Generating Station, Kansas' only nuclear power plant, recently used digital valve controllers to extend the life of its critical control valves. This action avoided a potential unplanned shutdown that in a plant this size could cost up to $1 million per day in lost revenue.

PdM analyst uncovers issues on 69 KV power line

2010-03-15T11:15:52-05:00

While performing an infrared and ultrasound inspection on the high-voltage power line connections, disconnects, fuses and transformers, as well as the electrical equipment and components, located in nine substations throughout the facility where he works, a predictive maintenance professional came across a potentially catastrophic situation.

ULIS to give talk on advances in uncooled infrared detectors

2010-03-05T08:39:12-06:00

ULIS, a leading infrared vision specialist making affordable uncooled thermal sensors for civilian and military applications, announced March 5 that it will give a presentation on the advances in uncooled infrared detectors at the SPIE Defense, Security and Sensing symposium, April 5-9, in Orlando, Fla.

Using iPhone application to analyze machinery vibration

2010-03-04T08:32:31-06:00

This video demonstrates the use of an iPhone application to analyze machinery vibration. If you would like to learn more, contact GTI Spindle Technology.

Access this 1-minute, 31-second video by clicking on the link below.

Bearing repair, PdM program address downtime at Gallatin Steel

2010-03-03T13:31:23-06:00

When your rolling mill equipment has an emergency, calling a vendor is like calling the paramedics. Timken recently helped bring Gallatin Steel's plant in Ghent, Ky., back to life after a period of downtime. The Gallatin site avoided further costly downtime in its rolling mill operations as the result of an emergency bearing repair and the installation of a predictive maintenance program.

PdMA, Snell offer motor circuit analysis certification course

2010-03-01T10:16:10-06:00

PdMA is proud to join with The Snell Group in presenting the motor circuit analysis certification training course. The Snell Group is the world leader in MCA training, consulting and inspection services.

How a reliability engineer improves reliability

2010-02-26T14:38:52-06:00

This article outlines some of the ways that a reliability engineer can improve your achieved asset reliability, saving your organization time and money.

5 steps to diagnose a soft foot condition on machinery

2010-02-26T13:09:56-06:00

Vibration analysis can be used to determine if a soft foot condition exists on a machine that is running. If you cannot shut the machine down to check for soft foot, using the simple procedure outlined in this article will help determine if soft foot is your problem.

Inspecting electrical cabinets with ultrasonic equipment

2010-02-22T15:53:49-06:00

This three-minute video explains how to use airborne ultrasound to scan for arcing, tracking, and corona discharge in MCC and other electrical cabinets.

Keynote speaker announced for Ultrasound World VI conference

2010-02-19T09:33:35-06:00

Going on its sixth year as the industry’s only international predictive maintenance conference focused on ultrasonic and complementary technologies, Ultrasound World has offered plant maintenance professionals the unique ability to share inspection challenges and learn about real world, proven strategies that result in immediate return on investment.

Performing vibration analysis with VibXpert

2010-02-17T14:26:09-06:00

The video demonstrates the features and benefits of the easy-to-use and powerful VIBXPERT vibration analyzer from Ludeca.

Access this 2-minute, 47-second video by clicking on the link below.

Lecture on vibration analysis and Rayleigh's Method

2010-02-17T14:24:05-06:00

This video lecture provides an explanation on vibration analysis and Rayleigh's Method. It is led by Professor Amitabha Ghosh from the Department of Mechanical Engineering at IIT Kanpur.

Access this 53-minute, 16-second video by clicking on the link below.

An introduction to vibration analysis, PdM

2010-02-17T10:38:10-06:00

Mike Anderson of Newark, Ohio-based Anderson Engineering describes the technologies of a predictive maintenance program and the benefits such a program can bring to the modern factory.

Access this 6-minute, 16-second video by clicking on the link below.

Overview on the benefits of thermography

2010-02-17T10:33:25-06:00

This short video from from Fluke outlines the benefits of infrared thermography.

Access this 2-minute, 51-second video by clicking on the link below.

Infrared thermographic study of a ball mill

2010-02-17T10:31:26-06:00

This video provides a thermographic study of the heat dissipation of associated equipment in a ball mill.

Access this 1-minute, 37-second video by clicking on the link below.

Optimizing oil drain intervals using BN vs. AN

2010-02-20T11:43:22-06:00

Safely extending oil drain intervals by using fluid analysis to monitor oil condition and engine wear has always been a significant means for reducing a maintenance department's consumable costs. But in today's economic environment, it is becoming even more critical to achieve optimal drain intervals and, at the same time, minimize engine damage.

