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Excerpt from
Effective
Maintenance
Management
by V. Narayan
Courtesy of
Industrial Press
Failure - a systems
approach
Failure is the
inability of an item
of equipment, a
sub-system, or
system to meet a set
of predetermined
performance
standards. This
means that we have
some expectations,
which we can express
quantitatively. For
example, we can
expect the discharge
pressure of a
centrifugal pump to
be 10 bar gauge at
1000 liters per
minute. In some
cases, we can define
our expectations
within a band of
acceptable
performance. For
example, the
discharge flow of
this pump should be
950-1000 liters per
minute at 10 bar
gauge. The
performance
standard may be for
the system,
sub-system,
equipment, or
component in
question. These
standards relate to
what we need to
achieve and our
evaluation
of the item’s design
capability and
intrinsic
reliability.
More...Read Failure,
Its Nature and
Characteristics
(562k pdf) |
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Benchmarking
Fundamentals
excerpted from
Benchmarking Best
Practices in
Maintenance
Management by Terry
Wireman
courtesy of
Industrial Press
Benchmarking. Best
practices.
Competitive
analysis. All these
terms are used in
business today. But
are they just
buzzwords, or do the
words have real
meaning? Are they
useful tools that
can be used to
improve business
practices today?
Let’s begin with
some definitions.
More...Read Chapter
2 Benchmarking
Fundamentals (326k
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Paper excerpted from
Physical Asset
Management Handbook,
Third Edition, by
John S. Mitchell.
Used with
permission.
Published by Clarion
Technical
Publishers. info@clarion.org
www.clarion.org
713.521.5929 |
EVOLUTION OF ASSET
MANAGEMENT AT
EASTMAN CHEMICAL
COMPANY
by Gina A. Lewis,
Manager, Reliability
Engineering &
Rotating Equipment
Group of Eastman
Chemical Company
Setting the vision
is difficult but is
often easier than
determining the most
efficient path to
reach it. One
visionary manager at
Eastman Chemical
Company set the
vision to
proactively manage
ALL assets by
providing condition
based maintenance.
It has taken 6
years, the formation
of a new department,
and the continual
support of upper
management to
finally clarify the
vision and document
a corporate strategy
to attain it.
The proactive
management of assets
requires industry
established tools
such as predictive
technologies and
information systems,
but also requires
the less talked
about resources such
as money and
man-power, training
programs,
opportunity
assessment tools and
management
champions. This
presentation will
attempt to present a
series of learning’s
that conclude by
showing how all
these tools
interlock to provide
a comprehensive
Reliability Strategy
for Asset
Management.
More...Read the
full story here
(102k pdf) |
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This excerpt is
provided courtesy of
Reed Elsevier |
RCM LESSONS LEARNED -
Chapter 9 from
"RCM - Gateway to
World Class
Maintenance" by
Anthony "Mac" Smith
and Glenn R,
Hinchliffe
It is very likely
that most of the
people involved in
your company
maintenance program,
especially those
charged with its
improvement, have
heard the term
“RCM.” However, the
number of people who
actually have some
reasonable
understanding of RCM
is, in our
experience, quite
limited. Given that
such an
uninformed state
exists, it is
extremely difficult
to gain wide
acceptance of an RCM
program and the
value that can be
realized from it.
The necessity for
such
familiarization is
important at both
the management level
and the system
engineer and craft
personnel level.
Familiarization at
the craft level is
especially
important,
a point that is not
always fully
recognized or
appreciated.
Throughout this
book, we have
endeavored to
demonstrate how RCM
can and should be an
integral part of any
maintenance
organization,
especially those
wishing to be known
as World Class.
More...
