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
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Maintenance Technology September 2016 - 50
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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
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