Survey seeks respondents on how to sustain reliability

2010-02-08T09:00:34-06:00

ARC Advisory Group is undertaking a survey to better understand manufacturers’ approach to reliability for the management of physical assets.

How to identify, correct a resonance condition

2010-01-28T09:56:49-06:00

Many techniques can be used to identify and/or confirm a high vibration level in plant equipment caused by a resonance frequency. It is very important to confirm a resonance phenomenon by at least two different types of tests before trying to correct it. This article looks at a few techniques commonly used in industry.

Leveraging the power of IR cameras for condition monitoring

2010-01-21T15:01:58-06:00

With an increasing base of infrared camera users and applications, the challenge is to leverage the technology effectively. Proper use of infrared technology requires an understanding of the components and the fundamentals of the technology. Improve your infrared and condition monitoring efforts by reading this article.

PdM benefits overall maintenance strategy at Linde gas plants

2010-01-16T11:43:31-06:00

Henry Aung-Kyi, a reliability engineering manager for the Linde Group, knows that the key to successful maintenance operations is the right balance of techniques, systems and methodologies. He is convinced of the value of highly sophisticated online monitoring for critical machinery. But for some of the equipment at his gas plants, this level of technology and cost is not needed for optimum management of his company’s resources.

How to manage a multi-technology condition monitoring program

2010-01-16T11:49:23-06:00

Managing a multi-technology condition monitoring program at a large mining operation was a challenging task, especially when there has been a cultural shift required to integrate the ideas of condition monitoring into an already complex maintenance strategy.

Case studies in data analysis through predictive maintenance

2010-02-20T11:26:39-06:00

The case studies provided in this article are actual data analyzed by the author. The case studies representing vibration analysis will present examples and comparisons of bearing faults, unbalanced conditions and impact testing for natural frequencies. Each example will be represented as a spectrum and, in some cases, a timewave form which will provide evidence of a fault that is present in the particular segment of data.

Oil reports will also be presented to give conclusive evidence of a dirty oil condition, with the target ISO cleanliness level identified for reference.

Oil cleanliness is critical in eliminating premature component failure and extending equipment life. It enables maintenance departments to work toward increasing uptime and machine availability.

Infrared thermography is represented by thermal images of equipment components with temperature variations. Even slight temperature variations can indicate a potential problem in a machine component.

How does a PM program help eliminate component failures?

2009-07-07T00:00:00-05:00

In answering the question posed in the headline, we must first define what PM stands for. According to Life Cycle Engineering’s Rx Definitions, this could have one of many meanings. It could refer to periodic maintenance, planned maintenance, predictive maintenance (although normally abbreviated as PdM) and preventive maintenance. Despite the definition of each and how they differ, they all relate to asset care. A properly cared-for asset will net much higher utilization at a much lower total cost of ownership. This is accomplished by establishing a program that mitigates or eliminates failure.

Periodic maintenance is the cyclical maintenance actions or component replacements carried out at known regular intervals. Usually intrusive, they are often based on repair history and regulated by current inspection results. Periodic maintenance includes inspecting, testing, partial dismantling, replacing consuma

FLIR cameras as useful predictive tool

2009-07-02T00:00:00-05:00

This FLIR video explores predictive maintenance activities in production facilities, system failure prevention, and the safety of non-destructive testing.

Access this 3-minute video by clicking on the link below.

PdM centralization for significant energy savings

2009-01-21T00:00:00-06:00

All facilities lose energy dollars through overheated electrical distribution systems and overloaded and misaligned rotating assets, as well as lose expensive compressed air and steam through leaking pipes/fittings. Couple this with the increasing pressures of global competition, a thinning workforce and budget constraints, and you have significant issues/opportunities. A remedy is to improve equipment reliability by fully leveraging predictive maintenance (PdM) technologies.

This paper focuses on how the successful integration of standard PdM technologies along with centralized reporting can capture significant energy savings and simplify ROI calculations. By the way, any associated benefits of increased safety, reliability and enhanced facility capacity is purely coincidental.

Matching Knowledge and Information
Bailouts, barrels of oil at $150 per barrel, boom and bust of the housing markets, wars, elections, and the gloomy global economy have f

Vibration analyzer ensures bearing reliability in gearbox refurbishing

2009-01-14T00:00:00-06:00

Fifty years of ongoing development has given SKF a bearing vibration analyzer that can probe deep into rotating bearings while they are under load. Initially used as a production line tester, it’s now proving invaluable during the maintenance and refurbishment of gearboxes and other critical units in demanding applications such as aerospace.