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RCM LESSONS LEARNED
(234 k pdf) |
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This full chapter is
excerpted courtesy
of Elsevier
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Fundamental
Requirements of
Effective
Preventive/Predictive
Maintenance
excerpted from
Industrial Machinery
Repair Best
Maintenance
Practices Pocket
Guide by Ricky Smith
and Keith Mobley
When most people
think of preventive
maintenance, they
visualize scheduled,
fixed interval
maintenance that is
done every day,
every month, every
quarter, every
season, or at some
other predetermined
intervals. Timing
may be based on
days, or on
intervals such as
miles, gallons,
activations, or
hours of use. The
use of performance
intervals is itself
a step toward basing
preventive tasks on
actual need, instead
of just on a
generality.
The two main
elements of fixed
interval preventive
maintenance are
procedure and
discipline.
Procedure means that
the correct tasks
are done, the right
lubricants applied,
and consumables
replaced at the best
interval.
Discipline requires
that all the tasks
are planned and
controlled so that
everything is done
when it should be
done. Both these
areas deserve
attention. More...
Click here to read
Fundamental
Requirements of
Effective
Preventive/Predictive
Maintenance 978k
pdf) |
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CMMS: A Timesaving
Implementation
Process
By Daryl Mather
A prevalent system
in large
corporations for
quite some time,
Computerized
Maintenance
Management System
(CMMS) is now
penetrating moderate
to small
corporations on an
international level.
These corporations
need an efficient
method to implement
this effective but
complicated system.
However, most of the
texts currently
available are
written by theorists
and involve complex
approaches. In CMMS:
A Timesaving
Implementation
Process, a
practitioner-turned-consultant
presents his
field-proven,
practical approach
that can
dramatically reduce
the amount of time
and cost needed to
implement and
maintain CMMS in any
corporation. The
book presents a
comprehensive
template process
that can be used in
order to implement
and maintain CMMS in
any business,
industry, or
facility, thus
dramatically
reducing the amount
of time and the cost
needed to implement
the process.
More...Click here to
read
CMMS: A Timesaving
Implementation
Process (261k pdf) |
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The New Weibull
Analysis Handbook
by Dr. Robert
Abernathy
Weibull analysis is
the world's most
popular method of
analyzing and
predicting failures
and malfunctions of
all types. The
method identifies
the category of
failure: infant
mortality, random or
wear out. Weibull
analysis provides
the quantitative
information needed
for making RCM
decisions which are
often made from a
qualitative
approach. Weibull
failure predictions
are accurate even
with very small
samples of data.
Weibull analysis
calculates optimal
parts replacement
intervals for
minimizing cost.
Weibull analysis is
needed for making
risk based
inspection decisions
to take action or
defer action on
potential failures.
More...Click
here to read Chapter
1 (550k .pdf) |
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Making
Common Sense
Common Practice
by Ron Moore, P.E.
Making
Common Sense
Common Practice'
takes a good, hard
look at plant
design,
procurement, parts
management,
installation and
maintenance,
training and even
offers a chapter
on how to
implement a
computerized
maintenance
management
system.
More...Click
here to read
Chapter 1 (189k
.pdf) |
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published
by:
CLARION
3401
Louisiana
Houston, TX 77002
USA |
Physical
Asset Management
Handbook,
by
John
S. Mitchell
Physical
Asset Management is a
"better way" of managing
corporate equipment assets. It
blends the best processes,
practice and technology to assure
highest effectiveness in your
specific business, operating,
organizational and material
conditions. More...Click
here to read a full chapter excerpt (145k
.pdf) |
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Click
here to buy this
book online |
Precision
Shaft Alignment
Reference Guide
by
Vibralign
This
handy pocket-sized guide from
Vibralign allows you to give
each of your skilled tradesmen
who perform alignment a ready
reference they can carry with
them to any job site. More...Click
here to read
Section
4: Rim-Face Alignment
Method (706k
.pdf)
Note:
You may have to rotate the view
on your Acrobat toolbar |
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Case Histories
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The subject company
manufactures meat
products such as
sausage, salami, and
bologna. Most of
their load consists
of HVAC and
refrigeration as
they have about 6000
sq. ft. of cold room
storage. They also
have machinery such
as grinders, slicers,
and presses. The
facility is served
by a 120/240V
through a
utility-owned 500
kVA High-Leg Delta
transformer that
they share with
another factory.
