Maintenance Technology September 2016 - 9
ON THE FLOOR
Seldom do techs receive advanced
training, leading to plants feeling
that potential ROI from the tools
was overinflated to make the sale.
(As a side note, I believe the most
underutilized tools are the five senses
of personnel who are in contact with
very expensive equipment every day.)
Personally, it's difficult to quantify
predictive-technology ROI with my
clients. They don't track the saves
that these tools generate, and tribal
memory seems skewed in favor of a
higher save rate than I actually see in
their plants.
Most of my clients have wish lists.
Usually, their only reason for not
buying every tool available is lack of
funds. It's rare for maintenance teams
to compile documentation to establish
the business case for equipment
purchases.
Facility Superintendent,
Scientific Institution, West. . .
Our facility relies on several different
types of PdM technologies: fluid
analysis, IR, ultrasound and ultrasonic
testing. Fluid analysis has become a
staple with our gearboxes and glycolcooling systems. We typically take oil
samples bi-annually to ensure proper
viscosity, test for contaminants, and
look for bearing wear. Secondly,
testing our glycol fluids has proven
extremely valuable. It tells us if the
freeze point is correct and gives us
direction for adding inhibitors or
correcting fluid pH. Not all testing
is perfectly accurate, though. We
once received a glycol fluid-analysis
report indicating acceptable foaming
levels when, in fact, they were causing
circulation pumps to cavitate.
IR, a newer tool for our team,
has proven its value. Unfortunately,
training provided by the manufacturer wasn't in depth. Most of
our knowledge has come through
on-the-job usage. We've leveraged
this technology to uncover a range of
problems. A routine IR inspection of
our main building transformer room,
for example, found a loose splice
SEPTEMBER 2016
"The time it takes
to troubleshoot
uncommon
problems has
been cut by
more than half."
on one phase of our electrical main.
Gone unnoticed, it might have singlephased the building, causing serious
downtime or numerous equipment
failures.
Ultrasonic testing is our newest
tool. It provides data that benchmarks
and tracks bearing health and makes
our lubrication program more
efficient by reducing man-hours and
material use. It's also paid for itself
by locating small compressed air
leaks that would otherwise have gone
undetected. To properly use this tool
and its software, it was imperative
[for personnel] to attend a weeklong training class provided by the
manufacturer.
We use ultrasound to detect fatigue
and cracks in large wheel shafts. It
allows our technicians to trend log
anomalies within the shaft that point
to fatigue and impending failure. By
trend logging, we can determine when
to schedule shaft replacement and
eliminate breakdowns.
Lubrication Consultant,
Southwest. . .
I'm referring to a large process operation that had a long-standing, trained,
certified, and successful vibration
group. [Working there], I was
eventually asked to start a lubrication
program for the entire facility and try
to ramp up rotating-equipment reliability. Becoming the site's lubrication
specialist/engineer, I attended training
and obtained several certifications.
In time, we bought and started
a lubrication laboratory and began
pulling oil samples [from equipment]
and testing them and any lubricants
delivered to the site. In addition,
we provided training necessary for
many employees to achieve their own
certifications in the lubrication field.
Improvements in the rotating equipment were unbelievable.
We also bought and are continuing
to use thermal imaging at the site.
[Basing this statement on personal
experience], if sites would use these
three tools, i.e., vibration analysis,
lubrication analysis, and thermal
imaging, they will capture great
rewards in rotating-equipment
reliability and save significant money.
The key is to buy and keep up with the
most modern equipment available.
Technologies change more rapidly
than most people think.
Finally, [plants should] provide
much more professional training, for
everyone. Sites will get more for their
money from training than anything
else. Keeping personnel trained and
certified will always pay off. MT
About the MT Reader Panel
The Maintenance Technology Reader Panel includes approximately 100 working
industrial-maintenance practitioners and consultants who have volunteered to
answer monthly questions prepared by our editorial staff. Panelist identities are
not revealed and their responses are not necessarily projectable. Note that our
panel welcomes new members. To be considered, email your name and contact
information to jalexander@maintenancetechnology.com with "Reader Panel" in
the subject line. All panelists are automatically included in an annual cash-prize
drawing after one year of active participation.
