Up Time Magazine- June/July 2008

importantly, how it is being done. Figure 4 was taken during a Reliability Walk, and the following scenario is a good example of the sorts of issues that can be identified through this process. The task involves replacing an electric motor that is coupled at both ends. The job instructions contained no information on how this difficult double ended alignment should be done. There were no alignment tolerances for either coupling. There was no tolerance for soft foot. There were no jacking screws to facilitate adjustment. There were no specifications for the oil and grease required for relubricating the couplings. There were no specifications for bolt torques. So, in this instance, we were setting the tradesman up to fail. The tradesman’s approach to this task was to note the position of the old motor and put the new motor in the same position using the same shims. This is appalling; particularly given that we have a shaft alignment standard for the plant, laser alignment equipment in the plant, and people who know how to use it. So, we have the standard and the equipment, but not the ap4-20 MA OUTPUT PRODUCTS plication. To make matters worse, the tradesman was using shifting spanners to do the job. Shifters are not only dangerous because they slip, but they also damage fasteners and don’t provide the correct leverage for tightening or loosening. Having identified some issues for this particular task, we not only have to address them here, but also apply the lessons learned to all other alignment tasks. For example, we have to make sure that all tasks involving an alignment have, as a minimum, the alignment tolerances required, the soft foot tolerance, and jacking screws fitted, before the task is released for execution. In this way, we maximize the value obtained from the Reliability Walk. Figure 4 - Reliability Walk, a good way to uncover unaddressed issues. Skills and Practices “Flyers” At this point we can benefit from another lesson learned from our rapid improvement in safety performance. Our injuries have dropped rapidly, not so much because of hard changes such as separating pedestrians and moving vehicles, but because we talk about safety. We share lessons from incidents and practices issues, good practices to share, and things that need to be addressed in order for the tradesperson to achieve a reliable outcome. It is an opportunity to understand what is being done, why it is being done, and most IMI Sensors complete line of 4-20 mA output products provide reliable machinery health information that is fully compatible to existing Plant Information (PI) systems, assisting maintenance and reliability professionals in making critical manufacturing decisions. Quality Products: ■ 4-20 mA Output Industrial Vibration Sensors ■ Vibration Transmitters (Sensor and DIN Rail packages) ■ Patented Bearing Fault Detector ■ Exclusive Reciprocating Machinery Protector ■ Vibration Switches ■ Hazardous Area Approved Models ■ Full line of Meters, Enclosures, Cables and Accessories Toll Free in USA 800-959-4464 ■ 24-hour SensorLineSM 716-684-0003 E-mail imi@pcb.com ■ www.imi-sensors.com/UPT1 ISO 9001:2000 Certified ■ AS9100:2004 Certified 14 june/july 2008 © 2008 PCB Group, Inc. SensorLine is a service mark of PCB Group, Inc. PCB, ICP and IMI with associated logo are registered trademarks of PCB Group, Inc. Reliable 24/7 Machinery Protection at a Fraction of the Cost. http://www.imi-sensors.com/UPT1 http://www.imi-sensors.com/UPT1

Table of Contents Feed for the Digital Edition of Up Time Magazine- June/July 2008

Up Time Magazine- June/July 2008 Contents Upfront Upclose: The True Cause of Most Machine Failures Information Technology: Finding Future Perfect Lubrication: Building an Oil Analysis Winner Maintenance Management: Hidden Ways to Increase Safety Infrared: Air Barriers Lower Energy Costs, Increase Profits Motor Testing: Efficient Motor Repair, Part Deux Precision Maintenance: Good Maintenance, Smart Maintenance Reliability: Common Errors in Root Cause Analysis Ultrasound: Avoid the Baghouse Blues Vibration: Don't Let Your Sensors Get Eaten Alive Upgrade: Lining It All Up

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