Interruptions
occurred when a main
1200 amp circuit
breaker was tripped
frequently.
More...Click here to
read
Harmonics Generated
from the Source
(144k pdf) |
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Thumping Sounds in
the Closet
By Dranetz-BMI
Elevator control
panels for the lower
zone mid-rise
elevators were on
the nineteenth floor
of a forty story
office building in a
large Midwestern
city. It was fed
with 480V
transformer on the
same floor, with the
feeders to the
controls rated at
800A.
Excessive noise and
vibration of the
feeder wires and
conduit were noticed
on a number of upper
floors.
More...Click here to
read Thumping Sounds
in the Closet (282k
pdf) |
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Vertical Condenser
pump alignment case
history by
Ludeca
A 640HP vertical
flange mounted
Fairbanks-Morse
condenser pump,
consider critical
equipment at a South
Florida nuclear
power plant, needed
to be quickly
aligned after a
motor repair.
More...Click here
to read a Vertical
Condenser pump
alignment case
history (962k pdf) |
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Articles
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Effective Maintenance
Program
Development/Optimization
by Sammy Seifeddine,
HSB Reliability
Technologies
This paper describes a
proven process for
developing,
optimizing, and
managing effective
maintenance programs
for new and in-service
assets based on risk
and cost-benefit
principles. The
process calls for
utilizing operational
and maintenance
experience as long as
the experience is
documented for the
proper class of assets
in the form of
standard tasks. In
absence of standard
tasks, a more
comprehensive analysis
is performed using
Reliability-Centered
Maintenance (RCM2) or
Failure Modes Effects
Analysis (FMEA) to
develop an optimum
program. Asset
performance data is
used to continually
adjust the maintenance
program to meet user
objectives. More...
Read the full story
(572k pdf version) |
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Estimating Electric
Motor Life Using Motor
Circuit Analysis
by Dr. Howard W.
Penrose, Ph.D.
General Manager,
ALL-TEST Pro
Electric motor life is
a critical issue when
discussing predictive
maintenance and
reliability programs.
The primary question
is: When will the
motor fail?
Unfortunately, this is
not an easy question
to answer, in
particular as it
relates to electric
motor systems.
In this paper, we
shall discuss the
stages of a winding
failure, causes and
what effects the rate
of failure in the
winding. We shall then
conclude with a
discussion of the
reliability of several
winding faults over
time and at what point
action should be taken
to correct or repair
the fault. Based on
application,
electrical and
physical environment,
the materials
presented will provide
an average.
The motors covered by
this paper will
include low voltage
(<600 Vac), standard,
integral, three phase
motors. This paper
does not address
similar higher voltage
projects in progress.
More...
Read the full story
(146k pdf) |
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Using Reliability
Engineering Methods as
a Tool for Continuous
Process Improvement
by Bill
Keeter, ARMS
Reliability Engineers
– USA, LLC
Presented at the 18th
International
Maintenance Conference
(www.maintenanceconference.com)
Whether we call the
process TQM, TPM,
Kaizen, or Six-Sigma
the thing every
business is striving
for is continuous
improvement in all
forms of work to give
them a competitive
advantage and increase
bottom line results.
Often asset management
improvements are seen
as separate from
overall process
improvement issues.
The fact that TQM and
TPM have been seen as
different initiatives
is an example of that
line of thinking. This
paper will explore the
direct link between
improving asset
management strategies
and overall business
process improvement.
The paper will show
the value of using
Weibull Analysis,
Reliability Block
Diagrams, Root Cause
Failure Analysis, and
RCM techniques as
process improvement
tools. More...
