This is one of my favourite topics, since I had a large number of systems piping failures related to stress, mostly external.
One of the flange connections of the fire main systems on board a ship, couple of bolts used to break at the head frequently; more often if the ship had done some high-speed manoeuvres. Initially, we used to change the bolt and live with it, but a nagging doubt came into our minds and we did a root cause analysis. What we finally found was that, the last pipe that fitted into the system was a little oversized and had been forced into its slot using a chain pulley, thus leading to a stressed piping section. Whenever high vibrations occurred, the stress used to increase, thus resulting in the flange securing bolts at one end shearing.
I came across a nice article on the topic. Please read and be enlightened on the topic.
Posted in Compressed air systems, Continuous improvement, Hydraulics, Infrastructure Maintenance & Management, Maintenance cost, Pipe internal cleaning, Planning & Scheduling, Plant Services, Preventive maintenance, Processes, Reactive maintenance, Reliability, Root Cause Analysis, Safety, SOP, Steam systems
Many of the modern CMMS products in the Market has the facility to upload links to media files in almost all the modules within the system. Such Multimedia files will help users in quickly referring to documents, drawings, e catalogues, SOPs, viewing maps etc. I came across a document on the subject. You could read the full document through the link given below.
Well defined removal routes for critical equipment, lists of special equipment with their storage details, emergency procedures etc will add pep to the CMMS that can give access to such documents to the concerned people whenever the need arises.
Any CMMS worth its while needs to have this facility as a quality value add. Check MPulse software for this wonderful feature.
I keep getting updates on new products used in the maintenance field through various online subscriptions.
Here is a link that shows the us of Ultrasound devices in the condition based maintenance strategy. I am not trying to sell the product, but am just trying to propagate the techniques involved. Please connect to the link given below and learn more.
Posted in Compressed air systems, Continuous improvement, Electrical Panels and cabling, Electrical Safety, Energy conservation, Environment Friendly Ops, Generating Sets, HVAC, Hydraulics, Infrastructure Maintenance & Management, Maintenance cost, Planning & Scheduling, Plant Services, Predictive Maintenance, Preventive maintenance, Processes, Reliability, SOP, Steam systems, TPM, Ultrasound Scanning
How many of us market our “Continuous Improvement” ideas well within the organisation?
My experience is that it is very difficult to bring about even small changes since there is a natural resistance to any change.
I came across this article on marketing your ideas to internal clients and decision makers.
Selling your ideas to help make improvements in the workplace.
Read and hone your marketing skills.
One would not come across such down to earth articles every day.
Simple examples on using the right fasteners at the right places and tightening them correctly has been covered in the article linked below:
Machinery | Improper bolting Improper bolting has the biggest impact on machine reliability and life cycle cost | Plant Services.
Using the right tools to work on fasteners is also important. The tendency to use pipe wrenches as a one tool for all fasteners lead to rounded bolt heads and joints that cannot be opened easily. Same goes for adjustable jaw pump wrenches also.
Please read and be re-trained on fasteners tightening.
In some of my earlier posts I have spoken about reliability, simple “Look, Listen, Feel” strategy in condition based maintenance strategy etc.
I came across an article in “Plant Services” web site covering a few of the areas and working towards “Operations – driven reliability.
I conducted a workshop on Reliability Centred Maintenance where I had covered the aspect of “Managing User / Client / Operator” expectations.
Please read this article following the link given below.
Electrical Power is used by all the staff members in a work force, at all levels.
To be safe, it is essential that every one understands the importance of basic electrical safety. For those who work on powered equipment, it is vital that they know more about electrical safety.
To achieve near zero electricity power related accidents in any organisation it is a must that layered, regular training and refresher sessions are conducted. Audit on how people comply to safety rules is also essential to measure the training effectiveness and attitudinal change brought about.
Here is a link to an article on the importance of training and audit on electrical safety.
I have seen people getting jittery when confronted with the term Reliability Centred Maintenance or RCM. The management jargon related to RCM makes it virtually difficult for the layman to understand the concept to its practical applications.
While operating gas turbine propelled ships in the Indian Navy, we had a few simple methods to listen to running machinery through rudimentary mechanical stethoscope – a long thin rigid copper tube with a brass disc attached. This was in addition to the more sophisticated on-line vibration measurement equipment, recording the vibration signature continuously. This data used to be periodically analysed to get the vibration signature. At that time, the recording was being done on board, but the data analysis was done by specialists sitting in their labs and we used to get reports on the health of the equipment on a monthly basis.
In one of my earlier posts, I had mentioned a “Look, Listen, Feel” strategy which could be the basic condition monitoring technique. I strongly feel that If Looking, Listening and Feeling are made integral parts of regular visits to the equipment, it forms a practical method in improving reliability of equipment and systems.
Another management jargon that has caught on is “Autonomous Management”. This talks of the equipment and system operators joining hands with the maintenance personnel and getting cross trained with each other’s functions. The operators will be made responsible for the first line maintenance of the equipment or systems that they are in charge of and the maintainers will be trained in basic operations of the same equipment or system. This has the following advantages:
- Improved feeling of ownership among both groups – operators and maintainers
- Both the groups understand the equipment or system operations and the nuances of reliable operations
- Flexibility in operations and maintenance – Who to do what, when, where?
- Better operator – maintainer relationships. Lesser “We – They” conflict
- Resulting increase in reliability and Overall Equipment Effectiveness (OEE)
I came through an article in an old issue of Plant Services, covering a practical simple method to analyse reliability and achieve RCM. The link is given below:
Reliability | Hillbilly RCM | Plant Services.
Please read through to help you on the RCM path. No big statistical analysis, probability theory, mathematical modelling etc are involved.
Energy conservation and energy audits are two catch phrases that are flogged to death on many fora.
Is it possible to deny the need for us to adopt energy conservation measures? The answer is a big know.
So, how do we go about doing an audit and bringing in measures to achieve good results.
Today I went through the part 1 of a very well written article on the topic. The link is given below:
Break Energy Audits into Phases | Chemical Processing.
Please read and be enlightened.
Plants Services is one magazine that I subscribe to. It comes up with highly readable material, written by knowledgeable people.
The latest issue had an article on CMMS / EAM evolution. Please click on the link below to access and read the same.
CMMS/EAM Software Review: 9 trends spurring CMMS/EAM evolution.
Posted in Cloud computing, CMMS, Continuous improvement, Environment Friendly Ops, Infrastructure Maintenance & Management, Inventory & Stores, Maintenance cost, Planning & Scheduling, Plant Services, Processes, Reliability, Root Cause Analysis, SOP, Training