SKF vibration testing equipment is released by Rolls-Royce for noise testing of bearings during gearbox servicing. Release became necessary when Rolls-Royce Deutschland decided to transfer service work on gearboxes for secondary power systems to the sub-contractor Vector Aerospace in Almondbank, Scotland. Overhaul of these gearboxes requires detailed inspection of more than 3,000 components, some of which require testing with special equipment. This includes the various types of rolling bearings used in the gearbox that require stringent noise and vibration testing and measurement of the radial and axial clearances.

Vector Aerospace selected SK

Preventive maintenance vs. predictive maintenance

2010-02-20T11:27:24-06:00

For some time, a considerable amount of confusion has existed over the appropriate way to inspect for the presence of a given failure mode. Should I perform some type of sensory inspection? Should I perform some type of quantitative inspection? Should I apply one or more condition-monitoring technologies? Should I apply some combination of these techniques to maximize the conditional probability of finding the defect? Essentially, how do I identify the presence of a defect in such a way as to maximize the amount of time my planning department has to effectively and efficiently develop the job procedures, order the parts, and schedule and complete the work before the conditional probability of failure becomes too high? An explanation of the types of inspections and how they complement one another goes a long way toward clarifying which ones are most appropriate.

Sensory inspections have long been considered the backbone of any good inspection program. It was believed that sending so

Arc flash captured during PdM work

2008-06-28T00:00:00-05:00

In this video, a plant maintenance technician attempted to air-run a chiller for vibration analysis. There must have been a short to ground on the load side of the start contactor at the transistion resistor bank, behind a bundle of wires not visible if you are not looking for it. Needless to say, there was a short to ground and a pretty decent electrical explosion that looked like a fragmentation granade detonated in the starter panel.

Access this 37-second video by clicking on the link below.

Predictive maintenance systems show future ROI

2010-02-20T11:28:12-06:00

Even if high uptake causes the cost of predictive maintenance systems to drop, the systems will still remain expensive and their usage, restricted to high-cost production machinery. Even though some vendors look to the technical capabilities, future adoption of the systems will primarily depend on the price.

New analysis from Frost & Sullivan (http://www.technicalinsights.frost.com), Advances in Intelligent and Predictive Maintenance Systems, finds that predictive maintenance systems can be grouped together by experienced professionals, but numerous turnkey products are also avai

Why are you performing vibe analysis?

2008-05-12T00:00:00-05:00

Vibration analysis is the cornerstone of any condition monitoring program. The venerable Art Crawford (founder of IRD) said, "No single measurement can provide as much information about a machine as the vibration signature." Gross defects such as severe shaft misalignment to subtle conditions such as differences in grease types can be detected with vibration analysis. As powerful as this technology is, it's often the most misapplied of the condition monitoring tools. This article will focus on the proper philosophy behind the technology's use inside an overall condition monitoring program. While many maintenance and reliability initiatives incorporate vibration analysis, few people have a sound philosophical base for how it is to be utilized.

The proper use of a quality vibration analysis program can provide focus to the crafts personnel. The analysis of the vibration signature, when performed in a timely manner, pinpoints the precise nature and location of the problem. This empowers th

Oil analysis: 5 things you didn't know

2010-02-20T11:40:38-06:00

I'm sure that most readers of Reliable Plant are well aware of the value brought by oil analysis. Used appropriately, there is little doubt that an effective oil analysis program can help identify lubrication-related failures, often before any significant machine wear has occurred. But as a veteran instructor of oil analysis and lubrication courses, I find all too often that companies miss the boat on oil analysis simply because they don't understand what oil analysis can and can't do. So in the interests of setting the record straight, I present to you what I like to call the "five fallacies" of oil analysis - things that are often overlooked or not understood but vital to the long-term benefits of oil analysis as a conditioning monitoring tool.

Fallacy #1: Reservoir sampling is fine.

Fact: Oil analysis, just like real estate, is all about location, location, location. While certain homogeneous properties such as viscosit

The questions and answers that trigger PdM to work

2010-02-20T11:29:09-06:00

“I have a solid work control process and I am ready for the next step. I know predictive maintenance is more cost effective than my old preventive maintenance program, but how do I get a program started?”

When organizations look to truly embrace predictive maintenance, they typically have three questions that must be answered in order to move forward. These questions are the basic decisions that need to be made to get you moving in the right direction. All of this is contingent upon your facility having processes for identified work planned, scheduled and executed because without this, predictive maintenance will not be as effective. Simply put, you need to answer what, where and who. What technologies need to be employed, where in the plant and by whom? Once you know this you can begin to build your process, business case and justification to proceed.