Read the full story
(136k pdf version)
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Creating the
Environment for Root
Cause Analysis (RCA)
to Succeed: The
Reliability
Performance Process
(TRPP)
TRPP© is a training
model developed by
Reliability Center,
Inc. It
encompasses not only
the elements about
specific training
objectives necessary
to be successful, but
it also outlines the
specific requirements
of the
Executives/Management,
the Champions and the
Drivers who are
accountable for
creating the
environment for RCA to
be successful.
We will be outlining
specific information
from TRPP that is
pertinent to creating
the environment for
RCA to succeed.
More...Read the full
story here (30k pdf) |
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Infrared Predictive
Maintenance (IR/PM)
activities, especially
as they relate to
predicting
electrical/mechanical
systems equipment
failure, are
increasing in
popularity. This is in
no small part due to
the efforts of the IR
industry to educate
engineering and
maintenance department
managers as to the
advantages of
predicting, and
subsequently
preventing, problems
from becoming system
failures by using
infrared thermographic
equipment and/or
contract services.
However, many
companies and plants
have failed to achieve
what they really need:
An extensive and
effective Infrared
Predictive Maintenance
Program. One "Hot
Spot" survey per year
does not make a
successful infrared
program.
More...Read the full
story here (59k pdf) |
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How Norfolk Southern
Railway Company Keeps
Traction Motors at
Peak Performance
Over the past year,
Norfolk Southern
Railway Company’s
Mechanical Department
in Altoona, PA, has
changed
the way it looks at
its 3-ton, 750 hp
motors that keep its
locomotives in motion.
With a fleet of more
than 18,000 traction
motors, keeping them
all from failure is no
easy job.
More...Read the full
story here (14k pdf) |
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When asked to pen this
piece on Enterprise
Asset Management
(EAM), I was struck
with a radical idea. I
would script the
definitive and all
encompassing manual
for EAM. Not only
that, but it would be
written so that an 8
year-old could
understand it. As it
turns out not many
people involved with
EAM are of that age,
so I figured I’d just
keep it as simple as
possible.
More...Click here to
read EAM Made Simple
(90k pdf) |
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Shaft Alignment
Procedure
by Damian Josefsberg,
Acquip, Inc.
Shaft alignment should
be an organized and
simple process. It is
important to establish
a set procedure to
perform alignments.
This procedure should
be followed for every
alignment from
beginning to end.
After you perform
alignments over a
period of time using
the same procedure,
you will find yourself
spending less time per
alignment and doing a
much better job.
More...Click here
to read Shaft
Alignment Procedure
(29k pdf) |
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Creating a
Successful Corporate
Maintenance Council
by S. Bradley
Peterson, Strategic
Asset Management Inc.
Most large,
multi-plant companies
have launched
corporate “Maintenance
Councils” in the past
decade. While
some have achieved a
significant success,
most are still
floundering for
direction and concrete
results.
What are the
differences that make
some successful and
some status quo?
More...Click here to
read Creating a
Successful Corporate
Maintenance Council
(127k pdf) |
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Getting The Most From
Lube Oil Analysis
by Michael P.
Barrett, Insight
Services
The goal of an
effective oil analysis
program is to increase
the reliability and
availability of your
machinery, while
minimizing maintenance
costs associated with
oil change outs,
labor, repairs and
downtime.
Accomplishing your
goal takes time,
training and patience.
However, the results
are dramatic and the
documented savings in
cost avoidance are
significant! This
paper presents basic
oil analysis concepts
for the novice looking
to improve his/her
understanding of the
power of oil analysis.
More...Click here to
read Getting The Most
From Lube Oil Analysis
(278k pdf) |
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Fundamentals of Shaft
Alignment
by Damian Josefsberg,
Acquip, Inc.
Performing correct
shaft alignment saves
time and money.
Misalignment is the
most common cause of
machine vibration.
Understanding and
practicing the
fundamentals of shaft
alignment is the first
step in reducing
unnecessary vibration,
reducing maintenance
costs, and increasing
machine uptime. Every
alignment should be
performed from start
to finish using the
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