Condition Based Maintenance – Monitoring Tools

Hi,

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.

http://www.uesystems.com/new/applications/

KayCee

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Case Study on Advantages of Proper alignment of Rotating Machinery Assemblies

Hi,

Good, within tolerance, mechanical alignment between the driving motor and driven components is one of the basic health requirements.

I came across an excellent case study for which the link is given below.

Proper alignment helps one plant keep on pumping.

Please go through and be enlightened.

Kaycee

Operations-driven reliability

Hi all,

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.

Operations-driven reliability.

Kaycee

Reliability | Hillbilly RCM |

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.

Regards

Kaycee

Reliability: How to develop an effective root cause failure analysis process

Hi all,

We all wish that the equipment and systems that we operate would work for ever, efficiently, effectively and productively. Though the reliability factor gets embedded at the design stage itself, there are “Ifs and buts” that get into the operation. With the current corporates culture tends to move towards “No defects”, reliability in operations becomes important.

All the maintenance effort is focused to this end, but in real life, failures do occur and do recur too. This is where the reliability study will help. Root cause analysis is a tool to understand the most likely cause for a specific failure and implement processes and procedures to avoid recurrence.

We all would have done this process mechanically, informally many times. Making such a study formal helps in making systemic corrections.

Here is a link to a very well written article on the topic.

Reliability: How to develop an effective root cause failure analysis process.

Read and be more well-informed.

KayCee

Combine vibration monitoring and ultrasound for more cost-effective predictive maintenance

Hi all,

predictive maintenance is one area that needs no introduction. Combination of techniques and tools available currently makes this a very competitive process. With this process, we can determine when to do any maintenance. Yes, preventive maintenance processes also will be followed, but instead of doing them mechanically as per a time schedule, it gets done when it is required to be done.

In most cases, the buffer time provided for time based preventive maintenance schedules is too much and we end up over-maintaining the equipment causing the following:

  • Doing maintenance on fully functional, healthy and operational equipment
  • Replacing the mandatory spares and consumables every time we do maintenance
  • Creating a condition where the equipment could fail due to man-made mistakes during assembly of equipment, post-maintenance.

I came across a wonderful article covering predictive maintenance using a combination of techniques and tools. The link is given below.

Predictive Maintenance: Combine vibration monitoring and ultrasound for more cost-effective predictive maintenance.

Please take some time to look up the link, read and be enlightened.

KayCee