MAINTENANCETECHNOLOGY.COM | 9
http://www.MAINTENANCETECHNOLOGY.COM
Table of Contents for the Digital Edition of Maintenance Technology September 2016
Editorial
Uptime
On The Floor
Old-School Approach To New-World Technology
Art Meets Reliability Science
Commit To Safety
Robot-Human Interaction Getting Safer
Sanitary, Stainless Conveyors Not The Same
Reduce Hidden Process-Safety Costs
Pace Your Reliability Program
Win The War With 'Lubrication By Design'
SAP Tips And Tricks
Understand Pump Vibration
Select The Right Relay
Bearing Care
Clear Up HOA Confusion
Potato Waste Becomes Clean Water, Energy
Products
Showcase
Ad Index
Final Thought
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - Cover1
Maintenance Technology September 2016 - Cover2
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - 2
Maintenance Technology September 2016 - 3
Maintenance Technology September 2016 - Editorial
Maintenance Technology September 2016 - 5
Maintenance Technology September 2016 - Uptime
Maintenance Technology September 2016 - 7
Maintenance Technology September 2016 - On The Floor
Maintenance Technology September 2016 - 9
Maintenance Technology September 2016 - Old-School Approach To New-World Technology
Maintenance Technology September 2016 - 11
Maintenance Technology September 2016 - 12
Maintenance Technology September 2016 - 13
Maintenance Technology September 2016 - 14
Maintenance Technology September 2016 - 15
Maintenance Technology September 2016 - Art Meets Reliability Science
Maintenance Technology September 2016 - 17
Maintenance Technology September 2016 - 18
Maintenance Technology September 2016 - 19
Maintenance Technology September 2016 - Commit To Safety
Maintenance Technology September 2016 - 21
Maintenance Technology September 2016 - 22
Maintenance Technology September 2016 - 23
Maintenance Technology September 2016 - Robot-Human Interaction Getting Safer
Maintenance Technology September 2016 - 25
Maintenance Technology September 2016 - Sanitary, Stainless Conveyors Not The Same
Maintenance Technology September 2016 - 27
Maintenance Technology September 2016 - 28
Maintenance Technology September 2016 - Reduce Hidden Process-Safety Costs
Maintenance Technology September 2016 - 30
Maintenance Technology September 2016 - Pace Your Reliability Program
Maintenance Technology September 2016 - 32
Maintenance Technology September 2016 - 33
Maintenance Technology September 2016 - 34
Maintenance Technology September 2016 - 35
Maintenance Technology September 2016 - Win The War With 'Lubrication By Design'
Maintenance Technology September 2016 - 37
Maintenance Technology September 2016 - 38
Maintenance Technology September 2016 - SAP Tips And Tricks
Maintenance Technology September 2016 - Understand Pump Vibration
Maintenance Technology September 2016 - Select The Right Relay
Maintenance Technology September 2016 - Bearing Care
Maintenance Technology September 2016 - 43
Maintenance Technology September 2016 - Clear Up HOA Confusion
Maintenance Technology September 2016 - Potato Waste Becomes Clean Water, Energy
Maintenance Technology September 2016 - 46
Maintenance Technology September 2016 - 47
Maintenance Technology September 2016 - 48
Maintenance Technology September 2016 - 49
Maintenance Technology September 2016 - 50
Maintenance Technology September 2016 - 51
Maintenance Technology September 2016 - 52
Maintenance Technology September 2016 - Showcase
Maintenance Technology September 2016 - Ad Index
Maintenance Technology September 2016 - 55
Maintenance Technology September 2016 - Final Thought
Maintenance Technology September 2016 - Cover3
Maintenance Technology September 2016 - Cover4
Maintenance Technology September 2016 - 62
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