What predictive technologies make the most sense to introduce early in the startup of your pro

The basics of motor circuit analysis

2008-02-25T00:00:00-06:00

Quite a bit of confusion exists on the subject of motor circuit analysis. The confusion is centered on two issues:

The very name of the technology.

What this technology is capable of.

This article will focus on alleviating that confusion with a discussion of the technology's capabilities and its proper name.

One of the biggest reasons why confusion exists about the very name of this testing methodology is the prevalent use of three-letter acronyms (TLAs) in the condition monitoring industry. We have TLAs for everything: CBM (condition-based monitoring), PdM (predictive maintenance), RCA (root cause analysis), FFT (Fast Fourier Transform), etc., etc.

It is the pervasiveness of TLAs that has created this confusion around motor circuit analysis. MCA can mean two different things. Motor circuit analysis (MCA) is often and easily confused with motor current analysis (MCA), which is an abbreviated version of motor current signatu

Why trending is important to PdM

2010-02-20T11:26:14-06:00

This case study takes place in a packaging facility. The packer on Module 8J0 was checked for vibration integrity during a pre-machine care evaluation. A problem was detected in the folding arm gearbox. The frequency characteristics indicated that a bearing was deteriorating.

This photo, taken with a fiber-optic camera, shows damage to the packer's roller bearings.

This seems straightforward, but is it? The gearbox is located in a section of the packer that is not easily accessible. The necessary repairs require separating the two sections of the machine. When the packer is split, it will take an additional two days of work before the unit can be restored to service.

In this case, the maintenance leader does not believe in the technician's ability to make a vibration

Harley-Davidson: Born to be ... predictable

2007-06-25T00:00:00-05:00

"Get your motor runnin'. Head out on the highway. Lookin' for adventure and whatever comes our way . . ." - lyrics from Steppenwolf's 1968 classic song "Born to Be Wild"

The Harley-Davidson image is the antithesis of predictable. No schedules. No plans. No boundaries. No cares. The unknown lies around the bend. Just strap on the helmet, fire up the engine and ride.

It's the motorcycle riding image - the lifestyle - that's embraced by customers and glorified in music, movies, advertisements and TV shows. Harley-Davidson is the off ramp from the same-old, punch-the-clock, 8-to-5, report-to-your-boss world.

The Harley-Davidson manufacturing image, however, is all about predictability. No surprises. No bottlenecks. No breakdowns. No downtime. What lies ahead is known. Just turn on the production equipmen

The value of predictive analytics: A sampling of power gen catches

2010-02-20T11:29:32-06:00

Power generation companies have implemented well-developed plans to improve equipment performance in terms of availability, reliability, efficiency and compliance. However, most companies have reached a performance plateau — undermining their ability to achieve corporate goals, objectives and strategies. The problem is exacerbated by aging equipment; “right-sizing” initiatives; the retirement of skilled blue-collar workers; younger, inexperienced staff; and restrictive OEM service agreements.

The result is an equipment performance gap that inhibits corporate performance. In fact, when equipment fails to perform to expectations, it sends a shock wave throughout an enterprise — disrupting normal operations, maintenance procedures and financial performance.

For power generation companies who are looking to close the equipment performance gap, SmartSignal’s EPI*Center software solution enables operators to increase equipment reliability, availab

Bombardier launches innovation in predictive maintenance

2010-02-20T11:27:51-06:00

André Navarri, president of Bombardier Transportation, announced the official international launch of Bombardier ORBITA, a new capability which is designed to redefine predictive maintenance in the rail sector.

Bombardier ORBITA, which is being heralded as "The Future of Maintenance", has been developed by Bombardier with the aim of helping operators to increase fleet utilisation, improve reliability and availability, reduce in-service failures, and ultimately improve the passengers’ overall journey experience.

Navarri launched the product at Bombardier’s official press conference at Innotrans on September 20 in Ber

Energizer goes with the flow

2006-07-13T00:00:00-05:00

Global lean enterprise director
Steve Hockridge (left) and lean coordinator
Dana Billings have seen the benefits of
bringing together lean and reliability.

There are three types of manufacturing companies that implement lean:

Those that do it in name only to satisfy or attract investors. Lean is confined to buzzword status in annual reports and ads.
Those that do it on the surface. They construct a few U-shaped cells, paint the walls and throw out some clutter, then exclaim, “That’s it; we’re lean.” Lean is a “home improvement” project for the plant.
Those that do it right.

Just the Facts

S